special - ALU

Transcription

special - ALU

OFFICIAL MEDIA SPONSORS
Special: ALUMINIUM
2008 – Fair preview
Aleris – Advance to
new dimensions in
hot rolling of
aluminium plate
Reed Exhibitions
Giesel Verlag GmbH · Postfach 120158 · D-30907 Isernhagen · www.alu-web.de – PVST H 13410 – Dt. Post AG – Entgelt bezahlt
OFFICIAL MEDIA PARTNER
SMS Demag – A special type of rolling
plant modernisation
Volume 84 · September 2008
International Journal for Industry, Research and Application
9
Ultrasonic Testing.
Heavy duty short stroke saw.
Automatic stacking and packing system.
Billet Sawing and
Packing Plant
Saw with manipulator for offcuts.
Visit us at
ALUMINIUM 2008
September 23 to 25
Hall 3, Booth No. 3A40
Essen, Germany
Leading technology in the aluminum casthouse.
There are many benefits in one-stop shopping –
even for industrial goods. Reliable, cooperative
planning, specifications, which meet exactly your
demands and individual service-packages to operate
on first-class level throughout the whole lifetime of
the plant – this can be realized by one of the most
experienced suppliers: Hertwich Engineering.
Major benefits
Hertwich Engineering is dedicated to leading technology in the aluminum casthouse. We add value
by designing integrated turnkey solutions. From
melting and remelting to testing and packing. The
results are convincing: highest quality of products
at lowest cost-of-ownership. This has been proven
by numerous plants all over the world.
Billet Sawing and Packing Plant
The complete line including all auxiliary
equipment from one supplier
Various configurations and options in order to
streamline the plant to the client`s requirement
Sophisticated operating system with automatic
restarting program, error detection and diagnosis
System improve operation and maintenance
More than 50 plants installed within 10 years
MEETING your EXPECTATIONS
HERTWICH ENGINEERING GMBH
Weinbergerstrasse 6
5280 Braunau, Austria
Phone: +43 (0) 7722 806-0
Fax:
+43 (0) 7722 806-122
E-mail: [email protected]
Internet: www.hertwich.com
EDITORIAL
Volker Karow
Chefredakteur
Editor in Chief
Der Countdown zur
ALUMINIUM 2008
ist eingeläutet
The countdown to
ALUMINIUM 2008
has started
ALUMINIUM · 9/2008
Der Aufschwung ist vorbei, die starke
Konjunktur der letzten Jahre Vergangenheit, erklärte Mitte August eine
der fünf „Wirtschaftsweisen“, Beatrice
Weder. Ein schwacher privater Konsum, gepaart mit drastisch steigenden
Lebensmittel- und Energiepreisen,
und ein starker Euro hinterlassen ihre
konjunkturellen Bremsspuren: Die
deutsche Wirtschaft schrumpfte im
zweiten Quartal. Von einer unmittelbar drohenden Rezession in Deutschland zu sprechen wäre allerdings
verfrüht. Die Stimmung ist schlechter als die Lage, die eingeleiteten
Strukturreformen wirken, das Land
steht besser da als manche anderen
europäischen Länder.
Wie stark der konjunkturelle
Knick auf die Aluminiumindustrie
durchschlägt, ist derzeit schwer auszumachen. Die nur noch wenige
Wochen vor uns liegende ALUMINIUM-Messe wird über die weitere
Entwicklung der Branchenkonjunktur näher Aufschluss geben können,
wenn sich von den Hüttenbetreibern
über die Halbzeugwerke und Gießereien bis hin zu den Weiterverarbeitern die deutsche und internationale
Branchenelite inklusive ihrer Ausrüster und Technologiepartner in Essen
versammelt. Die Redaktionen dieser Zeitschrift und der metallorientierten Schwesterpublikationen aus
dem Giesel Verlag freuen sich schon
auf die interessanten Gespräche mit
Ausstellern; dabei wird es neben der
Diskussion um konjunkturelle und
Marktperspektiven natürlich auch
um neue technologische Projekte und
innovative Entwicklungen gehen.
Der Besuch zahlreicher Firmen auf
ihren Messeständen ist fest eingeplant.
Umgekehrt laden Verlag und Redaktion an den ersten beiden Messetagen
ab 17 Uhr zum „Bier & Talk“ auf dem
Messestand des Giesel Verlags (2D22).
Aussteller und Besucher der Messe,
Leser unserer Zeitschriften und die,
die es (noch) nicht sind, haben Gelegenheit, mit den Chefredakteuren,
Innen- und Außendienstlern des Verlages zu diskutieren, Branchennews
und Branchenklatsch auszutauschen
oder einfach bestehende Kontakte zu
pflegen und neue zu knüpfen – und
den Messetag auf diese Weise entspannt ausklingen zu lassen.
Beatrice Weder, one of the five economic ‘gurus’ in Germany, explained
in mid-August that the upswing has
ended and the strong market positions of recent years are in the past.
Weaker private consumption, paired
with drastically rising food and energy prices and a stronger euro are
leaving the skid-marks of harsh braking on commercial activity: Germany’s economy dwindled in the second quarter. It would be premature,
however, to speak of an imminent
threat of recession in Germany. The
mood is worse that the true position
warrants, the structural reforms introduced are having an effect, and the
country is better off than many others
in Europe.
How strong an impact the downturn is having on the aluminium industry is at the moment difficult to
assess. It will be easier to draw conclusions about the further development of activity in the branch after
the ALUMINIUM fair now only a few
weeks away, when everyone, from
smelter operators to semis producers
and foundries, and further processors
representing the elite of the branch as
well as their suppliers and technology
partners, will gather together in Essen. The editors of this journal and its
metal-orientated sister publications
from Giesel Verlag are already looking forward to interesting discussions
with exhibitors, which besides economic and market perspectives, will
no doubt also be concerned with new
technological projects and innovative
developments.
Firm plans have already been made
for visits to numerous companies on
their stands at the fair. Conversely, the
publisher and editors invite visitors
on the first two days of the fair, from
5.00 p.m. onwards, to ‘Beer & Talk’ at
the Giesel Verlag stand (2D22). Exhibitors and visitors at the fair, readers of our journal and those who are
not (yet) among them, will have the
opportunity for discussions with the
Editors in Chief and with those who
provide internal and external services
for the publisher, to exchange branch
news and gossip or simply to renew
existing contacts and make new ones
– and so to round off their day at the
fair in a relaxing way.
3
I N H A LT
EDITORIAL
Der Countdown zur ALUMINIUM 2008 ist eingeläutet ................... 3
A KT U E L L E S
Personen, Unternehmen, Märkte ............................................ 6
WIRTSCHAFT
Englischsprachige Artikel: s. nebenstehendes Verzeichnis
Aluminiumpreise .............................................................. 10
74/80
Produktionsdaten der deutschen Aluminiumindustrie .................. 12
Emissionshandel darf Aluminiumproduktion nicht weiter verteuern .. 14
SPECIAL: ALUMINIUM 2008 – MESSEVORSCHAU
I.A.S. – Induktive Erwärmung setzt sich weltweit durch ............... 22
Carl Kind – Werkzeugpartner der Strangpressindustrie ................ 24
Siemag – Innovative Transport- und Lagertechnik ...................... 30
O. Junker – Vom Schmelzofen bis zum Profilpaket alles aus einer Hand 32
LOI – Wärmebehandlungsanlagen für hoch belastete Automobilteile 38
110
SAG – Individuelle Werkstofflösungen für breites Anwendungsspektrum 43
ItN – Innovativer Permanentschutz für Masselformen .................. 44
ECKA Granulate – Pulver und Granulate jeder Art und Größe ........ 46
Kasto – Hochleistungsbandsägen für Aluminium ....................... 48
This issue contains
an enclosure from
DGM Deutsche Gesellschaft
für Materialkunde e. V.
to which we draw
your kind attention.
Ebner – Industrieöfen mit Hochkonvektions-Technologie .............. 51
Dienes –Werkzeugsysteme für Längs- und Querteilanlagen .......... 52
BWG – Spitzentechnik für hochwertiges Aluminiumband ................ 56
Eloxalwerk Ehingen – Bearbeitung von Alubauteilen aus einer Hand 72
T E CH N O LO G I E U N D A N W E N D U N G
Neue Bolzengießerei bei Neuman Aluminium ............................. 90
Pezzorgna Armando erweitert Produktpalette um automatische
A.T.I.E. – Strangpresswerkzeuge prozesssicher mit Stickstoff kühlen 100
List of advertisers
SAG – Komplexe Geometrien in fast porositätsfreier Qualität ....... 104
ABB Switzerland Ltd., Switzerland
113
Achenbach Buschhütten GmbH
23
AE Light Metal Casting GmbH & Co. KG
129
Alcutec Engineering GmbH
127
Aleris Recycling (German Works) GmbH
79
Almax Mori Srl, Italy
101
Almeq Norway A.S., Norway
34
Arno Werkzeuge Karl-Heinz Arnold GmbH 55
Astech Angewandte Sensortechnik GmbH
6
A.t.i.e. Uno Informatica Srl, Italy
45
Bano Recycling Srl, Italy
57
Böhler Edelstahl GmbH & Co. KG, Austria
19
Bruker Quantron GmbH
43/45
Buss AG, Switzerland
15
Buss ChemTech AG, Switzerland
119
BWG Bergwerk- und WalzwerkMaschinenbau GmbH
11
Calderys Deutschland GmbH & Co. OHG
27
Coiltec Maschinenvertriebs GmbH
14
4
Werkzeuglagersysteme ...................................................... 98
Inserenten
dieser Ausgabe
Otefal – Farbaluminiumbleche für Fassaden ............................ 110
I N T E R N AT I O N A L E B R A N C H E N N E W S .................. 118
V E R A N S TA LT U N G E N / D O K U M E N TAT I O N
Termine, Fortbildung ........................................................ 136
Patente ........................................................................ 139
Literaturservice ............................................................... 140
Impressum .................................................................... 161
Vorschau....................................................................... 162
B E Z U G S Q U E L L E N V E R Z E I C H N I S . . . . . . . . . . . . . . . . . . . . . . . . 143
S T E L L E N A U S S C H R E I B U N G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ALUMINIUM · 9/2008
CONTENTS
EDITORIAL
The countdown to ALUMINIUM 2008 has started ........................ 3
NEWS IN BRIEF
People, companies, markets . . . . . . . . . . . . . . . . . . . ............................... 7
ECONOMICS
Emission trading must not increase cost of aluminium production ..
EU to start anti-dumping probe on Chinese aluminium foil ...........
Hydro to seek acquisitions in the second half of 2008 .................
US aluminium can recycling rates hit 6-year high .......................
UC Rusal continues ecological modernisation of its smelters .........
14
19
19
20
20
S P E C I A L : A L U M I N I U M 2 0 0 8 – FA I R P R E V I E W
I.A.S. – Inductive heating establishes itself worldwide ................ 22
Carl Kind – Die partner of the extrusion industry ....................... 24
Siemag – Innovative transport and storage technology................ 30
O. Junker offers the complete production chain for extrusion ........ 32
LOI – Heat treatment furnaces for high-strength car components ... 38
Achenbach – Rolling plant specialist with an extended product line 40
Heavy-duty strapping technology from Signode ......................... 42
ItN – Innovative permanent protection for ingot moulds .............. 44
ECKA Granulate – Powder and granulates of all types and sizes .... 46
Hydro brings climate protection to the focus of its fair presentation .. 48
Gautschi – From furnace equipment to complete casthouses ........ 50
Ebner – Industrial furnaces with high-convection technology ........ 51
Dienes – Tool systems for slitting and cutting machines .............. 52
BWG – Top-class technology for high-grade aluminium strip ......... 56
Italian extrusion and rolling technology in Essen: Almax Mori, ATC,
Phoenix International, OMS, Fata Hunter, Presezzi Extrusion,
Estral, Bruno Presezzi, Profilglass, Turla, Otefal, Selema ........... 59-68
Autel – New solution for packaging extrusions ......................... 70
ESK Ceramics – Securely adhering casting ladle coatings ............. 70
T E C H N O L O G Y A N D A P P L I C AT I O N
Aleris – Advance to new dimensions in hot rolling of aluminium plate 74
SMS Demag – A special type of rolling plant modernisation ......... 80
Vesuvius – A well-established provider of refractory lining services .. 86
New casting line for billets at Neuman Aluminium ..................... 90
Profilglass extends its aluminium semis basis ............................ 92
Pezzorgna Armando extends its product range with automatic
die storage systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................. 98
A.T.I.E. – Die cooling with liquid nitrogen . . ............................ 100
SAG – Complex geometries in virtually pore-free quality ............. 104
Otefal – Coloured aluminium sheet for façades ........................ 110
Dantherm – A concept for dioxin and furan abatement .............. 116
C O M PA N Y N E W S W O R L D W I D E
Aluminium smelting industry . . . . . . . . . . . . . . . . . . ............................ 118
Bauxite and alumina activities . . . . . . . . . . . . . . . . . ............................ 124
Recycling and secondary smelting . . . . . . . . . . . . ............................ 126
Aluminium semis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 128
On the move. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 129
Suppliers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 130
RESEARCH
Compes – Die design solutions to avoid weld streaks .................. 132
E V E N T S / D O C U M E N TAT I O N
Dates . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 136
Literature service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 140
Imprint . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 161
Preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 162
S O U R C E O F S U P P LY L I S T I N G . . . . . . . . . . . . . . . . . . . . . . . . . . 143
J O B A D V E R T I S E M E N T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ALUMINIUM · 9/2008
Compes Spa, Italy
49
Coperion Hartmann GmbH
83
Dantherm Filtration GmbH
7
Drache Umwelttechnik GmbH
108
Ebner Industrieofenbau GmbH, Austria
18/19
Ecka Granulate GmbH & Co. KG
75
Edimet Spa, Italy
68
EKW Eisenberger GmbH
103
Elster Kromschröder AG
33
ESK Ceramics GmbH & Co.KG
87
Estral Spa, Italy
41
Fata Hunter Spa, Italy
29
Gautschi Engineering GmbH, Switzerland
163
Glama Maschinenbau GmbH
121
Haarmann Holding GmbH
39
Hengen Ingenieurbüro GbR
28
Herrmann + Hieber GmbH
35
Hertwich Engineering GmbH, Austria
2
High Performance Industrie-Technik GmbH,
Austria
93
Honsel AG
73
Hydro Aluminium Deutschland GmbH
111
I.A.S. GmbH + Co. KG
50
Innovatherm Prof. Dr. Leisenberg
GmbH & Co. KG
53
Inotherm Industrieofen- und
Wärmetechnik GmbH
22/31/125
IST Industrieofen + Stranggießtechnik GmbH 131
ItN Nanovation AG
58
Otto Junker GmbH
91
Kasto Maschinenbau GmbH & Co. KG
26
Kind & Co. Edelstahlwerk
123
Knauf Interfer SE
47
Lechler GmbH
31
LOI Thermprocess GmbH
43
Micro-Epsilon Messtechnik GmbH & Co. KG
9
Micro-Epsilon Optronic GmbH
8
Mifa Aluminium b.v., The Netherlands
30
Novelis PAE, France
107
Oilgear Towler GmbH
51
Omav Spa, Italy
69
O.M.S. Impianti Srl, Italy
71
Outotec GmbH
164
Phoenix International Spa, Italy
25
Bruno Presezzi Spa, Italy
59
Plasmatreat GmbH
40
Presezzi Extrusions Spa, Italy
88
Pyrotek Inc., USA
115
Reed Exhibitions
97
Reisch Maschinenbau, Austria
46
Riftec GmbH
46
S+C Märker GmbH
30
SAG Aluminium Lend, Austria
86
Sapa Holding AB, Sweden (job advertisement) 13
Seco/Warwick S.A., Poland
89
Selema Srl, Italy
63
Shanghai Jieru, PR China
105
Signode System GmbH
77
SMS Demag AG
36/37/81
Spectro Analytical Instruments
GmbH & Co. KG
54
SRS Amsterdam BV, The Netherlands
85
Sucden Financial Niederlassung Deutschland 17
Trevisan Cometal Spa, Italy
65
Trimet Aluminium AG
21
Troostwijk BV, The Netherlands
60
Turla Srl, Italy
61
Vesuvius becker & piscantor GmbH
95
Windhoff Bahn- und Anlagentechnik GmbH 109
Zwick GmbH & Co. KG
24
5
AKTUELLES
PSI übernimmt 4Production
Die PSI AG, Berlin, hat die 4Production AG mit Sitz in Würselen bei Aachen erworben. 4Production hat sich
auf die Planung und Steuerung der
Prozesse in der Metall- und Papierindustrie spezialisiert. Das Unternehmen zählt zahlreiche internationale
Konzerne aus der Stahl-, Aluminium- und Kupferindustrie zu seinen
Kunden.
4Production bietet „Metals Supply Chain“-Beratung und -Systemintegration für die optimale Nutzung
der Wertschöpfungskette. Zu seinen
wichtigsten Produkten für die Aluminiumindustrie zählt die 4Production
Suite. Das PSI-Tochterunternehmen
Non Contact Measurement with Light
Velocity + Length
Knowhow-Bündelung in “Metals Supply Chain”-Beratung
Metallindustrie begrüßt aktivere
Rohstoffpolitik der Bundesregierung
%!" ' #
)*
$( & '
6
PSI BT nimmt mit dem Branchenstandard PSImetals eine führende Rolle
als Anbieter von Produktionsmanagementlösungen in der Stahlindustrie
ein. Mit der Integration der 4Production verstärken beide Unternehmen
ihr Leistungsangebot und bauen ihre
Marktpositionen weiter aus.
PSI entwickelt und integriert
auf Basis eigener Softwareprodukte
komplette Lösungen für das Energiemanagement, unternehmensübergreifendes Produktionsmanagement
(Stahl, Automotive, Maschinen- und
Anlagenbau, Logistik) sowie Infrastrukturmanagement für Telekommunikation, Verkehr und Sicherheit.
N
Der von der Bundesregierung vorgelegte Bericht zur aktuellen Situation
der Rohstoffversorgung zeigt erste
positive Ansätze zur nachhaltigen
Verbesserung der Versorgung und
des Handels mit Rohstoffen. Der politische Wille, eine aktivere Rohstoffpolitik zu betreiben, sei erkennbar, erklärte jüngst Ulrich Grillo, Präsident
der Wirtschaftsvereinigung Metalle
(WVM) und zugleich Vorsitzender
des Rohstoffausschusses beim Bundesverband der Deutschen Industrie
(BDI).
Eine nationale und vor allem eine
noch zu formende europäische Rohstoffpolitik müsse sich den handelsund geopolitischen Aspekten der
Rohstoffversorgung widmen. Dies gelte für primäre Rohstoffe wie Energie,
Erze, Mineralien und Tonerde ebenso
wie für sekundäre Rohstoffe (Schrotte,
Verarbeitungsreste, Gebrauchsgüter).
Die handelspolitischen Fortschritte
seit dem BDI-Rohstoffkongress im
vergangenen Jahr seien eher ernüchternd. Beim WTO-Beitritt der Ukraine
wurde zwar erreicht, dass sich dieses
Land verpflichtet, die Exportzölle in
einem künftig zu verhandelnden Freihandelsabkommen abzuschaffen. Bis
dahin bleiben die Zölle jedoch auf
einem für die Unternehmen der NEMetallindustrie prohibitiv wirkenden
hohen Niveau. Viele andere Länder,
allen voran Russland und China, setzen handelsund steuerpolitische Instrumente aktiv ein, um Material- und
Rohstoffflüsse aktiv zu ihren Gunsten
zu beeinflussen.
Die von der Bundesregierung angekündigte Förderung des effizienten
und damit Rohstoff sparenden Materialeinsatzes in der Industrie ist nach
Ansicht der WVM von zentraler Bedeutung für ein rohstoffarmes Land
wie Deutschland. Allerdings bedürfe
es hier kaum zusätzlicher staatlicher
Flankierung, denn der effiziente Materialeinsatz erfolge marktgetrieben
infolge der Preisentwicklung und des
Substitutionsdrucks. Lediglich für
Forschung und Entwicklung seien
steuerliche oder investive Anreize
sinnvoll.
Die WVM hofft auf eine anspruchsvolle und ehrgeizige rohstoffpolitische Initiative der EU-Kommission,
wie sie von Deutschland im Rahmen
der jüngsten Ratspräsidentschaft angestoßen wurde.
N
ALUMINIUM · 9/2008
Novelis records profit in Q1 of FY 2009
Novelis Inc. reported net income of
USD25 million for the first quarter
of fiscal year 2009, which ended on
30 June 2008. In the corresponding
period a year earlier the company
booked a net loss of USD142 million
which included a number of non-recurring expenses related to the acquisition by Hindalco.
Shipments of flat-rolled aluminium
products increased in the first quarter
in all of the company’s reported regions
except Europe. Total rolled products
shipments increased three percent to
777,000 tonnes over the correspond-
ing period a year earlier. The primary
driver of this increase was strong global demand for aluminium can sheet.
This was partially offset by decreases
in light gauge and speciality products
due to weaker construction markets
in North America and Europe.
Novelis reported pre-tax income of
USD62 million on sales of USD3,103
million for the first quarter, an improvement of USD176 million over
the corresponding period a year earlier when it incurred a pre-tax loss of
USD114 million on sales of USD2,828
million.
N
Your Partner for
Air Cleaning Systems
in Primary- and SecondaryAluminium Industry
Sale of QVC shareholding completed
Norsk Hydro has completed the sale
of its 29.7 percent interest in Qatar
Vinyl Company (QVC) to Qatar Petroleum. The transaction represents
net proceeds to Hydro of USD136
million (NOK735m). The transaction
is expected to result in a gain of approximately NOK100 million to be
recorded in the third quarter results.
This completes the divestment of Hydro’s Polymers activities.
Hydro entered into an agreement to
sell its Polymers activities to Ineos in
late May 2007, consisting of production facilities in Norway, Sweden and
the UK, and the 29.7 percent interest
in QVC. The sale to Ineos was completed 1 February 2008, excluding
the QVC interest as Qatar Petroleum
exercised its pre-emptive right to acquire the QVC ownership interest.
N
Alufoil expectations remain optimistic
Exports of aluminium foil from Europe showed an increase of three
percent in the first half of 2008
bucking a general downward trend
in sales which showed a decline to
432,800 tonnes from the record level
of 452,000 tonnes in the first half of
the previous year, according to figures
from European Aluminium Foil Association (EAFA).
Deliveries inside the EAFA region*
dropped by five percent; volumes of
thinner gauges mainly used for flexible packaging declined by seven percent and thicker materials used for
containers and technical applications
were down by two percent.
There is optimism that the negative
trend is slowing down with figures for
the second quarter figure showing a
drop of only three percent to 216,000
ALUMINIUM · 9/2008
tonnes, against record growth in the
previous two years.
While the intra EAFA usage
dropped by five percent in the second
quarter, exports rose by nine percent
despite the challenging US Dollar exchange rate.
“The overall economic situation
means that the general reluctance
to consume is an unfortunate fact to
which our customers and their customers have to adapt. However, the
slight trend recovery in the second
quarter underlines the optimism of the
European aluminium foil industry for
the rest of the year 2008”, commented
EAFA President Fred McDonogh.
* Armenia, Austria, Bulgaria, Czech Republic, EU15, Hungary, Norway, Russia,
Slovenia, Switzerland and Turkey.
N
You are invited:
Aluminium 2008 in Essen
23 - 25 September
Hall Galeria
Stand G95
Industriestraße 9
D-77948 Friesenheim
www.danthermfiltration.com
ALUMINIUM 2008 in Essen
23.09. - 25.09.08 Halle 6 / Stand 6E50
Neue Geschäftsführung bei Otto Junker
-EPSIL
RO
O
ON ptr
ic Gmb
ASCOspeed
die neue
Generation.
www.micro-epsilon.de
MICRO-EPSILON Optronic GmbH
D-01465 Dresden-Langebrück
Tel. 035 201 / 729-0
[email protected]
tionen inne, u. a. als Vorsitzender der
Geschäftsführung der Maerz Gautschi Industrieanlagen GmbH. 2006
bis 2008 leitete Hans Rinnhofer als
Sprecher der Geschäftsführung die
Austrian Research Centers in Wien,
das größte außeruniversitäre Forschungsunternehmen in Österreich
„Wir sind sehr froh, mit Dr. Rinnhofer einen ausgewiesenen Fachmann
auf den Technologiegebieten unserer
Unternehmernsgruppe gewonnen zu
haben. Mit seinen fundierten Marktund Produktkenntnissen und seiner
großen internationalen Erfahrung
wird er unserem Unternehmen wertvolle neue Impulse für dessen weitere
Entwicklung geben“, sagte der Vorsitzende des Junker-Aufsichtsrates
Klaus K. Moll.
N
Energiekrise macht Standort
Deutschland attraktiver
Der Anstieg der Energiepreise macht
den Standort Deutschland für den
Mittelstand wieder attraktiver. Knapp
jedes vierte mittelständische Unternehmen glaubt, dass die Produktion
im Inland gegenüber der Beschaffung
in Ländern wie China oder Indien wegen der gestiegenen Transportkosten
wieder an Bedeutung gewinnt. Dies
geht aus einer aktuellen Umfrage
von PricewaterhouseCoopers unter
509 mittelständischen Unternehmen
hervor.
Der Trend könnte sich verstärken,
wenn die Energie- und Rohstoffpreise
bis Ende dieses Jahres weiter steigen
und sich damit die Logistikkosten erhöhen. Davon gehen neun von zehn
befragten Unternehmen aus. Knapp
die Hälfte der Firmen erwartet eine
Teuerung um mindestens zehn Prozent, gut jedes zehnte Unternehmen
hält sogar Preissteigerungen um 30
Prozent und mehr für möglich. Schon
heute leidet jeder zweite Mittelständler nach eigener Einschätzung stark
oder sogar sehr stark unter den hohen
Energiepreisen.
Der Anstieg der Energie- und Roh-
ALUMINIUM
H
15 Jahre
Der Aufsichtsrat der Otto Junker
GmbH,
Simmerath-Lammersdorf,
hat Hans Rinnhofer (45) mit Wirkung
zum 18. August 2008 zum Vorsitzenden der Geschäftsführung bestellt.
Weiterer Geschäftsführer ist Alexander Großhäuser, der nach dem Ausscheiden des früheren Vorsitzenden
Gunther Voswinckel seit Ende Mai
2008 die Geschäfte vorläufig alleine
geleitet hatte.
Rinnhofer ist Österreicher. Er studierte an der TU in Wien Maschinenbau und promovierte 2001 berufsbegleitend. Seine industrielle Laufbahn
begann er 1989 im Flüssigbereich der
Metallindustrie. Nach einer vierjährigen Tätigkeit in der Voest Alpine
Gruppe in Australien trat er 1997 in
die RHI-Gruppe ein und hatte dort
verschiedene Geschäftsführungsposi-
on
berührungslos
messen
MIC
Geschwindigkeit
Länge
Reckgrad stand alone
Die Strompreise kennen derzeit nur einen
Weg – den nach oben
stoffpreise hat die Beschaffung im
Mittelstand in den letzten zwölf Monaten im Durchschnitt um 29 Prozent
verteuert. Dabei sind die Unternehmen je nach Branchenzugehörigkeit
in unterschiedlichem Maße vom Anstieg der Energie- und Rohstoffkosten
betroffen.
N
ALUMINIUM · 9/2008
Wir stellen aus:
23.09. - 25.09.08 ALUMINIUM 2008 in Essen
Halle 6 / Stand 6E50
Alunorf orders twin-chamber melting
furnace from LOI Italimpianti
Alunorf GmbH, Neuss, the world’s
largest aluminium rolling mill, is investing in highly advanced plant technology for aluminium recycling. As a
key component of its plant, Alunorf
has selected LOI Thermprocess recycling technology.
LOI Thermprocess, an LOI Italimpianti subsidiary, has been awarded
a contract to supply a twin-chamber
melting furnace. The recycling system
will be designed for a capacity of 150
tonnes of molten metal per day, produced entirely from aluminium scrap.
Various types of aluminium scrap are
to be melted and the molten metal
will be used to produce new rolling
ingots.
LOI Thermprocess equipment was
chosen for the project because of its
Messung
Berührungslose Inlineofil
outstanding performance and its environmentally compatible, energy-efficient operation.
Contaminated scrap does not require pre-treatment. The integrated
waste gas treatment system ensures
that pollutants are reliably and effectively combusted. The recycling
furnace is equipped with a regenerator system ensuring a high level of
waste heat recovery from the waste
gas. The cooler, reduced waste gas
flow reduces the capital expenditure
for the filter system. In addition, the
LOI regenerator system rapidly cools
the waste gas, improving the environmental compatibility of the plant.
The recycling plant is due to be
commissioned in the autumn of
2009.
N
für Dicke, Breite und Pr
- Dynamische Messung bei
hoher Genauigkeit
China tax to cut alloy export
China’s exports of unwrought aluminium alloy will probably fall from
September on a new tax, which will
increase metal supply in the country
but cut availability in Asia. Chinese
exporters have cancelled booked exports, which may force the overseas
buyers to liquidate shorts on the London Metal Exchange hedged for the
bookings, a move that would push
up LME aluminium prices. Falling alloy exports from China would force
buyers in Asia to switch to primary
aluminium, which could drive up
premiums of the metal, according to
analysts and traders.
Beijing would impose a 15 percent
tax on exports of unwrought aluminium alloy from 20 August, said the
Chinese Ministry of Finance. The tax
would apply only to those that are exported under normal trade, meaning
the alloy is made by local materials.
The ministry did not mention those
that are exported under tolling and
processing trade, a duty-free policy
that alloy makers use for importing
scrap and exporting up to 30,000
tonnes of alloy ingots per month.
Unwrought aluminium alloy nor-
ALUMINIUM · 9/2008
- Spezielle Temperaturkompensation
mally is made of scrap in China and
the production of the alloy is encouraged by Beijing’s policy to use recycled materials. But this year, Chinese
smelters increased exports of alloy,
which differ from normal alloy ingots
and are made of primary aluminium
and other metals such as magnesium,
silicon and manganese, to take advantage of strong international prices in
the face of weak domestic demand.
Exports jumped some hundred
percent from a year earlier to 113,908
tonnes in June. The exports alarmed
Beijing as the government is trying to
cut exports in order to cool investment
in the energy-intensive aluminium industry, Wang Feihong, senior analyst
at Antaike, a state-owned research
group, said. He added, smelters would
cut alloy output and make more metal
after tax on the alloy rose to the same
level as primary metal.
A trade manager at a large aluminium smelter said he estimated that
more than 50,000 tonnes of primary
metal would be added to the domestic
market each month as alloy exports
fell.
- Vollautomatisierte Kalibrierung
- Traversierbreite bis 6 m
- Platinendicke bis 200 mm
- Materialtemperatur bis zu 600 °C
- Für Aluminium und Stahl
- Strahlungsfrei
e
www.micro-epsilon.d
N
MICRO-EPSILON Messtechnik
94496 Ortenburg
Tel. 0 85 42/168-0 · [email protected]
WIRTSCHAFT
10
ALUMINIUM · 9/2008
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WIRTSCHAFT
Produktionsdaten der deutschen Aluminiumindustrie
Primäraluminium
Sekundäraluminium
Walzprodukte > 0,2 mm
Press- & Ziehprodukte**
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Jun
46,5
7,8
74,5
13,4
164,8
0,7
51,7
8,1
Jul
48,7
8,1
73,1
14,2
167,1
1,5
53,3
9,8
Aug
49,0
8,5
65,6
10,1
164,6
-1,1
51,5
7,2
Sep
47,0
9,8
71,1
7,2
156,7
-2,3
50,2
-1,8
Okt
50,2
13,8
76,0
17,1
170,7
0,4
55,4
6,0
Nov
49,7
18,5
75,0
2,6
155,8
-4,9
53,7
3,1
Dez
52,2
21,9
57,2
-7,1
119,1
-4,1
30,9
-10,6
Jan 08
52,8
28,9
71,1
-2,6
154,3
4,4
51,4
0,6
Feb
49,4
33,0
69,3
-3,8
159,2
2,9
53,1
6,4
Mrz
52,6
26,9
64,2
-17,0
166,2
-6,1
48,4
-11,5
Apr
50,6
21,1
74,0
6,6
175,2
10,9
55,2
16,9
Mai
52,6
13,5
65,2
-10,2
159,3
-4,4
47,4
-6,8
Jun
50,6
9,2
68,4
-8,2
164,0
-0,5
51,6
-0,1
* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
Walzprodukte > 0,2 mm
12
Sekundäraluminium
Press- und Ziehprodukte
ALUMINIUM · 9/2008
Job advertisement
Business Area
Vice President Production Development
Sapa Heat Transfer can look back at a successful year with good profit
growth and higher productivity and we have plans for large expansion in
the upcoming years. Organic growth, acquisitions and investments in
greenfields will help us grow geographically. We also intend to broaden
our assortment and integrate further into the value chain of our key
business.
To enable these plans, we need to strengthen the Business Area
Management Team with a Vice President Production Development. This
will be a new, global and challenging position, which requires an extremely
skilled and experienced person with the right attitude and mindset.
Your main focus in this new position, will be to support and challenge
our operations in:
– Productivity development
– Capital expenditure programs
– Genesis (Toyota Production Systems)
– Safety
– People Management
The business area management team consists of six people, including
Business Area President, to whom you will report. You will have one person,
working halftime with Genesis and Health-Safety-Environment, reporting
directly to you. Extensive travelling is required, probably around 100 days/
year. The position is preferably based at HQ in Stockholm.
Your profile
You have comprehensive management experience in the areas of
production and operations including those areas listed above.
In addition to having a proven track record in those areas, experience
from rolling mills and/or from other heavy process industries is an asset.
International experience is also vital for the success of this position, thus
experience in production outside of Sweden is a must. You need to have
excellent skills in English and other language skills are an asset.
As a person you are driven, self-motivated and you are keen to deliver
results. You have excellent interpersonal skills and you are a strong
communicator. You are seen by both your colleagues and your peers as
a motivating leader and colleague, as well as being energetic and a good
listener. You seek this position because you are someone who wants a
challenge, and who wants to work strategically in an exciting international
environment.
How to apply
In this recruitment Sapa Heat Transfer works with Academic Search
International. You apply by sending your CV and a cover letter, both written
in English, to [email protected]. We need your application as
soon as possible and no later than Monday, September 29.
If you have any questions, please contact Mats Nordin, Senior Executive
Consultant, at Academic Search (+46 707516740 or via e-mail)
Sapa Heat Transfer AB
www.sapagroup.com
Sapa Heat Transfer is a part of the Sapa
group, which is owned by the Norwegian
company Orkla ASA. Sapa Heat Transfer is
one of the worlds leading companies in the
production of aluminium heat-exchanger
strip for the automotive industry.
The Business Area Heat Transfer includes Sapa Heat Transfer AB in Finspång,
Sweden, Sapa Heat Transfer Shanghai Ltd,
Shanghai, China, Remi Clayes Aluminium,
Lichterwelde, Belgium and Sapa Heat
Transfer Tube GmbH, Remscheid, Germany.
Production plants are located in Finspång,
Sweden and Shanghai, China, Value adding
in Lichterwelde, Belgium and Remscheid,
Germany. We also have a sales joint
venture called Norca Heat Transfer in North
America.
Heat Transfer has a net sales of ca
500 m €, a good profit and around 1 000
employees. Sapa Group has a net sales of
nearly 4000 m€ and 15 000 employees.
Please read more about Sapa and business
area Heat Transfer at
www.sapagroup.com
WIRTSCHAFT
Emissionshandel darf
Aluminiumproduktion nicht weiter verteuern
J. Clemens, Bonn
Ab 2013 werden die Aluminiumunternehmen für ihre Emissionen an
relevanten Treibhausgasen, die bei
der Produktion von Aluminium entstehen,
Emissionsberechtigungen
Emissions trading must not
increase cost of aluminium production
J. Clemens, Bonn
Corus Voerde
Die europäische Aluminiumindustrie wird, wie von der EU-Kommission vorgeschlagen, ab 2013 in
das europäische Emissionshandelssystems einbezogen. Darüber
gebe es auf politischer Ebene in
Brüssel grundsätzlich keinerlei
Differenzen mehr, stellt Stefan
Altenschmidt, Wirtschaftsanwalt
in der Düsseldorfer Kanzlei Freshfields Bruckhaus Deringer, im
Gespräch für diese Zeitschrift
fest. Allerdings kann die Aluminiumbranche seiner Einschätzung
nach noch auf gewisse Ausnahmeregelungen hoffen. Sie sollen
dafür sorgen, dass insbesondere
die Global Player unter den EUUnternehmen im Wettbewerb
mit Konkurrenten aus Drittländern, die keinen entsprechenden
Klimaschutzanforderungen zu
genügen haben, nicht zusätzlich
schlechter gestellt werden. Ohne
derartige Regelungen seien deutliche Kostensteigerungen über
die gesamte Aluminiumindustrie
hinweg unausweichlich, betont
Altenschmidt. Ob eine solche Entwicklung letztlich die Produktion
von Aluminium am Standort Europa insgesamt gefährdet, wird nach
seiner Einschätzung insbesondere
auch von der weiteren Preisentwicklung am Aluminiumweltmarkt abhängen.
Mit der Einbeziehung in den Emissionshandel ab 2013 drohen weitere Kostenbelastungen
für die Aluminiumindustrie
The aluminium industry is threatened with an additional cost burden with its inclusion in
the EU emissions trading scheme from 2013 onwards
According to proposals made by
the EU Commission, the European aluminium industry will
be included in the European
Union Emissions Trading System
from 2013 onwards. As Stefan
Altenschmidt, a lawyer specializing in business matters at the
Düsseldorf office of Freshfields
Bruckhaus Deringer, pointed out
in an interview with this publication, there are basically no longer
any differences at a political level
in Brussels. However, according
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You are welcome to visit us: ALUMINIUM 2008, Essen hall 3, booth H 25
14
to his assessment, the aluminium
industry can still hope for certain
exemption clauses. These should
ensure that in particular the EU
businesses that are also global
players, and thus have to contend with competitors from third
countries that do not have any corresponding regulations concerning
climate protection, are not put
at an even greater disadvantage.
Without such regulations, significant cost increases throughout the
whole of the aluminium industry
will be unavoidable, emphasizes
Altenschmidt. In his opinion,
whether such a development eventually puts the whole production
of aluminium in Europe at risk
will depend in particular on the
future development of the price of
aluminium on the world market.
From 2013 onwards, aluminium companies will have to hand over emissions
ALUMINIUM · 9/2008
Freshfields Bruckhaus Deringer
ECONOMICS
Stefan Altenschmidt: „Es kann nicht Sinn
und Zweck des Emissionshandels sein,
die Produktion von den sauberen europäischen Anlagen in Länder außerhalb
Europas mit geringeren Umweltstandards zu verlagern.“
abgeben müssen. Darauf sollte sich
die Branche grundsätzlich schon
einstellen, rät der Experte. Wesentlich bedeutungsvoller sei für die betroffenen Unternehmen jedoch die
Frage, wie sie künftig in den Besitz
der Emissionszertifikate gelangen
werden. Darüber besteht nämlich
auf politischer Ebene derzeit noch
keine Einigkeit. Bislang schlägt die
EU-Kommission dazu vor, zunächst
80 Prozent der Emissionsberechtigungen von 2013 an kostenlos an die
Aluminiumindustrie auszugeben. Als
Grundlage für diese Zuteilung sollen
die historischen Emissionen des laufenden Emissionshandels-Zeitraums
dienen.
„Hierzu gibt es allerdings auch noch
keine präzisen Festlegungen“, kritisiert Altenschmidt die bestehenden
Unsicherheiten. Derzeit macht er jedoch in den politischen Diskussionen
die Tendenz aus, dem Kommissionsvorschlag zu folgen. Demnach würde
die kostenlose Zuteilung von 80 Prozent der benötigten Emissionsberechtigungen an die Aluminiumunternehmen dann bis 2020 linear bis auf Null
verringert. Für den Zeitraum bis 2020
bedeute dies bewusst nur eine Übergangsregelung, stellt die Brüsseler Behörde ausdrücklich fest. Daraus folgt:
Nach dem Willen der EU-Kommission erhält die Aluminiumbranche ab
2020 – wie die übrige Industrie ©
Stefan Altenschmidt: “The raison d‘être
of emissions trading cannot possibly be
to shift production from clean European
facilities to countries outside Europe
with less stringent environmental standards.”
permits for the relevant greenhouse
gases emitted during the production
of aluminium. The expert is advising
the industry to be prepared for this. Of
significantly more importance for the
companies concerned, however, is
the question of how to obtain carbon
credits in future. At present there is
still no agreement on this at a political
level. Up to now, the EU Commission
has been proposing to initially give the
aluminium industry 80 percent of the
emissions permits free of charge from
2013 onwards. The historic emissions
during the current emissions trading
period were to act as the basis for this
allocation.
“However, there are still no precise
rules for this” was how Altenschmidt
criticizes the current uncertainty. At
present, though, he detects a tendency in the political discussions for
the Commission’s suggestion to be accepted. This would lead to the free allotment of 80 percent of the required
emissions permits to aluminium
companies being reduced linearly to
zero by 2020. The authorities in Brussels point out specifically that this is
deliberately only a transitional arrangement for the time period until
2020. It follows, therefore, that according to the wishes of the EU ©
ALUMINIUM · 9/2008
WWW.BUSSCORP.COM
The leading Mixing Technology
for Anode Pastes
For over 50 years BUSS Kneader Series KE and CP are
the benchmark in reliable and economical compounding
of anode pastes. Benefit from the expertise of the
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WIRTSCHAFT
auch – keine kostenlosen Emissionszertifikate mehr. Vielmehr sind von da
an alle benötigten Emissionsberechtigungen in Auktionen oder an der
Börse zu erwerben. Doch über diesen
Punkt ist sowohl im EU-Parlament als
auch im europäischen Rat das letzte
Wort noch nicht gesprochen.
Die Entscheidung über die Zuteilung der Zertifikate wird nach Ansicht
des Experten wesentlich mit darüber
bestimmen, welche Auswirkungen die
Einbeziehung in den Emissionshandel
für die Aluminiumbranche letztlich
konkret haben wird. Zumindest warnen die betroffenen Unternehmen in
Europa schon jetzt davor, dass sie ohne
eine kostenlose Zuteilung ihre globale
Wettbewerbsfähigkeit verlören. Auch
aus Sicht Altenschmidts handelt es
sich hierbei um eine weitreichende
Festlegung: Denn im ärgsten Fall wäre
die Aluminiumindustrie durch den
Emissionshandel doppelt betroffen.
Zum einen, weil die Branche ab 2013
selbst mit einbezogen ist, und zum
anderen durch den Effekt, dass der
Emissionshandel den insbesondere
für die Herstellung von Primäraluminium reichlich benötigten Strom
deutlich verteuert. Denn auch die
Stromproduzenten sind gezwungen,
am Emissionshandel teilzunehmen.
Sie müssen ab 2013 die von ihnen
benötigten Emissionsberechtigungen
sogar zu 100 Prozent ersteigern oder
kaufen. Dementsprechend seien steigende Strompreise vorprogrammiert,
stellt Altenschmidt fest. Er verweist
dazu auf eine Ankündigung von RWE,
Essen, der zufolge die zusätzliche Belastung durch den Emissionshandel
für einen durchschnittlichen Privathaushalt zu höheren Stromkosten in
einer Größenordnung von rund 500
Euro im Jahr führen wird. Vor diesem
Hintergrund sei zu ermessen, was der
Emissionshandel unter dem Strich an
Mehrbelastung für die stromintensive
Aluminiumindustrie bedeute, verdeutlicht der Experte.
Infolgedessen befürchtet er eine
Verteuerung der Aluminiumproduktion und -bearbeitung über die gesamte Wertschöpfungskette hinweg.
„Die Entwicklung, die sich unterdessen bereits bei Stahlanwendungen
zeigt, wird dann auch für Aluminium
gelten“, warnt Altenschmidt. Letztlich
16
sei zu erwarten, dass sich der Kostenanstieg bis auf die Endverbraucherebene fortsetzen wird, fügt er hinzu.
Ob es allerdings soweit kommen
muss, wie es einige „Worst-case“Szenarien an die Wand malen, dass
nämlich die Aluminiumherstellung in
Europa infolge der Belastungen durch
den Emissionshandel insgesamt ihre
Wettbewerbsfähigkeit einbüßt, erscheint Altenschmidt noch fraglich.
Dies werde wesentlich mit davon abhängen, wie sich der Weltmarktpreis
für Aluminium weiter entwickelt und
welche Gewinnspannen unter diesem
Aspekt auch hier in Europa weiterhin
möglich sind, erläutert er. Derzeit
deuten die Zeichen an den Börsen
nach seiner Interpretation eher auf
steigende Aluminium- und Stahlnotierungen hin. „Insofern mögen es
hohe Weltmarktpreise ermöglichen,
dass man auch in Europa weiterhin
zu auskömmlichen Bedingungen Aluminium produzieren kann“, sagt er.
Ausnahmeregelungen unverzichtbar, um Wettbewerbsverzerrungen zu verhindern
Wie Altenschmidt zu erkennen glaubt,
sieht unterdessen auch die Politik zunehmend die grundsätzliche Tendenz
des Emissionshandels, die Produktion
in Europa deutlich zu verteuern. Es
sei schließlich nicht mehr zu ignorieren, dass eine Schwelle überschritten
zu werden droht, an der sich die Belastungen für die betroffenen Industrien als untragbar erweisen. Deshalb
werde nun auf politischer Ebene
verstärkt überlegt, welche Ausnahmeregelungen für die besonders im internationalen Wettbewerb stehenden
Branchen sinnvoll seien. Dazu gehört
auch die Variante, die Emissionsberechtigungen über 2020 hinaus weiterhin zu 100 Prozent kostenlos zuzuteilen.
Allerdings will sich die EU-Kommission, die sich die Befugnis für derartige Sonderregelungen ausbedingt,
damit erst ab 2010 beschäftigen. „Das
ist für die betroffenen Industrien jedoch zu spät, weil ihnen so die Planungssicherheit verloren geht“, kritisiert Altenschmidt. Demgegenüber
argumentiert die Brüsseler Kommission, dass es schwer werde, ©
Commission, the aluminium industry
– as with other industries – will no
longer receive any free carbon credits
after 2020. On the contrary, after that
the required emissions permits will
have to be acquired at auctions or on
the climate exchange. The jury is still
out on that, however, both in the Parliament and the Council of the EU.
In the opinion of the expert, the decision on the allotment of certificates
will markedly influence what effects
the inclusion of the aluminium industry in the emissions trading scheme
actually has on the industry in the end.
The businesses in Europe concerned
are already warning that they could
lose their global competitiveness if
there is no free allotment of credits.
In Altenschmidt’s opinion, too, there
are far-reaching implications because
in the worst-case emissions trading
would be a double blow to the aluminium industry. Firstly, because the
industry itself is included from 2013
onwards and secondly because emissions trading will make electricity,
which is needed in large quantities
to produce primary aluminium, significantly more expensive because
the electricity producers will also
be forced to participate in emissions
trading. After 2013, they will have to
purchase all of the emissions permits
they need or buy them at auction. Rising electricity prices are thus pre-programmed, notes Altenschmidt. In this
connection he refers to an announcement by RWE, Essen, according to
which emissions trading will lead to
about 500 euros a year being added
to the electricity bill of an average
private household. The expert made
clear that it is against this background
that one should gauge the additional
burden that emissions trading will
have on the bottom line of the electricity-intensive aluminium industry.
As a consequence, Altenschmidt
fears there will be a cost increase for
aluminium production and processing across the entire value-added
chain. “The development that has already manifested itself in the use of
steel will then affect aluminium too”,
warns Altenschmidt. In the end, he
adds, it is to be expected that the cost
increase will work its way through to
the consumer.
©
ALUMINIUM · 9/2008
www.sucden.de
Your Future
in Hedging
Sucden. Broker für
Futures und Optionen auf
Rohstoffe und Financials
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Besuchen Sie uns
auf der Aluminium 2008.
Halle 7, Stand 7H55
Sucden Financial
Sucden (UK) Limited
Niederlassung Deutschland
Haus an der Börse
Schillerstr. 15-17
60313 Frankfurt am Main
Tel.: +49 (0) 69 26 48 48 0
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Web: www.sucden.de
WIRTSCHAFT
andere Staaten zu überzeugen, ihre
Industrien ihrerseits entsprechenden
Klimaschutzauflagen zu unterwerfen,
wenn Europa für die eigenen Industrien jetzt schon umfangreiche Ausnahmen zulasse.
Für Altenschmidt besteht jedoch
kein Zweifel daran, dass ein Wettbewerbsgleichgewicht zwischen der europäischen Aluminiumbranche und
deren außereuropäischer Konkurrenz erreicht werden muss. Als Alternative zu einer kostenlosen Zuteilung
kommen für ihn nur noch politische
Lösungen in Betracht: So schlug kürzlich die französische Regierung die
Einführung von entsprechenden Importzöllen vor, um die Staaten außerhalb Europas dazu zu drängen, sich
selbst strengen Klimaschutzvorgaben
zu unterwerfen und ihre Industrien
vergleichbar mit den europäischen
belasten. Ansonsten müssten sich diese Länder darauf einstellen, dass ihre
Produkte zukünftig durch entsprechende Grenzzölle verteuert werden,
hieß es dazu aus Paris.
Einer solchen WTO-Regelung
steht Altenschmidt jedoch äußerst
skeptisch gegenüber. Denn so etwas
würde nach seiner Ansicht nicht in
die bisherige WTO-Systematik passen. Daher sei es sehr schwer, eine
solche Regelung durchzusetzen, erwartet er. Darüber hinaus befürchtet er als negative Auswirkung eines
derartigen Vorgehens, dass Produktion aus Europa abgezogen werden
könnte. „Dann werden voraussichtlich zunehmend Aluminium und Aluminiumteile im außereuropäischen
Ausland hergestellt werden. Doch es
kann nicht Sinn und Zweck des Emissionshandels sein, die Produktion
von den sauberen europäischen Anlagen in Länder außerhalb Europas
mit geringeren Umweltstandards zu
verlagern“, warnt er. Daher erscheint
es ihm sowohl sinnvoller als auch
wahrscheinlicher, dass es auf europäischer zu den genannten Ausnahmeregelungen kommen wird.
Autor
Jürgen Clemens ist Fachredakteur mit den
Branchenschwerpunkten Energie, Metalle, Rohstoffe.
18
Altenschmidt has his doubts, though,
whether things will actually turn out
to be as bad as some worst-case scenarios predict, namely that aluminium production in Europe will lose its
competitiveness altogether because
of the burdens imposed by emissions
trading. This will depend mainly on
how the world market price for aluminium develops and what profit
margins are still possible in Europe
under such conditions, he explains.
According to his view of the situation,
the signs coming from the exchanges
are tending to point to rising prices
for aluminium and steel. “In this respect, high world market prices may
enable aluminium production to also
continue in Europe under adequately
favourable conditions”, he says.
Exemption clauses essential to
prevent distortion of competition
Altenschmidt believes there are now
signs that politicians are increasingly
recognizing the fundamental tendency of emissions trading to make
production in Europe significantly
more expensive. One can, after all, no
longer ignore the fact that one is about
to cross a threshold beyond which the
burdens for the industries concerned
will prove to be unbearable. Increasing consideration is thus now being
given at a political level to exemption
clauses that would be meaningful for
those branches of industry that are
particularly exposed to international
competition. This also includes an
alternative: continuing to allocate
emissions permits completely free of
charge until beyond 2020.
The EU Commission, which stipulates the need for such special provisions, only wants to involve itself
with this matter from 2010 onwards.
“That will be too late for the industries concerned, however, because it
will rob them of planning reliability”,
says Altenschmidt critically. On the
other hand, the Commission in Brussels argues that it will be difficult to
convince other states to subject their
industries to corresponding climate
protection requirements if Europe is
already allowing extensive exemptions for its own industries.
There is no doubt as far as Alten-
schmidt is concerned that a competitive equilibrium has to be achieved
between the European aluminium
industry and its non-European competitors. For him, political solutions
are the only alternative to allotting
credits free of charge: for example,
the French government recently proposed imposing corresponding import duties in order to force countries
outside Europe to introduce strict environmental protection requirements
themselves and subject their own industries to comparable pressures as
the European ones. Otherwise, Paris
added, these countries would have
to be prepared in future to have their
products subjected to correspondingly high import duties.
Altenschmidt is extremely sceptical, however, about the WTO introducing such a rule. In his opinion,
such a move would be out of keeping
with the approach hitherto adopted
by the WTO. He thus expects it would
be very difficult to get such a rule accepted. In addition, he fears that this
would have a negative effect and
could lead to production being moved
away from Europe. “Aluminium and
aluminium parts are then likely to be
produced increasingly outside the EU.
But the raison d‘être of emissions trading cannot possibly be to shift production from clean European facilities to
countries outside Europe with less
stringent environmental standards”,
he warns. Thus it seems to him to be
both more sensible as well as more
likely that the exemption clauses
mentioned above will be introduced
at a European level.
Author
Jürgen Clemens is a trade journalist specializing in the energy, metals and raw
materials fields.
For subscribers
www.alu-archiv.de
Knowledge with
a lasting impact!
ALUMINIUM · 9/2008
ECONOMICS
EU to start anti-dumping probe on Chinese aluminium foil
The European Commission will
soon start an anti-dumping investigation on aluminium foil imports
from China, Armenia and Brazil,
according to China’s commerce
ministry.
“The European Commission recently
informed us that it has received the
complaint from its domestic industry
and will start related anti-dumping
investigations soon”, said an official
from the ministry’s Bureau of Fair
Trade for Imports and Exports. “If the
European Commission decides to impose anti-dumping duties on aluminium foil imports from China, it could
have a strong impact on the Chinese
aluminium foil industry“, said an analyst from Beijing.
China’s aluminium foil exports
have surged in recent years to 320,000
tonnes in 2007, up 78% from a year
earlier, according to customs statistics.
In 2007 58.4% of China’s aluminium
foil exports went to Asia, and 21.6% to
Europe. There is a 13% tax rebate for
aluminium foil exports, which has en-
couraged some producers to export.
Meanwhile, demand from the overseas market is also strong because of
the reasonable price and high quality
of Chinese products.
The fabricated aluminium industry has been developing very quickly
in recent years and aluminium foil
output has been growing rapidly. So
far, China consumes most of the aluminium foil production domestically.
China produced around 950,000
tonnes of aluminium foil in 2007, up
from 740,000 tonnes in 2006.
N
Hydro to seek acquisitions in the second half of 2008
Hydro hedges very little of its production and does not plan to increase its
hedge book in the near future. Hedging production is not desirable given
rising input and energy costs. The
company prefers direct exposure to
the market and uses a model in which
around 83% of its production is forward priced for the third quarter of
2008 at USD2,856 per tonne.
Hydro cited rising alumina, freight,
carbon and caustic soda prices as the
reason for the 38% year-on-year drop
in profits in the second quarter. The
company mitigates some higher costs
through long-term contracts, but is
also forced to do more business on
ALUMINIUM · 9/2008
Hydro
Norwegian aluminium producer
Norsk Hydro is seeking to make
more acquisitions by the end
of the year and will continue to
invest heavily in organic growth.
The company expects aluminium
prices to remain strong despite a
slackening in demand.
a short-term basis. Hydro expects
variable costs, excluding alumina and
power, to increase by about NOK200250m (USD39-49m) in the second half
of 2008 compared with the second
quarter. Despite rising crude oil and
electricity prices, Hydro keeps its energy costs stable thanks to producing
50% of its electricity as in-house hydroelectricity and buying 50% through
long-term contracts until 2015.
Hydro now expects a compromise
deal over the future ownership of its
hydropower plants in early October,
after the Norwegian parliament postponed making a decision. The ©
19
ECONOMICS
future of the company’s hydropower
assets was called into question following the government’s green paper on
asset ownership in March, according
to which two thirds of Hydro’s captive hydropower supply would revert
back to government hands in 2022
and the other third in 2050.
Profits in the company’s aluminium products division in the second
quarter rose by 45% compared with
the first quarter, which was attributed
to remarkably strong sales volumes
in Europe and good performances in
high-margin products and good cost
control. This strong performance is
unlikely to last in the second half of
the year due to softening demand.
The prospect of aluminium reaching USD4,000 per tonne by the end
of the year – a hot topic of debate
in the aluminium market at present
– is largely speculation, but depends
on the extent to which high energy
prices are mitigated by the softening
global economy. Nevertheless, high
prices will continue because of rising
energy costs.
In anticipation of the potentially
softening demand in the second half
of the year, managing margins and
keeping costs low are key targets for
the company.
N
Alcoa
US aluminium can recycling rates hit 6-year high
U.S. aluminium can recycling rose by
26,303 tonnes in 2007, raising the recycling rate to 53.8% of cans shipped,
compared with 51.6% for
2006. That is the rate‘s
largest jump in ten years,
and takes it to a six-year
high, according to a tally
released by the Aluminum Association (AA),
the Institute of Scrap
Recycling Industries and
the Can Manufacturers
Institute.
The rate peaked at
67.9% in 1992 and then fell for the
next decade, bottoming out at 50% in
2003. One factor in that decline was
an increasing proportion of canned
beverages being consumed outside
the home.
AA and the Can Manufacturers
Institute have a joint programme in
more than 40 communities that prods
households to get their discarded cans
into curbside pickup arrangements
for recyclables. The trend towards
ever thinner aluminium cans may
have reached its limit. To a microscopic extent the trend reversed itself
in 2007, with a pound of aluminium
alloy yielding 34.17 cans as against
34.21 the previous year.
N
UC Rusal
UC Rusal continues ecological modernization of its smelters
bers clean over 250,000
m3 of gases and remove
dust from reduction cells
per hour, and replace 15
foam scrubbers at VgAZ.
The technology, which is
widely used worldwide,
is focused on one of the
qualities of alumina, the
key raw material for the
smelting operations, alPart of the environmental modernization programme
– the Bratsk smelter of UC Rusal
lowing to adsorb fluorides
and tarry substance. Almost 100% of
the pollutants are contained and the
UC Rusal has commissioned a dry
fluorinated alumina is returned back
scrubber system at its Volgograd Aluto the process.
minium Smelter (VgAZ). This is the
The modernization programme at
key element of the modernization
VgAZ aimed at enhancing the ecologiprogramme at the plant. The new syscal performance of the smelter already
tem removes 99.5% of environmenincluded switching all reduction cells
tally harmful fluoride and carbonyl
to dry anode technology, installing
emissions. The investment into the
new filters, construction and putting
new gas treatment system exceeded
into operation of a solid waste yard.
USD12m. The new dry gas scrub-
20
By 2009, the whole ventilation system
will be reconstructed.
Reducing the environmental impact is a key priority for UC Rusal.
Since 2000 the enterprises which now
make up UC Rusal, have invested over
USD1bn in environmental initiatives.
From 2007 to 2013 the company will
invest USD1.4bn in its ecological optimization.
UC Rusal’s modernization programme is being implemented at
two of the world’s largest aluminium smelters – Bratsk and Krasnoyarsk plants – as well as at smallerscale production facilities including
Irkutsk, Novokuznetsk, Bogoslovsk
and Ural smelters. Projects are currently underway there to switch part
of production to pre-bake anode
technology. This programme should
reduce harmful emissions by 35 percent by 2015.
N
ALUMINIUM · 9/2008
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ALUMINIUM 2008 – MESSEVORSCHAU
I.A.S. Induktions-Anlagen und Service GmbH
Induktive Erwärmung setzt sich weltweit durch
Bei der Warmumformung ist die Erwärmung der Ausgangsform in mehrfacher Hinsicht besonders anspruchsvoll. Da die Temperatur einen wesentlichen Einfluss auf den gesamten
Umformprozess besitzt, ist die Temperaturspanne meist eng begrenzt.
Darüber hinaus kann für schwierige
Aufgaben mit Temperaturfeldern anstatt mit einer gleichmäßig verteilten
Temperatur gearbeitet werden – eine
Technik, die besonders hohe Ansprüche an die Erwärmung stellt.
Letzteres ist bei der Erwärmung von
Strangpressbolzen der Fall. Die von
I.A.S. entwickelten Erwärmungsanlagen haben die Voraussetzung geschaffen, den Umformprozess mittels eines
gezielt einstellbaren Temperaturfeldes
im Bolzen so zu steuern, dass einerseits über den gesamten Presszyklus
mit maximaler Pressgeschwindigkeit
gearbeitet werden kann, andererseits
jedoch die aus metallurgischen Gründen vorgegebene Maximaltemperatur
in der Umformzone nicht überschritten wird. Im Betrieb zeigt sich, dass
dies zu einer signifikanten Produktivitätssteigerung führen kann.
Der moderne Anwärmprozess im
Presswerk erfolgt heute in zwei Stufen: Zunächst wird der Pressbolzen auf
ein Basis-Temperaturniveau erwärmt,
anschließend wird ein axiales Block-
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I.A.S. Induktions-Anlagen und Service GmbH
Inductive heating establishes itself worldwide
Since the introduction of
the TEM-Pro Heater concept
developed in 1996 by I.A.S.
Induktions-Anlagen und
Service GmbH, in Iserlohn,
Germany, this technique has
become established in numerous extrusion plants.
In the field of hot forming the
heating of the initial form is
a particular demanding operation from several points of
view. Since temperature has a
major influence on the entire
forming process, the temperature range is usually closely
restricted. Moreover, for difficult jobs it may be necessary to
work with temperature profiles Induktions-Bolzenerwärmungsanlage TEM-Proinstead of a uniformly distrib- Heater
uted temperature – a technique TEM-Pro Heater induction heating unit for billets
which makes particularly great
demands on the heating process.
accurately as possible in accordance
The latter is true in the case of heatwith the material used, the batch
ing extrusion billets. The heating units
size, the billet dimensions and other
developed by I.A.S. make it possible to
parameters. As demonstrated by the
control the shaping process by means
experience of the past few years, this
of an appropriately adjustable temis best achieved by a combination
perature profile in the billet, in such
of gas heating – sometimes but not
manner that on the one hand maxinecessarily followed by the hot shear
mum extrusion speed can be main– and a multi-zone induction furnace.
tained throughout the pressing cycle,
During this the basic heating is done
but on the other hand the maximum
in a conventional multi-zone gas furtemperature in the deformation zone,
nace. Fine adjustment of the temperaspecified for metallurgical reasons, is
ture then takes place in an induction
not exceeded. In practice it has been
furnace.
found that this can lead to a significant
The breakthrough in the aluminincrease in productivity.
ium branch took place in 1996 when,
A modern extrusion plant heatfor the building of the new 56-MN exing process nowadays takes place in
trusion press at the Hannover works,
two stages: the extrusion billet is first
Alcoa decided to go for the then comheated to a basic temperature level,
pletely new ‘TEM-Pro Heater’ offered
and then an axial billet temperature
by I.A.S. The commissioning of that
profile (taper) is produced, which
unit at the same time marked the startcompensates for the heat generated by
ing point of an extraordinary success
deformation in such manner that an
story in the aluminium industry.
isothermal extrusion process at maxiIn Germany today it can be said
mum extrusion speed is achieved.
that inductive billet heating has been
Ideally, this heating procedure
largely accepted. The technique is used
should be adjustable flexibly and as
by most new plants that have been
ALUMINIUM · 9/2008
I.A.S.
Seit Einführung des TEM-ProHeater-Konzeptes der in Iserlohn
ansässigen I.A.S. Induktions-Anlagen und Service GmbH im Jahre
1996 hat sich diese Technik in zahlreichen Presswerken durchgesetzt.
S
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A LPU E
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– M E S S EAVL O
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U 2008 – FAIR PREVIEW
planned or have begun operating during the past few years. In many cases
the heating unit is planned in combination with a gas heating furnace. For
such designs I.A.S. collaborates with
noted gas furnace suppliers.
Meanwhile, exports too have become increasingly important for I.A.S.
The sequence of projects shows clearly how the technology, developed in
this country, is beginning to make its
mark all over the world – at first in
Central Europe and later also outside
Europe.
So far over two-third of the orders for European extrusion plants
have been completed. Another point
of focus is China, where since 2004
some important concerns have begun
investing in modern extrusion technology. The technique will open up
export possibilities for Chinese producers. The same also applies in the
Gulf Region, where nowadays there
are almost as many extrusion plants in
operation as there are in Germany. In
that region the potential of inductive
heating has not nearly been exhausted.
I.A.S. also regards Eastern Europe and
Russia as promising markets.
N
temperaturprofil (Taper) erzeugt, das
die entstehende Umformwärme derart kompensiert, dass ein isothermer
Pressprozess mit maximaler Pressgeschwindigkeit erreicht wird.
Dieser Erwärmungsvorgang sollte
idealerweise nach Maßgabe von Einsatzmaterial, Losgröße, Bolzenabmessungen und anderen Parametern flexibel und möglichst genau einstellbar
sein. Am besten erreicht man dies,
wie die Erfahrungen der letzten Jahre belegen, mit einer Kombination
von Gaserwärmung – eventuell, aber
nicht zwingend, mit nachgeschalteter
Warmschere – und einem Mehrzonen-Induktionsofen. Die Grunderwärmung findet hierbei mit einem
konventionellen Mehrzonen-Gasofen
statt. Die Feineinstellung der Temperatur geschieht anschließend im
Induktionsofen.
Der Durchbruch in der Aluminiumbranche wurde 1996 erreicht, als
sich Alcoa beim Bau der neuen 56MN-Strangpresse im Werk Hannover
für den seinerzeit völlig neuen „TEMPro-Heater“ von I.A.S. entschied. Die
Inbetriebnahme dieser Anlage war
gleichsam der Startpunkt eines au-
ßerordentlichen Erfolgsweges in der
Aluminiumindustrie.
In Deutschland kann man heute
von einer weitgehenden Akzeptanz
der induktiven Bolzenerwärmung
sprechen. Die meisten Neuanlagen,
die in den letzten Jahren projektiert
bzw. in Betrieb genommen worden
sind, nutzen diese Technik. In zahlreichen Fällen werden die Erwärmungsanlagen in kombinierter Ausführung mit einem Gasanwärmofen
projektiert. Bei diesen Ausführungen
kooperiert I.A.S. mit namhaften Anbietern von Gasöfen.
Inzwischen hat bei I.A.S. auch der
Export deutlich an Stellenwert gewonnen. Dabei lässt sich an der Abfolge
der Projekte deutlich ablesen, wie sich
die hierzulande entwickelte Technologie weltweit durchzusetzen beginnt
– zunächst in Mitteleuropa und in der
Folge auch außerhalb Europas.
Bisher wurden mehr als zwei
Drittel der Aufträge für europäische
Presswerke abgewickelt. Ein weiterer
Schwerpunkt ist China, wo seit dem
Jahre 2004 einige namhafte Adressen
begonnen haben, moderne Strangpresstechnologie zu investieren. ©
TECHNOLOGY FOR FUTURE CONCEPTS
SETTING THE COURSE IN ROLLING MILL MACHINERY
Aluminium Rolling Mills · Heavy Metal Rolling Mills · Automation Systems · Rolling Oil Systems · Foil Slitting Machines
23.-25.9.2008
Messe Essen
Hall 3 K40
ACHENBACH BUSCHHÜTTEN GMBH
Siegener Straße 152 · 57223 Kreuztal
Germany
ALUMINIUM
· 9/2008
23
phone: +49(0)2732/799-0
fax.: +49(0)2732/799-799
e-mail: [email protected]
ALUMINIUM · 9/2008
23
www.achenbach.de
Diese Technik soll den chinesischen
Produzenten Exportmöglichkeiten
eröffnen. Dieses Kriterium trifft auch
auf die Golfregion zu, in der heute
annähernd so viele Strangpresslinien
in Betrieb sind wie in Deutschland.
In dieser Region ist das Potenzial der
induktiven Erwärmung noch nicht
annähernd ausgeschöpft. Als einen
viel versprechenden Markt sieht man
bei I.A.S. weiterhin Osteuropa und
Russland an.
I.A.S. ist Aussteller auf der
ALUMINIUM 2008 in Essen.
Halle 6, Stand C30
www.ias-gmbh.de
Aluminium-Kongress
Aluminium Congress
Auch in diesem Jahr wird der Aluminium-Kongress die Messe ergänzen.
Organisiert wird er von der Deutschen
Gesellschaft für Materialkunde (DGM),
die im Kongress Center West der Messe
Essen Referenten aus Unternehmen und
Forschungseinrichtungen versammelt
hat. Die Vorträge und Präsentationen
kreisen um die Themen Automotive,
Luftfahrt, Verarbeitung und Werkstoffentwicklung.
Der Aluminium-Kongress ist Teil des
ICAA Kongresses, der – ebenfalls von
der DGM – in Aachen veranstaltet wird.
Ein Shuttle-Service wird die beiden Kongresse miteinander verbinden.
The Aluminium Congress will again
complement this year’s trade fair. The
congress is organized by Deutsche
Gesellschaft für Materialkunde (DGM),
which brings together speakers from
companies and research institutions at
the Congress Center West of the Essen
Exhibition Centre. The topics should be
of interest to the aluminium application
sector and deal with aerospace and automotive as well as processing and alloy
development.
The Aluminium Congress is part of
the ICAA Congress, which will be held
in Aachen. A shuttle service will link the
two events.
Carl Kind & Co. GmbH
Werkzeugpartner der Strangpressindustrie
Die unmittelbare Umgebung
der Umformzone beim Strangpressen – Aufnehmer, Stempel
Matrize bzw. Dorn – gehört zum
Arbeitsgebiet des im bergischen
Wiehl-Bielstein ansässigen Familienunternehmens Kind & Co. Mit
seinem Know-how und seinen
Fertigungsmöglichkeiten hat das
Unternehmen heute anerkanntermaßen Weltgeltung erlangt.
Kind & Co. befasst sich intensiv mit
Warmarbeitsstählen für Umformwerkzeuge. Neben der Strangpressbranche
gehören auch die Druckgießereien
und die Gesenkschmieden zu den
Kunden. Nahezu alle in Deutschland
in Betrieb befindlichen Strangpressen
zählen – in der einen oder anderen
Weise – zu den Kunden des Unternehmens, sei es, dass der Aufnehmer
in Wiehl gefertigt worden ist, sei es,
dass er regelmäßig oder sporadisch in
Wiehl gewartet wird.
Blockaufnehmer haben sich von
der großen „Büchse“ früherer Jahre
inzwischen zu einem Hightech-Werkzeug entwickelt. In dem Maße, in dem
die Produktivität der Presse gesteigert
werden konnte, sind auch die Anforderungen an den Blockaufneh- ©
24
Carl Kind & Co. GmbH
Die partner of the extrusion industry
The area of work in which the
family-owned company Kind & Co.
in Wiehl-Bielstein, Germany, specialises is the direct surroundings
of the deformation zone during extrusion – container, ram, die and/
or mandrel. With its know-how
and production facilities the company has now achieved worldwide
recognition.
The company works intensively on
hot-working steels for deformation
dies. Besides the extrusion industry,
pressure diecasting foundries and die
forging businesses are also among its
customers. Almost all the extrusion
presses operating in Germany are
– in one way or another – among the
company’s customers, whether because the container was made ©
ALUMINIUM · 9/2008
www.phoenix-spa.com
OKGROUP
NEDERLAND
PHOENIX ALUMINIUM
EXTRUSION DIES
PHOENIX GROUP
ESSEN
ALUMINIUM 2008
VISIT US
AT HALLE 1
STAND G15
PHOENIX INTERNATIONAL S.p.A. - Main Ofce: Via Romiglia n. 9 - Factory in Paderno: Via Trento n. 34
25050 PADERNO F.C. (BS) ITALY - Tel.: +39 030-6858300 Fax: +39 030-6858384 - Factory in Verdello: Viale
Lombardia n. 18 24049 VERDELLO Loc. ZINGONIA (BG) ITALY - Tel.: +39 035-4816200 Fax: +39 035-4816210
mer gewachsen. Im Aufnehmer sind
heute wichtige Funktionen integriert,
die für den Betrieb der Strangpresse
unerlässlich sind. Um dem Ziel des
isothermen Strangpressens nahe zu
kommen, hat es sich als notwendig erwiesen, die Temperaturverteilung in
der Umformzone über den Mantel zu
beeinflussen. Das kann durch lokales
Heizen oder Kühlen geschehen. In den
Aufnehmerkomponenten sind dazu
Heizpatronen und Kühlkreisläufe eingebracht, die in die Pressensteuerung
integriert sind. Die Auslegung dieser
Temperierung gehört gleichfalls zum
Arbeitsbereich von Kind & Co.
Auslaufseitig ist der Arbeitsraum
der Presse durch die Matrize abgeschlossen. Bei dem formgebenden
Werkzeug, das den Prozess besonders stark beeinflusst, teilt man sich
die Verantwortung mit den Matrizenherstellern. In den Kompetenzbereich
von Kind & Co. gehört die Bereitstellung des optimalen Basiswerkstoffs
und die Wärmebehandlung (Härten,
Nitrieren). Nicht minder komplexe
Anforderungen sind an Stempel und
Dorne gestellt, die gleichfalls zum Arbeitsgebiet gehören.
Um den hohen Qualitätsstandard
aufrechterhalten zu können, erachtet
es Kind & Co. als notwendig, die gesamte Produktionskette in der Hand
zu behalten. Das beginnt beim Vormaterial, das bei Kind & Co. in einem
zweistufigen Schmelzprozess erzeugt
wird. Die in einem Induktionsofen erschmolzenen Blöcke werden, je nach
den späteren Einsatzbedingungen,
durch das Elektro-Schlacke-Umschmelzverfahren (ESU) einem zweiten Schmelzprozess unterzogen, um
spezifische Qualitätsmerkmale des
Werkzeugstahls hinsichtlich Reinheit und Zähigkeit und Polierbarkeit
reproduzierbar herzustellen. Im Jahre 2004 wurde eine weitere Anlage
dieser Art für Blockgewichte bis 25
Tonnen installiert. Mit dieser neuen
Anlage wurden die Produktionskapazitäten entscheidend erweitert. Auf
Schmiedepressen werden anschließend die Ausgangsformen manipulatorgesteuert zu Rund-, Rechteck- oder
Freiformschmiedeteilen umgeformt.
In diesem Arbeitsgang wird schließlich die spezielle Gefügestruktur
(Korngröße, Faserverlauf) erreicht,
26
Neu – das Vortragsforum
New – the lecture forum
Unabhängig vom Kongress bekommt die
ALUMINIUM 2008 erstmals ihr eigenes
Vortragsforum. Um die Themen Gießen,
Schweißen und Primärproduktion auf der
Messe noch weiter zu vertiefen, gestalten die drei Partner der jeweiligen Themenpavillons – die GDM, der DVS-Verlag
und die GDMB Gesellschaft für Bergbau,
Metallurgie, Rohstoff- und Umwelttechnik – eine Vortragsreihe. Tagesweise
stehen unter den Oberthemen Aluminiumherstellung, Aluminiumschweißen und
-fügen sowie Aluminiumguss insgesamt
23 Vorträge auf dem Programm. Der
Vortragstag zum Thema Guss wird von
der ae light metal casting GmbH u. Co.
KG, der Thementag Schweißen von der
Linde AG unterstützt. Das Vortragsforum
befindet sich in Halle 6, der Besuch ist
kostenfrei.
For the first time, ALUMINIUM 2008
will have a lecture forum of its own,
independent of the Congress. In order to
treat the subjects of casting, welding and
primary production in more depth at the
fair, the three partners of the respective
theme pavilions – GDM, DVS-Verlag
and GDMB (the German Society for
Mining, Metallurgy, Raw Materials and
Environmental Technology) – are organizing a series of lectures. The programme
features a total of 23 lectures grouped
under the overall headings of producing,
welding and joining, and casting of aluminium, each of which will be dealt with
on a separate day. The day of lectures on
casting is sponsored by the company ae
light metal casting, the welding theme
day by Linde AG. The lecture forum is
located in hall 6, admission is free.
die die überragenden mechanischen
Eigenschaften des Stahls ermöglicht.
Ihre endgültigen mechanischen
Eigenschaften erhalten diese Komponenten in der Vergüterei und Härterei
des Unternehmens. Für die individuelle, auf den jeweiligen Verwendungszweck abgestimmte, Wärmebehandlung stehen unterschiedliche
Aggregate zur Verfügung.
in Wiehl, or because it is maintained
regularly or from time to time there.
Meanwhile, billet containers have
developed from the large ‘sleeves’ of
earlier years, to become a high-tech
tool. To the extent that it has been possible to increase productivity, the demands made upon the container have
increased correspondingly. Today,
the container integrates important
ALUMINIUM · 9/2008
– M E S S EAVL O
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MSI CNHI U
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Kind & Co.
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Elektro-Schlacke-Umschmelzanlage für Blöcke bis 25 Tonnen
Electro-slag re-melting unit for ingots up to 25 tonnes
functions that are essential for the operation of the extrusion
press. To approximate
to the ideal of isothermal extrusion, it has
been found necessary
to influence the temperature distribution
in the deformation
zone by means of the
mantle. This can be
done by local heating or cooling. For
that purpose heating
elements and cooling
circuits are incorporated in the container
components, which
are integrated in the
press control system.
The design of these
temperature control
means is also part of
the work of Kind &
Co.
On the run-out
side the working ©
Der abschließende Arbeitsgang ist die
mechanische Bearbeitung, die durch
die teilweise großen Abmessungen
und durch die nicht ganz einfache
Zerspanbarkeit der zu bearbeitenden
Stähle gekennzeichnet ist. Das wesentliche Merkmal ist hier die Individualität der Bauteile, die eine Serienfertigung nicht zulässt. Im Falle der
Rezipienten gehören auch ein oder
mehrere Schrumpfprozesse zum Fertigungsgang, mit dem die Zwischenund Innenbüchse in den Aufnehmer
eingebracht wird.
Heute reichen die Geschäftsverbindungen des Unternehmens weit
über die deutschen Grenzen bis nach
Übersee hinaus. Diese Verbindungen
lassen sich nach Einschätzung des
Unternehmens in dem Maße weiter
ausbauen, in dem sich der Trend zu
einer leistungsfähigeren Strangpresstechnik durchsetzt. Besonders groß
ist der Modernisierungsbedarf in Osteuropa. Darüber hinaus laufen derzeit
in Asien, speziell in China, viele neue
Projekte.
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· 9/2008
27
ALUMINIUM · 9/2008
27
area of the press is bounded by the
die. For the shaping die itself, which
influences the process particularly
markedly, responsibility is divided
with the die manufacturer. The competence field of Kind & Co. includes
the provision of the best possible basis material and the heat treatment
(hardening, nitriding). Requirements
no less complex apply to the ram and
mandrels, which also belong to the
company’s area of work.
To be able to maintain the highest quality standards, Kind & Co.
regards it as necessary to keep the
entire production chain in mind.
This begins with the pre-material,
which is produced at Kind & Co. in
a two-stage melting process. Depending on the subsequent conditions of
use, the ingots melted in an induction
furnace are subjected by the electroslag-remelt process (ESR) to a second
melting stage in order to produce
specific quality characteristics of the
die steel related to purity, toughness
and polishing properties in a reproducible way. In 2004 a second unit
28
of this type was installed for ingots
weighing up to 25 tonnes. With this
new unit production capacities were
increased substantially. Using forging
presses, the initial shapes are then
produced by controlled manipulation
to give round, rectangular or hammerforged components. Finally, during
this working step the special metallurgical structure (grain size, fibrous
texture) responsible for the outstanding mechanical properties of the steel
is produced.
The resulting components are
given their final mechanical properties in the company’s heat treatment
and hardening workshop. Various
aggregates are available for the individual heat treatments needed for the
respective applications.
The final work step is mechanical
machining, which is characterised by
sometimes large dimensions and by
the not very simple machinability of
the steels to be processed. Here, the
essential characteristic is the individuality of the components, which precludes series production. In the case
of the containers the production procedure includes one or more shrinking processes by means of which the
intermediate and inner sleeves are
incorporated in the container.
Today the company’s business
connections extend far beyond the
frontiers of Germany. Numerous
extrusion plants in Europe and also
overseas do business with Kind & Co.
In the company’s estimation these relations will extend further, the more
the trend towards better extrusion
technology becomes established. The
need for modernisation is particularly
great in Eastern Europe. Furthermore,
at present many new projects are under way in Asia, especially in China.
Kind & Co. will be an exhibitor
at ALUMINIUM 2008 in Essen.
Hall 2, Stand C18
www.kind-co.de
European
Aluminium Award
European
Aluminium Award
Bereits zum sechsten Mal wird auf der
Messe der European Aluminium Award
„Industrial Design & Engineering“ verliehen. Der renommierte Preis wird
vom Aluminium Centrum (Niederlande)
in Zusammenarbeit mit der European
Aluminium Association (EAA), dem Gesamtverband der Aluminiumindustrie
(GDA) sowie der Messe organisiert. Mit
den Branchengrößen Alcan, Alcoa, Hydro
und Novelis hat der Award auch in diesem
Jahr wieder hochkarätige Förderer gefunden. Exklusiver Medienpartner ist der Giesel Verlag mit seinen Branchentiteln ALUMINIUM International Journal, Aluminium
Praxis, APT News und APT Aluminium.
Die nominierten Produkte in den
beiden Kategorien „Industrial“ and
„Consumer Products“ werden während
der Messe in der Galeria ausgestellt, die
Preisübergabe findet am 23. September
im Rahmen der festlichen Abendveranstaltung der ALUMINIUM statt.
The European Aluminium Award ‘Industrial Design & Engineering’ will be
presented at the fair for the sixth time.
The renowned prize is organized by the
Aluminium Centrum (Netherlands) in cooperation with the European Aluminium
Association (EAA), the German Aluminium Association (GDA) and ALUMINIUM
2008. Supported by the flagship companies Alcan, Alcoa, Hydro and Novelis, the
award once again enlisted high-calibre
sponsors this year. Exclusive media partners are the trade journals of the Giesel
Verlag publishing house: ALUMINIUM
International Journal, Aluminium Praxis,
APT News and APT Aluminium.
The products nominated in the two
categories ‘Industrial’ and ‘Consumer
Products’ will be on display during the
fair in the Galeria; the award-giving
ceremony will be held on 23 September
during the ALUMINIUM evening gala
event.
ALUMINIUM · 9/2008
Siemag – Innovative Transport- und
Lagertechnik für die Aluminiumindustrie
Siemag – Innovative
transport and storage
technology
Die in Netphen ansässige Siemag
GmbH kann auf mehr als 135 Jahre
Erfahrung in der Bergbau-, Förder-,
Hütten- und Lagertechnik sowie Logistik blicken. Die Automatisierungstechnik ist im Zusammenhang mit der
Entwicklung von Logistiklösungen
ein Schwerpunkt der Geschäftstätigkeit. Der Optimierung der Lager- und
Siemag GmbH, located in Netphen,
Germany, can look back over more
than 135 years of experience in the
mining, conveyor, smelter and storage
technology and logistics sectors. A focal point of its business is automation
technology in connection with the development of logistics solutions. When
throughput and storage times have to
be made shorter in order to make work
sequences more efficient and thereby
improve the economy of production,
optimisation of the store and transport
systems plays a central role.
Today, Siemag acts as a general
contractor for coil-handling and storage systems. Its supply range extends
from analysis of the existing situation
and the provision of advice on systems, through planning, delivery and
assembly, to commissioning of the
result. In recent years the automation
of store logistics has come to be recognised as particularly important. For
Siemag
Transportsysteme kommt eine zentrale Rolle zu, wenn es darum geht,
Durchlauf- und Lagerzeiten zu reduzieren, Abläufe effizienter und so die
Produktion insgesamt wirtschaftlicher
zu gestalten.
Bei den Anlagen für Coil-Handling
und -Lagerung tritt Siemag heute als
Generalunternehmer auf. Das Ange-
Automatischer Coiltransport im modernisierten Hamburger Hydro-Walzwerk
Automatic coil transport at the modernised Hydro rolling mill in Hamburg
High Performance Tooling
for the Tube Industry
Based on 125 years of experience the
Schmidt + Clemens Group offers an in-depth
of metallurgical consultation for many
manufacturing situations.
Visit us at the
Aluminium 2008
23rd - 25th Sept. 2008
Essen/Germany
Stand 1E23
S+C MÄRKER supplies the complete range
of extrusion tooling such as container
mantles, liners, liner holders, stems,
mandrels and dies etc. For this tooling a
comprehensive stock of high-quality hot
work tool steels is available. The scope
of supply is completed by an excellent
customer service including developement
and re-lining of extrusion containers in
the re-lining centre of S+C MÄRKER.
S+C MÄRKER GmbH
Steel Technologies
P.O. Box 11 40
51779 Lindlar
Germany
30
Phone: +49 (0) 2266 92-211
Fax: +49 (0) 2266 92-509
www.sc-maerker.de
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ALUMINIUM · 9/2008
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– M E S S EAVL O
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MSI CNHI U
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Advertisement
www.inotherm-gmbh.de
this, Siemag has developed a series of
material flow and store management
systems which provide the customer
with plant technology tailored to his
needs.
The development of self-navigating, driverless transport vehicles
(ACT, Automatic Coil Transporters)
is for Siemag an important step towards production with the minimum
of personnel. This development supplements corresponding trends on the
rolling mill and adjustment sides, so
that the customer can now be provided with a modernisation package
complete in every respect.
When Siemag brought out its ACT
system in 1999, users showed a great
deal of interest. Since then the system
has become a successful alternative
to driver-controlled mandrel stack-
ers and is used to good effect in both
the steel and aluminium industries,
among others in the modernised rolling plant of Hydro Aluminium.
The advantages of the automatic
coil transporter compared with a
conventional mandrel stacker can be
described as follows:
• better transport quality – no
damage to the coils, the transport
vehicle or the storage equipment
• planning reliability thanks to
accurate estimation of the
transport performance in advance
• continuous tracking of the material, thanks to transport control
integrated in the overall logistical
system
• emission-free operation and
saving of space thanks to the
elimination of fixed structures
such as rails or foundations.
Against this background, the low operating costs of the ACT very quickly
result in economic advantages. Decisive factors in this are the low energy
costs, the absence of personnel and
the better quality of transport.
N
botsspektrum reicht von der Ist-Analyse und Systemberatung über die
Planung, Lieferung und Montage bis
hin zur Inbetriebnahme. Einen besonderen Stellenwert hat die Automatisierung der Lagerlogistik in den
letzten Jahren gewonnen. Siemag hat
dafür eine Reihe Materialfluss- und
Lagerverwaltungssysteme entwickelt,
die dem Kunden eine maßgeschneiderte Anlagentechnik bieten.
Die Entwicklung der selbstnavigierenden, fahrerlosen Transportfahrzeuge ACT (Automatic Coil Transporters) ist ein wichtiger Schritt auf
dem Wege zur personalarmen Fertigung. Diese Entwicklung ergänzt
die entsprechenden Trends auf der
Walzwerks- und Adjustageseite, so
dass dem Kunden heute ein in jeder
Hinsicht abgerundetes Modernisierungspaket zur Verfügung steht.
Als Siemag 1999 ihr ACT-System
vorstellte, war das Interesse der Anwender groß. Inzwischen ist das System eine erfolgreiche Alternative zum
fahrergesteuerten Dornstapler und
sowohl in der Stahl- als auch in ©
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ALUMINIUM · 9/2008
31
der Aluminiumindustrie erfolgreich
im Einsatz – unter anderem im modernisierten Hamburger Walzwerk
der Hydro Aluminium.
Die Vorteile des automatischen
Coiltansporters im Vergleich zum
konventionellen Dornstapler sind:
• eine höhere Transportqualität,
keine Beschädigungen an den
Coils, am Transportfahrzeug oder
an den Lagereinrichtungen
• Planungssicherheit durch genaue
Abschätzung der Transportleistungen bereits im Vorfeld
• kontinuierliche Materialverfolgung
dank einer in die Gesamtlogistik
integrierten Transportsteuerung
• emissionsfreier Betrieb und
Platzersparnis durch den Verzicht
auf feste Einbauten wie Schienen
oder Fundamente.
Vor diesem Hintergrund führen die
geringeren Betriebskosten des ACT
sehr schnell zu wirtschaftlichen Vor-
teilen. Maßgeblich dafür sind vor
allem die geringeren Energiekosten,
der Wegfall von Personal sowie die
höhere Transportqualität.
Siemag ist Aussteller auf der
Halle 3, Stand A40
www.siemag.com
Otto Junker Group: Vom Schmelzofen bis zum
Profilpaket – die komplette Produktionskette
des Strangpressens aus einer Hand
32
Otto Junker Group: From melting furnace to
packaged sections – the complete production
chain for extrusion from a single source
itself. At the end of 2007 Junker com“We are on a buying trip and want to
bined all these activities in the Otto
expand still more in the coming years”,
Junker Extrusion business division.
said Gunther Voswinckel, then Chairman of the Board of the Otto Junker
Among the important acquisitions
Group, to this journal two years ago
made by Junker in recent years is the
at ALUMINIUM 2006. The imminent
Swedish industrial furnace specialist
fair in 2008 now provides an opporUIT. This has reinforced the group’s
tunity for a provisional assessment of
extrusion sector in that the company
the results of that intention.
group can now offer the complete
production chain for extrusion techTo describe the supply possibilities
nology all from a single source.
of the Junker group is no simple matThe Dutch subsidiary Thermcon
ter. Even considering the aluminium
Ovens, which is now one of the most
sector alone, the group’s plant techimportant furnace suppliers in the
nology is multifaceted. The company
melting context, specializes in ©
supplies induction melting and casting furnaces, billet heating units
(both
inductive
and gas fired) including handling
equipment, and
heat
treatment
units for heating,
homogenizing
and
tempering
castings, formats,
strips, coils and
foils. There are
also complete extrusion equipment
packages which
now include even Automatische Lagerung und Zuführung von Stangen vor der Presse
the extrusion press Automatic storage and transport of bars to the extrusion press
ALUMINIUM · 9/2008
Otto Junker
„Wir befinden uns auf Einkaufstour
und wollen in den kommenden Jahren verstärkt expandieren“, sagte
Gunther Voswinckel, damals Vorsitzender der Geschäftsführung der Otto
Junker Gruppe, dieser Zeitschrift vor
zwei Jahren auf der ALUMINIUM
2006. Der unmittelbar bevorstehende
Messetermin 2008 gibt Gelegenheit,
eine vorläufige Bilanz zu ziehen.
Die Lieferpalette der Otto Junker
Gruppe zu beschreiben, ist nicht
ganz leicht. Selbst wenn man sich auf
den Aluminiumbereich beschränkt,
ist die Anlagentechnik der Gruppe
noch immer vielfältig. Das Unternehmen liefert Induktions-Schmelz- und
Gießöfen, Bolzenerwärmungsanlagen
(induktiv und gasbeheizt) einschließlich Handlingseinrichtungen, Wärmebehandlungsanlagen zum Anwärmen, Homogenisieren und Vergüten
von Gussteilen, Formaten, Bändern,
Bunden und Folien. Hinzu kommt
das komplette Paket an Strangpressausrüstungen, zu dem jetzt auch die
Strangpresse selbst gehört. All diese
Aktivitäten wurden Ende 2007 zum
Geschäftsbereich Otto Junker Extrusion zusammengefasst.
Zu den bedeutenden Akquisitionen, die Otto Junker in den vergangenen Jahren getätigt hat, gehört
der schwedische Industrieofenspezialist UIT. Er verstärkt den Strangpresssektor der Gruppe in der Weise,
dass die Unternehmensgruppe heute
in der Lage ist, die komplette ©
Geben Sie Ihrem Unternehmen
einen Energieschub!
Auch im globalen Wettbewerb entscheidet die Leistung
vor Ort. Schön, dass Sie sich auf die Brennertechnologie
von Elster Kromschröder überall und jederzeit verlassen
können. Denn in über 60 Ländern finden Sie unseren
kunden- und anlagenspezifischen Service. Dadurch
haben Sie an jedem Einsatzort den unverzüglichen Zugriff
auf das komplette Sortiment und das Fachwissen von
Spezialisten.
Die Brenner lassen sich aufgrund ihrer modularen Bauweise einfach und schnell warten sowie an unterschiedliche Prozessanforderungen anpassen. Zeitvorteile
verschaffen Ihnen ebenfalls leicht verständliche
Dokumentationen, praxisgerechte Schulungen
sowie Unterstützung bei Inbetriebnahme und Wartung.
Sind Sie auf den Geschmack gekommen?
Dann fordern Sie weitere Informationen an!
Elster GmbH
Postfach 2809
49018 Osnabrück
T +49 541 1214-0
F +49 541 1214-370
[email protected]
www.kromschroeder.de
Produktionskette der Strangpresstechnik aus einer Hand anzubieten.
Auf den Schmelz- und Gießprozess
als erste Stufe in der Prozesskette des
Strangpressens hat sich die niederländische Tochtergesellschaft Thermcon
Ovens spezialisiert, die heute zu den
bedeutenden Ofenanbietern auf der
Flüssigseite gehört. Den Umfang des
Geschäftes charakterisiert ein Großauftrag über fünf stationäre Schmelzöfen und fünf stationäre Warmhalteöfen für ein türkisches Halbzeugwerk,
den Thermcon Ovens im Vorjahr
buchen konnte. Wenn ein Presswerk
heute im Gießereibereich investiert,
gehört Otto Junkers mit großer Sicherheit zu den Anbietern.
Für die Homogenisierung von
Pressbolzen liefert Otto Junker Kammer- oder Herdwagenöfen für die
chargenweise Wärmebehandlung. Bei
den Kammeröfen wird mit Glühgestellen und Chargiermaschinen die Beschickung der Öfen durchgeführt, so
dass gegenüber den Herdwagenöfen
Energie gespart wird und die Anlage
flexibler arbeiten kann. Da zwischen
den Bolzen kein Temperaturausgleich
stattfinden kann, werden die Anlagen
mit reversierendem Luftstrom ausgeführt. Die Charge wird wechselseitig
durchströmt, so dass die Temperaturspreizung in der Charge klein bleibt
und lange Ausgleichszeiten entfallen.
Für die Trennung der in der
Presse benötigten Bolzenlänge vom
Aluminiumstrang gibt es grundsätzlich zwei Möglichkeiten: den Bolzen vom erwärmten Strang in einer
Warmblockschere abzuscheren oder
aber vom kalten Strang mittels einer
Säge abzutrennen. Otto Junker bietet
beide Systeme an. Die Kaltsägeanlagen haben den Vorteil einer glatten
Trennfläche am Bolzen ohne Verformung des Bolzenendes. Es muss
jedoch mit Materialverlust aufgrund
der Sägeblattdicke gerechnet werden. Warmblockscheren und Kaltsägen sind in der Regel mit StrangrestOptimierungssystemen ausgestattet.
Moderne Strangpressen optimieren
die Bolzenlänge, um die bestmögliche
Nutzung des Auslauftisches zu erreichen. Neuerdings bietet Otto Junker
ein System an, das den Stangenrest
mit der nachfolgenden Stange durch
Reibschweißen verbindet.
34
the melting and casting process as
the first step in the process chain. The
scope of its business is typified by a
major contract for five static melting furnaces and five static holding
furnaces for a Turkish semis plant,
awarded to Thermcon Ovens last
year. Nowadays, when an extrusion
plant invests in casting equipment it
is more than likely that Junker will be
one of the suppliers.
For extrusion billet homogenization Junker supplies chamber or
hearth wagon furnaces for heat treatment in batches. In the case of chamber furnaces the furnace is loaded
by means of annealing frames and
charging machines, so that compared
with hearth wagon furnaces energy
is saved and the plant can operate
more flexibly. Since no temperature
equalization can take place between
the billets, the units are designed with
a reversing air flow. Air flows through
the charge from both sides in alternation so that the temperature spread in
it remains small and long equalization
times are not necessary.
For cutting the billet lengths required for the press from the aluminium strand there are basically two options: to cut the billets from the hot
strand in a hot billet shear, or to cut
them from the cold strand by means of
a saw. Junker offers both systems. The
cold saw option has the advantage of
producing a smooth cut surface on the
billet without deformation of the billet
end, but some material loss must be
allowed for because of the thickness
of the saw blade. Hot billet shears and
cold saws are as a rule equipped with
strand residue optimization. Modern
extrusion presses optimize the billet
length in order to achieve the most
effective possibly utilization of the
run-out table. Recently, Junker has
been offering a system which joins the
strand residue to the next bar in line
by friction welding.
The strands or billets are mainly
heated by gas-fired or induction furnaces, or a combination of the two.
In gas-fired furnaces active, highconvection heating is also used. Junker is the only plant supplier capable
of providing all these systems from a
single source and therefore provides
competent and objective advice about
ALUMINIUM · 9/2008
ALUMINIUM
· 9/2008
35
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Otto Junker will be an exhibitor
Hall 3, Stand D20
the design most suitable for each case.
There is no doubt that gas-fired furnaces have clear advantages in relation to energy costs. On the other
hand, induction furnaces allow more
exact temperature regulation and
control, take up less space, and are
more flexible. To make the most of the
advantages of both systems, it often
makes sense to use a combination of
both heating methods.
The extrusion presses offered by
Junker are based on the know-how of
the French company Clecim. When
the Spanish GIA group took over
Clecim in 2006, important designers
changed over to Junker. Under the
Junker label an independent press
programme was created, but so far no
reference plants can yet be cited.
In contrast, comprehensive references and experience are available
in the press run-out sector. In this
field the subsidiary company Elhaus
has been successfully active for many
years. Its run-out systems are now installed in numerous extrusion plants in
Europe and the Gulf Region. Recently,
Eduard Hueck awarded the contract
for the complete run-out system for
its 28-MN press, which will begin operating at the end of 2009. The scope
of the contract includes the cooling at
the exit of the strand, a double puller
with flying saw, transverse transport,
a stretching bench and a finishing saw
with stacking machine.
In a Polish extrusion plant Elhaus installed
two complete run-out systems
Für die Erwärmung der Stränge bzw.
der Bolzen werden hauptsächlich gasbeheizte Öfen oder Induktionsöfen eingesetzt oder eine Kombination beider
Systeme. Bei den gasbeheizten Öfen
wird außerdem die aktive Hochkonvektionserwärmung angewendet. Otto
Junker ist als einziger Anlagenbauer in
der Lage, all diese Systeme aus einer
Hand zu realisieren und damit kompetent und objektiv bei der Auswahl
der jeweils günstigsten Ausführung
zu beraten. Unstrittig ist, dass der gasbeheizte Ofen in Bezug auf die Energiekosten eindeutige Vorteile besitzt.
Für den Induktionsofen sprechen die
exakte Temperaturführung und -kontrolle, der geringere Platzbedarf und
die höhere Flexibilität. Um die Vorteile
beider Systeme zu nutzen, macht es oft
Sinn, eine Kombination beider Erwärmungsverfahren anzuwenden.
Die Strangpresse, die Otto Junker
anbietet, basiert auf dem Knowhow
der französischen Clecim. Das Unternehmen verfügt über ein gewachsenes Knowhow bei Pressen im oberen Kraftbereich. Als die spanische
GIA-Gruppe 2006 Clecim übernahm,
wechselten wichtige Konstrukteure
zu Otto Junker. Es entstand unter dem
Label von Otto Junker ein eigenständiges Pressenprogramm, von dem allerdings bisher noch keine Referenzanlage zur Verfügung steht.
Umfassende Referenzen und Erfahrungen liegen hingegen auf dem
Sektor des Pressenauslaufs vor. Hier
ist die Tochtergesellschaft Elhaus seit
vielen Jahren erfolgreich aktiv. Deren
Auslaufsysteme finden sich heute in
zahlreichen Presswerken Europas
und der Golfregion. Zuletzt erteilte
Eduard Hueck den Auftrag über das
komplette Auslaufsystem für seine
neue 28-MN-Presse, die Ende 2009
in Betrieb gehen wird. Zum Auftragsvolumen gehören die Kühlung am
Strangauslauf, Doppelpuller mit fliegender Säge, Quertransport, Reckbank und Fertigsäge mit Stapler.
Die Werkzeuganwärmöfen für
diese Linie kommen von der Tochter
IUT, die zu den führenden Herstellern
zählt. Die Stärke von IUT sind Homogenisieröfen für Profilabschnitte. Hier
gehören die fünf neuen Ofen der Gutmann Werke in Weißenburg zu den
IUT-Referenzen.
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Trust ...
Solid competence for the aluminum industry.
Being able to trust in the expertise and performance
of every team member, is the foundation for success.
To our customers around the world this means being
able to count on a comprehensive offering in the area
of aluminum production. From thermal pre-treatment
to shaping and refining, we always meet the constantly rising challenges of the market.
Whether in new plant construction or revamp projects, our
solid process know-how encompasses the complete production cycle, including the integration of the latest electrical engineering and automation solutions.
Confidence through performance – SMS metallurgy.
Visit us at
ALUMINIUM 2008
September 23 to 25
Hall 3, Booth No. 3A40
Essen, Germany
MEETING your EXPECTATIONS
SMS metallurgy
Eduard-Schloemann-Strasse 4
40237 Düsseldorf, Germany
Phone: +49 (0) 211 881-0
Fax:
+49 (0) 211 881-4902
Internet: www.sms-metallurgy.com
LOI Thermprocess – Wärmebehandlungsanlagen
für hoch belastbare Automobilkomponenten
Zu den besonderen Stärken des
Unternehmens zählt nicht zuletzt
die Flexibilität, mit denen spezielle
Kundenanforderungen auf innovative
Weise realisiert werden: z. B. bei der
Wärmebehandlung von gegossenen
Automobilbauteilen. LOI Thermprocess hat bereits in den 1990er Jahren
Anlagen zum kontinuierlichen Wärmebehandeln von gegossenen Automobilkomponenten mit Wasserabschreckung entwickelt und geliefert.
Mit neuen Techniken der Wärmebehandlung gelingt es heute, die
mechanischen Bauteileigenschaften
(Streckgrenze, Bruchdehnung und
Zugfestigkeit) zielgerichtet aufeinander abzustimmen. Das Automobil der
Zukunft benötigt deshalb Komponenten mit optimalen mechanischen
Eigenschaften und mit einem minimalen, gegen Null tendierenden Eigenspannungsniveau.
Dieser Zielstellung kommt man mit
einer serientauglichen Luftabschreckung näher. Sie verspricht für eine
Reihe von Bauteilen eine noch gleichmäßigere Abkühlung über den gesamten Bauteilquerschnitt, als dies mit Polymer möglich ist. Das Abschreckmedium Luft bietet sich zunächst einmal
für dünnwandige Strukturbauteile an;
heute gelingt es, dieses Konzept auch
auf dickwandige Teile wie Zylinderköpfe zu übertragen.
In Zusammenarbeit mit der Belte
AG hat LOI Thermprocess eine Anlagentechnik entwickelt, die unterschiedliche Abschreckvarianten in
einer kontinuierlichen Anlage kombiniert. Es handelt sich hierbei um einen
Rollenherdofen in kompakter Ausführung, bei dem Lösungsglühofen und
Auslagerungsofen übereinander ange-
38
LOI Thermprocess – Heat treatment furnaces
for high-strength automobile components
Belte AG
Die Aluminiumsparte der in Essen
ansässigen LOI Thermprocess
kann bei Schmelz-, Gieß- und
Wärmebehandlungsöfen auf eine
lange und erfolgreiche Geschäftstätigkeit zurückblicken. In den
vergangenen Jahren wurden in
dieser Zeitschrift immer wieder
interessante Anlagen dieses Lieferanten vorgestellt.
Wärmebehandlungsanlage für Gussteile mit universellen Abschreckmedien
Heat treatment for castings, with universal quench media
The aluminium division of LOI
Thermprocess in Essen, Germany,
can look back over long and successful business activity in the
field of melting, casting and heat
treatment furnaces. In recent years
interesting units by this supplier
have often been described in this
journal.
The particular strengths of the company include the flexibility with which
it responds to the special needs of its
customers in innovative ways: e. g. in
the sector of heat treatment for cast
automobile components. Already in
the 1990s LOI had developed and delivered various units for the continuous heat treatment and water quenching of cast automobile components.
With new heat treatment techniques it is nowadays possible to match
mechanical component properties
(yield point, elongation at fracture and
tensile strength) to one another. The
cars of the future need components
with optimum mechanical properties
and with internal stress levels that are
minimal, tending towards zero.
This objective is approached by
means of an air quenching method
suitable for series production. For
many components this method
promises more uniform cooling over
the full cross-section of the components than is possible with the use of
polymer. As a quench medium air is
particularly suitable for thin-walled
structural components, but now the
concept is being extended to thickwalled components as well, such as
cylinder heads.
In collaboration with Belte AG,
LOI Thermprocess has developed
a plant technology which combines
different quench variants in one continuous unit. This is a roller hearth
furnace of compact design, in which
the solution annealing furnace and
the ageing furnace are arranged one
above the other. That concept on the
one hand saves space, but also offers
a series of design advantages. As with
the previously usual parallel arrangement of the two furnaces, the loading
and unloading station is located at one
end. Opposite, at the other end of the
furnace are arranged the quench stations – in this case optionally air, polymer or water.
To allow the globularisation of the
Mg and Si alloying elements cast aluminium components need relatively
long treatment times. This demands a
corresponding length of the solution
annealing furnace. When the loading
ALUMINIUM · 9/2008
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carriers measuring 1.5 m x 1.5 m x 0.8
m, stacked two at a time, move into
the furnace they are first heated in the
heating zones up to the solution annealing temperature. The maximum
furnace space temperature is 600°C.
The furnace is gas fired. The circulator fans are built into the sidewalls. The heated components pass
through the so-termed holding zones,
in which a temperature accuracy of ±
3 K is maintained. In this area only the
heat losses have to be made up. Total
travel time through the furnace can
amount to 60 to 420 min. Throughput
performance is 2,500 kg/h.
At the furnace outlet are arranged
one after the other the air quench
and the baths for polymer and water quenching. When the annealed
material is to be quenched with air,
the racks have to be de-stacked. In
the polymer and water baths the two
racks on top of one another are immersed together. This has to be done
as quickly as possible so that the
structural constituents are kept in the
dissolved state. The heat given up to
the bath is removed by bath cooling
equipment so that uniform cooling
conditions can be maintained.
For air quenching, air is blown
onto the racks with their components from both sides and from underneath. To ensure that cooling air
flows around the entire content of a
rack, the components have to be appropriately arranged in the rack. This
can in many cases only be done with
racks specially designed for the component in question.
The racks with the cooled components then pass into the ageing
furnace on the upper level. The cycle time for this furnace transit can
certainly be made shorter than for the
solution annealing furnace. Depending on the alloy, a higher temperature
during artificial ageing can be used to
shorten the duration of holding ©
PROFHAL ALUMINIUM PROFIL
BEARBEITUNG GMBH
© Ka
Kastenhuber
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Ein Unternehmen der
HAARMANN-GRUPPE
Dettenheimer Straße 30
D-91781 Weißenburg
Tel. +49-(0)91 41-8 55 65-0
www.profhal.de
ALUMINIUM
· 9/2008
39
ordnet sind. Dieses Konzept ist nicht
nur platzsparend, sondern bietet auch
eine Reihe konstruktiver Vorteile. Wie
bei der bislang üblichen Parallelanordnung beider Öfen befindet sich an
einer Stirnseite die Be- und Entladestation. Ihr gegenüberliegend sind am
anderen Ofenende die Abschreckstationen – hier wahlweise Luft, Polymer
oder Wasser – angeordnet.
Gegossene Aluminiumteile benötigen zur globulitischen Einformung
der Mg- und Si-Legierungselemente
relativ lange Behandlungszeiten. Dies
bedingt eine entsprechende Länge
des Lösungsglühofens. Wenn die 1,5
m x 1,5 m x 0,8 m großen Ladungsträger, jeweils zweifach gestapelt, in den
Ofen eingefahren werden, werden sie
zunächst auf Lösungsglühtemperatur
aufgeheizt. Die max. Ofenraumtemperatur beträgt 600 °C.
Die Ofenanlage ist mit einer Gasbeheizung ausgerüstet. Die Umwälzventilatoren sind in der Seitenwand ©
PROFHAL entwickelt, fertigt und veredelt
hochwertige Aluminium-Profil-SystemKomponenten für unterschiedlichste
Anwendungsgebiete.
INDIVIDUELLE LÖSUNGEN
AUS ALUMINIUM
ALUMINIUM · 9/2008
39
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eingebaut. Die aufgeheizten Teile
durchlaufen die sog. Haltezonen, in
denen eine Temperaturgenauigkeit
von ±3 K aufrechterhalten wird. In
diesem Bereich müssen lediglich die
Wärmeverluste ersetzt werden. Die
Gesamtdurchlaufzeit durch den Ofen
kann insgesamt 60 bis 420 min betragen. Die Durchsatzleistung beträgt
2.500 kg/h.
Am Ofenausgang sind hintereinander die Luftabschreckung sowie
die Bäder zur Polymer- und Wasserabschreckung angeordnet. Wenn das
Glühgut mit Luft abgeschreckt werden
soll, müssen die Körbe entstapelt werden. In das Polymer- und in die Wasserbäder werden die beiden übereinander gestapelten Körbe gemeinsam
abgesenkt. Das muss möglichst schnell
geschehen, damit die Gefügebestandteile in Lösung gehalten werden. Die
in die Bäder eingebrachte Wärme wird
mit Hilfe der Badkühlung abgeführt,
so dass gleichmäßige Abkühlbedingungen beibehalten werden können.
Bei der Luftabschreckung werden die Gestelle mit den Bauteilen
von beiden Seiten und von
unten angeblasen. Damit
der gesamte Gestellinhalt
gleichmäßig von der Kühlluft umströmt wird, muss
die Anordnung im Gestell
stimmen. Das lässt sich in
vielen Fällen nur mit speziellen
Gestellkonstruktionen erreichen, die auf
das jeweilige Bauteil abgestimmt sind.
Die Körbe mit den abgekühlten Teilen durchlaufen
anschließend in der oberen Etage
den Auslagerungsofen. Die Taktzeit
dieses Ofendurchlaufs kann durchaus
kürzer eingestellt sein als für den Lösungsglühofen. Mit höheren Temperaturen während der Warmauslagerung lässt sich – legierungsabhängig
– die Haltedauer im Auslagerungsofen verkürzen. Dieser Ofen ist für
eine Maximaltemperatur von 300 °C
ausgelegt. Am Ausgang des Auslagerungsofens werden die Körbe mittels einer Chargiermaschine auf das
Hallenniveau zurückgefördert.
N
LOI Thermprocess
Heat treatment for
castings, with water quenching
in the ageing furnace. The furnace is
designed for a maximum temperature
of 300°C. At the exit of the ageing
furnace the racks are brought back to
floor level by a charging machine.
LOI Thermprocess will be an exhibitor
Hall 3, Stand K50
www.loi-italimpianti.com
Achenbach Buschhütten
Rolling plant specialist with
an extended product line
For interested customers the rolling plant specialist
Achenbach Buschhütten will be ready at Aluminium
2008 in Essen to discuss with them their future ideas
about the production of first-class strips and foils of aluminium. The company’s aluminium rolling plants are the
product of experience from more than 250 strip, lightgauge strip and foil rolling mills installed all over the
world.
The product range includes the most varied plant
designs for every conceivable field of application. The
performance of Achenbach rolling mills, attested by the
large number of reference plants, is based on advantages
such as automatic strip feeding, roll cooling to pinpoint
accuracy and roll gap measurement, as well as defined
roll stabilisation and high-speed roller bearings.
The new generation of ‘Optiroll’ automation technology, the Optiroll i2 system, regulates the rolling process at
the customer digitally and proactively, and also co-ordinates the entire production sequence in the rolling plant.
‘Optipure’ filtration technology ensures the economical
and ecological efficiency of the cooling and lubrication
systems used.
More than two years ago the company extended ©
40
ALUMINIUM · 9/2008
BE AT
WILL
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its product range with aluminium cutting technology for thin strip and foils.
The provision of doublers, separators
and slitters in combination with a
new plant design has attracted great
interest in the market, showing that
the strategic decision to do this was
correct. Already within the first year
a number of leading aluminium rolled
product producers in Asia and Europe
had opted to adopt Achenbach foil
cutting technology.
Achenbach
Achenbach will be an exhibitor
Hall 3, Stand K40
www.achenbach.de
The Achenbach product range includes the most varied plant designs for every
conceivable field of application
From its original pioneering work
in strapping technology 95 years
ago to its present global scale of
operation, Signode is outstanding
in the field of packaging technology. Early in 2008 the company
achieved another milestone: the
1,000th AK 200 HD 25 head was
delivered to Hertwich Engineering
in Austria in February 2008.
Many AK heads have been installed in
the aluminium industry, where they
are renowned for their low purchase
and running costs, their reliability and
the high applied strap tension. Recent
equipment sales include orders from
the new Quatar smelter and also
from the Oman smelter which is fully
equipped with AK 200 HD, to mention
just some few examples.
This heavy-duty strapping head
range for Tenax polyester strapping,
installed in aluminium smelters all
over the world, is being extended with
a new model, the AK 200 HDX: this,
in response to the Signode non-ferrous specialist team’s observation of a
market trend towards heavier billets,
up to 685 mm diameter.
The company has developed the
AK 200 HD head into the AK 200
HDX to operate with Tenax strapping
up to 32 mm wide with a breaking
42
strength of up to
18,000 N. A survey has already
been conducted
in
Germany
and the Middle
East, to identify
billet saws that
are candidates
for conversion
to AK 200 HDX
25/32.
An average
joint strength
of 85 percent
of
breaking
strength
provides maximum
security
and
creates
new
opportunities
for the replacement of heavyduty steel strap
applications,
which was pre- The new heavy-duty strapping head – AK 200 HDX
viously not possible. Tenax is much tougher than
Signode will be an exhibitor
steel strap. Compared with a 32 mm
at ALUMINIUM 2008 in
high tensile steel strap a 32 mm Tenax
Essen.
strap requires 11.5 percent more enHall 2, Stand C24
ergy to break, and an amazing 18.75
times more energy than standard steel
strap.
www.signode.com
ALUMINIUM · 9/2008
Signode
Heavy-duty strapping technology from Signode
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SAG – Individuelle Werkstofflösungen
für ein breites Anwendungsspektrum
Die im Jahre 1992 im Rahmen eines Management-Buyouts gegründete Salzburger Aluminium
AG (SAG) ist an einem der traditionsreichsten
Aluminiumstandorte der Welt beheimatet – im
österreichischen Lend. Die Unternehmensgruppe
verfügt über umfassende Erfahrungen sowohl auf
dem Werkstoffsektor wie auch in der Verarbeitung.
Das Arbeitsgebiet umfasst die Entwicklung von
Hochleistungswerkstoffen für zukunftsweisende Lösungen in Aluminium, die Herstellung und Optimierung von qualifizierten Aluminiumkomponenten
und die Planung und Lieferung von schlüsselfertigen Anlagen und Produktionslinien.
• Aluminium-Gusswerkstoffe („Maxalloy“) als genormte
Legierungen in Form von Masseln, die beim Verarbeiter
ohne Materialverluste eingeschmolzen werden können
• Aluminium-Schmiedematerial („Flowforge“), das im
Horizontal-Strangguss hergestellt wird
• Aluminium-Fließpressmaterial („Flowform“) in Form
von Stangen, Aluminium-Pressbolzen („Tec(X)trusion“).
Unter dieser Bezeichnung sind eine Vielzahl von
gängigen Strangpresslegierungen, auch solche mit
©
Bruker Quantron
Die Herstellung von Vormaterial für unterschiedliche
Verarbeitungsbranchen ist das Arbeitsgebiet der SAG
Materials Group. Die vielfältigen Einsatzmöglichkeiten
von Aluminium verlangen nach Werkstoffen mit teilweise sehr unterschiedlichen Eigenschaftskombinationen.
Die Unternehmen der SAG Materials Group stellen für
nahezu alle Anwendungsbereiche den jeweils optimalen
Werkstoff zur Verfügung:
• Aluminium-Gussplatten („Plancast“) aus AluminiumKnetlegierungen
Wir machen
Metall zu Qualität...
ADVANCED METALS ANALYSIS
think for ward
Protecting
the environment
and cutting costs.
TCF (Twin-Chamber Furnace)Recycling Plant:
melting of contaminated scrap
TCF-Process
metal circulation system
automatic charging equipment
integrated control system
Visit us!
Aluminium 2008 Essen
September 23-25, Booth 3K50
ALUMINIUM
· 9/2008
43
Benefits:
easy pouring
very safe operation
fully automatic operation
environmental friendly
reliable operation
LOI Thermprocess GmbH - Am Lichtbogen 29 - 45141 Essen / Germany
Phone +49 (0)201 1891.1 - Fax +49 (0)201 1891.321
[email protected] - www.loi-italimpianti.com
ALUMINIUM · 9/2008
43
speziellen Eigenschaften (z. B.
Glänzlegierungen), zusammengefasst
• Aluminium-Stromschienen
(„Superamp“) in Längen bis zu
18 Meter – ohne störende
Schweißverbindungen
• Thixotrope Aluminiumlegierungen („Thixalloy“), die im halbflüssigen, teigigen Zustand auf
modifizierten Druckgießmaschinen verarbeitet werden.
In den Unternehmen der SAG Motion
Group wird die Werkstoffkompetenz
in eine materialgerechte Verarbeitung
umgesetzt. Dem Kunden steht auf
Wunsch anstatt des Vormaterials ein
Bauteil oder sogar ein einbaufertiges
Produkt zur Verfügung.
Die SAG-Gruppe gewinnt durch
die Verarbeitung im eigenen Hause
das notwendige Knowhow zur optimalen Werkstoffentwicklung. Die
Synergieeffekte nutzen dem Kunden
und dem Lieferanten gleichermaßen. Zum Arbeitsgebiet gehören die
Nutzfahrzeug- und Automobilindustrie, Luftfahrt, Schienenfahrzeuge,
Motorradhersteller und schließlich
auch Spezialanfertigungen wie Sondertanks für Spezialfahrzeuge und
Kleintransporter, Hydrauliktanks für
Autokrane, aber auch Motorrad-Enddämpferrohre, die individuell nach
Kundenwunsch zu fertigen sind.
Als ein zunehmend interessantes
Arbeitsgebiet erweisen sich modifizierte
Tanklösungen.
SAG
entwickelt
und
fertigt modifizierte
Standard-Kraftstofftanks (OEMStandard) für alternative Treibstoffe.
Die Tanks können
wahlweise als Einzel- oder Kombi- Cockpitträger – Bauteil für Motorräder
tanks ausgebildet
die HPI GmbH. Darüber hinaus übersein. Je nach Art des verwendeten
nimmt SAG Tech die Planung, FertiTreibstoffes kann in den Tank eine
gung, Lieferung, Montage und InbeBeheizung eingebaut werden, die
triebnahme schlüsselfertiger Anlagen
den Kraftstoff auf Betriebstemperatur
und kompletter Produktionslinien für
vorwärmt bzw. diese Temperatur aufdie eigene Gruppe, aber auch für die
rechterhält. Für den Einsatz bei sehr
weltweite Aluminiumindustrie. Auf
niedrigen Außentemperaturen oder
dem Gebiet des Horizontalgießens
für spezielle Treibstoffe können die
besitzt SAG mit seiner BeteiligungsTanks mit Doppelwand und dazwigesellschaft HPI eine starke Position
schen liegender Isolierschicht ausgeim internationalen Maßstab.
führt sein.
Die SAG Tech Group repräsentiert
das dritte Arbeitsgebiet der Gruppe,
SAG ist Aussteller auf der
indem sie innovative Prozess- und
Anlagetechnologien zur Verfügung
Halle 7, Stand C40
stellt. SAG Tech fasst die Engineewww.sag.at
ringaktivitäten der gesamten Gruppe zusammen. Der Geschäftsbereich
umfasst die SAG Engineering und
Innovativer Permanentschutz
für Masselformen in der Aluminiumproduktion
In der Metallproduktion spielen
Trennmittel eine wichtige Rolle. Die
Permanentbeschichtungen der Nanocomp MetCast-Reihe MI für Kokillen
im Open-moulds-Gießverfahren stellen eine innovative Entwicklung der
Firma ItN Nanovation dar, die den
permanenten Schutz von Massel-,
Pellet- oder Sow-Formen vor Metallschmelze bietet.
Auf Basis von nano-keramischen
Materialien entwickelt, zeichnet sich
Nanocomp MetCast durch eine wesentlich längere Lebensdauer als herkömmlich verwendete Schlichten aus.
Die Erfahrungen aus der Praxis zeigen
eine Standzeit von vier bis sechs Wo-
44
Innovative permanent protection
for ingot moulds in aluminium production
Release agents play an important role
in metal production. The permanent
coatings of the Nanocomp MetCast
MI series of ItN Nanovation represent a significant breakthrough in this
field. When used in open-mould casting, they provide ingot, pellet and sow
moulds with lasting protection from
molten metal.
The service life of Nanocomp MetCast, developed from a nano-ceramic
base material, far exceeds that of conventional release agents. In day-to-day
use, the coating exhibits a service life
of four to six weeks without requiring
any recoating or other maintenance;
after this time, only a partial recoating is required to once again achieve
the same service life. The coating also
features extremely low consumption
levels, since a layer thickness of only
5 to 50 μm is required to attain full efficacy. The result is a significant relief
within the foundry.
Another advantage is the coating’s
insensitivity to thermal shock during
ALUMINIUM · 9/2008
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chen – ohne jedes Nachschlichten oder sonstige Wartung.
Anschließend ist lediglich partielles Nachschlichten erforderlich, um erneut die gleiche Standzeit zu erreichen.
Darüber hinaus ist die Beschichtung sehr verbrauchsarm,
da sie bereits bei Schichtdicken von nur 5 bis 50 μm voll
wirksam ist. Dies alles entlastet die Gießereien deutlich.
Ein weiterer Vorteil ist die absolute Unempfindlichkeit
gegenüber Thermoschocks beim Gießen, auch in Verbindung mit einer direkten oder indirekten Wasserkühlung.
Dank der Nichtbenetzbarkeit und der keramischen Struktur der Beschichtung gibt es keine chemischen Reaktion
mit der Schmelze. Nano-keramische Beschichtungen
haben einen nachhaltig stabilisierenden Einfluss auf die
Prozessqualität und -effizienz. Eine einfache Handhabung mittels Sprühen auf prozesswarme oder vorgeheizte
Kokillen lässt die Beschichtung sofort trocknen.
Weitere Produktreihen von Nanocomp MetCast für
Anwendung auf keramischen Substraten sowie für Gießkokillen im Aluminium- und Messing-Kokillenguss zeigen ähnlich herausragende Eigenschaften.
casting – even when combined with direct or indirect
water cooling. The non-wettability and ceramic structure
of the coating does not permit any chemical reaction with
molten material. Nano-ceramic coatings have a long-lasting stabilizing effect on process quality and efficiency.
Simply spraying the coating on moulds that are warmed
by process heat or preheating allows the coating to dry
immediately.
Additional product ranges from Nanocomp MetCast
for use on ceramic substrates and for casting dies in
aluminium and brass permanent mould casting display
similar, superior properties.
N
Bruker Quantron
...mit Q4 TASMAN!
CCD Spektrometer
für Metallanalyse
ItN Nanovation ist Aussteller auf der
Halle 6, Stand F42
Besuchen Sie uns auf der
Aluminium Stand 7C45
www.itn-nanovation.com
Bruker Quantron GmbH
www.bruker-quantron.com
ADVANCED METALS ANALYSIS
think for ward
EXTRUSION MANAGEMENT SYSTEM
25 yearinsthe
the spirit of the aluminium®
A.t.i.e. Uno Informatica S.r.l.
Phone +39 0341 210444 - Fax +39 0341 210808
www.unoi.it - e-mail: [email protected]
one, from the customer’s
order to the delivery of the
finished product; its modules could be also personalized and upgrade basing on
customer necessity.
Alykè Comunicazione
✓ Orders
ce
of experiemn extrusion
✓ Real-time connection with SAP® AS400® Navision® ecc...
iu
in
m
lu
a
®
✓ EMS-CAD (EMS and AutoCAD integration)
✓ Alloys and Castings
✓ Cycles and phases
✓ Working planning and progress
✓ Dies Management
✓ Connection with automatic warehouse for dies
✓ Dies Oven
✓ Press management and optimization
✓ Finish Saw
FROM THE ORDER TO THE FINISHED PRODUCT
✓ Ageing Furnaces
✓ Connection with automatic warehouse for profiles
✓ Packing, Weighing, Delivery
✓ Painting, anodizing, wood effect
✓ Thermal Break
Extrusion Management
System is a modular soft✓ Machining
ware, conceived for the
✓ Troubleshooting
aluminium
extrusion
✓ Maintenance
sector. It could manage
✓ Quality
both the technological
✓ Die cooling with liquid nitrogen
process and the production
We will be at: “Aluminium 2008” • Essen, 23-25 September • Stand 6C24
ALUMINIUM
· 9/2008
45
ALUMINIUM · 9/2008
45
ECKA Granulate – Pulver und Granulate jeder Art und Größe
ECKA Granulate ist in den drei
Leistungsschwerpunkten Legierungs-, Metallpulver- und Anwendungstechnologie zu Hause.
Das Unternehmen verfügt über
weltweit 18 Produktionsstätten.
Das Produktionsprogramm umfasst die Herstellung von NE-Metallpulvern aus den Reinmetallen
Aluminium, Magnesium, Kalzium,
Kupfer, Zinn, Blei, Zink, Silizium
und deren Legierungen. Die Produkte werden als Pulver, Granulate, Fertigmischungen, Masseln
und Pellets geliefert. Produziert,
be- und verarbeitet werden unter
anderem 70.000 Jahrestonnen Aluminium, 19.000 Tonnen Magnesium, 25.000 Tonnen Kupfer.
Die Produktionsverfahren umfassen
Mahlen und Zerkleinern, elektrochemische Abscheidung, Luft-, Wasser- und Gasverdüsung bis hin zum
Granulieren aus der Schmelze, das
Schmelzen und verschiedene Recyclingverfahren. Dadurch steht dem
Kunden jede Art und Größe von Pulvern und Granulaten zur Verfügung.
Die Kunden kommen aus der Automobil-, Elektro-, Elektronik- und chemischen Industrie sowie dem Schiffbau und der Medizintechnik.
Innovative Entwicklungen finden
sich in den pressfertigen Sintermischungen ECKA Bromix und ECKA
Alumix, in Leichtbauwerkstoffen wie
„Alulight“, einem neuartigen Werkstoff aus Aluminiumschaum, und
ECKA Tix, einem Magnesiumgranulat
für Thixomolding-Verfahren.
ECKA produziert feines Aluminiumpulver zur Herstellung von Al-Solarpaste, die in der leitfähigen Rückseite von Solarzellen eingesetzt wird. Mit
seinen verschiedensten AluminiumVerdüsungstechniken unterstützt das
Unternehmen Pastenhersteller ©
Double-Puller
with Flying Saw
and Pincer
Packaging Systems
Tool Handling
Equipment
(Press-Rest Shear
and Tool-Dismantling
Press)
Billet Saw and Shear
Billet Loader
…
Sonnenbergerstraße 4, A-6820 Frastanz
Tel. (+43) 5522 / 51 7 10-0, Fax (+43) 5522 / 51 7 10-13, www.reisch.at
46
ECKA Granulate –
Powder and
granulates of all
types and sizes
ECKA Granulate is fully conversant with the three major performance aspects of alloys, metal
powder and applications technology. The company has 18 production facilities worldwide. Its production programme includes the
production of NF-metal powders
from the pure metals aluminium,
magnesium, calcium, copper, tin,
lead, zinc, silicon and their alloys. The products are supplied in
the form of powders, granulates,
ready-made mixtures, ingots and
pellets. Among other things it produces and processes 70,000 tpy of
aluminium, 19,000 tpy of magnesium and 25,000 tpy of copper.
Some like
it hot ...
...wir schweißen kalt.
Qualitativ hochwertige
Schweißverbindungen
in Aluminium?
Wir machen das!
ALUMINIUM 2008
Halle 6, Stand 6C18
www.riftec.de
ALUMINIUM · 9/2008
The production processes include milling and pulverising, electrochemical deposition, air, water and gas atomisation and granulation from a melt, melting, and various
recycling processes. These provide customers with any
type and size of powders and granulates. The customers come from the automobile, electrical, electronic and
chemical industries and from shipbuilding and medical
technology.
Innovative developments exist in the ready-for-pressing sinter mixes ECKA Bromix and ECKA Alumix, in
lightweight construction materials such as ‘Alulight’, a
new type of material made from aluminium foam, and
ECKA Tix, a magnesium granulate for the thixomoulding process.
ECKA produces fine aluminium powder for the production of Al-solar paste, which is used in the conductive rear sides of solar cells. With its varied aluminium
atomisation techniques the company assists paste manufacturers to investigate the effects of powder condition,
chemical additions and grain size distribution on the
solar paste.
For many years ECKA has also been involved in
methods for reducing the weight of automobile components. The need for weight and size reduction in vehicle construction provides opportunities for lightweight
components made from ECKA aluminium alloy granulates, besides their technical and economic advantages,
to bring lasting ecological benefits. ECKA is responding
to the growing demand for lightweight components, in
particular for automotive engineering, by investing in
new melting, atomisation and mixing equipment at its
works in Velden.
Ecka Granulate will be an exhibitor
Hall 2, Stand B60
www. ecka-granules.com
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ALUMINIUM
· 9/2008
47
ALUMINIUM · 9/2008
47
Die Forderung zur Gewichts- und
Massenreduzierung im Fahrzeugbau
bietet für Leichtbauteile aus ECKA
Aluminium-Legierungsgrießen die
Chance, neben technischen und
wirtschaftlichen Vorteilen auch die
ökologischen Anforderungen nach-
dabei, die Auswirkungen von Pulverbeschaffenheit, chemischen Zusätzen
und der Korngrößenverteilung auf die
Solarpaste zu untersuchen.
Seit vielen Jahren beschäftigt sich
ECKA auch mit der Gewichtsreduzierung von Automobilbauteilen.
haltig zu erfüllen. Der zunehmenden
Nachfrage von Leichtbauteilen, insbesondere im Motorenbau, kommt
ECKA mit der Investition in eine neue
Schmelz-, Verdüsungs- und Mischanlage im Werk Velden nach.
N
With even more energy-efficient processes and products in the field of solar technology as well, the Norwegian
aluminium concern Hydro intends to
reinforce its commitment to climate
protection. The approach chosen for
this will be explained at ALUMINIUM
2008 in Essen by Eivind Reiten, Chairman of the Board of Hydro.
Recently, Hydro has invested substantially in extending its recycling
activities. In the company’s main
market area, in Germany, recycling
capacities now amount to more than
200,000 tpy. At present recycling furnaces are being built in Hamburg and
Rackwitz; in Neuss a furnace began
operating in September last year; a recycling centre at Alunorf, the world’s
largest aluminium casting and rolling
plant operated together with Novelis,
is to be approved shortly.
Hydro is becoming increasingly
involved in solar technology as well,
particularly in the production of silicon and wafers and the development
of building systems with integrated
photovoltaic equipment. In June the
silicon disc factory at Norsun, of which
Hydro has a share, was opened. At the
fair in Essen the concern will present
Hydro
Hydro brings climate protection
to the focus of its fair presentation
Hydro is investing substantially in extending its recycling activities
information, among other things,
about façade lamellae with thin-layer
solar cells. In numerous product applications aluminium helps to save
energy and CO2 emissions. “At the
same time we are working on further
upgrading the technology for primary
production – which we regard as crucial in order to lessen the ecological
footprint of our metal even further”,
says Reiten.
Since June 2008 Hydro has for the
first time in the group been testing
electrolysis cells with a current increased to 420 amps. The new HAL4e
technology for aluminium production
uses raw materials more efficiently
and thereby cuts specific emissions.
In addition, Hydro is looking into
energy recovery, the concentration,
precipitation and capture of carbon
dioxide from the process gases, and
is working on a modernised process
control system.
Hydro will be an exhibitor at
Hall 3, Stand A20
www.hydro.com
Kasto – Hochleistungsbandsägen für Aluminium
Kasto Maschinenbau ist ein in fünfter
Generation betriebenes, erfolgreiches
Familienunternehmen mit den Geschäftsfelder Metallsägetechnik, automatische Lang- und Flachgutlagersysteme sowie Materialhandling. In
der Metallsägetechnik ist Kasto ein
international anerkannter Marktführer, davon zeugen nicht zuletzt mehr
48
als 130.000 in alle Welt gelieferten
Sägemaschinen. Dank der frühzeitig
in das Lieferprogramm aufgenommenen Lang- und Flachgutlagertechnik sowie den Einrichtungen für das
Materialhandling in Produktion und
Metallhandel überstand das Unternehmen auch schwierige Phasen wie
jene Krise im Werkzeugmaschinen-
bau in den Jahren 1993/1994.
Kasto hat Metallsägemaschinen
zu
hochwertigen
Werkzeugmaschinen entwickelt, die sich durch
Funktionalität, Leistung und Produktivität auszeichnen. Für das Hochgeschwindigkeitssägen von Leichtmetallen wie Aluminium bietet das
Unternehmen die Kastotec- ©
ALUMINIUM · 9/2008
Kasto
der Konzeption wurde auf
Stabilität und Führung der
Sägeeinheit, eine leistungsfähige
Antriebseinheit,
Technologie- und Vorschubeinstellung sowie auf
die Entsorgung der Späne
geachtet.
Für die Hochgeschwindigkeitsbearbeitung
von
Leichtmetallen wurde die
Kasto-Baureihe in den Größen AM 4 und AM 5 mit
Die KASTOtec AM 4 – für das HochgeschwindigkeitsBandsägen von Aluminium
Arbeitsbereichen 430 x 530
mm bzw. 530 x 630 mm für
Bandgeschwindigkeiten bis 1500 m/
Bandsägemaschinen mit Aluminimin ausgelegt. Zur Steuerung der Maumpaket an. Sie zeichnen sich durch
schine kommt die Sägemaschinengutes Handling, kurze Nebenzeiten
steuerung BasicControl zum Einsatz,
und hohe Sägeleistungen aus. Bei
die über einen Auftragsspeicher für
die Eingabe von 98 Längen/StückzahlKombinationen verfügt. Aufgrund der
sehr hohen Zerspanungsvolumina
beim Aluminiumsägen ist die zuverlässige Entsorgung des großen, ständig
anfallenden Spänevolumens wichtig. Dazu säubern zwei Späneräumbürsten das Sägeband von Spänen,
wobei der Späneförderer für die
großen Mengen Späne ausgelegt ist.
Kasto ist Aussteller auf der
Halle 1, Stand E30
www.kasto.de
Gautschi – From furnace equipment to complete casthouses
Gautschi Engineering, Switzerland,
offers a product range from individual items of equipment to complete
casthouses. The main products of the
company are melting and holding furnaces for casting directly from smelter
reduction cells or integrated in remelt
lines; ingot casting and stacking machines for foundry ingots, horizontal
and vertical casting machines for
billets to produce the universal feedstock for remelt, rolled and extruded
products; heat treatment furnaces for
further treatment.
Gautschi has more than 80 years
of experience in the design of melting
and holding furnaces for light metal
which, owing to their robust construction and modern technologies, are in
service all over the world. More than
500 furnaces, in the range of 500 kg
to 130 tonnes liquid metal capacity,
have been installed up to date.
The ingot casting/stacking facility
produces smelter grade or remelt ingots and automatically packages the
aluminium ingots into compact stacks;
robot stacking is employed. The ingot
casting machine can be operated on a
continuous or semi-continuous basis
depending on the furnace and metal
supply capacity.
Robust construction with high
precision and modern measuring
and control techniques guarantee
high quality billets. ‘Airsol Veil’ or
the ‘Airglide’ system mould is used.
These mould systems are exclusively
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Regarding heat treatment furnaces, state-of-the-art design, competent
manufacturing and installation, and
effective commissioning ensure fulfilment of relevant metallurgical requirements. PLC control systems and
industrial computers facilitate the operation of the heat treatment plants
and make a fully automatic production possible.
Gautschi Engineering will be an exhibitor at ALUMINIUM 2008 in Essen.
Hall 3, Stand G50
www.gautschiengineering.com
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50
ALUMINIUM · 9/2008
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– M E S SAELVUOMR ISNCIHUAMU 2 0 0 8 –
FAIR PREVIEW
Ebner Industrieofenbau
Industrial furnaces
with high-convection
technology
Industrieöfen mit
Hochkonvektions-Technologie
The product range of the company
Ebner Industrieofenbau, founded
just 60 years ago, includes heat
treatment furnaces for the steel
and also the aluminium and copper industries. Its hood annealing
furnaces are first in line, but continuous -throughput furnaces for
strips, sheets, plates and tube coils
and also chamber furnaces play
an important part as well. In general, the name Ebner is associated
with the term ‘Hicon’.
©
Das Lieferprogramm des vor
knapp 60 Jahren gegründeten Unternehmens Ebner Industrieofenbau umfasst Wärmebehandlungsöfen sowohl für die Stahl- als auch
für die Aluminium- und Kupferindustrie. In erster Linie sind das
Haubenglühöfen, daneben spielen
Durchlaufglühöfen für Bänder,
Bleche, Platten und Rohrbunde sowie auch Kammeröfen eine Rolle.
Dabei ist der Name Ebner mit dem
Begriff „Hicon“ verbunden.
Ebner
Ebner Industrieofenbau
Ebner Werkstatt in Leonding, Österreich
Ebner workshop in Leonding, Austria
Hicon steht für
„High Convection“ und bedeutet den Einsatz von HochkonvektionsTechnologie,
die sich durch
eine funktionsspezifische und
verlustarme
Umwälzung der
Ofenatmosphäre, optimierten
Medienfluss
um die gesamte
Charge sowie
einen sehr geringen Energieverbrauch dank einer effizienten Isolierung und externer Rekuperatoren für
jede Ofenzone auszeichnet.
In der Aluminiumindustrie gehört
Ebner heute zu den weltweit führenden Spezialisten für Wärmebehandlungsöfen. Das Spektrum reicht von
Stoßöfen für das Homogenisieren und
Anwärmen von Walzbarren, Kammer-Glühöfen für Aluminiumbunde
in Einzel- oder Mehrfachbelegung,
Bandschwebeöfen zum kontinuierlichen Glühen von Bändern und
nicht zuletzt auch Rollenherdöfen für
hochwertige Aluminiumplatten und
-bleche in Luftfahrtqualität.
Auf dem Sektor der Stoßöfen für
Walzbarren gilt Ebner mit bisher
mehr als 30 weltweit gebauten Anlagen als Marktführer. Stoßöfen werden eingesetzt zum Homogenisieren
und Anwärmen auf Walztemperatur
von Walzbarren mit Gewichten bis
zu 30 Tonnen und Abmessungen bis
zu 8650 mm x 2200 mm x 650 mm.
Bei diesen Anlagen erreicht Ebner mit
Hilfe der Hicon-Technologie kürzestmögliche Anwärmzeiten mit einer
maximalen Temperaturdifferenz von
6°K über die gesamte Charge.
©
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ALUMINIUM
· 9/2008
51
ALUMINIUM · 9/2008
51
Speziell für Stoßöfen hat Ebner das
sogenannte „Pusher Optimisation
System (POS)“ entwickelt – ein PCgestütztes mathematisches Modell zur
Bestimmung der Temperatur jedes
einzelnen Walzbarrens im Ofen. Das
System ermöglicht die Einhaltung der
korrekten Aufheiz- und Haltezeiten
jedes einzelnen Walzbarrens. Das
Ergebnis ist nicht nur eine hervorragende Qualität der Walzprodukte,
sondern zugleich auch eine optimale
Nutzung der Anlage.
Ebner Industrieofenbau gehört zu
jenen Unternehmen, die frühzeitig
erkannt haben, dass es vorteilhaft ist,
in wesentlichen Marktregionen durch
eigene Produktion vertreten zu sein.
Bereits 1987 wagte Ebner den Schritt
in die USA. Die Investition in den
Wachstumsmarkt China ist ein weiterer, konsequenter Schritt in diese
Richtung. Ende 2004 nahm die im
österreichischen Leonding ansässige
Firma ein neu errichtetes eigenes
Werk in China, im Großraum Shanghai, in Betrieb, um die Wachstumsmärkte in Asien zu bedienen.
So lieferte Ebner u. a. für die chinesische Nanshan-Gruppe zwei Stoßöfen zum Anwärmen von Walzbarren.
Die beiden direkt gasbeheizten HiconStoßöfen zum Homogenisieren und
Anwärmen der Walzbarren mit einem
Querschnitt von 2100 mm x 610 mm
und Längen bis 8,65 m werden von
einer gemeinsamen Vorrichtung beschickt und entladen. Die Öfen besitzen eine Kapazität von je 750 Tonnen
und fassen jeweils 25 Walzbarren.
N
‘Hicon’ stands for High Convection
and refers to the use of high-convection technology, which is characterised by function-specific and low-loss
circulation of the furnace atmosphere,
optimized media flow around the entire charge, and very low energy consumption thanks to effective insulation and an external recuperator for
each furnace zone.
In the aluminium industry, today
Ebner is one of the world’s leading
specialists for heat treatment furnaces.
The range extends from pusher-type
furnaces for homogenising and heating rolling slabs, through chamber
annealing furnaces for single- or multiple-charge aluminium coils, floating
strip furnaces for the continuous annealing of strips and, not least, also
roller hearth furnaces for high-grade
aluminium plates and sheets of aviation quality.
In the sector of pusher furnaces
Ebner, which has so far built more than
30 such plants worldwide, is the market
leader. Pusher-type furnaces are used
for homogenising rolling slabs that
weigh up to 30 tonnes and measure up
to 8650 mm x 2200 mm x 650 mm and
heating them to the rolling temperature. In these plants, with the aid of
Hicon technology Ebner achieves the
shortest possible heating times with a
maximum temperature difference of 6
K across the whole charge.
Specially for pusher furnaces,
Ebner has developed the so-termed
‘Pusher Optimisation System’ (POS)
– a PC-supported mathematical model for determining the temperature
of each individual rolling slab in the
furnace. The system makes it possible to maintain the correct heating
and holding times for each individual
rolling slab. The result is not only outstanding rolled product quality, but at
the same time also optimum utilisation of the plant.
Ebner Industrieofenbau is among
those companies which recognised
early on that it is an advantage to be
represented with one’s own production facility in important market regions. Already in 1987 the company
moved into the United States. The investment in China’s growth market is
another, consistent step in that direction. At the end of 2004 the company,
located in Leonding, Austria, began
operating a newly constructed plant
of its own in China, in the Greater
Shanghai area, in order to serve the
growth markets in Asia.
Thus, among other things Ebner
has supplied the Nanshan Group in
China with two pusher-type furnaces
for heating rolling slabs. The two, directly gas-fired Hicon pusher furnaces
for homogenising and heating rolling
slabs with a cross-section of 2100 mm
x 610 mm and lengths up to 8.65 m,
are loaded and unloaded by a shared
machine. Each furnace has a capacity
of 750 tonnes and each can accommodate 25 rolling slabs.
Ebner will be an exhibitor
Hall 3, Stand H30
www.ebner.cc
Dienes – Werkzeugsysteme für Längs- und Querteilanlagen
Schneidspezialist Dienes darf für sich
in Anspruch nehmen, das Längs- und
Querteilen von Aluminiumfolien und
Dünnband zur Präzisionstechnologie
entwickelt zu haben. Wo heute Materialbahnen aus Kunststoff, Papier, Textilien und zunehmend aus Aluminium
längs- oder quergeteilt werden müssen, ist das Unternehmen mit seinen
Remscheider Tochtergesellschaften
Neuenkamp und Johann Krumm mit
großer Wahrscheinlichkeit als ©
52
Dienes – Tool systems
for slitting and cutting machines
The cutting specialist Dienes can
claim to have developed the slitting
and cross-cutting of aluminium foils
and thin strips into a high-precision
technology. Nowadays, where material lines of plastic, paper, textiles
and increasingly aluminium as well
have to be slit or cross-cut to length,
the company with its subsidiaries
Neuenkamp and Johann Krumm are
very probably called in to supply the
tools.
Today aluminium foils and this
strips are produced and processed by
high-productivity units. These plants
have integrated the cutting ©
ALUMINIUM · 9/2008
Dienes
Werkzeuglieferant im Gespräch.
Aluminiumfolie und -dünnband
wird heute auf hochproduktiven Anlagen erzeugt und verarbeitet. Diese
Anlagen haben die Schneidoperationen in den kontinuierlichen Prozess integriert. Schneideinrichtungen
für Aluminium werden vorwiegend
an Rollenschneidmaschinen, Dopplern,
Besäumanlagen,
Längsteilscheren, Separiermaschinen und
Walzgerüsten
eingesetzt.
Auf diesen
Sektoren
arbeitet
Dienes
mit allen
namhaften AnlagenScherenschnittmesserhalter bauern eng
zusammen,
Knife holder
für die das Unternehmen drei unterschiedliche Schneidverfahren zur
Verfügung stellt:
• Der Rasierklingenschnitt ist vor
allem für extrem dünne Folien geeignet. Hierbei handelt es sich um einen
freien Schnitt. Das Schneidwerkzeug
ist eine Klinge, die auswechselbar in
einem Messerhalter aufgenommen
ist. Die relativ einfache Anordnung ist
kostengünstig.
• Das Konzept des Scherenschnitts
ist gleichfalls für dünne Folien einsetzbar. Das Obermesser taucht hier in die
Schneidnuten einer unteren Messerwelle ein. Das zu schneidende Material wird dabei (wie bei einer Schere)
zwischen den beiden Schneidkanten
des Ober- und Unterwerkzeuges abgeschert.
• Beim Rollscherenschnitt handelt
es sich um eine stabile Werkzeuganordnung, die auch für dickere Materialien und entsprechend höhere
Beanspruchungen geeignet ist. Der
Einsatzbereich beginnt bei etwa 400
μm Dicke; für die Folienindustrie
ist diese Schnittversion deshalb in
den Vorstufen der Folienproduktion
– für dünne Bänder – geeignet. Mit
dem Verfahren lassen sich auch sehr
schmale Streifen erzeugen.
Für die verschiedenen Verfahrensvarianten hat Dienes Messerhalter
mit einem vielfältigen Zubehör entwickelt. So kommt es im Schneidbetrieb
unter anderem darauf an, dass Oberund Untermesser extrem feinfühlig in
jeder Richtung positioniert werden
können. Man hat dazu eine Reihe
von spezifischen Einstellgrößen definiert, die ihrerseits wiederum vom zu
schneidenden Material abhängen. Die
notwendige Präzision wird mit spielfreien Kugelführungen erreicht. Darüber hinaus hat Dienes die Halter mit
zusätzlichen Funktionen ausgestattet,
die das Schneidergebnis verbessern,
die Rüstzeiten reduzieren helfen und
einen störungsfreien Schneidbetrieb
sicherstellen.
N
Metallanalyse mit SPECTROMAXx
Wenn Sie mit (zu) hohen Betriebskosten
kämpfen - mit SPECTROMAXx können Sie
sparen. Weil der neuartige Funkenstand
sehr wenig Argon verbraucht. Und weil Sie
kaum noch Zeit für die tägliche Wartung
benötigen.
Sie haben Anforderungen
Wir haben die Lösung
54
Profitieren Sie von der Leistungsfähigkeit des
Marktführers. Sprechen Sie mit uns und lassen
Sie sich informieren, warum Metallanalysatoren
von SPECTRO eine Investition in bessere
Effizienz und höhere Rentabilität sind.
Tel. +49.2821.892-2110,
[email protected],
www.spectro.de/maxx
Besuchen Sie uns: Aluminium 2008,
23.-25. September, Essen,
Halle 2, Stand 2E28
ALUMINIUM · 9/2008
simplex.de | 08.08
SPECIAL
operations in the process as a whole.
Cutting devices for aluminium are
mainly used on roller cutting machines, doublers, trimming machines,
cut-to-length shears, separators and
rolling mills. In these sectors Dienes
collaborates closely with all the noted
equipment manufacturers, for which
the company provides three different
cutting methods:
• Razorblade cutting is appropriate above all for extremely thin foils.
In this case a free cut is made. The
cutting tool is a blade held in a blade
holder, in which it can be replaced.
The relatively simple arrangement is
inexpensive.
• The concept of shear cutting can
also be applied for thin foils. In that
case the upper blade plunges into the
cutting grooves of a lower blade shaft.
The material to be cut is sheared between the cutting edges of the upper
and lower tools (as in a shearing machine).
• Roll shear cutting is done with a
stable tool arrangement, which is also
suitable for thicker material and correspondingly higher loads. The useful
range begins at about 400 μm, so in
the foil industry this cutting version is
appropriate in the preliminary stages
of foil production, i. e. for thin strips.
The method can also be used to produce very narrow ribbons.
For the various process variants
Dienes has developed blade holders with numerous accessories. For
example, in cutting operations the
upper and lower blades have to be
positioned very sensitively in all directions. A series of adjustment magnitudes has therefore been defined,
which in turn depend on the material
to be cut. The required precision is
achieved with play-free ball guides.
In addition, Dienes has equipped the
holders with additional functions
which improve cutting results, help
to reduce fitting times and ensure
trouble-free cutting operations.
Dienes will be an exhibitor
Hall 7, Stand B30
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ALUMINIUM · 9/2008
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BWG – Spitzentechnik für hochwertiges Aluminiumband
Die Firmengründer starteten 1955 mit
Ausrüstungen für den Bergbau und
die sich entwickelnde Stahlindustrie
im Revier. Mit dem aufstrebenden
Werkstoff Aluminium kam das Unternehmen erstmalig 1976 in Kontakt. In jenem Jahr erhielt die BWG
den Auftrag über eine komplette Anlage für das Werk Grevenbroich der
damaligen VAW. Die Reck-, Entfettungs- und Chromatierlinie für Aluminiumbänder war der erste Auftrag
für eine komplette Bandprozesslinie,
und er diente lange Zeit als Referenz
für neue Projekte.
Die hervorragende Planlage der
Bänder weckte das Interesse weiterer
Bandproduzenten. Bis heute wurden
mehr als 20 dieser Streck-Richt-Anlagen (Bezeichnung: Levelflex) gebaut.
Es waren zunächst vor allem amerikanische Kunden, die diese neue Technik in großem Umfang bestellten. So
begann in den 1980er Jahren eine intensive, bis heute andauernde Zusammenarbeit mit der amerikanischen
Alcoa. Das Lithographiezentrum für
Alcoa Davenport (geliefert 1994)
bestand aus einer Entfettungs- und
Levelflex-Linie sowie einer separaten
Besäum- und Längsteillinie.
Daneben entwickelte sich auch die
Zusammenarbeit mit dem Kunden
VAW erfreulich. Im Jahre 1985 lieferte
BWG eine komplette Reck- und Entfettungslinie für das Werk Grevenbroich.
1992 folgte das Lithozentrum II, das
die Kapazität des Werkes etwa verdoppelte. Ein besonderer Meilenstein
ist das Lithozentrum III für Bandbreiten bis 2100 mm. Diese hochmoderne
Anlage mit einer Kapazität von etwa
75.000 Tonnen repräsentiert Spitzentechnik in der Bandbehandlung. Mit
dieser Investition ist Hydro eindeutiger Marktführer am schnell ©
56
BWG – Top-class technology
for high-grade aluminium strip
The company BWG Bergwerk- und
Walzwerk-Maschinenbau GmbH
located in Duisburg is one of the
important equipment suppliers for
the worldwide aluminium rolling
plant industry. Above all when
the quality of the strip has to be
particularly high, noted processors
all over the world turn to BWG
technology.
In 1955 the founders of the company
started with equipment for mining
and for the developing steel industry
in the area. The company came into
contact with the then up-and-coming material aluminium for the first
time in 1976. In that year BWG was
awarded the contract for a complete
plant to go to the Grevenbroich works
of the then VAW. The stretch-straightening, degreasing and chromating line
for aluminium strip was the first contract for a complete strip process line
and it served for a long time as a reference for new projects.
The outstanding flatness of the
strips awakened the interest of other
strip producers as well. So far, over
20 of these stretch-straightening units
(known as Levelflex) have been built.
It was at first mainly American customers who took up this new technology to a substantial extent. Thus, in
the 1980s an intensive collaboration
began with Alcoa in America, which
has lasted to the present day. The
lithography centre for Alcoa Davenport (delivered in 1994) consisted of
a degreasing and Levelflex line and a
separate trimming and slitting line.
In addition, the collaboration with
the customer VAW also continued to
develop gratifyingly. In 1985 BWG
supplied a complete stretching and
degreasing line for the Grevenbroich
plant. This was followed in 1992 by
Lithocentre II, which approximately
doubled the capacity of the plant. A
particular milestone in Lithocentre III
for strip widths up to 2100 mm. This
highly modern unit, with a capacity of
around 75,000 tonnes, represents the
very best available in strip treatment
technology. With that investment Hydro has become the clear leader in the
rapidly growing market for litho strip.
As the material aluminium grew
in importance through the 1980s,
at BWG it established an independent position of its own alongside the
original work sector of ‘steel’. Progressively, the extensive experience
accumulated from the steel sector
– appropriately modified to suit aluminium – was converted for aluminium processing. More and more often
other producers, too, turned ©
Fotos: BWG
Die in Duisburg ansässige BWG
Bergwerk- und Walzwerk-Maschinenbau GmbH zählt zu den
bedeutenden Ausrüstern der weltweiten Aluminium-Walzwerksindustrie. Vor allem bei besonders
hohen Anforderungen an die Qualität des Bandes greifen namhafte
Verarbeiter aus aller Welt auf
BWG-Technologie zurück.
Lithographiezentrum III im Hydro-Werk Grevenbroich (2005)
Lithography centre III at the Hydro plant in Grevenbroich, Germany (2005)
ALUMINIUM · 9/2008
wachsenden Markt für Lithoband.
In dem Maße, in dem der Werkstoff Aluminium in den 1980er Jahre an Bedeutung gewann, konnte er
sich auch bei der BWG neben dem
angestammten Arbeitsgebiet „Stahl“
eigenständig positionieren. Dabei
gelang es immer wieder, die umfangreichen Erfahrungen auf dem Stahlsektor – werkstoffgerecht modifiziert
– auf die Aluminiumverarbeitung zu
übertragen. Immer öfter griffen auch
andere Produzenten auf die BWGTechnologien zurück. Einer neuen
Herausforderung sah sich das Unternehmen gegenüber, als Aluminiumbleche zunehmend in der Automobilkarosserie Verwendung fanden.
Als Corus Aluminium im belgischen
Duffel 2002 eine neue HochleistungsKontiglühe mit Bandvorbehandlung
(CALP-Linie) zur Produktion von
Aluminium-Karosserieband plante,
wurde BWG als Lieferant für die
komplette maschinelle Ausrüstung
ausgewählt.
N
Lithographiezentrum für Alcoa Davenport (1994)
Lithography centre for Alcoa Davenport (1994)
toward BWG technology. The company was faced by a new challenge as
aluminium started to be used increasingly for automobile body components. When Corus Aluminium in Duffel, Belgium, planned a new, high-performance continuous annealing line
with strip pretreatment (CALP line)
for the production of aluminium auto-
body strip, BWG was chosen to supply all of the mechanical equipment.
BWG will be an exhibitor at ALUMINIUM 2008 in Essen.
Hall 3, Stand O30
www.bwg-online.de
gy
olo ing
n
ch st
ote ot ca
n
Na ing
for
Protect your moulds
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COMP MetCast
The innovative release coating for greater productivity
Nanocomp MetCast is the world’s first permanent nano-ceramic release coating
– perfectly suited for open-mould casting in metal production. The working
principal: applied in a thin layer to the mould, it allows long-term production with
excellent process stability. Nanocomp MetCast is insensitive to temperature
shock, molten metal and cooling water. Even in continuous production, a
MetCast coating holds up for several weeks, after which it merely needs to be
reapplied on specific areas.
Your benefits:
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58
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ItN Nanovation AG
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● Improved quality due to consistent
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Tel.: +49 (0) 681 / 50 01 – 561
Fax: +49 (0) 681 / 50 01 – 499
[email protected]
www.itn-nanovation.com
ALUMINIUM · 9/2008
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FAIR PREVIEW
Italian extrusion and rolling technology in Essen
Italy is not only one of the countries
with the highest concentration of extrusion presses in the world, rolling of
advanced aluminium products is also
very important. It is not surprising,
therefore, that this flourishing market
also encourages plant manufacturers to develop advanced equipment
for producing aluminium rolled or
extruded semi-finished products. Together with some of Italy’s major producers of aluminium semis, many of
these companies will be exhibiting at
the Aluminium 2008 trade fair in Essen in order to meet their customers
from all over the world and present
their latest technologies. In the following a summary report.
Almax Mori – The ‘butterfly’ experts
ALUMINIUM
· 9/2008
59
an alliance that benefits
from synergies in the commercial and administrative
fields but still allows both
companies to act independently when it comes to
technical development, customer service and tooling
manufacture.
Looking for a way to improve
extrusion press productiv- ©
Almax Mori
Almax Mori Srl was established
following the closure of Alcoa
Transformazioni’s in-house toolmaking facility in 2004; Alcoa
Transformazioni was originally
founded in 1965 as Almax Italia.
The company had previously
worked closely together with Alumat, which was formed in 1993
and also specializes in the manufacture of extrusion tooling. The
two companies have thus formed
Butterfly die
ALUMINIUM · 9/2008
59
ALUMINIUM 2008 – FAIR PREVIEW
ity, Almax Mori has developed extrusion tooling with bridges that have
an arched shape instead of the usual
angular shape. The butterfly-like appearance made finding a name for the
new product easy: ‘butterfly die’. The
shape of the bridge enables the alu-
minium to flow better as a result of
reduced friction. This in turn leads to
extrusion speeds that are up to 80%
higher than those with conventional
dies and thus to a marked increase in
the productivity of extrusion presses.
Almax Mori Srl will be an exhibitor at
Hall 1, Stand E14
www.alumat.it
ATC
ATC – ‘Full liner’ for extrusion presses and surface treatment
ATC Aluminium Trevisan
Cometal is presenting itself as a ‘full liner’ when
it comes to plant for the
production and surface
treatment of extruded
profiles. With its
‘Cometal’ brand, the
group is particularly
active in engineering
and manufacturCometal balanced intensive cooling system
ing of complete
remelting foundries, having also developed a new ‘double chamber’ melting furnace for melting contaminated
scrap. Other products are complete extrusion lines, in-
cluding extrusion presses. Cometal has developed both
back- and front-loading extrusion presses. Regarding
vertical and horizontal coating lines, the ‘Trevisan’ brand
has confirmed its position as a market leader thanks also
to its new self-cleaning booths and the international patents obtained. Autel, a wholly owned subsidiary of Trevisan Cometal, has gained a consistently large share of
the market for packing lines and is building on this success by now offering anodizATC will be an exhibitor at
ing lines (see
article about
Hall 3, Stand J50
Autel’s packwww.atccompany.com
aging solutions
on p. 70).
ONLINE AUCTION SALE
due to BANKRUPTCY of
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Nobelstr. 24 – 3846 CG Harderwijk (The Netherlands)
Aluminium and
Metalworking Machines
3 CNC 5-AXIS PROFILE MACHINING
CENTERS “Handtmann” PBZ NT 800 AS (‘03/‘02/
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“Okuma” MX 45 VAF, xyz 760x460x450 mm, 2x “Supermax” YCM-V116A (‘99/’95), xyz 1100x600x630 mm,
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“Victor“ Vcenter 105 (‘98), xyz 1050x560x560 mm, with
controls “Okuma”, “Mitsubishi”, “Fanuc”; CNC autom.
LATHE “Okuma” LB15 II (‘96), ø 340x1000 mm, with
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CLOSING: Thu 11 SEPTEMBER from 2.00 pm
VIEWING: Tue 9 September from 10.00 am till 4.00 pm.
Photobrochure / Catalogue on our website
www.troostwijkauctions.com
60
Omav – Competence from
log handling to ageing ovens
Omav Spa, located in Rodengo Saiano near Brescia, will
take the opportunity in Essen to inform visitors about its
complete range of extrusion line equipment, which the
company has been producing for over 40 years. Omav’s
capabilities cover log handling and everything downstream of the extrusion line as far as the ageing oven.
Press feeding lines include gas-fired billet heaters and
hot shears. Extrusion handling systems feature various
designs of cooling system, such as a water spray with
standing wave, spray cooling or air cooling, which are selected in accordance with the customer’s requirements.
Omav’s range also includes hot saws and various designs
of puller as well as a variety of stretcher designs, finishing
saws and stackers.
Besides Italy, the company has achieved an excellent
reputation in the North American market. This position
was recently confirmed by two orders from Kaiser Aluminum Kalamazoo in the USA for two handling systems
– one for a 40 MN press and the other for a 60 MN press.
In addition, the company is presently working on an order for a handling system for a 50 MN extrusion press
for Nanping Aluminium in China.
In order to guarantee that customers achieve added
value in terms of higher quality, reliability and after- ©
ALUMINIUM · 9/2008
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ptember
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Hall 3, Bo
sales service, Omav produces everything in Italy and only uses components made in Europe.
Omav has recently invested in
a new division, Omav Combustion,
which is dedicated completely to
manufacturing ovens and alumin-
ium foundry plants. With this move
the company plans to commit more
resources to the design and implementation of technological solutions
that enable energy consumption to be
reduced.
Omav will be an exhibitor at
Hall 3, Stand C60
www.omav.com
Phoenix International – Simulation helps find right die
Phoenix International Spa offers extrusion simulation as a means of ‘closing the loop’ in die-design.
Extruders are constantly faced with
demands for product performance
and productivity, surface quality and
profile tolerances. Presses, cooling
systems, anodizing and coating equipment are constantly in use in order
to achieve an optimal product. The
die system plays an important role in
extrusion so it needs to be designed
carefully. A non-optimized design
can negatively influence the profiles
produced in terms of temperature,
speed and productivity; in the worst
case, bad design can lead to deformation or deflection of the die, resulting in profiles with a poor surface
finish and unacceptable tolerances.
Simulation and technical devices
allow the extruder to know exactly
what is going to happen to both the
profile and the die when a particular
design is chosen. It helps find the die
that fulfils the extruders’ needs in
terms of productivity, profile heating
and welding, tolerances and deflection. And it does so without the need
for expensive trials.
Simulation offers die-makers the
opportunity to operate what is effectively a ‘virtual’ press. It allows loading movements, aluminium flow and
welding processes to be reproduced
from the starting billet through to the
profile exiting the die. For example,
critical parts can be investigated for a
given profile speed and local pressure
fields in order to evaluate dimensions
and tolerances; temperature distribution checks can be carried out to
find overheated zones that can have
a negative effect on profile quality;
and local pressure analysis also helps
investigate profile microstructure in
terms of welding quality and grain
recrystallization.
Phoenix International will be an exhibitor at ALUMINIUM 2008 in Essen.
Hall 1, Stand G15
www.phoenix-group.it
OMS Impianti Srl from Artegna in
northern Italy specializes in the design and construction of complete
aluminium extrusion plants. The
company’s product range comprises
complete billet handling, heating
and cutting upstream of the extrusion press. Downstream of the press,
OMS’s portfolio is complemented by
single, double and triple puller systems with flying cut-off or mobile
system, stretcher systems, final gauge
tables, stacking and destacking machines. Various ageing systems are
also part of OMS’s product range:
traditional ageing ovens with low baskets as well as semi-automatic ageing
with tall baskets and systems without
any baskets.
In addition to traditional systems,
OMS also offers two automatic and
innovative solutions for extrusion
plants: the patented FTS system (Fixed
62
OMS
OMS – Successful with ‘Moby Dick’ continuous ageing system
Translation System) and the patented
‘Moby Dick’ system, which is an automatic continuous-ageing system.
Traditional ageing processes normally take 70 to 90 minutes to heat
up the profiles and baskets from room
temperature together with an ageing
time of approx. 4 hours. Such systems
require stackers, manipulators, baskets and spacers – all expensive items
ALUMINIUM · 9/2008
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that take up space and need constant
maintenance. The Moby Dick concept
improves the management of the profiles, eliminating the need for baskets,
spacers, manipulators and operators;
it completely automates the whole operation from the final cut through to
packaging. After the final cut, the material is fed in batches and transferred
automatically to a powered roll-way
lift at the entrance to the oven. Inside
the oven there a number of horizontal
levels to position and transfer the profiles. Once inside the oven, the profiles move in a transverse direction,
following the thermal cycle.
After ageing, the profiles are re-
moved from the oven by means of an
unloading lift. Loading and unloading
is continuous, and with it the whole
ageing treatment. The system has a
thermal efficiency that is 40 to 50%
higher than traditional systems. The
oven is always at the desired temperature, thus totally eliminating any
preheating time. The temperature remains constant, making the treatment
more homogeneous on all faces and
over the whole length of the profiles.
A traditional system complete with
basket management has a floor space
requirement of approximately 1200
m2, whereas the Moby Dick system
only requires approx 800 m2.
FAIR PREVIEW
Moby Dick can be adapted to all types
of plant (old and new) and its height
or length can be modified depending on the layout of the plant or customer requirements. Moby Dick has
already been installed at major Italian
extruders, where it is operating very
satisfactorily with fast returns on investment.
OMS will be an exhibitor at
Hall 6, Stand D34
www.omsimpianti.com
Fata Hunter – Successful supplier to the flat-rolled product sector
Italian flat-products technology will
be shown in Essen not only by some
of the well known plant makers, but
also by several rolling mills exhibiting
their advanced rolled products.
Fata Hunter is one of the most successful suppliers of technologies, engineering and equipment for the aluminium flat rolled products industry.
Thanks to its continuous innovation
and proven technology, the company has become a preferred supplier
worldwide, ensuring outstanding operational flexibility and the capability
to provide each customer with ©
CUT-TO-LENGTH LINE
research, innovation, experience
aluminium | copper | brass | stainless steel
ROTATING SHEAR
for scroll cut
performances
aluminium
and alloys |
from 0.1 to 3.5 mm
till 120 mpm
with rotating shear
stainless steel |
from 0.2 to 5.0 mm
till 120 mpm
ALUMINIUM
· 9/2008
63
advantages
special devices
cutting accuracy,
strip oiling (DOS),
absence of scratches
and marks,
scroll die,
quick and precise
adjustments of the
blades position,
fast coil change and
easy maintenance
strip thickness control,
in line strip trimming,
in line tension levelling,
in line holes detection,
vacuum stacker
our programme
degreasing, coating,
tension levelling,
slitter,
cut-to-length,
ingot milling,
oiling, trimming,
revamping
ALUMINIUM · 9/2008
63
a unique combination of in-house
technological expertise, production
equipment and engineering services
for the successful implementation of
stand-alone equipment (such as continuous casting lines; cold and foil
rolling mills; finishing equipment, like
tension and stretcher levelling lines,
foil separators, and slitters; and coil
coating lines for aluminium and steel)
or complete turn-key plants for the
manufacture of aluminium flat rolled
products.
Fata Hunter is a division of Fata
Spa, a diversified group of companies
active in the field of industrial plant
engineering and contracting, fully
owned by Finmeccanica Spa, a leading Italian industrial group in the field
of advanced technologies. The group
is active in aeronautics, helicopters,
space and defence.
During this year’s exhibition, the
company will highlight an order that
Fata Spa’s Fata EPC division was
awarded by Qatar Petroleum and
Hydro Aluminium for engineering,
procurement and construction (EPC)
of the casthouse and anode baking
Fata Hunter
Twin-roll caster at Otefal
plant at the new Qatalum aluminium
smelter. Construction works started
at the beginning of 2008, and production of the casthouse and the anode
baking plant will commence in the
latter part of 2009. Qatalum will be
the largest-ever new aluminium plant,
with a first phase capacity of 585,000
tpy of primary aluminium.
Fata Hunter will be an exhibitor at
Hall 3, Stand G30
www.fatahunter.com
Presezzi Extrusion Spa is one of the
fastest growing manufacturers of
extrusion presses. The company developed from a highly specialized
manufacturing plant that focused at
first on the production of components
for rolling mills and extrusion presses, offshore platforms and turbines.
Since receiving its first contract for a
new 16.5 MN extrusion press in 1993,
Presezzi Extrusion, as the division of
Bruno Presezzi came to be known,
has supplied more than 80 extrusion
presses, with capacities up to 65 MN,
to important extruders all over the
world. Today, Presezzi Extrusion is
synonymous with first-class technology coupled with reliability, flexibility
and competitiveness.
The company’s product range includes direct and indirect presses with
loading either at the front or back; ten
more presses with capacities ranging
from 1,800 to 5,800 tonnes will be
built in 2008; including a 25 MN front-
64
Presezzi Extrusion
Presezzi Extrusion – Full order book for extrusion presses
Final assembly
loading press scheduled for installation at the end of this year at a plant
in Germany. Current export orders include projects in Brazil (a front-loading 24.5 MN press), China (55 MN),
Russia (18 MN), England (18 MN), the
USA (a 55 MN back-loading press) and
Serbia (an 18 MN back-loading press,
for a company that is already operating a 30 MN back-loading press).
Presezzi Extrusion has extended
its supply capability to include ©
ALUMINIUM · 9/2008
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the delivery of complete, turn-key
extrusion lines by collaborating
with specialist suppliers of the various plant components upstream and
downstream of the press. If the client
wishes to deal with a single supplier,
Presezzi Extrusion takes on the lead
role in such projects.
The company expects to maintain
its course of continuous growth in
2008, meeting demand for heavier
and more powerful presses from extruders in Europe and the rest of the
world.
Presezzi Extrusion will be an exhibitor
Hall 3, Stand K20
www.presezziextrusion.com
Estral – From micro to automotive
It is not only plant makers from Italy
that will be exhibiting in Essen: some
Italian extrusion companies will also
be there to demonstrate the high technological standards of their products
to European and overseas customers. One of these companies is Estral
Spa which has been working side by
side with its clients to study, develop
and produce custom-shaped aluminium extruded profiles. The company
started operation in 1974 with a small
6-MN extrusion press. Annual production was 2000 tonnes of profiles
with tiny sections, thicknesses down
to 0.8 mm (microprofiles of 35 g/m)
and narrow dimensional tolerances.
Nowadays, Estral is equipped with six
extrusion press lines with capacities
of 13, 16.5, 20 (two presses), 25 and 45
MN and produces more than 55,000
tpy of high-precision profiles. The
company refers to this development
as being ‘from micro to automotive’,
describing its experience, capabilities
and cutting edge technology plant for
producing a wide range of sections.
The latest extrusion press to be installed is a 45 MN Schloemann frontloading press utilizing 10-12” billets.
It produces large profiles with weights
of more than 20 kg/m and lengths of
up to 18 m, in different alloys, including hard ones. Intensive cooling is
achieved using a new system developed by and patented for Estral. The
company also engineered the run-out
equipment, including a double puller,
itself. No baskets are in use from press
to truck.
In order to meet its customers’
needs, Estral also supplies value-adding services such as anodizing, powder coating, thermal breaks and different mechanical treatments.
Estral will be an exhibitor at
Hall 3, Stand D50
www.estral.it
Bruno Presezzi Spa is based in Burago Molgora (Milan, Italy) and during its more than 30 year existence
it has become a reliable supplier of
cores and shells for twin-roll casters
worldwide, both in Presezzi patented
and traditional configurations. In May
2003 the company started up the first
TT1000 continuous casting line at the
Profilglass facility in Fano, Italy, based
on Presezzi engineering and manufacturing. This first caster was followed
by installation of four additional machines of the same size at Profilglass.
A further Presezzi twin-roll casting
line comprising a TT800 caster is operating at AK Aluminyum in Konya,
Turkey.
Presezzi recently signed a contract
with the Al Hamad Group of Dubai for
the supply of engineering, construction, delivery and commissioning of
a complete plant for the production
of aluminium strip for the Alumill-
66
B. Presezzi
Bruno Presezzi – Reliable supplier for twin-roll casters
Erection of twin-roll casters at Profilglass
tech Gulf greenfield project. When
it enters full production in 2009, one
of the plant’s main targets will be to
increase the initial production capacity in the following two to three years
to allow the company to keep pace
with future growth in the booming
Gulf area.
The scope of supply includes two
complete twin-roll continuous casting
lines comprising melting and holding
furnaces with degassing and filtration
ALUMINIUM · 9/2008
S
AML 2 0 0 8
A LPU E
M ICN II U
equipment, one 4-high cold rolling
mill and one annealing furnace. Alumilltech Gulf will produce aluminium
strip and cold rolled coils for the civil
construction business (roofing profiles, sandwich panels, etc).
The casters will be Presezzi type
TT600 with rolls having the already
well known Presezzi patented configuration.
The contract also includes a programme of technical/technological
support for a minimum of one year.
FAIR PREVIEW
Bruno Presezzi will be an exhibitor
Hall 3, Stand K20
www.brunopresezzi.com
Profilglass Spa will be presenting
its special products made from thin
aluminium strip produced at its own
plant in Fano. In just 26 years the
company has grown from a small
operation producing spacer bars for
double glazing to become the world
market leader for these and similar
thin-walled aluminium products.
Moreover, in 2001 the company initiated a programme to install melting, casting and rolling facilities of
its own, which not only produce the
starting material for further downstream processing, for example into
spacer bars, but also produce a range
of flat aluminium products for the
international market. In 2009, when
the current extension is completed
with the installation of a new hot-
Profilglass
Profilglass – Market leader for thin-walled aluminium products
The new cold-rolling mill
and cold-rolling mill, there will be a
substantial increase in the present capacity of 90,000 tpy of rolled aluminium products (see our article about
Profilglass on pp. 92-96).
Profilglass will be an exhibitor at
Hall 1, Stand E50
www.profilglass.it
Turla – Highlighting intensive quenching systems
Turla Srl has supplied more than
400 customized handling systems to
aluminium extrusion plants all over
the world during the past 30 years
or more. The family-owned business
serves the global extrusion market
with all kinds of press-peripheral
equipment, from log heating and log
saws through to entire finishing lines
and including ageing ovens and rack
circulation systems.
Intensive quenching systems are
a speciality of Turla. 2008 has confirmed the company’s excellence in
this technology, achieved through
years of cooperation with the most
important producers of aluminium
profiles for industrial, automotive and
aerospace applications.
Turla offers three types of intensive quenching system, thus ensuring
that the complete range of alumin-
ALUMINIUM
· 9/2008
67
ium extruded products can be properly treated: the intensive air quench
model Q-A is used for soft alloys and
small-to-medium sized profiles; the
intensive air/water model Q-AH is
designed for soft and hard alloy bars
and medium-to-large sized profiles;
the intensive standing wave quench
model Q-SW is ideal for hard alloys,
heavy bars and large profiles.
This year, Turla has supplied two
combined intensive quenching units
for handling systems for a 27 MN and
a 55 MN press to a leading extrusion
company in Turkey. The two Q-AHSW
systems have the following features:
total length: 10 m (27 MN) and 13 m
(55 MN); manufactured completely
in stainless steel; air supply to upper
hood with three independent fans
that permit electronically adjustable
flow; water spray lines distributed
360° around the profile/bar section.
The water flow in every line is completely adjustable through PLC-controlled proportional valves; standing
wave with adjustable wave height to
optimize the treatment of various bars
and profiles.
Combined systems like these provide Turla’s clients with the maximum production flexibility, permitting proper quenching of even the
most difficult solid bars and heavy
profiles for use in the most challenging applications.
Turla will be an exhibitor at
Hall 3, Stand I60
www.turla.it
ALUMINIUM · 9/2008
67
Otefal – Specialist producer of coated aluminium strip and plate
minium composites with a polythene
core. The fire-resistance of the material coupled with its strength and recyclability are important competitive
criteria. (see article about Otefal on
pp. 110-114).
Otefal will be an exhibitor at
Hall 3, Stand N20
www.otefalgroup.com
Otefal
Otefal Spa is a specialist producer of powderand liquid-coated aluminium strip and plate,
mainly for architectural
applications. The company supplies the well
established
DMAX
product range. Pre-lacquered aluminium sheet
finished with PVdF lacquer, such as DMAX, is
becoming increasingly
more popular than alu-
Continuous coating line
Selema – Slitting line specialist
Selema specializes in the design and
construction of slitting lines for coiled
aluminium strip that are characterized
by high cutting accuracy, reduced burring, scratch-free handling and perfect
winding. The company also supplies
strip coating lines for use with liq-
uid and powder coatings. These lines
feature simultaneous coating on both
sides of the strip, continuous production and the shortest times for colour
changes. Tension levelling lines and
cut-to-length lines complement the
Selema product portfolio.
Selema will be an exhibitor at
Hall 6, Stand A20
www.selema.com
adnord.it
International Exhibition on Technologies for the Recovery and Recycling
of ferrous and non ferrous metals, Environmental quality and
Energy efficiency
recovery
scrap
recycling
technologies
equipments
energy
environment
3 rd edition 2 nd-4 th April 2009
Garda Exhibition Centre - Montichiari - Brescia - Italy
Organizing Secretariat:
Edimet SpA, Via Brescia 117
25018 - Montichiari (Brescia) - Italy
Ph. +39 030 9981045
Fax +39 030 9981055
[email protected]
www.metalriciclo.com
68
ALUMINIUM · 9/2008
Always in the forefront
in extrusion system since 1952
With the complete control over the entire extrusion process, has reached excellent levels in quality, safety and
reliability. Our results make us a referent point throughout the world. As a leader, we are even more committed to
quality, safety and reliability…a virtuous circle with a well defined scope: offer an adequate solution to each request.
OMAV S.p.A. - Via Stacca, 2 - 25050 Rodengo Saiano (Brescia) Italy - TEL. +39.030.6816.21 - FAX +39.030.6816.288
www.grafocom.it
IUM 2008
IN
M
U
L
A
Visit us
ber 2008
m
te
p
e
S
5
23–2
oth: 3C60
Hall: 3 Bo
Autel – New solution for packaging extrusions
The packaging of extruded sections
has taken on new importance for several reasons. For example, the cost
of packaging is often almost as much
as the cost of extrusion, primarily
due to labour requirements. In addition, the ergonomic problems related
to repetitive motions, bending and
stooping are no longer acceptable in
developed industrialised countries.
Furthermore, profiles are often damaged during transit due to inadequate
packaging.
Improvements have been made
to a wide range of ‘traditional’ fully
automatic packaging lines for aluminium extrusions, designed and built for
wrapping profiles and forming them
into larger packages or bundles. These
systems are standard in Europe and
are beginning to be adopted in American plants and throughout the industrialised world.
Many customers require interleaving of plastic or paper between the
sections for protection. The cost of
providing this service may be deceptively high, due to the time loss and
ergonomics of unrolling the paper and
cutting it to length. To optimize this
step Autel, a group member of ATC
Aluminium Trevisan Cometal, uses
a paper stretcher device, where the
operator can preset the quantity and
length of the sheets needed for the
interleaving.
Spiral wrapping systems require
that groups of sections be tightly
bound together before wrapping; otherwise the spiral wrap will not hold
together. Older systems require the
operators to assemble the group manually and wrap one or both ends with
tape to hold it tight. To eliminate this
step and further speed up the operation, a package tightening group has
been developed and installed on the
loading benches of the packing line.
In response to the ‘traditional’ spiral wrapping of aluminium sections,
Autel has developed a new system
for bagging single aluminium sections, termed ‘Blistal’. Each section is
placed between two sheets of film and
individually sealed on both sides. The
innovative system offers several advantages: high speed, less consumption of the plastic material, superior
section protection, and two-colour
packing with logo.
Some applications require protection of extrusions until they are actually installed and ready to use, such
as in many construction applications
where damage may occur after initial
installation. A common solution has
been the use of ‘peelable’ films applied to critical section surfaces. How-
ever, traditional application machines
are slow and complicated to adjust
properly. In response, Autel has applied new technology (termed ‘Tailormatic’) to this concept to improve its
practicality. Tailormatic is characterized by an increased feeding speed, a
protective film cutting system, automatic learning and motor-driven film
coil positioning.
Summary
Brand new, totally automated lines
have recently been installed at extruders’ sites with several of these packing options combined in one single,
large system, where the leading feature is the high degree of automation
driven by a single operator in charge of
managing the line’s operation. These
solutions allow the plant to offer any
kind of packing solution by using the
different sections of one single central
system. That is the future of packaging
for aluminium.
Autel will be an exhibitor at
Hall 3, Stand J50
www.atccompany.com
ESK Ceramics – Securely adhering casting ladle coatings
ESK Ceramics is unveiling a newly
developed coating for aluminium
casting at ALUMINIUM 2008. It
adheres securely to metal substrates, reliably separates the melt
from the substrate, and is easy to
apply. At the same time, it is environmentally friendly and reduces
handling costs.
The newly developed water-based
‘EKamold Cast-M’ coating forms
an effective release layer wherever
molten aluminium comes into contact with metal. One example is the
application to casting ladles. For the
first time ever, foundries can use a
coating that can be easily applied and
70
adheres securely to metal substrates,
the company says. The suspension
ensures that the castings have highquality surfaces. At the same time, it
increases the lifetime of the tools, reduces the effort required for application and slashes energy costs.
The new coating forms a smooth,
long-lasting protective layer on the
surface of the casting ladle, which
is not wetted by molten metal – the
melt simply rolls off the casting ladle like water off a leaf. It reliably
separates the hot aluminium melt
from the substrate and ensures that
the end product is not contaminated
with dissolved foreign matter. The oxide skin too, which rapidly forms on
the surface of the hot aluminium, does
not stick to the ladle – it is clean after
each casting.
EKamold Cast-M is water-based
and does not pollute the environment
with harmful or toxic emissions. Unlike oil-based coatings, it does not
burn off noxious fumes and is generally clean to handle during application and cleaning. Water-based coatings also have another advantage:
EKamold Cast-M is so viscous that it
can be applied by brush. Alternatively
it can be diluted with water and then
sprayed on.
A newly developed binder makes
the dried coating so firm that it does
not chip off even when applied in
ALUMINIUM · 9/2008
ESK
up with a brush.
EKamold
Cast-M
is also easy to handle
after casting: it can be
easily washed off with
water. This contrasts
with traditional coating materials, which
must be removed by a
labour-intensive process of sand-blasting or
cleaning in chemical
baths.
The new suspension
features low
Quick and easy recoating of a hot casting ladle with
ESK‘s EKamold Cast-M suspension for metal substrates
thermal conductivity,
and therefore the melt
maintains
its
temperature
for longer
very thick layers, giving it a long life.
in
the
casting
ladle.
That
means
that a
Moreover, the coating thickness is
lower
melt
temperature
can
be
used
not critical, and accidental variations
in
the
production
shop.
Moreover,
in thickness can be tolerated within
more time is available for casting. This
wide limits. If the coating is damaged,
makes it unnecessary to heat the melt
it is easy and inexpensive to repair.
back up to the correct temperature in
Holes or cracks can be easily touched
the holding furnace. There is no risk
of overheating.
According to ESK, the early experiences from foundries show that the
life of the protective coating has been
increased to several times that of traditional coatings, and can withstand
several casting cycles. ESK’s experts
will give detailed reports of the operational results obtained with EKamold
Cast-M. At its booth in Essen, ESK will
be presenting a casting ladle treated
with the new coating. Furthermore,
the company will present its complete
range of high-performance ceramic
products for aluminium casting.
ESK Ceramics will be an exhibitor at
Galeria, Stand G10
www.esk.com
Eloxalwerk-Ehingen & Eloxalwerk Weil der Stadt Automotive
Eloxalwerk
Bearbeitung von Aluminiumbauteilen aus einer Hand
Eloxalwerk-Ehingen und Eloxalwerk
Weil der Stadt Automotive haben
sich darauf spezialisiert, Aluminiumwerkstücke für den jeweils geplanten
Einsatz von ihrer besten Seite zu
zeigen. Quasi unter einem Dach finden hier Veredelungsprozesse wie
vollautomatische Wärmebehandlung,
mechanische Bearbeitung (CNC-Fräsen und Bauteilemontage) sowie die
Oberflächentechniken Waschen, Beizen, Konversionsbeschichten (WBK),
Eloxieren und Pulverbeschichten – inklusive der dekorativen Oberfläche
„Decoral Design“ – statt. Dieser vom
Eloxalwerk Weil der Stadt angebotene „Automotive Workflow“ reduziert
deutlich den Aufwand für Logistik
72
und Fertigung, verkürzt den Fertigungsprozess und schützt am Ende
auch die Umwelt. Der Auftraggeber
hat statt drei Ansprechpartner nur einen, der das Projekt begleiten und bis
zur Serienreife zur Seite stehen kann.
Veredelt werden in Ehingen und
Weil der Stadt die unterschiedlichsten Teile: von dünnwandigen
Strukturbauteilen bis zu Motorblöcken für den Automobilbereich,
Aluminiumblechlegierungen
und
Hydraulikteile für die Luftfahrt, Maschinenbaukomponenten wie auch
Fassadenbleche und Fensterprofile.
Dass auch die optimalen Behandlungsparameter für neu eingehende
Aluminiumbauteile in individuellen
Versuchen
erarbeitet
werden, zählt bei den
Eloxalwerken zum Service.
Eine besondere Pulverbeschichtung kommt
im Eloxalwerk-Ehingen
zum Einsatz. AluminiumProdukte, die im Sichtbereich verbleiben, können
ganz nach Wunsch mit einer dekorativen Oberfläche, dem „Decoral-Design“ versehen werden: zum Beispiel
Aluminium-Fensterläden in Holzoptik, Fassadenpaneele in Steinoptik
oder auch Fantasiemuster. Geeignet
ist diese Pulverbeschichtung für den
Innen- wie auch Außenbereich.
Eloxalwerk-Ehingen und Eloxalwerk
Weil der Stadt Autmotive sind Aussteller auf der ALUMINIUM 2008 in Essen.
Halle 2, Stand B36
www.eloxalwerk.de
ALUMINIUM · 9/2008
W ir f
auf Ihrreuen uns
en Bes
uch!
23.25
Alumin . Sept.
i n H aium ‘08
St an d l l e 3
3E30
100 Jahre HONSEL. Ein Motor des Fortschritts.
1908 bis 2008: Seit einem Jahrhundert produziert Honsel hochwertige Erzeugnisse aus Leichtmetall. Heute sind
wir führender Zulieferer von Komponenten und Systemlösungen aus Aluminium und Magnesium für Motor,
Getriebe, Fahrwerk und Karosserie von PKW und Nutzfahrzeugen. Aber auch andere Branchen vertrauen auf
unsere Kompetenz und traditionelle Innovationskraft. Mit Standorten in sechs Ländern auf zwei Kontinenten
sind wir weltweit aktiv. Und wir nehmen jede Herausforderung an. Sicher auch in den nächsten 100 Jahren.
www.honsel.com
A member of HONSEL INTERNATIONAL TECHNOLOGIES
TECHNOLOGY AND APPLICATION
Photo: Airbus
For major aircraft manufacturers, Aleris is among the top three suppliers
The new 160” rolling mill at Aleris Koblenz exceeds all expectations
Photos: Aleris
Advance to new dimensions in
hot rolling of aluminium plate
Alfred Haszler, President of Aleris Rolled
and Extruded Products in Europe: “With
this investment in the new rolling mill
we have moved somewhat ahead of the
competition.”
The new hot rolling mill of Aleris
Aluminium Koblenz GmbH has
been in operation since the beginning of this year. With its technological features it is the most
74
modern that exists in the field of
hot rolling today. The plant not
only eliminates existing production bottlenecks, but also enables
still better qualities and new types
of products. According to Alfred
Haszler, President of Aleris Rolled
and Extruded Products in Europe,
the 160” rolling mill lays the foundations for a successful future.
The idea behind it is Aleris’ intention to expand in the field of aluminium aviation products and to
strengthen further the company’s
market position in that globally
orientated business characterised
by ever-increasing competition.
Although the new 160” rolling mill is
neither the largest nor the widest of
its type, with its twin-drive of 2 x 7000
kW and a torque of 4278 kNm it is the
world’s most powerful hot rolling mill
for aluminium plates. Compared with
the previous 148” mill, it has around
twice the drive power and torque.
This opens new possibilities for the
production of aviation plates, in relation to plate thickness and metallurgical properties.
It was necessary to invest in a new
rolling mill because the drive system
of the existing 148” mill had aged and
was from time to time responsible
for production interruptions for one
reason or another. At the time, discussions with the engineers of SMS
Demag made clear that modernisation
of the drive and gear systems would
not be enough. From the beginning
Aleris wanted to have a twin drive
instead of the old pinion gear unit, in
order to drive the upper and lower
rolls separately, and to back this up
with sufficient installed power. For
the existing 148” mill this drive train
would be oversized and it would not
have been possible to use the associated power.
“In the end we decided for a
ALUMINIUM · 9/2008
Photo: SMS Demag
The 160’’ rolling mill in production
10 January 2008: Alfred Haszler and Hartmut Schauerte, State Secretary in the Federal Ministry of Economics and Technology,
commissioning the new 160’’ rolling mill
complete new rolling mill, in order
to benefit from a series of further
advantages: a capacity increased by
10,000 tonnes and the particular ability to deform the material all the way
through thickness”, explains Haszler.
The important point here is that with
the large pass reductions made possible by the more powerful drive,
deformation can reach down into the
core of the rolling slab and plates 250
mm thick or more no longer have a
quasi-cast structure in the middle,
with correspondingly inferior characteristic values in relation to fatigue,
porosity, toughness, etc. Besides the
metallurgical advantages there are
also operational benefits, since with
pass reductions up to a third greater
achieved by the 160” mill (compared
with its predecessor), the same rolling speed produces the desired final
thickness more rapidly.
©
The Key to
New Technologies
Competence from raw material
to engineered components!
ECKA ® Standard Powder Products:
Aluminium, Magnesium, Copper, Bronze, Brass,
Lead, Tin, Solder/Brazing Alloys.
Ready-to-press blends:
ECKA Alumix®: Ready-to-press blends for light
weight sintered structural parts.
Light weight materials:
ECKA® Alloys: Al-primary foundry alloy ingots.
Al- Master alloy ingots.
ECKA® Aluminium: Al-alloy, pre- and master alloy
powders. Al-powders for high performance
PM-Materials and parts.
ALUMINIUM 2008
7th World Trad Fair & Conference
23.-25. September 2008
Exhibition Centre
Essen · Germany
Hall: 2 · Booth: 2B60
Alulight® : Metal foam products based on
aluminium and magnesium powders for semifinished and finished products.
Hydrostatically pressed profiles: Bars, tubes and
wire based on aluminium and magnesium powders.
ECKA TIX: Magnesium alloy powders and granules
for Injection Molding.
CONTACT:
ECKA Granulate GmbH & Co. KG
Kaiserstraße 30
D-90763 Fürth
Germany
Tel.:
(+49) (911) 9747-0
Fax:
(+49) (911) 9747-365
Mepura
Metallpulvergesellschaft m.b.H.
Lachforst 2
A-5282 Ranshofen
Austria
Tel:
(+43) (7722) 62216-0
Fax:
(+43) (7722) 62216-11
Alulight
International GmbH
Lachforst 4
A-5282 Ranshofen
Austria
Tel:
(+43) (7722) 64564-620
Fax:
(+43) (7722) 64564-610
non ferrum Metallpulver
Gesellschaft m.b.H. & Co. KG
P.O. Box 11
A-5113 St. Georgen bei Salzburg
Austria
Tel:
(+43) (6272) 2919-0
Fax:
(+43) (6272) 8439
E-Mail:
[email protected]
Internet: www.ecka-granules.com
Internet: www.alulight.com
ALUMINIUM · 9/2008
75
New 160’’ Mill
Quarto
3,900
8 to 800
180
~ 1,175
~ 1,750
~ 60,000
2 x 7,000
4,278
Previous 148’’ Mill
Mill type
Width (mm)
Thickness (mm)
Max. speed (m/min)
Work roll diameter (mm)
Backup roll diameter (mm)
Max. load (kN)
Drive power (kW)
Torque (kNm)
Quarto
3,600
8 to 600
180
920
1,525
45,000
6,640
2,450
in order to produce uniform and porefree thick plates as required, for example, for tooling and moulding.
Slabs 800 mm thick are not yet
cast at present, but on the existing
remelt slab widths up to 2600 mm
are already being cast and widths up
to 3000 mm are envisaged. To process
these also demands a powerful rolling
mill with corresponding drive forces
and torques.
In practical operation since the beginning of the year it has been demonstrated that the rolling mill more than
fulfils every expectation. “The run-up
phase to maximum power took place
without problems and already by April
it was evident that the target quantity
had been exceeded by more than 650
tonnes. It is already clear that in two
to three years the plant will be able to
produce around 10,000 tonnes more
than the planned 160,000 tonnes”,
says Haszler.
Table: Comparison of performance data of the old and new hot rolling mills in Koblenz
Greater focus on market
for thick aircraft plate
“In this way we deform the metal almost as if it were being forged. We can
work it all the way through thickness
even in the case of very thick plates,
The mill offers the possibility of usand so produce properties at the core
ing a new rolling technique, the sowhich were previously unattainable”,
termed ‘Snake Rolling’. With this
stresses Haszler.
method Aleris aims to intensify the
deformation even more, so as to imThe new technology has already
prove the fatigue properties of aviabeen experimentally investigated at
tion plates still further. Snake rolling
the Corus Research Centre in Ijmuiis the outcome of extensive research
den, which Aleris too can use owing
and development work by Aleris and
to a long-term agreement, and is being
involves shear deformation in which
prepared for large scale application in
the top and bottom sides of the materithe 160” mill. According to Haszler the
al are deformed by different amounts.
result is an improvement of fatigue
properties by up to 50 percent, besides
producing properties that
are uniform throughout the cross-section.
There are also significant improvements
in other properties,
such as toughness.
Another novel
feature associated
with the new rolling
mill is its larger rolling gap of 800 mm.
In future Aleris will
be casting and rolling even larger slabs,
Aleris supplies brazing products for various heat exchangers
For a long time Koblenz has been a
specialised works in which, above
all, aviation and brazing products
are made. No more standard goods
or building products. Production is
divided between aviation plates, with
an annual capacity of 60,000 tonnes,
and clad brazing coils (mainly for heat
exchangers), of which around 75,000
tonnes are produced. The remaining
25,000 tonnes are divided between
commercial plates for special applications: for tooling and moulding, for
silo and tanker vehicles, and armour
plates. In addition, many distributors
are supplied.
The particular focus at Koblenz is
on the production of aluminium plates
for aircraft design, and further growth
is expected to take place mainly in this
demanding sector. Around two-thirds
of the 60,000 tonnes go directly to aircraft manufacturers, and one third to
tier 1 suppliers and distributors. Aleris
supplies the three largest manufacturers Boeing, Airbus and Embraer.
For the major aircraft manufacturers
Aleris is among the top 3 suppliers.
In recent years the market for aircraft plates has changed substantially. According to Haszler’s estimate,
New rolling technology further
improves material properties
76
ALUMINIUM · 9/2008
There ist particular focus at Koblenz on the production of aluminium plate for aircraft
for the rolling process and the equipment connected with them.
The general market perspectives in
the aircraft industry are positive. The
market is growing dynamically, even
though delivery delays of the Airbus
A 380 long-haul aircraft created some
uncertainty in the market. Nevertheless, the aviation branch expects air
new players are appearing mainly in
the segment of thin (up to 100 mm)
and narrow (up to 2000 mm) plates.
“In that segment there are already a
number of suppliers”, he says, “but for
dimensions above those the hurdle to
entry is high”. This applies to approval
by aircraft manufacturers and the associated technological requirements
traffic to double by 2026, freight carriage will grow substantially, demand
for cost efficiency and environmental
protection will increase and will enhance the growth of the aircraft industry. Branch experts consider that by
2026 the demand for new aircraft will
increase by around 25,000. One-third
of that alone will go to replace older
aircraft, not least because of increasing
pressure due to the drastic rise in fuel
prices. Small economical downturns
will not change that basic trend.
Aluminium plates and sheets are
used for wings, fuselages, structural
components and floor beams, for
which stringent material specifications and approval criteria exist.
Above all wings, spars and floors are
made from thick aluminium plates.
They are machined from the solid
plate, so as to have as few joints as
possible, i. e. to produce monolithic
structures. Wide and long sheets
and plates will reduce the number
of components in an aircraft. ©
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" $ # (%& ' # !"" ALUMINIUM · 9/2008
)
! ! *+, -. $ /01
23/40 2 *
5 # 637 0/3 /7 30 $5 637 0/3 /7 387
59
: : 77
In contrast to many of its competitors Aleris has no machining centres
of its own. Near end shape manufacturing is limited to sawing plates and
sheets close to their final dimensions,
for example wing plates, which are
cut to trapezium shape. “In the long
term, however,” says Haszler, “it may
become more interesting for us to go
more into further fabrication.” One
aspect of this may be greater value
added and another that customers
are reluctant to become involved in
dealing with the scrap generated during machining. But since the scrap is
becoming more valuable all the time
as the price of aluminium increases, it
makes sense to do machining in-house
and set up a ‘closed-loop’ recycling
system, particularly since with the recycling centres operated by Aleris in
Europe and the USA know-how and
logistics are already existing.
The development of alloys with further improved properties is especially
important in the aircraft industry. In
Koblenz at present over 100 different
alloys are produced. For example,
work is currently in progress on a new
generation of aluminium-magnesiumscandium alloys in order to develop
an alternative to composites for the
fuselage. Compared with classical aviation alloys AlMgSc alloys are lighter,
weldable, and they can be produced
by conventional manufacturing.
Further investments carried
out in Duffel and Koblenz
Looking at the plant in Koblenz
also entails a glance towards Duffel
– the Aleris rolling plant in Belgium.
“Koblenz and Duffel constitute a linked
production facility and we regard the
two locations as a single plant producing in combination”, explains Haszler.
At Duffel, following the investments
made a year ago commercial plate
production has increased to around
10,000 tonnes and brazing products
are also made. When the 148” mill
from Koblenz starts operating there
after extensive modernisation, even
more will be produced. At the same
time this will relieve the bottlenecks in
the Koblenz plant for those products.
The mill should be set up in December this year and it will begin regular
78
The 148’’ rolling mill will be installed at the Aleris plant in Duffel in December 2008
operation in the spring of 2009. The
investment programme in Duffel, costing around 42 million euros, is hardly
less extensive then in Koblenz but it
also in part involves modernisation
and infrastructural measures.
The production capacity in Duffel
amounts to a total of 260,000 tonnes
of aluminium plates and coils, and
in 2008, when 220,000 tonnes were
produced, that capacity was not quite
used to the full. Around a third of the
products are commodities, along with
approximately 60,000 tonnes of autobody sheet, clad brazing sheet and
other special products for the automotive industry.
For plate production a further
shed started operating in Duffel in
2007. Among other things, the shed
is equipped with a modern stretcher
from SMS Meer, an Ebner horizontal
furnace for heat treatment and a plate
furnace from Junker for annealing and
ageing.
Aleris paid around 45 million euros for its 160” hot-rolling mill and
a further 10 million euros for auxiliary equipment. This concerns a
homogenising furnace also supplied
by Ebner for rolling slabs, which at
Aleris are separately homogenised
before preheating – first because
of the long times involved and secondly because when homogenising,
the temperature has to be close to
the melting temperature. In addition
a casting station for wide slabs was
put up, and an additional segment
was added to the horizontal furnace
in order to provide the necessary capacity. In this furnace the first few
zones, which serve for heating up, are
gas-fired whereas the holding zones
are electrically controlled to achieve
a closer temperature tolerance. Furthermore one of the three stretchers
was strengthened for thicker plates,
testing equipment for the laboratory
was purchased and because of the
larger slabs the crane capacity was
also increased. Finally, a quench was
installed in a second, smaller continuous-horizontal furnace, so that in
Koblenz not only sheets but also thin
plates can be quenched.
With all those investments Haszler
considers that Aleris Rolled Products
in Europe is well equipped for the future. “The project is the highlight and
expression of our long-term market
strategy. Although new rolling plants
have appeared in Asia and some Third
Countries and will continue to do so,
for decades we have held a leading
position in the world market with our
technologically high-grade products
and processes. With this investment
in the new rolling mill we have moved
somewhat ahead of the competition,
as with our previous investments.”
Aleris will be an exhibitor
Hall 3, Stand B40
www.aleris.com
ALUMINIUM · 9/2008
FlüssigAluminium
... das schnellere Aluminium
Aleris Recycling (German Works) GmbH
Aluminiumstraße 3
D-41515 Grevenbroich
Postfach (P.O. Box) 100 634
T +49(0)2181-16 45-0
F +49(0)2181-16 45-100
www.aleris-recycling.com
[email protected]
Wir stellen auf der
ALUMINIUM 2008
in Essen aus –
vom 23. – 25.09.2008
Halle 3 Stand 3B40
Photos: SMS Demag
Rolling the first plate on the 160“ mill
A special type of rolling plant modernisation
B. Rieth, Meerbusch
Problems with an ageing drive
system, a collaboration between
an innovative equipment manufacturer and an open-minded operator, and at the end, two winners
– that, in brief, is the story of how
the most efficient and powerful
hot-rolling mill for aluminium
has smoothly started operating
and, besides enlarging the product
range, is increasing the rolling capacity of the two European Aleris
plants in Koblenz and Duffel.
At the time, the motive for the modernisation was the existing 148” rolling mill at Aleris Aluminium Koblenz
GmbH. This had been delivered in the
early 1960s to the then Kaiser Aluminium in Koblenz and during the next
decades served as a roughing stand
for the rolling of aluminium plates
and strips. The rolling mill made its
successive owners Kaiser, Hoogovens
Aluminium, Corus Aluminium and finally Aleris one of the leading suppliers of plates for the aviation industry,
with a large market share among renowned aircraft manufacturers such
80
as Airbus, Boeing and Embraer. Technological changes in aircraft engineering brought ever more strict requirements in many respects: new alloys,
closer dimensional tolerances and
thicker plates for the production of
structural components meant that the
loading of the 148” mill was constantly
increasing. To an increasing extent
the load limits were becoming more
evident, and these could not be overcome even by a number of rebuilding
measures – during which for example,
in the 1980s the two-stage drive was
refurbished and provided with two additional motors. In 2004 the decision
was made to install a complete new
main drive system, whose characteristics would satisfy every need.
To be able to satisfy the growing
demands of the market with suitable
products in the future as well, Aleris
worked out a schedule of requirements containing the following measures as the most important objectives
of the rolling plant modernisation:
• The rolling mill design should be
such that at a relatively slow rolling
speed at high torque, large reductions
per pass are possible in order to deform the material more intensely and
reduce porosity, and also to improve
the toughness and fatigue properties
of aircraft plates.
• A more powerful gear unit should
be fitted, in order to transmit higher
torques.
• The drive should be converted to
a twin-drive system to enable separate powering of the upper and lower
rolls, in order to later to implement
the ‘Snake rolling’ technology originally developed by Corus Aluminium
and promoted by Aleris as a forwardlooking process.
• The roll gap should be enlarged to
allow initial pass of thicker and wider
rolling slabs.
• The roll diameter should be increased in order to improve the gripping behaviour.
• The rolling forces should be increased.
Plans for the implementation of this
schedule of requirements were made
in close collaboration between the engineering staff of Aleris and SMS Demag. After all, they knew one another
ALUMINIUM · 9/2008
through the partial reconstructions of
earlier years, which led to great mutual trust between them. On the basis
of its detailed knowledge of the rolling
plant SMS Demag first submitted various proposals to Aleris and thereby indicated how, as an equipment builder,
it could envisage such an extensive revamp. “In Aleris we found a customer
which, for its part, was prepared to listen to our technical staff and their proposals”, remembers Michael Schäfer,
Head of the Aluminium Product Sector at SMS Demag. The result of every
alternative considered was always the
same: the drivetrain could be strengthened, but the existing 148” mill still remained the limiting factor. It became
clear that not just the drive, but also
the mill itself had to be larger, in other
words a new one was needed.
The ultimate solution lay in the
concept of a new 160” rolling mill
combined with a new and more powerful drive train. However, this raised
two new problems: first the financing,
and second the installation of the substantially larger and heavier mill in
the existing plant as a whole, without
appreciably affecting the production
flow. In this respect too SMS Demag
emerged as an innovative partner for
Aleris: well acquainted with the ©
The 148” mill in operation. Preparatory work on the foundations for the new drive train
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Bitte gleich anrufen: +49 (0)511 7304 148
oder E-Mail an: [email protected]
Is the DVD from SMS Demag missing?
Please phone: +49 (0)511 7304 148
or send an e-mail to: [email protected]
ALUMINIUM · 9/2008
81
situation not only at the Aleris plant
in Koblenz but also at its plant in Duffel, SMS Demag developed a concept
according to which the existing 148”
mill would not be scrapped, but instead, after thorough overhaul and
modernisation, used to replace the
old two-high roughing stand in Duffel
and would therefore enable new and
extended production possibilities for
that location. As regards the installation of the new mill in Koblenz, SMS
Demag was in a position to apply
its many years of experience in the
relocation of pre-assembled rolling
mills, which had already been tried
and tested many times, for example
at Outokumpu and Salzgitter.
The new 160” rolling mill
The new mill is the result of a commercial and technological decision
between the operator Aleris and the
equipment manufacturer SMS Demag.
“Although in terms of plate width it is
not the largest in the world, it is nevertheless certainly the most powerful
hot-rolling mill for plates in terms of
the thickness of the rolling slabs, the
rolling force and the torque that can
be transmitted”, comments Schäfer.
Its size alone sets new standards: the
roll housing of the 4-high stand has
an overall height of 13 m and weighs
355 tonnes. To improve the gripping
behaviour the diameter of the work
rolls has been made 1175 mm, with
1750-mm back-up rolls. This makes
them much larger than those of the
old 148” mill, at 920 and 1525 mm
respectively.
The larger roll gap enables
slabs 800 mm thick to be rolled.
In addition, the enlargement of
the rolling width from the previous 3600 mm to 3900 mm
in future has advantages for
the production of wider and
thicker aluminium plates for
the aviation industry, to enable
monolithic structures to be
made in order to have fewer
joints and to reduce weight.
But the new mill achieves truly
new dimensions with its rolling
force increased by 33 percent
to 60 MN in combination with
a drive power of 2 x 7000 kW
and a torque transfer capability
of 2 x 5000 kNm, taking into account the permissible overload
factors. These characteristics
make it by far the most powerful hot-rolling mill for alumin- Erection of one of the 160”-mill rolling stands
ium plates currently existing
In detailed respects too, the mill has
anywhere in the world. At the same
various innovative features compared
time it fulfils the declared aim of subwith its predecessor: this concerns,
stantially better deformation through
for example, the arrangement of the
thickness during rolling as the prereqhousing roller tables with hydraulic
uisite for improving the metallurgical
fine-adjustment from below. In comproperties. In this connection Aleris
bination with the hydraulic roll gap
sees realistic possibilities for offering
setting which also acts from below,
the market new products in future,
flexible conditions that can in each
both as monolithic plates and ‘multicase be optimised are made available
clad’ strips for heat exchangers.
for adapting the pass line. In view of
Almost incidentally, just a few
the high proportion of clad brazing
weeks after commissioning another
coils also rolled on the same stand
advantage emerged, namely that the
this possibility is important for Aleris.
larger reductions per pass have reWith their wipers the housing roller
sulted in appreciably greater throughtables extend as far as the rolls. Their
put performance from which Aleris
horizontal adjustability provides the
can now expect plate production
customers with almost every possibilto increase by a further 10,000 tpy.
ity of manipulation for optimising the
rolling process.
Besides the sophisticated mechanical equipment, the SMS Demag
supply included the electrical and automation systems, the supply of media
for transport to the installation site,
and of course assembly and commissioning.
Transport, assembly and
commissioning – three
logistical master-performances
Loading a rolling stand at the Hilchenbach works
82
Before its delivery the new mill was
pre-assembled at the workshops of
SMS in Hilchenbach, which ©
ALUMINIUM · 9/2008
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speeded up final assembly on site
by several weeks. After dismantling
into transportable structural groups,
within two weeks respective four-day
transport operations were carried out
to move the two halves of the housing on special vehicles along roads
with many bends, down to the Rhine
valley 150 km away. The highlight of
the transport operation was crossing
the Rhine on heavy-load floating pontoons, since none of the nearby bridges over the Rhine would have been
able to support the individual load
of up to 510 tonnes made up by the
roll housing weighing 355 together
with the weight of the 22-axle special
transporter. Transport was planned a
year in advance and proved to be the
largest such operation in the history
of SMS Demag.
Aleris’s demand for the shortest
possible and reliably timed interruption of production due to the installation of the new rolling mill could only
be met by dividing the whole process
into two annual closures, which take
place traditionally around Christmas
in Koblenz.
Reconstruction phase 1: Already
while production was in progress,
the preliminary work for installing
the new motors and drive system
began in May 2006. Without interfering with production, a foundation
pit was made behind the old drive, in
which the new motors and the drive
were assembled on a movable foundation block. The new drive system
was also tested in shadow operation
while production was in progress.
During the closure at the end of
Plug & work: simulation of the rolling process at SMS using the original control panels
2006, the old drive train was demolished and the foundation adapted in
only 17 working days instead of the
planned 18. This included new sideguides and new roller tables. Then,
the new drive system with its foundation block was moved to its final
position where the previous motor
had been before. After this, the drive
spindles were fitted and the new main
drive was operated with the old 148”
mill. To avoid any risk to the latter
during the year until its demolition,
the new drive had to be temporarily
throttled.
Particularly difficult was the reinforcement of the foundations of the
existing mill for later accommodation
of the new, substantially heavier mill.
This was done by means of a special,
high-pressure injection process in
which liquid concrete was injected
under high pressure into pre-drilled
boreholes and reinforced with a steel
core.
Sliding the 1,250 tonne 160”-mill rolling stand into its final position
84
Reconstruction phase 2: However,
the greatest challenge for all those
involved was the assembly of the
new rolling mill and the subsequent
commissioning of the equipment
as a whole. The reason for this was
Aleris’s demand that there should be
no extension of the scheduled 21-day
closure and for the rolling personnel
there should not be any major changes in operator interface. The only way
to satisfy these requirements was to
operate the new and old rolling mills
in parallel. “To fulfil that requirement
we had to create extensive infrastructure and organisational means, to an
extent that hardly any other company could manage”, stresses Hendrik
Langer, Head of the Hot-Rolling Mill
Design and Construction Unit and at
the same time responsible technical
project manager of SMS Demag for
this major contract. Still during the
operation of the 148” rolling mill,
which was already being driven by
the new drive train, the assembly of
the new 160” mill including all the
mechanical and electric components
went ahead immediately next to the
existing rolling mill, on a previously
built provisional foundation.
The new mill was tested mechanically, electrically and hydraulically
and then run in ‘shadow operation’
at the same time as the old mill still
in production. This enabled all the
functions of the new rolling mill to
be optimised under realistic production conditions before the actual
commissioning. Great support, which
ultimately also enabled the commissioning time to be made shorter, was
ALUMINIUM · 9/2008
provided by the company by integrating the ‘X-Pact’ system developed by
SMS Demag into the overall electrical
system of the equipment.
At the end of the preparatory work
the actual ‘hot phase’ of reconstruction
began: the old machine was stopped
and the 148” mill dismantled.
The next exciting step was again
to move the mechanically and electrically completely pre-assembled 160”
mill to its final location. With the help
of special crane and transport systems
the total weight of 1250 tonnes was
raised and moved into position over a
distance of 20 metres. Connection of
the millimetrically accurately pre-assembled pipes for the supply of media
was then a routine matter.
“The reward for all the efforts
made by our customer’s and our own
personnel was that we were able to
start operating again a day earlier than
agreed”, says Langer. That this was no
short-term fluke has since been amply demonstrated by Aleris. Already
within the first week after restarting,
full-scale production was achieved,
and since then the company foresees
a planned capacity 10,000 tonnes per
year larger than that originally specified.
In summary, Michael Schäfer
comments: “With the delivery of the
160” mill we have demonstrated not
only our ability to build heavy rolling
plants, but again, our experience in the
creation of a modernisation plan and
its problem-free implementation.”
The reconstruction in Duffel will
result in a substantial capacity boost
and an improvement of product properties, for example by virtue of better
strip profiles. In future the plant in
Duffel will be able to take over from
Koblenz the production of thinner
plates for commercial applications,
which will in turn leave additional
capacities free in Koblenz for heavygauge aircraft plates.
Extended possibilities in Duffel
Author
The previous 148” rolling mill from
Koblenz is being modernised by SMS
Demag and in part provided with new
components. These include new electric and automation systems. The mill
is being inspected and overhauled
with a view to many more years of
operation. Probably in the spring of
2009 the revamped mill will begin operating again at the Aleris Aluminium
Duffel B.V. plant in Belgium. It will
replace the present two-high roughing mill in the existing 1+ 3 hot-rolling
configuration.
Dipl.-Ing. Bernhard Rieth is a marketing
specialist and freelance technical journalist. As proprietor of Marketing Xpertise
Rieth in Meerbusch, he advises equipment
partners of the NF metals semis industry
on marketing-related matters.
Phone +31 (0)20 693 5209
Fax +31 (0)20 693 5762
SMS Group will be an exhibitor
Hall 3, Stand A40
www.sms-demag.com
Mail [email protected]
Web www.srsamsterdam.com
Aluminium 2008 Essen
Halle 1 · Stand E55
Vesuvius – A well-established provider of
refractory-lining services to the aluminium industry
Vesuvius Construction and Installation (VCI), based in Sheepbridge near
Chesterfield, England, is a well-established provider of refractory-lining
services for furnaces in the aluminium,
cement, iron and steel industries. The
company is part of the linings business within the Industrial Processes
Division of Vesuvius, a world leader
in the development, manufacture and
marketing of high performance ceramics and refractory products. VCI is
closely linked to two other enterprises
within the linings business – the UK’s
monolithic refractories manufacturing plant at Sheepbridge, and an R&D
facility in Barlborough.
VCI offers the full package of refractory lining/relining services to the
aluminium industry; the company is
able to provide innovative solutions
86
Photos: Vesuvius
UK-based Vesuvius Construction
and Installation offers advanced
monolitic refractories and innovative installation services, which
together speed up furnace relines
and provide enhanced refractory
performance.
The R&D section with a wide range of mixers and blenders as well as a large brick press
based on an in-house research and
development facility. VCI’s ability to
supply an advanced range of cementfree refractories guarantees a faster
furnace dry-out period and a speedy
return to production, with all its financial advantages. The customer
can obtain a detailed cost analysis, a
site installation record and an indication of day-by-day expenditure. The
enterprise has a permanent staff of
16, although employment can reach
as high as 100, depending on the size
and scope of relining contracts.
VCI provides a comprehensive monolithic relining service, based on a range
of specialized machines including remote-controlled ‘robotic’ wrecking
units, a variety of shotcreting pumps
and low cement gunning equipment.
Central to the company’s success is
the use of advanced refractories, including the ‘Triad’ range of ‘no-cement’ castable materials. These can
be cast or pumped behind formers,
or shotcreted into place. Such refrac-
ALUMINIUM · 9/2008
Visit us at ALUMINIUM 2008 from
September 23 to 25 in Essen, Galeria G10
tories contain little or no water, so are characterized
by rapid dry-out; they require no curing and are not
susceptible to contamination. The Triad products also
exhibit very good strength properties, especially hot
crushing strength. Other advantages include minimal
mixing intensity, good adherence to worn linings, and
a minimum shelf life of 12 months. Hot repair versions
are available. The Triad materials also include a grade
which provides permeable ventilation channels with
voids of less than one micron. This refractory is said
to be ideal for aluminium contact areas.
Also included in the list of products is ‘Aluguard’,
which contains an additive that prevents wetting and
penetration in aluminium furnaces. There are several
different Aluguard specifications, including one for
AlSi alloys.
Pumping systems
VCI’s success is also based on the development of specialized pumps and nozzles tailored to the properties
of the range of advanced refractories.
In Surgun low-cement gunning materials, the necessary water is added into the stream of dry refractory
through a ported circumferential injection ring. This
mode of application is particularly suited to lining upper walls. At least 80% of shotcreting by VCI is evolving
toward this new technology using Surgun machines,
developed especially for use with low-cement materials. These machines employ a special patented nozzle, in which the refractory is combined with water
as it exits the machine. The procedure provides the
same high-specification installed properties associated with shotcreting, but provides greater flexibility on
site, because the equipment is smaller. The shotcreting technique, which is virtually dust-free when using
low-cement refractories, provides properties similar to
a cast lining. However, it also gives the rapid installation rates associated with gunning methods, with the
possibility of 40 tonnes in one shift.
In the shotcreting method, SurShot castable refractory is mixed with an activator as it leaves the nozzle
of the machine so that it can be sprayed in place.
Monolithic refractory production
Adjacent to VCI’s facility at Sheepbridge is the Vesuvius monolithic refractory production plant. The entire
facility, which includes batching, mixing and packing,
is computer-controlled. The arrangement is linked to
management software and is under the supervision of a
Scada system. The control is such that the R&D department can, from its offices some 15 km distant, make
changes to formulations, with an instant response from
the batching plant.
The raw materials – which may include bauxite,
tabular and white fused alumina, cement, chammote,
etc – are held in silos or two-tonne-capacity tote bins.
The central batching plant creates a single raw ©
ALUMINIUM · 9/2008
EKamold® Cast-M
REVOLUTIONARY COATING
FOR THE CASTING INDUSTRY
• Adheres securely to metal substrates
such as casting ladles
• Provides reliable separation of the melt
and substrate
• Its high resistance permits highly durable
coatings
• Optimum handling thanks to ease of
application and uncomplicated cleaning
• Ensures high-quality castings and is
environmentally compatible
For more details see www.esk.com / foundry
rial and for lining ladles. The spacious
three-bay monolithic production facility employs 80 people.
Research and development
Part of the R&D equipment is this electron scanning microscope
each tote bin containing the required
materials is transferred to Eirich mixers or a wet mixing plant. In the case
of dry mixes, the material is conveyed
to a new £250,000 bagging system.
This, simultaneously, weighs a charge,
makes a plastics bag, fills it, seals the
top and transfers the bag to a palletizing unit. The material processed in the
wet mixing plant is finally extruded,
cut to length, wrapped in polythene
film and boxed. A typical product in
this category is Blu-Ram HS, a refractory used as a furnace ramming mate-
www.grafocom.it
08/08
material stock which improves traceability and reduces inventory. Central
to the batching process are the tote
bins, each of which carries a wireless
‘RF’ tagging system. Such tote bins are
filled with raw materials from the silos and the grade of each constituent
is written to the RF tag. Further tote
bins, each bearing a specific recipe on
its tag, are then loaded into the system, where they travel through the
plant, stopping off at the appropriate tote-bin-loaded dosing stations to
compile a batch of product. Finally,
The R&D facilities at Barlborough,
Derbyshire, are part of the Industrial Process Division. As such, they
serve the refractory linings business
throughout Europe. Overall, the extended Vesuvius organization has no
fewer than seven major R&D centres
in the USA and Europe. Employing 25
people, the UK resource undertakes
work on flow-control products, including those concerned with sliding
gates and stoppers for ladles; foundry
products and materials; fused silica,
and refractories for the lining and construction business. The section works
closely with a similar R&D facility in
Betsville, Ohio, to pool knowledge
and avoid duplication of effort. The
programme is application orientated.
The teams within the facility work
closely with product development
sections, sales and end-users. A substantial amount of work is concerned
ALUMINIUM 2008
HALL3 Stand K20 September 23-25
WE MAKE BIG MACHINES TO PRODUCE PERFECT SHAPES
OUR LIFE FOR
PERFECT SHAPES
Thanks to the experience of our designers and the use of highly
sophisticated programs, we carry out and supply solid, reliable extrusion
presses and with extreme simplicity of use in order to optimise operating
performances. We offer various levels of control: only for the press, for
the entire extrusion line. We can also perform complete mechanical,
hydraulic, electrical revamping operations.
Get in touch with us, we will be very proud to become your partner!
Galleria Piazza Marconi, 7/D - 20059 Vimercate (MI) - ITALY
PRESEZZI EXTRUSION S.p.A.
88
Tel. +39 039 635011 - Fax +39 03963501220
www.presezziextrusion.com - [email protected]
ALUMINIUM · 9/2008
with used refractory products in a bid to understand
wear mechanisms and reasons for failure.
In the context of refractory investigations and
development, the laboratories are well equipped.
Amongst the resources are the following:
• Pilot plant facilities, including a very wide range
of mixers and mills, of varying capacity
• Crushers and screening equipment
• Gunning test facilities for trial of materials
• Slag-attack testing rigs
• High-temperature furnaces (1,760°C)
• Programmable curing ovens (600°C) for drying
out monolithic materials
• Gunning nozzle test facilities
• Programmable 800 tonnes Laecis brick press
• Wide range of testing rigs for refractory investigation and development, including those for
apparent porosity, bulk density, cold crushing
strength, cold modulus of rupture and modulus
of elasticity
• High temperature testing equipment, including
versions for assessing hot modulus of rupture,
creep of refractories under load and thermal
expansion in air or in a gaseous atmosphere
• Optical microscopes and a scanning electron
microscope used for failure investigation and
development projects
• A comprehensive range of analytical equipment,
including Leco units for determining N2 and C,
an automated ARL 8480 XRF analyser, and
facilities for X-ray diffraction.
Innovative approach
As shown, Vesuvius Construction and Installation
has several strengths, last but not least an innovative range of shotcreting machines and ancillary
plant and an equally-advanced selection of low and
ultra-low cement castables. The combination of application expertise and specialized refractories provides significant down-time savings in the relining
of furnaces, due to reduced dry-out times. According to Vesuvius, a reduction of two days in downtime can save as much as £260,000 in a cement
plant relining project. Proportionate gains are the
rule in aluminium applications. The third strength
is the ready availability of an advanced R&D facility,
geared to the introduction of ever-more advanced
refractory systems and their application in furnace
relining projects.
Vesuvius will be an exhibitor
Hall 3, Stand L30
www.vesuvius.com
ALUMINIUM · 9/2008
TECHNOLOGIE UND ANWENDUNG
Neue Bolzengießerei bei Neuman Aluminium
Die Anlage produziert in der ersten
Ausbauphase bis zu 10.000 Jahrestonnen Pressbolzen. Mit der Lieferung, Montage und Inbetriebnahme
wurde die Firma HPI in Ranshofen
beauftragt. Mitentscheidend für die
Vergabe an HPI war das spezielle
Schmelzofenkonzept. Es erlaubt ununterbrochenes Gießen, häufigen
Legierungswechsel bei präziser
Legierungszusammensetzung,
das
Schmelzen von Langschrott und in
der weitern Ausbaustufe von Spänen, Dünnschrott und Krätze sowie die Reparatur und Wartung des
Schmelzofens bei Aufrechterhaltung
einer reduzierten Produktion. Abnehmer sind das eigene Presswerk sowie
die zur Neuman-Gruppe gehörenden
Aluminiumschmieden.
Um für den unterschiedlichen Bedarf an Bolzendurchmessern (von 45
bis 203 mm) gerüstet zu sein, wurde
eine horizontale Stranggussanlage gewählt. Der Vorteil dieser Technologie
ist, dass kostengünstig und flexibel
von kleinen bis großen Durchmessern
alles auf einer Maschine kontinuierlich gegossen werden kann.
Die wichtigsten Anlagenteile entlang des Produktionsablaufs sind
die Schrottchargiermaschine, der
Schmelz-/Gießofen, das Rinnensystem, die Stranggussanlage mit fliegender Säge, der Durchlaufhomogenisierungsofen, die Kühlstation, die
Ultraschallprüfanlage und der Verpackungsplatz.
Bei Projekten für eine komplette
Schmelzlinie liegt der Vorteil für den
Kunden darin, dass er nicht nur eine
hoch moderne Anlage ersteht, sondern
gleichzeitig erprobtes Prozess-Knowhow im Bereich der Kokillentechnologie sowie in der Hochlaufphase einkauft. Dadurch verlief die Inbetriebnahme reibungslos und Neumann
90
– kann die Anlage mit einem Mann
pro Schicht sehr wirtschaftlich betrieben werden. Die zweite Ausbauphase
zur Erhöhung der Produktion ist bereits in Planung.
konnte vom ersten Tag an voll produzieren. Durch die vollautomatisierte,
kontinuierliche
Produktionsweise
– Schmelzen, Gießen, Durchlaufhomogenisieren und Ultraschallprüfen
New casting line for billets at Neuman Aluminium
complete casting line, the advantage
of this co-operation for the customer
is that he will not only receive state-ofthe-art equipment, but also rely on existing process and technology knowhow. The result was a short and successful commissioning period leading
to production quality right from the
first day on. Due to the continuous
production process – remelting, casting, homogenising and ultrasonic test-
Since the beginning of this year a
new casting line for billets has been
operating at Neumann Aluminium
Austria. The new line was built because Neumann wants to remelt the
scrap coming from the own forging
and extrusion operations and, in this
context, generate added value for the
semi-finished goods in-house.
The equipment was designed to produce extrusion billets up to 10,000
tonnes per year in the first phase of
operation. The contract was awarded
to HPI in Ranshofen, Austria, for the
engineering, manufacturing, delivery,
installation and commissioning. Crucial for this decision was the process
design concept of HPI which allows
continuous casting, frequent change
of alloy at precise alloy composition,
remelting of long scrap and, in a further expansion, remelting of chips,
thin scrap and dross, and repair and
maintenance works during upkeep of
a reduced production. Customers for
the billets are the captive extrusion
plant and the forging companies of
the Neumann group.
To satisfy the production needs for
a dimensional variety of billets with
diameters ranging between 45 to 203
mm, the decision was taken to use
a horizontal casting machine. This
technology is beneficial as it allows
an economical and flexible production from small to big diameters in a
continuous process on one machine.
The most important parts of the
equipment are the scrap charging
machine, the combined remelt and
casting furnace, the launder system,
the horizontal casting machine with
a flying saw, the continuous homogenising furnace, the cooling station,
the ultrasonic testing facility for the
inspection and a packing station.
When talking about projects for a
HPI
Seit Anfang 2008 ist bei Neuman
Aluminium Austria die neue Bolzengießerei in Betrieb. Wichtigster
Auslöser für die Investition war,
die im Konzern anfallenden Schrotte aus den Press- und Schmiedevorgängen selbst umzuschmelzen
und die sich daraus ergebende
Wertschöpfung im Hause zu halten.
Ultraschallprüfanlage mit Durchlaufhomogenisierungsofen im Hintergrund
Ultrasonic testing facility with continuous
homogenising furnace in the background
ing in one sequence – the equipment
can be operated by one person per
shift in a very efficient way.
The second phase, means the expansion of the capacity, is already being planned.
Neuman Aluminium will be an exhibitor at ALUMINIUM 2008 in Essen.
Hall 1, Stand F07
www.neuman.at
HPI will be an exhibitor at
Hall 7, Stand C40
www.hpi.at
ALUMINIUM · 9/2008
We understand Aluminium
Plants for Rolled Products
Pusher Type Furnace:
Reheating and Homogenising
of Rolling Slabs
Horizontal Heat
Treatment Line:
Solution Heat Treatment and
Quenching of Aluminium Plates
Chamber Furnaces:
Ageing, Annealing, Homogenising
and Cooling of Products like Strip
Coils, Foil Coils, Slabs and Plates
Come and see us
in Essen, Germany,
from September 23-25, 2008:
Hall 3, Booth D20
Multi Chamber Melting
Furnace: Recycling of Contaminated Aluminium Scrap
Profilglass extends its aluminium semis basis
B. Rieth, Meerbusch
Motivated by a market with development potential, in the short time since
its foundation by the Paci brothers in
1982 Profilglass has developed thanks
to continual new investments to become a special operation in particular
for the manufacture of spacer bars and
decorative sections for double glazing. With an output of 20,000 tpy the
company is the world market leader
for these special products, which are
sent to customers in 85 countries and
account for about 90 percent of its
export turnover. To provide a better
indication of such a quantity of thinwalled sections, they would cover a
distance of 600 million metres, or 15
times the circumference of the Earth.
Photos: Profilglass
In only 26 years the company
Profilglass, established in Bellocchi di Fano to the north of Ancona
in Italy, has grown from a small
operation producing spacer bars
for double glazing, to become the
world market leader for these and
similar thin-walled aluminium
products. Moreover, in 2001 the
company set in motion the building of melting, casting and rolling
facilities of its own, which produce
not only the starting material for
further downstream processing,
for example into spacer bars, but
also produce a range of flat aluminium products for the international market. In 2009, when the
current extension by a new hotand cold-rolling mill is completed,
the present capacity of 90,000 tpy
of rolled aluminium products will
be increased substantially.
Spacer bars for double glazing are made in
250 different forms
The spacer bars, in around 250 different versions, are produced from rolled
aluminium strips 0.20 mm thick by
roll forming. The special equipment
needed for this, which besides 20 rollforming machines also includes special coating units, has from the beginning been designed, constructed and
continually developed further by the
company’s own engineers.
The company serves other special applications with the production
each year of around 10,000 tonnes of
thin-walled, welded aluminium tubes,
labelled as ‘Eurotubi’, which are proc-
essed further for example to make ski
sticks. In the last year Profilglass focused its investments and projects on
aluminium flat rolled products. Discs
from 100 to 1350 mm in diameter for
the pressing of cooking pans,
traffic signs, lighting
and parabolic mirrors,
amounting to a further
12,000 tpy, are another important market for Profilglass. For
this, five fully automatic
cutting lines with a total
capacity of 250,000 discs
per day are in use. The product range is supplemented by
aluminium Coils and Strips from
12 mm to 1650 mm width (30,000
tpy) with 8 slitting lines, Sheets and
Plates in the dimension range up
to 1650 mm wide and 6100 mm
long for various applications (20,000
tpy) with 5 cut to length lines. Tread
plates, stucco, degreasing material,
tension levelled material and triangle
production complete the wide range
of products in the alloys 1xxx, 3xxx,
4xxx, 5xxx series that Profilglass is
able to offer to the European market.
On a built area which has grown
originally from 7,000 m2 to the present
200,000 m2 the company, with around
500 employees, is currently producing 80,000 tonnes per year of aluminium semis and finished products. In
2007 its turnover was 240 million eu-
The Profilglass factory in Bellocchi di Fano. At the left is the site for the new hot-rolling mill.
92
ALUMINIUM · 9/2008
ros, an increase of about 70 percent in only two years. The
company’s customers have been extended from the building
sector to manufacturers of consumer goods, electric appliances and automotive components. Slightly less than half of
its turnover comes from the domestic market, the remainder
being exported all over the world.
Early on, Profilglass recognised that a time-flexible and
qualitatively reliable supply of rolled aluminium strips for
the production of its end products demanded the establishment of its own semis basis. Besides independence from the
supply market, this would in particular ensure the required
product quality. In several construction stages this led to
the creation of a melting plant and casthouse, which besides
primary aluminium, processes mainly aluminium scrap. The
construction of a rolling operation with cold-rolling mills and
cutting lines, begun in 2001, now enables Profilglass itself to
produce some of the aluminium strips it needs. These range
from 12 to 1650 mm in width, in the thickness range 0.080
to 6 mm, and are supplied as thin strips, strips, sheets, and
shapes such as discs and triangles.
Strips, which for capacity-related reasons or because of
limitations of the existing equipment Profilglass was hitherto
unable to produce itself, were previously bought in as hotrolled strip and then processed further for the company’s
own needs. From this process a close collaboration with the
Egyptian company Egyptalum developed. As the leading
producer of primary aluminium in the Near East (capacity
500,000 tpy), Egyptalum has played an important part in the
development of Profilglass. As part of this, Profilglass has
been the exclusive agent for Egyptalum products in Italy.
A provisional final construction stage of the plant in Bellocchi will be reached in 2009, when a new hot- and coldrolling mill will boost the present capacity of 90,000 tpy at
first by a further 50,000 tpy. Among other things this unit will
enable the production of alloys which cannot be made with
the roll-casting equipment currently in use.
Casthouse
The first, smaller melting furnaces and casting machines from
local manufacturers, used in the company’s early days, now
serve for the production of pre-products such as T-bars, ingots and sows for further processing by the company itself.
Motivated by rising demand for finished products, the
melting equipment and casthouse have continually been extended. After Profilglass had achieved positive results with
the roll-casting process, it was decided to build five more
units of the same type. These were constructed by the Italian
plant supplier Bruno Presezzi. The first three lines, installed
between 2003 and 2006, are being followed by two more,
which will begin operating in September 2008. Profilglass
will then operate a total of six strip casting units.
In this process the molten aluminium solidifies in the gap
between two casting rolls, one above the other and rotating
under a power. These rolls have a diameter of 970 mm, a
barrel length of 1900 mm, and are pressed together with a
force of 2,200 tonnes.
After edge milling the width of the cast strips ranges
from 800 mm minimum to 1700 mm maximum. The ©
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ALUMINIUM · 9/2008
leading to the lowest possible metal
loss.
The metal movement also evens
the temperature in the bath, leading
to lower metal surface temperature
which has a positive impact on melt
rate, fuel consumption, metal oxidation, and on the hydrogen pick-up of
the metal.
Bruno Presezzi
Rolling plant
Twin-roll caster
94
capacity of 64 tonnes, a melting rate
of 7 tonnes per hour, and an annual
output of 32,000 tonnes. Besides reliability, the prime consideration for
selecting the furnace was the highest
possible melt rate along with minimal
metal loss, which is known to account
for the greatest part of operating costs
if the design is inferior. For that reason the Thermcon furnace keeps the
surface temperature of the melt low
and the flames a safe distance away
from the melt.
The furnace is equipped with electromagnetic stirrers, which makes it
possible to charge thin-walled scrap
into the moving metal heel. The metal
movement in the furnace submerges
the charged material immediately,
This photo: Thermcon
thickness is from 3 to 8 mm, as a rule
5.5 mm. The original design casting
speed of 6 m/min has meanwhile
been reduced to 4 m /min, utilizing a
drive power of 2 x 75 kW, with which
the best results have been obtained
until now.
After casting and edge milling, the
strips are wound into coils of maximum weight 13 tonnes at a maximum
diameter of 2000 mm.
Compared with their predecessors, who were equipped with analog thickness controls, the two new
casting machines will have a digital
thickness control system with which
in combination with roll bending
an even more accurate strip profile
should be achieved.
The introduction of twin-roll casting for the production of cast aluminium strips demands the use of modern
and particularly reliable melting and
holding furnaces, since the continuous strip-casting process does not allow any interruptions and therefore
requires a reliable and continuous
supply of molten aluminium. Two
strip casting lines at a time are in each
case supplied by a tilting melt furnace
and two holding furnaces.
For the construction of the two new
casting lines No. 5 and 6 Profilglass
decided to get a tilting melt furnace
from Thermcon, a member of the Otto
Junker Group, which will start operating in autumn 2008. The reverberatory furnace is equipped with regenerative burners, and is designed for a
At the time when it built the first stripcasting unit, Profilglass invested in its
first cold-rolling mill to reduce the
cast strips to their final thickness. This
first mill was modernised in 2001 by
the Italian rolling plant manufacturer
Mino, to make it capable of meeting
stricter demands for productivity and
strip quality. At present Mino is commissioning a further cold-rolling mill,
which will roll the cast, 6-mm thick
strips in several passes down to a
minimum of 0.080 mm. This opens up
a new market segment for Profilglass:
thin strip as ‘fin stock’ and ‘foil stock’.
The new, 4-high non-reversing
cold-rolling mill is equipped with the
most modern actuators and controls
available on the market today, for
example for automatic flatness and
thickness control to ensure the closest tolerances. It rolls strips up to 1650
mm wide at a speed of up to 1000 m/
min. The plant is fully automated. To
ensure the highest productivity, roll
change takes place automatically. The
same applies to coil handling, ©
Tilting melt furnace
ALUMINIUM · 9/2008
UK
engineered casthouse furnace technology
partners in performance
Vesuvius UK Limited
2 Midland Way, Central Park,
Barlborough Links, Derbyshire,
S43 4XA, England
Tel:
+ 44 (0) 12 46 57 17 00
www.vesuvius.com
including spool preparation.
For the intermediate and final
annealing of the cold-rolled coils, a
number of chamber furnaces from
Otto Junker are in use.
Behind the cold-rolling mills, several straightening, slitting and cutto-length machines are in operation.
These enable flexible adaptation of
the needs of the company’s own further processing to wide-strip rolling.
In addition, the requirements of outside downstream processing customers can be met, rapidly and flexibly.
Opening new markets with
an alternative production route
For Profilglass, in many respects 2009
will bring a development step into a
new era as an aluminium strip manufacturer. At present, construction and
building measures are progressing at
appointed equipment suppliers and at
the company’s land in Bellocchi for a
new production route with the steps:
DC casting of rolling ingots – ingot
scalping – hot rolling – cold rolling.
The capacity of this plant will at first
be 50,000 tpy. The aim of the new
plant, among others, is to produce aluminium strips of alloy groups such as
1xxx and 5xxx, which cannot be made
on the strip-casting units and have
therefore previously been bought
from outside. With the new rolling
facilities Profilglass targets for a main
thickness range from 0.5 to 1 mm, i.e.
strips for heat exchangers, fin stock,
The new Mino cold-rolling mill
foil stock, multilayer pipes, food containers and suchlike. Plate production
too will be extended further, for example with tread plates.
Since after its commissioning the
plant will be subject to a detailed report, here only a brief outline of the
equipment ordered will be given,
which is to be delivered by the end
of 2008:
• The DC slab caster, producing rolling ingots 5.50 x 1.80 x 0.52 m, will
be supplied by the Italian company
Almec.
• The ingot scalper will also be Italian made.
• Otto Junker of Germany is supplying the directly gas-fired pusher-type
furnaces with a central charging and
clearing machine. This will mainly
be used for homogenising the rolling
slabs, with a cycle time of 20 to 25
hours.
• Mino in Italy will supply a single
stand-4-high hot rolling mill for strip
width up to 1.700 mm.
• Mino will also supply the 4-high,
non-reversing cold rolling mill for
strip widths up to 1650 mm. Like the
mill currently being commissioned,
this mill too will have the most modern automation equipment.
• The shear lines are being supplied
by Salico, Italy.
When the above plant begins operating, Profilglass, as a family-run
company, will have a planned production output of around 130,000 tpy
and a planned turnover of more than
350 million euros, and will therefore
have entered a range of rolled aluminium production previously dominated mainly by large, multinational
companies. Besides this, the company
will make resolute efforts to extend
further the market position it has
achieved in the sector of thin-walled
aluminium sections.
Author
Dipl.-Ing. Bernhard Rieth is a marketing
specialist and freelance technical journalist. As proprietor of Marketing Xpertise
Rieth in Meerbusch, he advises equipment
partners of the NF metals semis industry
on marketing-related matters.
Profilglass will be an exhibitor at
Hall 1, Stand E50
www.profilglass.it
Otto Junker annealing furnaces for cold-rolled coils
96
ALUMINIUM · 9/2008
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Pezzorgna Armando erweitert Produktpalette
um automatische Werkzeuglagersysteme
Die derzeit 3.000 Strangpresswerkzeuge werden auf zwei Strangpressen (16 MN und 27 MN) eingesetzt.
Die Matrizen werden automatisch im
Hochregallager eingelagert und entnommen, wobei eine chaotische Einlagerungssystematik rechnergesteuert
zur Optimierung des verfügbaren Lagerraumes angewandt wird. Das Hochregallager darf mit eine Bauhöhe von
9 m, einer Breite von 4,60 m und einer
Länge von 15 m als kompakt gelten.
Die flachliegend eingelagerten Matrizen haben einen Durchmesser von max. 300 mm
und eine Tiefe
Einzelzeichnung des
Entnahmegeräts zum
Werkzeug-Hochregallagersystem von PA
Die-O-Matic
Detailed illustration of
PA’s Die-O-Matic recovery unit for the die
high-rise rack store
system
98
Pezzorgna Armando extends its product
range with automatic die storage systems
Since July 2007 Pezzorgna Armando s.r.l. (PA), located near
Mantua in Italy, has been working
on a contract from one of its best
Italian customers to plan, deliver
and install its first fully automatic
storage system for extrusion dies.
The ‘Die-O-Matic-3000’ die storage
system developed by PA is a classical, high-rise rack storage system
with a rack-serving unit for 3,000
extrusion dies, which can even be
extended later on with modules,
using the same recovery unit, for
up to 6,500 storage places for extrusion dies. The storage system
was delivered in May.
Figures: Pezzorgna Armando
Seit Juli 2007 wickelt die in
der Nähe von Mantova, Italien,
ansässige Pezzorgna Armando
s.r.l. (PA) den Auftrag eines ihrer besten italienischen Kunden
zur Projektierung und Lieferung
bzw. Installation ihres ersten
vollautomatischen Lagersystems
für Strangpressmatrizen ab. Das
von PA entwickelte Werkzeuglagersystem “Die-O-Matic-3000” ist
ein klassisches Hochregal-Lagersystem mit Regalbediengerät für
3.000 Strangpresswerkzeuge, das
modular auch nachträglich, mit
demselben Entnahmegerät, auf bis
zu 6.500 Lagerplätze für Strangpressmatrizen erweitert werden
kann. Im Mai wurde das Lagersystem nun ausgeliefert.
PA-Lagersystem Die-O-Matic
PA storage system Die-O-Matic
The currently available 3,000 dies are
used on two extrusion presses (16 MN
and 27 MN). The dies are automatically stored in and recovered from
the high-rise rack store, using a chaotic store-placement system computer controlled to optimize available
storage space. With a height of 9 m,
a width of 4.60 m and a length of 15
m, the high-rise store is comparatively
compact for its size. The dies, stored
in flat layers, have maximum diameter
300 mm, maximum depth 200 mm and
maximum individual weight 220 kg.
The PA system can also be designed
at any time for larger and heavier dies,
and is moreover suitable for much
larger item numbers. At present another automatic storage system for up
to 20,000 dies is on PA’s order books
for delivery in May 2008.
The cycle time for the recovery (or
placement in store) of an extrusion die
by the recovery unit is less than one
minute. This ensures high plant availability, with around 60 double working operations per hour and short
store placement and recovery times,
achieved by travel speeds up to 40 m/
min along the Y-axis, 30 m/min along
the X-axis and, with combined travel of
the rack-serving unit, up to 20 m/min.
All drives are frequency-regulated and
the entire plant is equipped with highquality components and controlled by
a Siemens Simatic S7 SPS system.
The delivery by PA includes not
only the frame and support structure
of the high-rise rack store, the rackserving unit and the recovery/placement device, but also the full range
of software and programming for all
the plant’s cycles and automatic operations.
The control system enables the
storage and recall of the following individual cycles and parameters:
• individual die number for each
extrusion die, with all its
historical data,
• classification category (flat, chamber, etc.) of each extrusion die,
• brief designation of the die and
its use,
• die status: ready for use, being
etched, in use on a press, before
or after nitriding, due for correction, etc.,
• customer article number (for the
associated section),
• name of the customer for whom
the die was designed,
• date when the die was last used,
ALUMINIUM · 9/2008
and tonnage extruded,
• date when the die was made,
• press allocation for each die
(including multiple fitting),
• linear section weight and number
of apertures,
• diameter and thickness of the die,
• die weight,
• supplier of the extrusion die in
each case.
Further data, which may be important and appropriate depending on
the customer’s needs, can also be recorded. The databank-based analysis
and evaluation of the statistical data,
times of use, number of times used,
etc., can be displayed at any moment.
The die databank can also be linked
to DXF- or DWG-data from Autocad
or other CAD/CAM systems.
The main advantages of automated
die storage systems are:
• Improved storage conditions –
the dies are stored cleanly and in
clearly assigned positions, which
improves availability by eliminating search times.
• Greater die availability compared
with manual storage systems; no
maintenance of floor-level transporters is needed, and personnel
costs are saved.
• Back-tracing of the die’s use, since
all its historical movement data
are on record; this makes the life
cycle of each die transparent.
• Compared with conventional storage system with manual placement or recovery, less space
is occupied.
• Substantially ©
von max. 200 mm bei einem max.
Stückgewicht von 220 kg.
Das PA-System ist jederzeit auch
für größere Abmessungen und Gewichte auslegbar und eignet sich auch
für deutlich größere Stückzahlen. Zur
Auslieferung im Mai 2008 ist derzeit
ein weiteres automatisches Matrizenlagersystem für bis zu 20.000 Werkzeuge im Auftragsbestand von PA.
Die Zykluszeit für die Entnahme
(oder Einlagerung) eines Strangpresswerkzeuges mit dem Entnahmegerät beträgt weniger als eine Minute.
Dadurch ergibt sich eine hohe Anlagenverfügbarkeit bei circa 60 Doppelspielen je Stunde und schnelle
Einlager- und Entnahmezeiten, die
mit Verfahrgeschwindigkeiten in YAchse bis zu 40 m/min, in X-Achse
bis zu 30 m/min und in Kombinationsfahrt des Regalbediengeräts bis zu
20 m/min realisiert werden.
Alle Antriebe sind frequenzgeregelt, die Gesamtanlage ist mit Qualitätskomponenten und einer SPS von
Siemens Simatic S7 ausgerüstet.
Zum Lieferumfang von PA zählen
nicht nur die Rahmen- und Ständerstruktur des Hochregallagers, das
Regalbediengerät und die Entnahme/Einlagervorrichtung, sondern auch
der gesamte Software- und Programmierumfang für alle Zyklen und Automatikabläufe der Anlage.
Die Steuerung erlaubt die Erfassung und das Abrufen der folgenden
Einzelzyklen bzw. Parameter:
•
Individuelle
Werkzeugnummer zu
jedem Strangpresswerkzeug
mit allen historischen Daten.
• Klassifikationskategorie für
jedes Strangpresswerkzeug
(Flach-, Kammer- usw.).
• Kurzbezeichnung des WerkAnsicht
der Wabenzeugs und Verund Ständerwendungsrahmenstruktur des
Werkzeug-Lagersystems
zwecks.
Die-O-Matic
• Werkzeugstatus:
einsatzbereit,
View of the honeycomb and support-frame structure of the DieO-Matic die storage system
zum Beizen, im
ALUMINIUM · 9/2008
Einsatz an Presse, vor bzw. nach
dem Nitrieren, zur Korrektur usw.
• Kunden-Artikelnummer (für das
dazugehörende Profil).
• Name des Kunden, für den das
Werkzeug eingeschnitten wurde
• Letztes Einsatzdatum der Matrize,
gepresste Tonnage.
• Herstelldatum der Matrize
• Pressenzuordnung für jede Matrize
(auch Mehrfachbelegung).
• Lineares Profilgewicht und Anzahl der Durchbrüche.
• Durchmesser und Dicke des
Werkzeugs.
• Gewicht der Matrize
• Lieferant für das jeweilige
Strangpresswerkzeug.
Darüber hinaus können weitere Daten, die je nach Kundenerfordernis
wichtig und sinnvoll sind, aufgenommen werden. Die datenbankmäßige
Analyse und Auswertung der Statistikdaten, Einsatzzeiten, Verwendungsanzahl usw. können jederzeit visualisiert werden. Auch eine Verknüpfung
der Werkzeugdatenbank mit den
DXF- oder DWG-Daten aus Autocad
oder anderen CAD/CAM Systemen
ist vorbereitet.
Die Hauptvorzüge automatisierter
Werkzeug-Einlagerungssysteme bestehen aus:
• Verbesserte Lagerbedingungen:
Die Werkzeuge lagern sauber
und eindeutig zugeordnet, das
verbessert die Verfügbarkeit, es
entfallen Suchzeiten.
• Erhöhte Matrizenverfügbarkeit
gegenüber manuellen Einlagerungssystemen, die Wartung für
Flurförderzeuge entfällt, Personalkosten werden eingespart.
• Rückverfolgbarkeit des Werkzeugeinsatzes aufgrund vollständiger
Erfassung aller historischer Bewegungsdaten; dadurch wird der
Lebenszyklus jeder Matrize
transparent.
• Gegenüber konventionellen
Lagersystemen mit manueller
Einlagerung/Entnahme wird
weniger Platz benötigt.
• Deutlich reduzierte Unfallgefahr
durch Entfall des manuellen
Werkzeughandlings vor allem bei
schweren Matrizen.
• Erheblicher Rationalisierungseffekt durch automatisierte
©
99
Abläufe; das führt zur Einsparung
von Personalkosten.
Zur Zeit erfolgt die Erfassung der
Werkzeug-Artikelnummer noch manuell, jedoch arbeitet PA bereits an
einem automatisierten System auf
Basis von Barcodes. Der Einsatz entsprechender Scanner ist zuverlässig
und beschleunigt die Erfassung bei
Ein- oder Ausgabe der Werkzeuge;
er eliminiert die Gefahr von Fehlerfassungen oder Fehlbuchungen im
Datenbestand.
Das System zur automatisierten
Einlagerung von Strangpresswerkzeugen kann sowohl im Gebäudeinnern als auch im bewitterten Außenbereich (isoliert) aufgestellt werden.
Mit eigenem Service und Kundendienst stellt PA darüber hinaus auch
in Deutschland die umfassende Verfügbarkeit und Unterstützung derart
hoch komplexer Systeme bei Kunden
und damit höchste Verfügbarkeit des
automatischen
Werkzeuglagersystems sicher.
N
Seitenansicht mit isolierter Eindeckung für
Außenaufstellung (Ausgabe innen)
Side view, showing the isolating covering
for an exterior installation (with recovery
from the inside)
reduced risk of accidents, due to
the elimination of manual die
handling, especially in the case of
heavy dies.
• Substantial rationalisation effect
thanks to automated sequences,
leading to a saving of personnel
costs.
At present the die article number is
still recorded manually but PA is
already working on a barcodebased automatic system. The use
of corresponding scanners is reliable and speeds up the recording
when the dies are put into store or
recovered, so eliminating the risk
of erroneous recording or erroneous registration in the database.
The automatic extrusion die
storage system can be set up either
indoors, or in the open (isolated).
With its own servicing and customer
care facilities, PA also ensure that in
Germany too, customers benefit from
comprehensive availability and support for such highly complex systems,
and therefore maximum utility of the
automatic die storage system.
Pezzorgna Armando will be an exhibitor at ALUMINIUM 2008 in Essen.
Hall 1, Stand F70
www.pasrl.it
N5 Nitrogen
Strangpresswerkzeuge prozesssicher mit Stickstoff kühlen
Viele Strangpresswerke wenden
bereits Stickstoff als Kühlmedium
zum Kühlen austretender Profile
bzw. der Strangpresswerkzeuge
an. Oft werden auch nur Ringkanäle im Pressenmaul zur Inertisierung der Atmosphäre und
damit zur „Verschönerung“ der
Profiloberfläche eingesetzt. Allen
bekannten und existierenden Anwendungen dieser Art gemeinsam
ist jedoch, dass die Durchflussmengen, die Temperaturen und
sonstigen Einstellungen mehr oder
weniger zufällig gewählt werden.
Von einer prozesssicheren Zuordnung von definierten Kühlparametern zu einem spezifischen
Aluminium-Strangpressprofil ist
die Praxis derzeit noch weit entfernt. Das Softwarehaus A.T.I.E.
Uno Informatica aus Italien hat gemeinsam mit Messer Group, Krefeld, nun eine prozesssichere und
innovative Regelung für diese
©
100
N5 Nitrogen
Die cooling with liquid nitrogen
Many extruders already use nitrogen to polish the sections emerging
from the press. They often use a
ring at the entrance of the press to
provide an inert atmosphere in order to enhance the appearance of
the extrusion’s surface. In all such
cases, the use of a ring at the entrance of the press results in flows,
temperatures and other parameters that are not fixed, but depend
on the personal experience of the
operator. This is because section
cooling parameters are inherently
uncertain. Together with the
Messer Group in Germany, A.T.I.E.
Uno Informatica in Italy has developed a new, safe and innovative
system – called ‘N5 Nitrogen’ – for
managing this process. This system will be introduced jointly by
both companies at the ALUMINIUM 2008 Exhibition in Essen.
Based on the well-proven Incal technology (Messer Group), liquid nitrogen
is injected onto the die, which has to
be channelled in accordance with the
specific design. To apply this new technology it is absolutely essential to use
dies designed as illustrated in Fig. 2.
An important innovation in the N5
Nitrogen system is that the cryogenic
valve, which controls the nitrogen
flow, is managed by a PLC independently and separately, and the system
takes into account the temperatures of
the billets and the sections (emerging
from the press), which are determined
by pyrometers, and uses them to enable the operator to regulate the process. There is an independent PLC, ©
ALUMINIUM · 9/2008
# "% !#$%"&& ( '
der Ein- und Austrittstemwhich controls the die cooling with
peratur geregelt (und auch
liquid nitrogen: it regulates the nitronachgeregelt); alle Eingen flow as a function of the temperastellungen und Parameter
tures at the entrance and exit of the
werden prozesssicher aufpress. Each setting and parameter for
gezeichnet und profilspezithe section currently being produced
fisch in der Profilrezeptur
is recorded to enable the operator to
gespeichert. Eine einmal
retrieve the optimum data set for prooptimierte Struktur von
ducing the same section again on the
Daten für ein Profil ist jebasis of previous successful results.
derzeit wiederholbar.
Using N5 Nitrogen the extruder
Ergebnis des Einsatzes
can increases the extrusion speed sigvon N5 Nitrogen sowie der
nificantly due to die cooling optimizaOptimierung der Werktion, resulting in a consistent increase
zeugkühlung durch diese
of productivity. N5 Nitrogen also optiAnwendung ist die Erhömizes the extrusion parameters on the
hung der möglichen Pressbasis of the temperature of the section
geschwindigkeiten für ein
emerging from the press. Working in
Profil und damit – nachhalthis way allows the extrusion speed to
tig und prozesssicher – die
be increased more and more while the
Erhöhung der Produktivität.
temperature so permits.
Es erfolgt eine Optimierung
In an extrusion plant in Italy (Proder Strangpressparameter
ferall Srl) N5 Nitrogen has been sucAbb. 1: A = ohne Kühlung der Matrize B = mit Ringmaulkühlung C = mit aktiver Insitu-Werkzeugkühlung
in Abhängigkeit der tatcessfully in operation for a year. N5
sächlichen Temperaturen
Nitrogen intervenes actively and dyFig. 1: A = without die cooling; B = with ring cooling;
C = with active in-situ die cooling
am austretenden Profil. Die
namically in the press operation (as
Strangpressgeschwindigdo Cadex, Midis or Picos) and sets the
keit wird dynamisch weiter erhöht,
parameters so that the net yield of the
Aufgabenstellung kreiert, die „N5
wenn
die
Austrittstemperatur
dies
press is consistently improved.
Nitrogen“ heißt und im September
zulässt.
auf der ALUMINIUM 2008 dem
The use of N5 Nitrogen can imIn einem italienischen Presswerk
Fachpublikum vorgestellt wird.
prove extrusion productivity more efin Italien (Proferall Srl) ist diese neue
fectively than using simple optimizaTechnologie seit einem Jahr erfolgtion software such as Cadex or Picos,
Auf der bewährten Incal-Technologie
reich im Einsatz. N5 Nitrogen greift
because for the first time, the system
von Messer basierend, wird flüssiger
dabei aktiv und dynamisch in die beuses the reduced die temperature as
Stickstoff in die radialen Kanäle der
stehende Pressensteuerung (wie Caa control and regulation parameter.
entsprechend vorbereiteten Matrize
dex, Midis, Picos ) ein und übersteuert
With this system the die life too is ineingebracht. Voraussetzung für den
die dort festgelegten Parameter – mit
creased, because of optimized cooling.
erfolgreichen Einsatz dieser Technodem Resultat nachhaltiger Steigerung
In addition the yield is improved since
logie sind entsprechend vorbereitete
der Nettoausbringung.
surface imperfections on the sections
Strangpressmatrizen ähnlich der Dar(extrusion defects such as heat streams
stellung in Abb. 2.
Mit N5 Nitrogen kann die Proor pickups) are reduced significantly.
Neu an der „N5 Nitrogen“-Techduktivität des Strangpressens weiter
nologie ist, dass alle Durchflussmenerhöht werden, als dies nur
gen-Regelventile der Kühlung automit vorhandenen Opmatisiert in eine separate speichertimierungen wie
programmierbare Steuerung (SPS)
Cadex, Midis
eingebunden sind, worin die mittels
oder Picos
Thermofühlern ausgelesenen Ist-Daalleine
ten der Bolzentemperatur und der
mögProfilaustrittstemperatur in die neue
lich
Steuerung übernommen und ausgewertet werden.
Das Herzstück dieser neuen Technologie ist die eigene SPS, die die
Steuerung dieses Unterprozesses
„Kühlen des Werkzeugs mit flüssigem
Stickstoff“ selbsttätig übernimmt:
Automatisch wird die Zufuhr von
Abb. 2: Matrize mit radial eingebrachten Kühlkanälen für flüssigen Stickstoff
flüssigem Stickstoff in Abhängigkeit
Fig. 2: Die with radial cooling channels for liquid nitrogen
102
ALUMINIUM · 9/2008
Abb. 3: Für den Einsatz von N5 Nitrogen
vorbereitete Strangpresswerkzeuge
Fig. 3: Extrusion die prepared for the use
of the N5 Nitrogen system
Abb. 4: Screenshot der Steuerung von A.t.i.e. Uno Informatica (Beispiel)
With N5 Nitrogen the parameters defined during the various operations
are completely independent of the
particular operating team involved,
and any quality variation due to modification of the cooling can easily be
traced.
N
Fig. 4: Screenshot of the A.T.I.E. Uno Informatica control system (example)
wäre, denn erstmals wird die tatsächlich durch die Kühlung aktiv
reduzierte Profilaustrittstemperatur
als Steuerungsparameter dynamisch
eingesetzt.
Gleichzeitig wird durch die optimierten Kühlstrategien auch die
Lebensdauer der Strangpresswerkzeuge sowie die Ausbringung erhöht
und zugleich die Profiloberflä- ©
Bitte besuchen Sie uns auf der Aluminium 2008 in Essen, Halle 4 Stand 4B04
ALUMINIUM · 9/2008
103
che verbessert. Pickups, Pressflöhe,
Warmstreifen und andere Pressfehler
gehen tendenziell deutlich zurück.
Die Kühleinstellungen sind auch
über Jahre hinweg unabhängig von
der Bedienermannschaft stabil einstellbar und Qualitätsveränderungen
aufgrund von Veränderungen der
Kühlparameter enger eingrenzbar.
A.T.I.E. Uno Informatica ist Aussteller
auf der ALUMINIUM 2008 in Essen.
Halle 6, Stand C24
Abb. 5: Darstellung der N5 Nitrogen integrierten Steuerung für das Stickstoffkühlen von
Strangpresswerkzeugen
www.unoi.it
Fig. 5: Illustration of the N5 Nitrogen integrated control system for the cooling of extrusion dies with nitrogen
Thixoforming – komplexe Geometrien in fast porositätsfreier Qualität
Lösungen aus einem Guss
C. Eder, Lend
Aufgrund des immer größer werdenden Kostendrucks streben
Automobil- und Nutzfahrzeughersteller Lösungen an, bei denen
sich komplexe Geometrien in NetShape-Qualität ohne nachfolgende
mechanische Bearbeitung realisieren lassen. Hierbei bietet sich das
Thixocasting-Verfahren der SAG
Thixalloy Components an.
Beim Thixocasting wird ein entsprechend behandeltes Vormaterial in
den Fest-Flüssig-Bereich erwärmt
und mittels einer handelsüblichen
Kaltkammer-Druckgussmaschine
vergossen. Durch den geringeren
Flüssiganteil (mit geringerer Erstarrungsschrumpfung) im Vergleich zum
herkömmlichen Druckgussverfahren
und durch die laminare Formfüllung
können Bauteile mit komplexen Geometrien in nahezu porositätsfreier
Qualität realisiert werden. Dadurch
eignet sich das Verfahren ausgezeichnet für Schweißanwendungen, Oberflächen- und Sicherheitsteile.
Vor dem eigentlichen Gießprozess
muss ein für das Verfahren geeignetes
Vormaterial bereit stehen. Die SAG
Thixalloy Components kooperiert
hierbei eng mit ihrer Schwestergesellschaft SAG Aluminium Lend, die intensiv an der Entwicklung von ©
104
Thixoforming – complex geometries in virtually pore-free quality
Solutions in one casting step
C. Eder, Lend
Because of continually increasing
cost pressures, automobile and
commercial vehicle manufacturers
are looking for solutions by means
of which complex geometries can
be obtained in net-shape quality
without subsequent mechanical
machining. A possibility for this
is provided by the thixocasting
process offered by SAG Thixalloy
Components.
In thixocasting an appropriately
treated pre-material is heated to the
solid-liquid range and cast using a
conventional cold-chamber pressure
diecasting machine. Due to the small
liquid proportion (and consequent low
shrinkage on solidification) compared
with ordinary
Abb. 1:
Komplette
LuftfederungsBaugruppe für Audi
aus dem Hause SAG
Fig. 1: Complete air-spring structural group
for Audi, from SAG
Photo: SAG
pressure diecasting, and thanks to the
laminar filling of the mould, components with complex geometries can
be made in virtually pore-free quality.
Thus, the process is eminently suitable
for welding applications, good surfaces and safety-relevant components.
Before the casting process itself a
pre-material suitable for the method is
required. In this regards SAG Thixalloy Components collaborates closely
with its sister company SAG Aluminium Lend, which works intensively on
the development of new alloys.
The per-material is produced in
a horizontal continuous-casting unit
in which, during the casting stage,
electromagnetic stirring takes place
so that growing dendrites are broken
up and form nuclei in the melt. This
produces the necessary globulitic
structure needed for the thixocasting
process. The bars produced in this
way are then processed to make
billets (of length according to the
shot weight), heated in an inductive heating unit up to the optimum
solid-liquid condition and pressed.
In principle any aluminium ©
ALUMINIUM · 9/2008
neuen Legierungen arbeitet.
Die Herstellung des Vormaterials
geschieht in einer Horizontalstranggussanlage. Während des Abgusses
erfolgt eine elektromagnetische Rührung, wodurch sich bildende Dendriten abscheren und zu Keimen in
der Schmelze führen. Dadurch bildet
sich das benötigte globulitische Gefüge aus, das für den Thixogussprozess
benötigt wird. Die so produzierten
Stangen werden anschließend zu
Bolzen (Länge je nach Schussgewicht)
verarbeitet und in einer induktiven
Erwärmungsanlage in den optimalen
Fest-Flüssig-Zustand erwärmt und
verpresst.
Prinzipiell sind alle Aluminiumlegierungen verarbeitbar, die ein
ausreichend großes Erstarrungsintervall aufweisen, um eine prozesssichere Wiedererwärmung in den
Fest-Flüssig-Übergangsbereich zu gewährleisten. Reine Metalle und naheutektische Legierungen sind beim
Thixoforming nicht verarbeitbar, da
diese kein bzw. nur ein sehr kleines
Erstarrungsintervall aufweisen. Standardlegierungen für den Thixoforming-Prozess sind die Legierungen
AlSi7Mg0,3 (TX630) und AlSi7Mg0,6
(TX650). Diese Legierungen können
durch entsprechende Wärmebehandlungen an die benötigten Anforderungen des Kunden angepasst werden.
Thixogeformte Bauteile zielen
insbesondere auf die Substitution
von Stahlschmiedeteilen, auf Strukturschweißungen und druckdichte
Schweißverbindungen (z. B. Luftfederung, bis 90 bar Berstdruck). Durch das
Thixogießverfahren werden deutliche
Gewichtsersparnisse bei gleichzeitig
guten mechanischen Eigenschaften
erzielt – hier ist vor allem die Bruchdehnung zu erwähnen. Die heute am
meisten verwendeten Legierungen
für den Einsatz im Thixoguss sind
die Legierungen AlSi7Mg0,3 (A356)
bzw. AlSi7Mg0,6 (A357). Neue Legierungen gehen in Richtung naturharte
Legierungen („Maxxalloy“ AlMg5Si),
die keine bzw. eine geringe nachfolgende Wärmebehandlung benötigen,
um die geforderten mechanischen
Eigenschaften zu gewährleisten.
Aufgrund der nur im sehr geringen Ausmaß auftretenden Porosi-
106
täten beim Thixoguss sind thixogeformte Bauteile sehr gut schweißbar
und mit hohen Drücken belastbar.
Ein aktueller Anwendungsfall ist die
Luftfederung des aktuellen Audi A6.
Auch für Anwendungen mit hohen
Anforderungen an die Optik und
an die Korrosionsbeständigkeit, ist
das Thixoverfahren bestens geeignet. Durch die geringe Porosität und
Lunkerneigung lassen sich komplexe
Bauteile in Net-Shape-Qualität mit
hohen mechanischen Festigkeiten realisieren. Diese Gussteile lassen sich
ohne aufwendige Nacharbeit mit den
herkömmlichen Verfahren wie Galvanik, Nass- und Pulvertechnologie
beschichten.
In verstärktem Maße werden bei
den OEMs Lösungen angestrebt, bei
denen sich durch das verwendete Verfahren Kostenersparnisse ergeben,
zum Beispiel durch geringere mechanische Nacharbeit. Hierfür bietet sich
wiederum Thixocasting an, mit dem
einerseits durch die Net-Shape-Fertigung das Ausmaß der nachfolgenden
Bearbeitungsschritte reduziert werden kann und anderseits die
Abb.
2: Heckklappenscharnier
Fig. 2: Rear hood hinge
hohen mechanischen Forderungen
an das Bauteil erfüllt werden können,
wie dies von der SAG Thixalloy Components beim Heckklappenscharnier
des neuen Volvo C70 umgesetzt
wurde. Durch Thixoforming kann
das komplex ausgebildete Bauteil in
einem Produktionsschritt ohne zusätzliche aufwendige Schweißverbindung hergestellt werden.
Die wesentlichen Vorteile im Gegensatz zum herkömmlichen Druckguss sind die laminare Formfüllung
mit geschlossener Fließfront. Damit
wird die Einbringung von Luft und
Trennmitteln in das Gussstück vermieden, wodurch im Bauteil keine
bzw. fast keine Porositäten und Einschlüsse auftreten. Durch die ©
alloy can be processed provided that
it has a solidification interval wide
enough to allow reliable heating to
the solid-liquid transition range. Pure
metals and alloys of near-eutectic
composition cannot be used for Thixoforming, since they have no, or only
a very narrow solidification range.
Standard alloys for the Thixoforming process are the alloys AlSi7Mg0.3
(TX630) and AlSi7Mg0.6 (TX650).
These alloys can by adapted to the
customer’s requirements by appropriate heat treatment.
Thixoformed components aim
above all to replace forged steel
components for structural welds and
pressure-tight weld joints (such as
air-springs with bursting pressure up
to 90 bar). The thixocasting process
allows substantial weight savings at
the same time as good mechanical
properties, particularly in relation
to elongation at fracture. The alloys
most widely used nowadays for thixocasting are AlSi7Mg0.3 (A356) or
AlSi7Mg0.6 (A357). New alloy development is moving in the direction
of naturally hard alloys (‘Maxxalloy’
AlMg5Si), which need no, or only little subsequent heat treatment in order
to ensure the necessary mechanical properties.
Thanks to the very low porosity in thixocastings, thixoformed
components can be welded very
successfully and will withstand high
pressures. A current application case
is the air-spring system of the present
Audi 6. For applications with high
demand in relation to appearance
and corrosion resistance as well, the
thixo-process is again best suited.
Thanks to low porosity and tendency
to form cavities, complex components
of net-shape quality with high mechanical strengths can be made. The
resultant castings can be coated by
conventional methods such as electroplating, wet-coating and powdercoating technology without elaborate
and costly preparatory work.
Increasingly, OEMs are looking for
solutions by virtue of which cost savings can be achieved by the method
used, for example because less mechanical finishing work is needed.
Thixocasting is again ideal for this,
since on the one hand net-shape ©
ALUMINIUM · 9/2008
novelis-annonce-presse-a4.qxp
29/07/2008
17:14
Page 1
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Booth 0
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[email protected]
www.pae.novelis.com
Abb. 3: Herkömmliches Gefüge und geeignetes Gefüge für die thixotrope Verarbeitung
Fig. 3: Conventional structure and structure suitable for thixotropic processing
laminare Formfüllung ergibt sich zudem eine wesentlich höhere Standzeit des Werkzeuges aufgrund der
geringeren Erosionsbelastung gegenüber der turbulenten Strömung beim
herkömmlichen Druckguss.
Ein weiterer Vorteil beim Thixogießen ist, dass sich, durch den teilfesten Zustand des Materials, dieser
Anteil bei der Erstarrung des Gussteils in der Form keine Phasenumwandlung mehr erfährt, wodurch
das Volumendefizit, das bei der Erstarrung auftritt, wesentlich geringer
ist. Durch eine Nachspeisung unter
Druck während der Resterstarrung
wird die Lunkerbildung fast vollständig verhindert.
Gegenüber dem Druckguss wird
das vorhandene Gefüge bereits durch
die Vormaterialherstellung und die
Erwärmung in den teilflüssigen Bereich festgelegt. Die Größe und Form
der festen Phase ändert sich auch
während der Resterstarrung nicht
mehr. Die Mikrostruktur ist gegenüber dem Druckguss nahezu unabhängig von lokalen Unterschieden
der Erstarrungsbedingungen, zum
Beispiel der Wanddicke.
production reduces the subsequent
machining steps needed and on the
other hand the components have
excellent mechanical properties, as
demonstrated by SAG Thixalloy Components with the rear hood hinge for
the new Volvo C70. By thixoforming,
this complex component is produced
in a single production step with no additional, costly weld joints.
Compared with conventional pressure diecasting the essential advantages of the method are laminar mould
filling with a closed flow front. This
avoids the incorporation of air and
parting agent in the casting, so that
the component contains no, or almost
no porosity and inclusions. Thanks to
the laminar mould filling the life of the
die is also substantially increased, because of lower erosion compared with
that produced by the turbulent flow
during ordinary pressure diecasting.
A further advantage of thixocasting
is that due to the partially solid condition of the material, this fraction does
not undergo any further phase trans-
C
D
C
D
m
u
i
m
n
u
i
i
min
f or Alucm
assttiinngg
Drache
umwelttechnik
108
ALUMINIUM · 9/2008
formation in the mould while the casting is solidifying, so that the volume
deficit produced during solidification
is much smaller. Cavity formation can
be prevented almost completely by
top-up feeding under pressure during
the solidification of the residue.
Compared with pressure diecasting the structure obtained is already
established by the preparation of the
per-material and the heating to the
partially liquid range. The size and
shape of the solid fraction no longer
changes even during residual solidification. Compared with pressure diecasting the microstructure is virtually
independent of local differences of
the solidification conditions, such as
wall thickness. In summary, the following criteria apply in the case of
thixocasting applications:
• no components with low quality
requirements
• large wall thickness differences
can be produced
• high design complexity and integration of functions
• pressure-tightness thanks to low
porosity
• thermal treatments: good welding
properties, heat treatment
• high surface quality demands are
satisfied
• thixocasting can in particular replace or reduce the following processes: mechanical machining, forging,
precision casting, gravity diecasting,
vacuum pressure diecasting
• replacement of joined sheets and
extruded components thanks to integration.
Author
Christian Eder, Research and Development, SAG Thixalloy Components.
SAG Aluminium Lend will be an exhibitor at ALUMINIUM 2008 in Essen.
Hall 7, Stand C40
Zusammenfassend lassen sich folgende Kriterien für Thixocasting-Anwendungen festhalten:
• keine Teile mit geringen Qualitätsanforderungen
• große Unterschiede in den Wanddicken realisierbar
• hohe Komplexität der Konstruktion und Integration von Funktionen
• Druckdichtigkeit durch porenarme
Qualität
• thermische Behandlungen: hohe
Schweißeignung, Wärmebehandlung
• Hohe Anforderungen an die Oberfläche
• Thixocasting kann insbesondere
folgende Prozesse substituieren: mechanische Bearbeitung, Schmieden,
Feinguss, Kokillenguss, VakuumDruckguss
• Ersatz von gefügtem Blech und
Strangpressteilen durch Integration.
Autor
www.sag.at
Christian Eder, Forschung und Entwicklung, SAG Thixalloy Components.
Transport Systems
! Anodes
! Ladles
! Oven charging
Windhoff Bahn- und Anlagentechnik GmbH
Hovestr. 10 · D-48431 Rheine · Phone: +49 5971 58-0
Fax: +49 5971 58-209 · [email protected] · www.windhoff.de
ALUMINIUM · 9/2008
109
DMAX von Otefal
Farbaluminiumbleche für Fassaden
Moderne Coil-Coating-Anlagen sind
über 200 m lang und können Aluminiumbänder bis zu 3 mm Dicke und im
Standardbereich bis zu 1600 mm Breite lackieren, in speziellen Fällen sogar
bis zu 2300 mm Breite. Die Bänder
durchlaufen verschiedene Stationen
bis hin zu einer bis zu vierschichtigen
Decklackierung mit bis zu vier Einbrennungen in verschiedenen Lacksystemen. Die Oberflächenlackierung
erfolgt meist im Walzenauftragsverfahren für Flüssiglacke wie PVdF. Einige Anlagen verarbeiten auch Pulverlacke im CC-Verfahren, die in höheren
Lackschichtdicken appliziert werden
können und dennoch nachträglich
abkantbar sind. Beide Systeme haben
Vor- und Nachteile, die je nach Endanwendung des Produktes und nach
den Qualitätsanforderungen abgewogen werden müssen.
Im Bereich der hochwertigen
Fassadenelemente (Kassetten, Panels)
etablieren sich mehr und mehr solide
vorlackierte Aluminiumbleche ©
110
DMAX by Otefal
Coloured aluminium sheets for façades
The product concept is a simple
one: you take solid aluminium
strips of a grade particularly suitable for façades such as the alloy
AA 5754, AlMg3, uses the roller
application method to paint it
continuously in a strip lacquering
unit and then, after stoving the
lacquer, cut it up into sheets. The
pre-lacquered sheets can be bent
through the recommended bend
radii without cracking or flaking
off the lacquer – an advantage
compared with the traditional
method, in which the blank sheets
are first bent and only then surface finished (e. g. by piecemeal
lacquering). Increasingly, pre-lacquered aluminium sheets finished
with PVdF-lacquers – such as the
DMAX product range by Otefal
– are gaining popularity compared
with aluminium composites with a
polythene core. The fire-resistance
of the material, its strength and
re-usability are important competition criteria for this.
Modern coil-coating plants are more
than 200 metres long and can paint
aluminium strips up to 3 mm thick and
up to 1600 mm wide in the standard
range, and even up to 2300 mm wide in
special cases. The strips pass through
various stations until they have been
given a covering coating with up to four
layers, stoved up to four times, using
a variety of lacquer systems. Surface
lacquering is carried out mainly by the
roller application method in the case
of liquid lacquers such as PVdF. Some
units also process powder lacquers by
the CC method, which can be applied
in thicker coatings but can yet be subsequently bent. The two systems each
have advantages and disadvantages,
which must be evaluated depending
on the end application of the product
and the quality demands.
In the area of high-grade façade
elements (cassettes, panels) solid, pre-
Otefal
Das Produktkonzept ist einfach:
Man nehme solide Aluminiumbänder in einer besonderen Fassadenqualität wie der Legierung AA
5754, AlMg3, lackiere sie im Walzenauftragsverfahren kontinuierlich auf einer Bandlackieranlage
und schneide sie nach dem thermischen Einbrennen des Lackes
zu Blechen. Die vorlackierten
Bleche sind mit den empfohlenen
Biegeradien abkantbar, ohne dass
der Lack reißt oder gar abplatzt
– ein Vorteil gegenüber dem traditionellen Verfahren, bei dem die
blanken Bleche zunächst abgekantet und erst abschließend oberflächenveredelt werden (z. B. durch
Stücklackierung). Zunehmend
etablieren sich vorlackierte Aluminiumbleche in PVdF-Lackierungen
– wie die DMAX-Produktreihe
von Otefal – gegenüber Aluminium Composites mit einem Kern
aus Polyethylen. Brandverhalten,
Materialsteifigkeit und Wiederverwertbarkeit sind dabei wichtige
Wettbewerbskriterien.
Objekte, die mit DMAX-Fassadenblechen
verkleidet wurden: das Hotel Le Crystal de
la Montagne in Montreal …
Examples of buildings clad with DMAX
façade sheets: hotel Le Crystal de la Montagne in Montreal …
lacquered aluminium sheets 2 and 3
mm thick painted with PVdF lacquers,
which have meanwhile given good
service as ideal exterior façades in all
climatic zones, are becoming more
and more widely accepted. This is
happening in competition with the
previously worldwide-dominant aluminium composites whose standard
grade consists of aluminium coversheets each only 0.5 mm thick (like
an aluminium veneer) with a core of
usually 3-mm polyethylene (LDPE).
The sandwich structure of aluminium composites gives exceptionally
flat, decorative plates which, however, consist three-quarters of plastic
and only a quarter of aluminium. This
combination leads to certain technical and qualitative consequences of
which building contractors and even
architects are often unaware:
• This applies, for example, to their
fire behaviour: polyethylene burns
with a bright flame. In accordance
with the relevant DIN 4102 standard (now EN 15301) building materials containing PE are classified
in category B2 (combustible, ©
ALUMINIUM · 9/2008
Besuchen Sie uns:
Aluminium 2008
Halle 3,
Stand A20
Ewig jung und stark und schön bleiben? Ein Traum für uns. Für Aluminium aber
ist er Wirklichkeit: Es lässt sich immer und immer wieder bei gleicher Qualität
recyceln.Es ist ein erneuerbarer Rohstoff, den auch künftige Generationen noch
nutzen können, in unendlich vielen Anwendungen.
Hydro ist Aluminium. Wir sind stolz, dieses erstaunliche Metall herzustellen,
zu verarbeiten und einzuschmelzen - für ein immer neues Leben.
www.hydro.com
in 2 und 3 mm Dicke in PVdF-Lackierungen, die sich mittlerweile seit
Jahrzehnten in allen Klimazonen als
ideale Außenfassaden bewährt haben. Das geschieht im Wettbewerb zu
bisher weltweit noch dominierenden
Aluminium Composites, die als Standardqualität aus je nur 0,5 mm dicken
Aluminium-Deckschichten (wie Aluminium-,,Furnier“) mit einem Kern
von üblicherweise 3 mm dickem
Polyethylen (LDPE) bestehen. Die
Sandwichfertigung der Aluminium
Composites führt zu äußerst planen,
dekorativen Platten, die allerdings zu
drei Vierteln aus Kunststoff und nur
zu einem Viertel aus Aluminium bestehen. Diese Kombination führt zu
einigen technisch-qualitativen Konsequenzen, die Bauherren und selbst
Architekten kaum bekannt sind:
• Das gilt zum Beispiel für das Brandverhalten: Polyethylen brennt mit
heller Flamme. Nach der relevanten
DIN 4102 (jetzt EN 15301) werden
Baustoffe aus PE der Kategorie B2
(brennbar, leicht entflammbar) eingestuft. Damit sind sie für Hochhausfassaden in Deutschland (über 22 m
Höhe) nicht zugelassen. Die Industrie
hat darauf mit der Entwicklung von
Aluminium Composites reagiert, die
einen Kern aus nicht brennbaren mineralischen Stoffen wie Aluminiumhydroxid enthalten. Damit wird die
Brandstoffklasse A2 erreicht, die angesichts der Brandproblematik die
einzige Qualität sein sollte, die unbedenklich empfohlen werden kann.
Allerdings haben sich in der Branche
weltweit inzwischen etwa 100 Composites etabliert, die fast alle lediglich
PE als Kern einsetzen oder bestenfalls schwer entflammbar, aber noch
immer brennbar sind. Hier müssen
Gesetze wie die Hochhausrichtlinie
in Deutschland auch international gefordert werden.
• Ein wichtiger Aspekt ist die Materialsteifigkeit: 4 mm dicke Aluminium
Composites sind sehr steif, stabil und
dennoch relativ leicht. Sie sind als
Glattbleche für sichtbare Befestigungen
oder als „infill panels“ geradezu ideal
in Bezug auf ihre statischen Werte.
Wenn jedoch allseitig eine Abkantung
zu Kassetten erfolgt, müssen die Panels
rückseitig eingefräst werden, um eine
Abkantung von 90 Grad zu ermöglichen. Dann verbleibt im Kantbereich
nur 0,5 mm dickes Aluminium, an dem
die Kassetten in die Unterkonstruktion
eingehängt werden. Die verbleibende
Stabilität ist dann natürlich im Vergleich zu 2 oder gar 3 mm dickem,
erst recht abgekantetem, solidem Aluminiumblech deutlich niedriger. Das
gilt besonders, wenn bei Composites
Standardlegierungen der Gruppe AA
3000 statt der wesentlich stabileren
Legierung AA 5754 für solide Aluminiumbleche eingesetzt werden.
• Nicht zu vernachlässigen: das Recycling. Aluminium, auch vorlackiertes, ist ein hoch werthaltiger Rohstoff,
der sich problemlos recyceln lässt.
Das ist bei Altmaterial aus Aluminium
Composites mit einem dominantem
Kunststoffanteil wesentlich schwieriger, vor allem in Ländern, in denen
noch kein funktionsfähiges, flächendeckendes Recyclingsystem aufgebaut
ist oder wo es logistische Hindernisse
gibt.
©
… sowie das America’s Cup Building in Valencia …
… and the America’s Cup Building in Valencia …
112
easily flammable). Accordingly, they
are not approved for high-rise building façades (over 22 m high) in Germany. The industry reacted to this by
the development of aluminium composites containing a core of incombustible mineral materials such as
aluminium hydroxide. This conferred
the fire-resisting material category A2
which, from the fire standpoint, is the
only grade that can be recommended without reserve. However, in the
branch worldwide approximately 100
different composites have been developed, almost all of which use PE as the
core or in the best cases are difficult to
ignite, but are still combustible. In this
connection laws such as the high-rise
building regulations in Germany must
also be insisted upon internationally.
• An important aspect is the rigidity
of the material: aluminium composites 4 mm thick are very rigid, strong,
yet relatively light. In terms of their
static values they are ideal for visible fastenings or as ‘infill panels’. But
when they are bent on all sides to form
cassettes, the panels have to be milled
on the back in order to allow bending
through 90°. Then, in the bend area
there remains aluminium only 0.5
mm thick, on which the cassettes are
suspended in the substructure. Naturally therefore, compared with solid
aluminium sheet 2 or even 3 mm thick
and already correctly bent, the residual strength is considerably lower. This
applies particularly when, instead of
the substantially stronger alloy AA
5754 used for solid aluminium sheets,
standard alloys of the AA 3000 group
are used in the composites.
• Not to be disregarded is the recycling aspect. Even when pre-lacquered, aluminium is a valuable secondary raw material that can be recycled without problems. With aluminium composite scrap with a dominant
plastic proportion this is substantially
more difficult, especially in countries
where there is not yet any effective,
widespread recycling system or where
there are logistical obstacles.
These three outlined drawbacks of
aluminium composites can of course
be overcome with technical effort and
the associated costs. An attractive
new option is the use of solid coloured
aluminium 2 or 3 mm thick for ©
ALUMINIUM · 9/2008
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DMAX-Vorzüge auf einen Blick
DMAX – advantages at a glance
• Perfekte Planität durch Einsatz von
streckgerichtetem Aluminiumband
• Hohe Materialdicke des Trägermaterials (2 bis 3 mm) für hohe
Festigkeit
• PVdF-Beschichtung in 2 bis 4
Schichten
• Glanzgrad PVdF typisch 35
Einheiten, ausgewogenes Farbsortiment in uni und metallic.
• Perfect flatness due to the use of
stretch-straightened aluminium
strip
• High material thickness of the
support material (2 to 3 mm) for
high strength
• VdF coating in 2 to 4 layers
• Typical PVdF gloss 35 units, in a
balanced colour choice of unior metallic finishes.
Diese drei skizzierten Handicaps von
Aluminium Composites können natürlich mit technischem Aufwand und
entsprechenden Kosten überwunden
werden. Eine attraktive neue Option
ist die Verwendung von solidem, 2
und 3 mm dickem Farbaluminium für
die Fassadentechnik. Nach der Devise: Warum ein kompliziertes, aus drei
Schichten bestehendes Produkt herstellen, wenn man ein etwas dickeres
Aluminiumblech einsetzen kann, das
von vornherein die erwünschten Kriterien erfüllt und das sich nach neuen
Investitionen in größere und breitere
Coil-Coating-Anlagen der Industrie
mit entsprechenden integrierten
Bandricht-Vorrichtungen neuerdings
als interessanter Wettbewerber präsentiert.
Eine speziell für den Fassadenbau
entwickelte Alternative sind DMAXFassadenbleche der italienischen
Otefal. Hier wurde ein Produkt entwickelt, das allen Ansprüchen im Fassadenbau gerecht wird und folgende
Eigenschaften aufweist:
• Hochfeste Legierung AA 5754 in
… und das rho Messezentrum in Mailand
… and the rho trade center in Milan
114
2,0, 2,5 oder 3,0 mm Dicke. Die Legierung ist korrosions- und sogar seewasserbeständig und weist eine besonders
hohe zulässige Spannung auf.
• Diese Legierung (auch vorlackiert)
ist als „nicht brennbar“ in der normenmäßig höchstmöglichen Kategorie A1
eingestuft, also auch für Hochhäuser
in Deutschland geeignet.
• Mit dem Dickenbereich von 2,0 bis
3,0 mm können bei Abkantungen zu
Kassetten mit breiten Seitenstegen
stabile Großkassetten hergestellt werden, ohne dass die vier Eckenbereiche
nochmals genietet und verstärkt zu
werden brauchen. Windlasten bis zu
5,4 kN/m2 sind mit entsprechender
rückseitiger Aussteifung realisierbar.
• Das Recycling der vorlackierten
DMAX-Bleche ist einfacher und lukrativer, als das meist bei Schrotten
aus Aluminium Composites mit deren
dominantem Kunststoffanteil möglich
ist.
Vollständig solide DMAX-Fassadenbleche in dekorativen PVdF-Lackierungen sind daher eine interessante Alternative für Bauherren und
Architekten.
Inzwischen
gibt es mindestens
vier
namhafte Hersteller von 2
mm
dickem
soliden CoilCoating-Farbaluminium am
Markt, die den
Bekanntheitsgrad
dieser
technischen
Alternative
weiter erhöhen
werden.
N
façade technology. One may ask: why
use a complex product consisting of
three layers, when one can use a somewhat thicker aluminium sheet which
satisfies the desired criteria from the
start and which, after new investment in larger and wider coil-coating
units, has recently presented industry
equipped with appropriate integrated
strip straightening machinery with an
interesting competing material.
An alternative specially developed
for façade construction are DMAX
façade sheets produced by the Italian
company Otefal. Here, a product has
been developed which satisfies every
requirement for façade construction
and has the following characteristics:
• High-strength alloy AA 5754 in
thicknesses of 2.0, 2.5 or 3.0 mm. The
alloy resists corrosion, even by sea
water, and withstands particularly
high permitted stresses.
• This alloy (even when pre-lacquered) is classified as ‘non-combustible’ and is therefore in the highest
possible category A1 and accordingly
approved for high-rise building construction in Germany.
• Using the thickness range of 2.0 to
3.0 mm, bending can be used to produce cassettes with wide lateral webs,
i.e. large and strong cassettes, without
having to re-rivet and reinforce the
four corner areas. With appropriate
stiffeners on the back, wind loads of
up to 5.4 kN/m2 can be resisted.
• The recycling of the pre-lacquered
DMAX sheets is simpler and more
profitable than is usually possible
with aluminium composite scrap with
its dominant plastic fraction.
Thus, solid DMAX façade sheets
with decorative PVdF lacquers are
an interesting alternative for building
contractors and architects. At least
four noted manufacturers of 2 mm
thick solid coil-coating coloured aluminium have appeared on the market,
and that will further increase awareness of this technical alternative.
Otefal S.p.A. will be an exhibitor at
Hall 3, Stand N20
www.otefalgroup.com
ALUMINIUM · 9/2008
A concept for dioxin and
furan abatement in the aluminium industry
Dioxins and furans are considered
the most toxic substances and are
suspected to be highly carcinogen. Once being in the focus of
the public for emitting these substances a company may face mostly emotional discussions bearing
the potential of severe damage
of the image of the entire industry. Certainly, dioxins and furans
represent quite stable chemical
compositions and threaten public
health. However, their emission
can be controlled by comparably
simple countermeasures.
There are several basic elements
which may form dioxins and furans,
such as: carbon (C), hydrogen (H), oxygen (O) and halogens (Cl, F) which can
be found in scrap impurities like plastics and fluxes. To create dioxins and
furans some minimum conditions are
required: simultaneous occurrence
and formation temperature. The formation of dioxins and furans mainly
takes place within a temperature window between 350°F and 800°F.
There are other conditions, which
promote the formation of dioxins and
furans, like the catalytic effect of metallic dust in the gas, but this is of minor importance in the context of this
article. It is to be noted that the mentioned temperature window leads to
the conclusion that the main potential for the formation of dioxins and
furans is not located in the furnace as
there usually are temperatures much
above this window. The main formation can be expected downstream in
the off gas flow.
Avoiding any of the above mentioned preconditions represent a possible approach to inhibit the formation
of dioxins and furans. That means the
occurrence of at least one of the precursors or the formation environment
has to be suppressed. These measures
are referred to as primary measures.
However, this is academical as most
of the precursors are contained in the
primary materials for the production.
116
(HCl, HF), which are not addressed by
There is a limited chance by blendthe afterburner.
ing different scrap qualities in order
Another proven technology is the
to keep the entrainment of impurities
removal of dioxins and furans from
within an acceptable limit. The other
the gas by means of dry absorption.
approach is to keep the temperature
Additives are injected into the offoutside the formation window. As the
gas upstream the baghouse. Many
remelting process mostly is a batch
aluminium furnaces are already
operation with the temperature reequipped with such a device in order
peatedly passing the formation winto reduce acidic emissions by means
dow it is almost impossible to realize
of lime hydrate. Actually, the lime
the required conditions.
hydrate already is capable to reduce
It has to be concluded that these
primary
measures
of avoiding
the formation conditions do
not lead to
the desired
result with
affordable efforts
and focus
needs
to
be taken on
secondary Fume gas cleaning for an aluminium melting furnace
measures.
also dioxins and furans, admittedly to
This means to accept the formation
a limited extend. Consumption can
of dioxins and furans, but undertake
be estimated with approx. 10 lbs per
appropriate counter-measures for
tonne of molten aluminium.
eliminating them properly.
The efficiency with regards to the
Continuing the considerations of
dioxin/furan abatement can excelthe formation temperature require
lently be improved by additional use
e.g. an afterburner that could guaranof activated carbon or lignite coke.
tee continuous high temperatures to
This usually is realized either by
destroy the candidates. But these high
separate injection or by a pre-mixed
temperatures can hardly be dealt with
additive introduced by a single injecby a regular baghouse. Consequently,
tor. A reduction of dioxins and furans
the temperature has to be brought
of more than 90% can be achieved by
down, which means passing the foradding 5 to 20% by weight of activated
mation window. The gas has to be
carbon to the additive. A further benquenched down as fast as possible to
efit of the activated carbon of lignite
minimize the re-formation. Considercoke is the effective removal of mering the above conclusion that dioxins
cury from the off gas.
and furans are most probably created
Dry absorption is a temperature
downstream the furnace, the heat
sensitive process. Generally, the effitreatment finally has to cover all the
ciency decreases with higher tempergas volume, which will lead to big afatures. Especially, when considering
terburners with the correlated investpossible condensation in the offgas
ment and running costs, mainly for
of aluminium remelters this conflicts
energy. A further aspect to consider
with the offgas treatment process. To
is the suppression of acidic emissions
ALUMINIUM · 9/2008
Photos: Dantherm
A. Hellwig, Friesenheim
overcome this dilemma recycling the
additive collected in the baghouse
may be an option. This enhances the
efficiency even at elevated temperatures and the abatement of dioxins
and furans achieves efficiencies in
the high nineties, too. In some cases
the consumption of additives, and
therefore also of the residuals can be
cut by half.
A great advantage of the dry absorption is the simultaneous abatement of dioxins, furans, mercury and
acidic compounds in a single process
step. The obvious disadvantage is the
generation of contaminated residuals
to be disposed off. A possibility could
be to find a local partner in the industrial neighbourhood processing lime
based materials at high temperatures
(e. g. cement kilns) which might be
able to use the material.
is assumed to be 6,000 hours per year.
The calculation is shown in the table.
It is obvious that disposal costs
represent the major portion of the
operation costs. Here is a big potential for reduction finding synergies
with other industry sectors, which
may reuse the material. It needs to be
noted that also afterburner systems
cause these costs as those systems
require additive injection in order to
eliminate acidic compounds from the
offgas.
Summary
er does not address acidic compound
in the gas, but they usually are also
limited in most operating permits. In
this case an additional lime injection
system is required, also producing
residuals.
The dry absorption process is a
simple alternative for many applications. Actually, most baghouses
installed for aluminium furnaces already are equipped with an injection
system. They may be easily modified.
The system offers a simultaneous removal of acidic compounds, dioxins
and furans as well as even mercury
from the emissions. There is a low additional energy demand. However, the
absorption operates at low tempera-
Under consideration of the preconditions favouring the formation of dioxins and furans taking into account
the
demands
of
operational
requirements
mainly two diFinancial Figures
oxin/furan abatement technoloThe following figures should be congies: afterburner
sidered as a simple rule of thumb and
with quench and
shall give a preliminary idea about the
dry absorption.
cost of ownership of a dry absorption
Both technoloinstallation.
gies have their
The capital investment to install
pros and cons.
a brownfield gas cleaning system is
Afterburner
approx. USD15 per installed actual
systems have the
cubic foot per minute (acfm). This inobvious advancludes a pre-separator for coarse partage that they ac- Dry absorption fume gas cleaning with heat recovery in an aluticles, the injection and recirculation
tually destroy di- minium melting furnace
system, the baghouse, fan and clean
oxins and furans
gas ductwork.
tures. A smart process design needs
by pyrolysis. However, the precurThe running costs comprise costs
to consider this. Main cost factor is
sors
are
not
removed
from
the
gas
for additives (USD0.005 per 1,000
the production of residuals.
stream.
So
there
is
a
residual
risk
of
acfm) and energy demand (4.0 HP per
The optimal selection of one of
reformation
downstream
the
system.
1,000 acfm), comprising main fan, filthese systems depends on individual
As dioxins and furans probably form
ter cleaning and additive dosing and
conditions and the specific application
downstream the furnace the entire
recirculation.
to be equipped. Dantherm Filtration
gas
volume
needs
to
be
treated.
To
Exemplary estimation for a 50,000
as the world’s number 2 supplier of
that
extend
the
inherent
high
energy
acfm installation: the following evaludust collectors having installed more
consumption
may
become
an
issue.
ation is based on cost for electrical
than 35,000 units has gained experiThe
temperature
is
kept
high,
which
power of USD0.05 per kWh and landence with both systems and is capable
reduces
the
risk
of
condensation
infill costs of USD100 per tonne of disto handle both processes. Dantherm
side
the
offgas
system.
The
afterburnposed material. Annual operation time
Filtration also provides solutions for
other applications in the primary and
Investment
50,000 acfm x 15 USD/acfm
USD750,000
secondary aluminium industry.
Yearly operating cost
Additives
Energy consumption
Disposal
ALUMINIUM · 9/2008
50 kacfm x 0.005 USD/kacfm
x 360,000 min/y
USD90,000
50 kacfm x 4 HP/kacfm x 0.75 kW/HP
x 6,000 h/y x 0.05 USD/kWh
USD45,000
approx. 1.000 tpy x 100 USD/t
USD 100,000/t
Author
Dipl.-Ing. Arndt Hellwig, International
Sales Manger, Dantherm Filtration GmbH,
Friesenheim, Germany.
117
CO M PA N Y N E W S W O R L D W I D E
Rio Tinto Alcan
Aluminium smelting industry
aluminium industry has been highly
welcomed by local industrialists, in
contrast to the Awaso Bauxite Mine
where bauxite is being extracted,
processed and shipped to UK for the
British Aluminium Co. (Baco). The
Ghana integrated aluminium industry
concept envisages mining bauxite deposits at Hyinahin in the Ashanti Region and Kibi, in the Eastern Region.
Ghana government looks at
power for mothballed smelter
China to build smelter in Trinidad
China will help build a USD400m
aluminium smelter in Trinidad’s
southern region. However, Prime
Minister Patrick Manning did not
say when construction would start
or how many tonnes of aluminium
would be produced yearly. Trinidad
would run the factory using its vast
resources of natural gas. The smelter
would be built close to Pitch Lake, the
world’s largest natural asphalt reservoir. Environmentalists who successfully lobbied against another smelter
two years ago have filed an injunction
against the project.
This project would be located
roughly 20 miles from where Alcoa
Inc. had planned to build a USD1.5bn
smelter. Manning had rejected Alcoa’s plans based on complaints from
local residents about air and water
pollution.
Tatas and Nalco to join hands for
aluminium plant in South Africa
India’s second largest aluminium
maker, National Aluminium Co. Ltd
(Nalco) and the Tatas are all set to ink a
joint venture agreement for a USD3bn
aluminium smelter and power plants
in South Africa. In the proposed joint
venture, Tata Group through Tata
Africa will have a 49% stake, while
Nalco will hold the remaining equity. Tata Africa would carry out the
project. Tata Group has already given
in-principle approval of the for the
project and expects to sign an MoU
with Nalco. However, the project is
118
still quite a distance away, as Nalco
has yet to get government approval for
it. As per the plans of the company,
the smelter plant of 500,000 tpy will
be set up at Richards Bay (Port) and
power will come from a 1,250 MW
plant up at Mpu-malanga.
However, the question arises, if
spending close to Rs100bn in South
Africa is a viable proposition, since
most of the aluminium produced
through the joint venture would not
be for India, which already has an
excess supply of aluminium. Nalco,
which is in the midst of a USD1.2bn
expansion plan to be completed in
December, also has similar plans for
Indonesia, Iran and Saudi Arabia. An
MoU already signed with the Indonesian government would set up a
500,000 tpy aluminium smelter and a
1,250 MW captive power plant with
investment to the tune of Rs140bn.
Ghana government
seeks new partner
Barely two weeks after buying the
remaining 10% shares of Alcoa in
Volta Aluminium Co. Ltd (Valco) for
USD2m, the government is searching for a new strategic investor to
partner it in running the aluminium
smelter. Companies that have already
expressed interest in the operations
of Valco already refine bauxite and
will help government to update its
concept of an integrated aluminium
industry. The country’s bauxite would
be mined, refined and processed to
near-end or end products in Ghana.
Ghana’s concept of an integrated
The government of Ghana is now
studying the option of building a
captive coal-fired power plant for its
idled Valco smelter. The 200,000 tpy
plant has traditionally relied for power on the Volta River hydro-electric
power system, which has led to multiple closures in recent years depending on water levels and pricing. The
most recent attempt to revive it, with
the help of then minority shareholder
Alcoa, foundered in the first quarter
of 2007.
Anglesey Aluminium
plant fights back after blaze
The fire at the Anglesey Aluminium
Metals plant near Holyhead in June
caused a four-hour power shutdown
to allow fire fighters to tackle the
blaze. It knocked out one potline and
left another at two-thirds capacity.
The situation was close to disaster
for the 540 jobs as extended loss of
power caused aluminium to solidify
in the smelter pots and so dealt a fatal
blow to the plant. Despite avoiding a
worst-case scenario, the potlines that
run through the smelters were affected. Experts are now working to
restore around 50 pots on the first 158
pots production line before moving to
line two. No stand-downs have been
called for and extra staff has been
drafted in from all over the world to
return the plant to full production;
that will take at least four months,
according to an update from Kaiser
Aluminum, which is a 49% minority
partner in the 145,000 tpy plant.
The majority owner and operator
is Rio Tinto Alcan. The smelter’s fu-
ALUMINIUM · 9/2008
ture is in doubt due to its failure to secure a power deal
beyond 2009.
Kitimat modernization project for Bechtel
Rio Tinto Alcan has awarded a contract to Bechtel, worth
approx. USD200m, to conduct the complete engineering, procurement and construction management of the
planned USD2.5bn Kitimat modernization project in
British Columbia, Canada. The project would increase
production capacity at the smelter by 40%, taking it up
to 400,000 tpy. Bechtel received an initial contract in
June 2007 for preliminary engineering, feasibility and
construction pre-work activity which has already begun.
It will have construction site offices in Kitimat as well
as engineering offices in both Vancouver and Montreal.
Final Rio Tinto Board approval of the Kitimat modernization project is expected before end of 2008.
The project would upgrade the existing 54-year old
smelter using state-of-the-art AP technology, and increase capacity by 125,000 tonnes using hydroelectric
power from Rio Tinto Alcan’s Kemano power station.
It would also reduce greenhouse gas emissions by more
than 40% per year. First metal from the modernized
smelter is expected in 2011.
Out of one hand:
Aluminium Fluoride Plants
Pitch Melting Plants
Green Anode Plants
HTM Plants
Nalco seeks to buy
Tajik Aluminum to double capacity
National Aluminium Co, India’s second-biggest producer of the metal, is seeking to buy a majority stake in
Tajikistan-based Tajik Aluminum Co. to more than double capacity as prices rise to a near record. Nalco plans
to spend USD9.4bn to expand in India as well as to set up
factories in Indonesia, South Africa and Iran to tap lowcost power, abundant gas and cheap labor. Nalco may
supply alumina to Tajik from its mines in India. Nalco
produces 1.6m tpy of alumina, more than twice the quantity needed to feed its 345,000 tpy smelter at Orissa.
National Aluminium’s proposal to buy a 51% stake in
Tajik is being considered by the Tajikistan government.
Tajik Aluminum, Central Asia’s only producer of aluminium apart from Eurasian Natural Resources Corp.’s
smelter in Kazakhstan, produced 413,800 tonnes and accounted for 75% of the country’s exports in 2006.
We engineer your plant
Dubal-L&T to double capacity
of Orissa smelter project
Dubai Aluminium (Dubal) and Indian conglomerate
Larsen & Tubro want to double the capacity of their proposed aluminium smelter in Orissa state to 440,000 tpy.
The revised proposal has to be cleared by the Orissa state
government before a fresh MoU can be signed. The capacity increase takes the project cost to Rs240bn (USD5.6bn),
from Rs 215bn. The project also includes a 3m tpy ©
ALUMINIUM · 9/2008
Hohenrainstrasse 10; CH-4133 Pratteln 1; Switzerland
+41 (0) 618 256 462; [email protected]; www.buss-ct.com
119
refinery and 1,000 MW captive power
plant. It has been granted a bauxite
prospecting licence for the Sijimalli
and Kuturmalli deposits in the Kalahandi and Rayagada districts, with
estimated reserves of around 250m
tonnes. Bauxite-rich Orissa plans to
raise its production of alumina and
aluminium to 6.5m tpy respectively
1m tpy in the next three years.
Columbia Falls to idle
potline and axe up to 160 jobs
Columbia Falls Aluminum Co. LLC
plans to lay off up to half of its workforce and shut one potline at its
Columbia Falls, Montana, primary
aluminium smelter by the end of the
month. Columbia Falls, wholly owned
by Glencore International AG, blamed
the high cost of energy and of raw
materials. Open-market price quotes
for power through spring 2009 are as
high as USD110 per MWh.
The Columbia Falls facility, which
came online in 1955, has total capacity of 180,000 tpy but is operating
only three of five potlines, producing primary aluminium in sheet and
T-bar. Each potline has a capacity of
35,000 tpy. By the end of the month,
the company will shut one potline
and is considering closing a second
at some point in the future. The plant
employs about 340 people, of which
some 225 are members of the Aluminum Workers Trades Council. The
company posted the names of 124
hourly workers to be laid off starting
on 21 July. The list of salaried workers will be posted in the near future,
which would translate to anywhere
between 120 and 160 jobs.
Vedanta starts trials at
250,000 tpy smelter in Orissa
Vedanta Aluminium, a subsidiary of
Vedanta Resources, has started trial
production at its 250,000 tpy aluminium smelter at Jharsuguda, Orissa
state. This takes Vedanta Resources’
total capacity to almost 700,000 tpy,
overtaking Hindalco as the largest aluminium producer in India. Hindalco
produced 477,726 tonnes in the fi-
120
nancial year 2007/08. Nalco is India’s
third largest aluminium producer with
a capacity of 345,000 tpy. Vedanta’s
other smelters include the 350,000 tpy
Balco at Korba in the eastern state of
Chhattisgarh, and the nearly 100,000
tpy Malco in South India.
The smelter currently operates on
bought-out power from the Orissa
state grid, and produces LME-grade
aluminium. The Jharsugada smelter
produces aluminium ingot and plans
also to produce billets, wire rod and
other value-added aluminium products by March 2009. It is due to roughly double its capacity by the start of the
next financial year on 1 April 2009.
Vedanta has also started work on
another 600,000 tpy brownfield aluminium smelter at Korba at the Balco
site as well as on a 600,000 tpy greenfield smelter at Asansol in West Bengal. The company expects to reach its
target of 1m tpy of aluminium capacity by the start of the next financial
year, when the second phase of the
Jharsuguda smelter is commissioned.
US sanctions dampen
Nalco’s Iranian smelter plans
The USA’s economic sanctions on
Iran are jeopardising Nalco’s plans to
set up a 310,000 tpy smelter in Iran,
because global consultancy firms are
not willing to provide services there.
The state-owned Indian company
received only one bid after it floated
a global tender to appoint a consultant for a techno-economic feasibility
study for the project. Nalco’s senior
officials blamed the tension between
the USA and Iran crises. Consultancy
companies also feel that they may lose
business from American companies if
they take up projects in Iran. The only
bid received by Nalco for the consultancy was from Fata Hunter of Italy.
The same company had also worked
on setting up a cold rolling mill for
Nalco in Orissa. Nalco floated the tender for the Iran project on 20 April,
setting last date for submissions as 20
May, but then extended this to 2 July.
The company will have to retender
and ‘hope for the best’. In a joint
venture with Iran’s Aluminium Pars
Hanza Co. (Alpha), which is promoted
by Kerman Development Organisation, the project involves setting up a
310,000 tpy aluminium smelter with
associated power plants, which will
be gas fired.
Nalco is interested in setting up
smelter projects at locations where
energy is cheap, as power accounts for
over 40% of the cost of smelting ©
Yunnan Aluminium in
2nd half 2008 power costs to rise USD15m
China’s Yunnan Aluminum expects its
production costs to rise by 100m yuan
(USD14.7m) in the second half of the
year due more expensive electricity tariffs. According to the recent announcement from the Development and Reform
Commission of Yunnan province, Yunnan
Aluminium’s electricity price jumped from
0.37 to 0.41 yuan per kWh as from 1
July, increasing power costs by 500 yuan
for each tonne of aluminium produced.
The 100m yuan cost rise more than
erases the company’s net profit of 77.3m
yuan in the first quarter of the year.
In June, China’s central government
announced that the average electricity
tariff will rise by 0.025 yuan per kWh
as from 1 July in an attempt to stem
losses at power generation companies
which must pay higher coal costs. The
average production cost for aluminium
producers in China is around 18,000 yuan
(USD2.647) per tonne now.
Yunnan Aluminium, located in
the southern province of Yunnan, is a
major aluminium producer in China. It
produced 404,000 tonnes of primary
aluminium in 2007 and is building an
80,000 tpy aluminium sheet and strip
rolling mill and a 40,000 tpy aluminium
alloy rod mill. The company plans to
accelerate construction of the sheet and
strip mill and the alloy rod mill in an attempt to add value downstream. It has
also started construction of its 800,000
tpy alumina refinery at its subsidiary
Wenshan Aluminium in Wenshan county,
Yunnan province in June 2008.
ALUMINIUM · 9/2008
aluminium. If the project materialises,
Nalco will ship alumina from its Indian refineries to the Iranian smelter
to produce metal.
Suriname establishes
new aluminium company
Officials have disclosed that the Suriname government plans a new stateowned aluminium company aimed at
advancing the industry. Minister of
Natural Resources and Energy, Gregory Rusland, presented a proposal to
the government to establish the entity.
However, the Council of Ministers has
yet to approve these plans. Rusland
said that he is opting for a new company, which would partner with either
BHP Billiton or Alcoa/Suralco or with
both multinationals together, to develop the bauxite deposits in the Bakhuys
Mountains in West-Suriname.
The Suriname government is aiming for an integrated aluminium industry in West Suriname, including
hydro-power facilities and a smelter.
Negotiations with the joint venture
partners BHP and Alcoa/Suralco have
so far failed to produce an agreement
on this issue. According to Mr Rusland, the two mining companies seem
only interested in mining the bauxite
in West Suriname for processing in
the Paranam refinery several hundred
miles east. Asked whether the government could finance the establishment
of its own aluminium company, the
minister disclosed that production of
the West Suriname deposits will cost
some USD800m. An international
consultancy bureau is currently making an assessment of the existing
infrastructure in the mining area, including roads and bridges as well as a
rail track and port facilities.
The government hopes to sign an
agreement as soon as possible to develop the West Suriname deposits,
since current deposits in East Suriname will be depleted by 2010. The
government is also starting talks with
other interested parties, as months
of negotiations with BHP and Alcoa/
Suralco have not yet produced any
positive results.
BHP and Alcoa eye
smelter build in Suriname
The Suriname government has entered
into talks with Alcoa Inc. and BHP Billiton to build an aluminium smelter
and hydroelectric dam, as the South
American country wants to generate
more revenue downstream from its
prosperous bauxite industry. The cost
and size of the potential smelter was
not disclosed, but in March 2007 the
country was seeking investors to build
a 250,000 tpy smelter. The country
is home to Suriname Aluminum Co.
LLC (Suralco), a bauxite miner and
alumina producer majority owned by
Alcoa World Alumina & Chemicals,
a 60:40 joint venture between Alcoa
and Australia’s Alumina Ltd.
Suralco owns 55% of the 2.2m
tpy Paranam alumina refinery in the
country; the other 45% is held by an
affiliate of BHP At the beginning of
2005, Suralco completed a 250,000
tpy expansion at Paranam, bringing
the operation to its current capacity.
Chinese interest in Valco smelter
A delegation from China’s Datang
Company Ltd visited Volta Aluminium (Valco) plant to start talks about
building a 1,200 MW power plant for
the aluminium smelter. Datang is one
of the foreign strategic partners that
Valco has contracted to assist it realise Ghana’s integrated aluminium industrialisation goals. The 1,200 MW
plant, to be powered by coal, could
cost about USD1.2bn. Strategic partners from China, India, Norway and
Brazil are also supporting Valco to put
up the plant.
The first phase of the projected
power plant, estimated to produce 600
MW, would start in October 2008. The
whole project would take 24 months
Jinneng reduces output at Shanxi smelter
Shanxi Jinneng Group New Oriental
Aluminium Co., which operates the
sixth-largest aluminium smelter in China’s
Shanxi province, has reduced output
because of power shortages. The government ordered the company to cut
electricity usage at its 80,000 tpy plant.
Production losses would depend on how
long the outage lasts. Jinneng brings total smelting capacity affected by power
shortages in the northern China province
to about 5% of national output.
Aluminium reached a record LME
price two days ago after a venture
of Aluminium Corp. of China Ltd, the
nation’s largest producer, first said the
government had cut power. China’s
122
aluminium market will turn into a deficit
from an expected surplus if the production loss reaches 250,000 tonnes.
Smelters in Shanxi may have shuttered as much as 120,000 tonnes of aluminium-making capacity, out of a total
annual capacity of 1.08m tonnes. Power
shortage in China, the world’s largest
aluminium producer, may spread to
Henan and other provinces from Shanxi.
Henan and Shanxi have a combined capacity of 4m tpy or 22% of China’s total.
Aluminium for delivery in three
months on the London Metal Exchange
rose to a record USD3,327 per tonne on
7 July. The spot price gained USD19, or
0.6%, to trade at USD3,164 per tonne.
Prices have rallied 31% this year after
power shortages in China and South
Africa curbed output. Electricity now accounts for between 30 and 40% of the
operating costs for aluminium smelters.
Reduced output affects Shanxi Huaze
Aluminum and Power Co., the Aluminum Corp. venture in Shanxi, with a capacity of 280,000 tpy, and Shanxi Guanlu
Co. with two smelters in the northern
China province with a combined capacity
of 330,000 tpy.
Prior to the power shortages China’s
aluminium production was expected to
rise 19% to 15m tpy in 2008, while demand will gain 20% to 14.76m tonnes.
ALUMINIUM · 9/2008
to complete. Since all the five potlines at Valco
required only 350 MW for full production, the
surplus power will be fed into the national grid.
The second phase would produce an additional 600 MW to feed the bauxite mines and
the alumina refinery at Nyinahin and Kyebi.
The excess power would be exported to Togo,
Benin and Burkina Faso. The power plant for
Valco would mark the start of the realisation
of the integrated aluminium industry and the
country’s industrialisation process.
Alcoa Inc., Pittsburgh, has reached a longterm power deal that will allow it to restart
a third potline at its Wenatchee, Washington,
aluminium smelter in 2012. The new 17-year
agreement with the Chelan County Public
Utilities District begins when the existing
contract expires in 2011. The Wenatchee
smelter has a nameplate capacity of 184,000
tpy and is currently operating at approx.
100,000 tpy. The new power deal will enable
output to increase to 142,000 tpy starting in
2012. The contract will provide Alcoa with
electricity equal to 26% of output from the
Rocky Reach and Rock Island dams in exchange for the company paying 26% of the
cost of producing and delivering the power,
plus other costs.
Alcoa will pay an estimated USD22.9m
of an USD89m capacity reservation charge
within 30 days of signing, with the balance
deferred as long as the plant continues to
run three potlines, according to the contract.
The company would pay additional penalties
if the Wenatchee smelter shuts down before
2028.
Alcoa has been forced into the open market for power there, where local costs have
risen to as much as USD2,000-4,000 per MWh
during peak-use periods.
Including new agreements in Quebec, Alcoa now has some 75% of its smelting production under long-term, competitive power
supply. About 25% of the company’s smelting
production uses self-generated power.
First aluminium ready for export
Sohar Aluminium’s first shipment of 21
tonnes of standard ingots has been loaded
aboard a Mersk feeder ship, ready for export
to Hong Kong. It is the first export of locally
produced metal since the Sohar smelter ©
ALUMINIUM · 9/2008
W W W . K I N D - C O . C O M
Alcoa gets 17-year power
deal for Washington smelter
Competence
in Tool Steel
Traditional tool steels and innovative
developments
From steel melting to ready to use
tooling
From design to project integration
Experience for more than 100 years
Kind & Co., Edelstahlwerk, KG
Bielsteiner Straße 128 – 130
D-51674 Wiehl
Telefon +49 (0) 22 62 / 84-0
Telefax +49 (0) 22 62 / 84-175
[email protected]
began operations on 11 June 2008
and is yet another major milestone
for the state-of-the-art facility located
at Sohar Industrial Estate. In December 2008, all 360 cells should be fully
operational.
Of its annual 350,000 tonnes, the
company will export some 140,000
tonnes from Sohar Industrial Port.
The remaining 210,000 tonnes will
be sold to local companies that have
created a new downstream alumin-
ium industry. Sohar Aluminium has
already commitments for 68,000 tpy
from two downstream partners – SAG
and Oman Aluminum Processing Industries Ltd. There is also an MoU
with another local company, Future Cables, to purchase 30,000 tpy.
All three companies will fabricate
products from Sohar’s liquid metal,
including electrical rods, cables and
conductors.
N
AOS
Bauxite and alumina activities
Metallica Minerals doubles
bauxite resource at Pisolite Hills
Metallica Minerals Ltd subsidiary
Cape Alumina has doubled its estimated resource at Pisolite Hills
project to 100m tonnes of in situ
bauxite on the Weipa bauxite plateau
of western Cape York, Queensland. A
valuable aspect of the new resource
estimate is the even better average
beneficiated grade, which improved
to 53.5% total Al2O3, and the lower
average low temperature reactive silic
at 7.4%. Pisolite Hills bauxite is suited
for blending feed to low temperature
Bayer process refineries in China.
CBA starts operations
at Miraí bauxite project
Brazil’s aluminium producer Companhia Brasileira do Aluminio (CBA) has
started operations at its Miraí bauxite
project in southeast Brazil’s Minas
Gerais state. All of the equipment has
been tested and it’s all going well. It
was said that the plant would enter
a rate of normal production in the
124
second half of July. Construction was
delayed by strong demand, not only in
Brazil, but also around the world, for
equipment, labour and metallic structures to set up mining projects. As a
result, the Miraí project was delayed
by about 5 months. Miraí required a
USD150m investment, and all of its
output will be sent to CBA’s aluminium facility in São Paulo state. After
four construction phases of 1.25m tpy
each the plant will be able to process
and treat up to 5m tpy of bauxite.
CBA is aiming for primary aluminium production of around 570,000 tpy
by 2009, which would be equivalent
to an increase of over 20% in capacity
compared with 2007. The company
produces 1.2m tpy of bauxite from its
Poços de Caldas operation and 1.5m
tpy from its Itamarati de Minas site,
both located in Minas Gerais state.
The aluminium producer also has
plans to develop another bauxite deposit, Barro Alto, located in Brazil’s
Goiás state, and aims to clarify the
project’s details by the end of this
year. Barro Altohas reserves of 20m
tonnes of bauxite. CBA, part of Brazilian conglomerate Votorantim, has no
plans to sell bauxite from its projects
to third parties.
Vedanta awaits go-ahead for
3.6m tpy alumina expansion
Vedanta Aluminium is waiting for
official approval to go ahead and expand its Lanjigarh alumina refinery in
Orissa, India, to 5m tpy, from 1.4m.
The brownfield expansion will need
secure bauxite sources, but Vedanta
requires Supreme Court permission
to start mining at its allocation in the
Niyamgiri hills, close to the refinery. The refinery itself also requires
environmental clearance from the
government. Vedanta is asking permission to mine at the Niyamgiri hills
via Indian-listed subsidiary Sterlite
Industries, after the Supreme Court
earlier turned down Vedanta on the
grounds that environmental breaches
by an overseas-listed company would
be more difficult to pursue. Access to
the Niyamgiri mines is crucial for the
expansion. The Lanjigarh refinery is
running at only half its capacity because of bauxite supply problems. It
buys bauxite from Balco’s mines in the
neighbouring state of Chhattisgarh,
but the quantity is insufficient. Also,
the Lanjigarh plant was originally designed to refine bauxite from Orissa,
and cannot adequately refine Balco’s
ore. Consequently Balco has not been
able to produce LME grade aluminium at its smelters in Korba because
of the low purity of alumina supplied
from Lanjigarh.
Chalco’s 700,000 tpy
alumina project approved
Aluminium Corp. of China (Chalco)
has obtained National Development
and Reform Commission approval for
a 700,000 tpy alumina project at its
Zhongzhou Branch. The project will
raise Zhongzhou Branch’s alumina
capacity to around 3m tpy, from 2.1m
tpy. The 700,000 tpy is only nominal design capacity: real production
could reach about 1m tpy. Construction will take ten months and will
start as soon as Chalco approves it.
Chalco’s Zhongzhou Branch based in
ALUMINIUM · 9/2008
Jiaozuo city in central China’s Henan province is a major
alumina producer with 2m tonnes in 2007.
Guinea government removes
Alcoa from CBG operations
The government of Guinea said that an interim management committee will take over the operations of Compagnie des Bauxites de Guinee SA (CBG) from Pittsburgh-based Alcoa Inc. The committee would run CBG
until March 2009, Reuters reported. The management
agreement with Alcoa had not met the government’s
expectations. CBG, the world largest bauxite exporter,
is owned 49% by the Guinea government and 51% by
Halco (Mining) Inc. Halco is a holding company in which
Rio Tinto Alcan has a 43% stake and Alcoa World Alumina and Chemical, a joint venture between Alcoa and
Alumina Ltd, Victoria, Australia, holds 45%. CBG aims
to produce a record 13.5m tonnes of bauxite in 2008, up
from 12.5m tonnes in 2007, when strikes and political
unrest hurt output.
8
Costs up for Alcoa’s Brazil
bauxite and alumina projects
Costs at Alcoa’s Alumar alumina refinery expansion and
Juruti bauxite project in Brazil have grown as much as
67% since January, said joint venture partner Alumina
Ltd. Alcoa and Alumina own 60:40 of Alcoa World Alumina & Chemicals (AWAC), which expects to make first
shipment from its Juruti bauxite project in the third quarter of 2009. Project costs have risen to USD2bn for AWAC
due to increased costs in infrastructure, construction and
labour, a rising Brazilian Real and a delayed construction
schedule from unseasonal wet weather and low contractor productivity. The Juruti mine is expected to supply
initially 2.6m tpy of bauxite towards the expanded capacity at the Alumar alumina refinery. AWAC owns 54%
of the Alumar refinery, which is due to add 2.1m tpy of
capacity to reach 3.5m tpy by mid-2009. Costs for the refinery’s expansion have risen 25%, taking AWAC’s share
to USD1.62bn. The statement also said the company has
committed undrawn debt facilities of some USD400m,
and will review during the second half of 2008 the most
appropriate way to fund its share of this increased capital
expenditure.
Yunnan Aluminium to raise 1bn Yuan in bond sale
Yunnan Aluminium Co., China’s fourth-largest producer
of the light metal, plans to sell 1.06bn yuan (USD155m)
of bonds to fund a new plant and to repay bank loans.
The bonds are for six years. China’s National Development and Reform Commission approved an application
by the metal producer to build an 800,000 tpy alumina
plant in Wenshan, Yunnan. The project will start ©
ALUMINIUM · 9/2008
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China and Japan in Vietnam’s
USD460m alumina deal
Vinacomin, Vietnam’s largest coal
producer, has signed a contract
with a Chinese company to build a
USD460m alumina plant in the Central Highlands. Vinacomin signed an
Engineering, Procurement and Construction (EPC) deal with China Aluminium International Engineering Co.
(Chalieco) in mid-July. Chalieco is the
engineering arm of Aluminium Corp.
of China Ltd (Chalco), China’s largest
nonferrous metal company and would
build the plant within two years. The
alumina plant, projected to turn out
600,000 tpy of alumina, is part of the
bauxite and aluminium complex in
the central highland province of Lam
Dong, 300 kilometres (190 miles)
northeast of Ho Chi Minh City.
Vietnam began building its first
bauxite and alumina complex, the
USD490m Tan Rai plant in 2006, but
a lack of money and domestic power
shortages forced the plant developers
to skip aluminium production in the
complex. Chalieco has placed an order with Marubeni Corp. under which
the Japanese firm would support and
provide advice on legal and procurement issues on the project. Vinacomin
would start negotiations in the fourth
quarter for another EPC contract to
build the Nhan Co. alumina plant in
the same Lam Dong complex, also to
produce 600,000 tpy of alumina.
Vietnam’s bauxite ore reserves
are estimated at between 5.6bn and
8.3bn tonnes, the world’s third-largest after Guinea and Australia, and
mostly unexploited. Vietnam needs
to invest about USD15.6bn in major
bauxite and alumina refining projects
by 2025, to make use of its vast and
bauxite ore reserves, most of them in
the Central Highlands coffee belt. In
May, the government said it would
allow Alcoa Inc. to own up to 40% of
a major alumina mining and refining
project in the central highland province of Dak Nong.
126
Alunorte’s third expansion startup on schedule
The start-up of the third expansion at
the Alunorte alumina plant in northern Brazil’s Pará state is on schedule.
The expansion will take alumina production capacity at Alunorte to 6.3m
tpy from 4.4m tpy. The first alumina
production from the third expansion is
expected in the third quarter of 2008.
Hydro has a 34% stake in the Alunorte
refinery, while Brazilian miner Vale
has a 57% share in the plant.
Vale and Hydro signed an MoU in
July 2007 to develop a new alumina
plant, which will also be located in
Pará state. The plant will have an initial
capacity of 1.85m tpy, with potential
to expand up to 7.4m tpy, the companies said at that time. Hydro will have
a 20% share in the new refinery.
Mytilineos signs 10-year alumina
supply deal with Glencore
Greek aluminium producer, Aluminium SA, a subsidiary of Mytilineos
Group, has signed a deal worth USD2bn to sell Glencore more than 5m
tonnes of alumina over a ten-year period. The alumina will be exported to
Europe, Africa and Asia, which will
add significant value to Greek bauxite.
N
Recycling and secondary smelting
Hydro
production in 2013. Yunnan Aluminium will also build a 1.8m tpy bauxite
mine in Wenshan and a power plant
for the project.
Battling Brock
seeks expansion abroad
Brock Metals is seeking to further expand its sales abroad to counter the
manufacturing downturn in the UK,
with an increased focus on special high
grade zinc alloys. As a small participant in an increasingly consolidated
global market, zinc and aluminium alloys producer Brock faces challenges
from the downturn in the automotive
industry, one of the company’s largest customers. Brock produces around
2,500 tpm of zinc alloy and 1,000 tpm
of aluminium alloys for the diecasting
industry, employing around 60 people
at the company’s plant near Birmingham, one of the traditional industrial
heartlands of Britain.
Brock’s exports have increased
steadily to 65% of its production, and
will move towards at least 80 to 90%
within the next two to three years.
This is inevitable, given that the UK
market for zinc diecasting alloys has
now dropped to around 8,000 to
10,000 tonnes, compared with around
30,000 to 35,000 tonnes a few years
ago. Rising energy and transportation
costs, unfavourable exchange rates,
stricter health and safety regulation
and environmental legislative pressures are hurting British manufacturing the most. Brock’s management is
pleased with the relationship it has
built with CZP since the Russian company acquired it from Alumasc Group.
Keane’s appointment as managing director, together with investment from
CZP, has injected a new lease of life
into the company’s operations, ©
ALUMINIUM · 9/2008
with several modernisation projects
at the plant completed or underway.
Cost explosion
jeopardises German
secondary aluminium industry
Rising costs are jeopardising the secondary aluminium industry, according
to VAR, the association of the aluminium recycling industry in Germany.
The cost of recycling aluminium has
increased by 40 to 50% since last year,
but further rises are expected. Rising
energy costs are of particular concern:
the oil price has risen by 98% in the
past twelve months, and the price
of gas and electricity is expected to
increase again in the Autumn. The
market will pay €1,800 per tonne
for 226 alloy but its production costs
some producers €1,900 because of
the higher price of scrap and energy.
That’s a loss of €100 per tonne. Market participants argued they have little option but to pay the higher energy
prices as all suppliers have increased
their charges, and existing contracts
are subject to price increases. Energy
is not the only cost that is increasing
for aluminium recyclers: it is silicon
too, and silicon is quite important.
The prices of silicon and magnesium,
both of which are used to make aluminium alloy, have increased by 60%
and 132% respectively in the past six
months. Aluminium recyclers were
finding the squeeze on margins increasingly difficult and now wonder
how they can pass on these increased
costs.
Commissioning of HPI remelting
plant at Neuman Aluminium
The first complete remelting plant of
the HPI (High Performance Industrietechnik GmbH) company has started
successfully at Neuman Aluminium in
Marktl, Austria. This remelting plant
recycles as much as possible of the
in-house aluminium scrap to make
extrusion billets for internal use in
Neuman’s extrusion and forging de-
partments. The new remelting plant
has a capacity of 10,000 tpy in the first
phase.
Alcoa selects top 10
aluminium scrap suppliers
Alcoa Materials Management listed ten
recyclers as its top aluminium scrap
suppliers, based on quality, volume,
performance and related standards.
The citations went to American Iron
& Metal, Montreal; David J. Joseph,
Cincinnati; Metal Conversion, Mansfield; Newco Metals, Pendleton; OmniSource, Fort Wayne; Service Aluminum, Ellicott City; Shapiro Sales, St.
Louis; Smelter Service, Mount Pleasant; State Metal Industries, Camden;
Weiner Iron & Metal, Pottsville.
Alcoa Materials Management
buys scrap for extrusions, foil, mill
products and primary smelting. Criteria for selecting candidates include:
scrap volume; scrap value/savings
to Alcoa; quality; proximity to Alcoa
plants; dealer growth and im- ©
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including some outlays already made,
for environmental countermeasures
in East Sparta.
The smelter residue, known as salt
cake, creates heat and bad odours
when it comes in contact with underground liquids.
The potential also exists for health
problems if certain substances are
produced by the chemical reactions
and get into the air. That issue seems
to have been laid to rest by recent
tests. Measurements by the U. S. Environmental Protection Agency showed
no significant emissions of the most
worrisome possibilities: benzene, pxylene and toluene.
proving scrap product; number of Alcoa plants supplied; timely delivery;
dealer safety programme; environmental compliance; and ISO 9000.
Aluminium alloy
producer SNR cuts 45 jobs
French aluminium alloy producer
Société Nationale de Révalorisation (SNR) has made 45 employees
redundant, brushing aside rumours
that it will shut. SNR has two plants in
France, which have total capacity of
40,000 tpy of aluminium alloy: 25,000
tpy at Premery and 15,000 tpy at St
Arnoult. The manager dismissed talk
in the secondary aluminium market
that the plants are under threat. They
will remain open and in production,
he says, though he would not give current production or other details.
Republic has promised to pay for gas
extraction wells and monthly flights
over the landfill to obtain thermal images of heat patterns. Underground
temperatures at the landfill were
measured as high as 195°F (90°C) last
year.
Republic has told shareholders it
is trying to obtain reimbursement for
some of the East Sparta costs from
unidentified third parties, presumably whichever smelters sent the salt
cake. Republic recently became a key
player in the garbage industry’s consolidation, seeking to buy one of its
competitors while trying to prevent its
own takeover by another.
N
Aluminium semis
Richards & Jerrom, the UK-based
aluminium ingot producer, is due to
bring a new furnace online in August. This is a sloping hearth furnace
with a holding chamber and an afterburner, which can melt 100 tonnes
of scrapped vehicle engines per day.
Over 20 tpd of aluminium will be acquired. The new furnace will replace
the current one to comply with all
nvironmental requirements. Richards
& Jerrom may be able to increase the
furnace’s capacity in the future. The
company is independently run by the
founding directors, brothers Michael
and Peter Richards.
Hydro
Richards & Jerrom
builds new 100 tpd furnace
EUROPE
Norsk Hydro
to cut workforce at Raufoss
Norsk Hydro ASA is to reduce the
size of its workforce at the Raufoss
car parts plant in central Norway, after orders fell by 15% in the second
half of the year from the first.
Secondary smelter waste
is proving costly for hauler
Alcan Packaging to invest in
packaging plant in Czech Republic
Republic Services Inc. has set aside
another USD34m pretax for landfill difficulties in East Sparta, Ohio,
caused by chemical reactions with
600,000 tonnes of waste from secondary aluminium smelters. It is the third
such charge taken by the Fort Lauderdale, Florida-based garbage collector
since the start of 2007. Republic has
now earmarked a total of USD79.3m,
Alcan Packaging, a division of Rio Tinto Alcan, will invest €17m (USD27m)
in the Central European packaging
market. Alcan Packaging will build a
flexible packaging facility in the Novy
Bydzov area, in the Czech Republic,
to supply the developing food market.
The new plant will focus primarily on
the production and printing of high
quality rotogravure flexible packag-
128
ing. It should start up operation in
the fourth quarter of 2009 and employ
100 people in the first phase.
AMERICA
BMW taps Novelis to provide
aluminium sheet for new SUV
Germany’s BMW AG has picked Novelis Inc. to supply aluminium sheet
for hoods on the automaker’s new X6
crossover sport utility vehicle (SUV).
The Atlanta-based aluminium producer boasts of supplying aluminium
sheet for a range of BMW models in
the United States and Europe, including the 3 Series, 5 Series and 7 Series,
in addition to the X5 and Z4.
The X6 is yet another landmark vehicle from BMW; Novelis was chosen
to supply its advanced aluminium sheet
for the vehicle’s hood. Aluminium for
vehicles manufactured in the U. S.
ALUMINIUM · 9/2008
On the move
Romanian aluminium producer Alro
has appointed Zvi Eldar as head of
sales.
Kaiser Aluminum Corp. has appointed Melinda C. Ellsworth to the
position of Vice President and treasurer. She replaces Dan Rinkenberger,
who was appointed Senior Vice President and Chief Financial Officer earlier
this year.
UC Rusal has appointed of Sergey
Borovik as the CEO of Armenal, Armenia. Mr. Borovik was previously the
Managing Director of the UC Rusal
Ural Foil Mill. Georgy Avetikyan, who
was previously the CEO of Armenal,
has been appointed Chairman of the
Board of Directors at the plant.
Jack Miller, President of Sapa
North America Extrusions has been
elected to the Board of Directors of
The Aluminum Association.
Professor Vittorio de Nora passed
away. He was 96 years old.
comes from Novelis plants in Oswego,
New York, and Kingston, Ontario.
Alcoa looking to fly higher
with aerospace and energy
Alcoa’s downstream group will continue to move away from automotive
investments and into more profitable
sectors, such as aerospace and energy exploration. Over the past two
years Alcoa’s Engineered Products
and Solutions Group, had abandoned
USD300m worth of non-strategic positions, most of which were in the automotive segment.
Alcoa bought into in aerospace expansions in investment casting and in
fasteners, which in part has allowed
to move the portfolio from being 40%
automotive sales in 2003 to 20% by
the end of 2008. Aerospace now represents 35% of the Engineered Products and Solutions Group’s portfolio.
Despite concerns about temporary
softness, Alcoa is still looking to grow
its aerospace segment. Both Boeing
and Airbus say they will increase single-aisle production as well as ramp
up the dual aisle 787 and A380.
Another market that the company
is ‘excited’ about is the energy sector,
where Alcoa supplies industrial gas
turbines and equipment for oil and
gas exploration, among other products. Alcoa also is starting to see increased activity in the United States.
Power generated by natural gas in the
U.S. increased 20% from 2008 over
2007 and 66% over 2006. The company also is investing on the exploration side of gas and oil.
JW Aluminum finishes upgrade
JW Aluminum Co., Mount Holly, South
Carolina, has completed a USD10m
upgrade programme at its manufacturing plant in Jackson, Tennessee.
The project begun shortly after JW
Aluminum bought the facility in May
2007 from Rollex Aluminum LLC
and improved nearly every area of
the plant, including investments ©
advanced engineering in light metal casting
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ALUMINIUM · 9/2008
Aluminium in Essen
23.-25.09.2008
Halle 2 | Stand B42
129
in melting, casting, rolling, finishing
and painting. The company said the
plant has already shipped the first direct current (DC)-based lithographic
sheet, and is producing high-quality
coated products. In addition, Jackson
has produced fin stock and automotive sheet, and has made internal reroll for high-quality DC converter foil
over the past few months.
representatives with any questions
about existing orders.
Aleris will close permanently
its rolling mill facility at Cap-de-laMadeleine in Quebec, following an
orderly shut down of all remaining
activities at the facility.
Aleris closes
Cap-de-la-Madeleine facility
Hydro’s Extrusion Americas unit recently expanded production capabilities and capacity at its facility in Guaymas, Mexico. Two new CNC lathes
and a cutoff machine allow the plant
to produce custom-fabricated parts
for industries such as automotive and
alternative power generation.
The CNC lathes from HAAS Automation are fully programmable. Each
has a maximum turning capacity of
10.3 x 20 inches (262 x 508 mm) and
bar capacity of up to 2 inches (51
mm) so they are flexible and can be
adjusted to run almost any size product. The cutoff machine performs cut-
Aleris Light Gauge Products, a business unit of Aleris International, has
declared force majeure and ceased
operations at its Cap-de-la-Madeleine,
Quebec aluminium rolling mill facility. Operations there ceased on 2 July
with the lockout of the unionised production workforce, which had been
working without a contract since the
previous collective bargaining agreement expired on 1 February. Customers are encouraged to contact their
normal sales and customer service
Suppliers
ABB wins USD113 million
smelter order in India
ABB has won orders worth USD113m from
Vedanta Aluminum Ltd to provide automation and power products, systems and
solutions for a greenfield expansion of an
aluminium smelter plant in Jharsuguda, in
the eastern state of Orissa, India. ABB will
supply 24 sets of high-power diode rectifier systems for four aluminium potlines.
“ABB automation and electrical systems
will become the manufacturing backbone
of this smelter plant”, said Tom Sjoekvist,
head of ABB’s Automation Products division. The expansion will double the smelter’s production capacity of aluminium
ingots, rods and rolled products.
ABB’s scope of supply also includes
a new 400/220 kV switchyard, a highperformance process control system with
fibre optic current sensors as well as an
MicroSCADA control system for the power
distribution network, substation switching
bays, power and station transformers.
130
More custom fabrication, growth
potential at Guaymas plant
ABB has already supplied rectifier systems for phase one of the Jharsuguda
plant expansion in 2007/08. When phase
two will be complete in 2009, Vedanta’s
total smelting capacity will be approx.
1,7m tpy, making it one of the largest
integrated aluminium producers in the
world.
GE gets USD500m equipment
deal for Abu Dhabi smelter
General Electric Co., Fairfield, Connecticut,
has signed a USD500m contract to supply equipment to power a new Emirates
Aluminium (Emal) processing complex
under construction in the United Arab
Emirates (UAE). The smelter, being built at
Al Taweelah, Abu Dhabi, will use natural
gas as its primary fuel. GE Energy will
provide Frame 9FA gas turbines, C7 steam
turbines, heat-recovery steam generators
and condensers. The power plant will
have a capacity of more than 2,000 MW
of electricity. The facility is being built
in two phases. The initial 700,000- tpy
phase, begun in early 2007, is scheduled
to-length and chamfering operations
simultaneously. It has increased Hydro’s output from 150 to 600 pieces
per hour for an automobile engine
mount used by one of the Big Three
Detroit automakers. The machines are
also being used to fabricate parts for
solar collection systems used at commercial power-generation facilities.
The Guaymas plant is located 385
miles south of Phoenix, where Hydro operates an aluminium extrusion
and drawn-tube manufacturing facility that provides raw material for
Guaymas as well as serving a diverse
customer base throughout the West.
The Guaymas facility covers 90,000
square feet and employs 228 employees in three shifts.
MIDDLE EAST
New Oman cable producer to
sign off-take deal with Sohar
Oman Aluminium Processing LLC
(Oapil), a newly established joint ven-
for completion in 2010; the second phase
will lift the smelter’s capacity to 1.4m tpy.
Emal is a joint venture between Dubal
and Mubadala Development Co. PJSC, the
investment vehicle of the government of
Abu Dhabi.
Vimetco completes upgrade
of Alro cold rolling mill
Vimetco NV, has announced the commissioning of Alro’s cold rolling mill in
Slatina, Romania, following a USD4.8m
investment to modernize the unit. The
enhancements, which were implemented
together with Fata Hunter, will double the
mill’s processing capacity to 36,000 tpy
and also improve the quality of flat rolled
products such as sheets and coils. The mill
has been running at full capacity since the
end of April. Gheorghe Dobra, General
Manager of Alro SA, said: “The revamping
of the cold rolling mill marks an important
step in increasing the capacity of our flat
rolled products operations in Slatina. We
look forward to seeing the positive results
of the upgrades in due course.”
ALUMINIUM · 9/2008
ture, signed an agreement covering
the purchase of hot metal as feedstock
from the new Sohar Aluminium (Sohal) smelter. The 350,000 tpy smelter
which has just come on stream is a
joint venture between Oman Oil, the
Abu Dhabi Water and Electricity Authority and Rio Tinto Alcan. It is the
centrepiece of a strategy to develop
a significant aluminium processing
hub in the Persian Gulf country. The
smelter has committed to supply up to
60% of its production to local manufacturers. It is 51% owned by Oman
Cables Industry and 49% by Takamul
Investment Co., an offshoot of Oman
Oil. The aluminium supply deal will
run for 10 years and will cover the
needs of Oapil, which plans to develop a 48,000 tpy rod mill.
USD100m aluminium rod facility
to be built in Abu Dhabi
Abu Dhabi Basic Industries Corp.
(Adbic) and Midal Cables Ltd, one of
the world’s largest manufacturers of
aluminium rod and conductors, have
signed an MoU aimed at the joint establishment of an aluminium rod plant in
Taweelah, Abu Dhabi, with combined
investment of approx. USD100m. The
MoU was signed early in July.
Using state of the art equipment
imported from Europe and the US, the
plant will manufacture 150,000 tpy of
aluminium rod that will be converted
locally into other value-added products or supplied as feedstock to other
downstream industries, with the balance to be exported. Molten aluminium
metal for the project will be sourced
from the new 700,000 tpy Emirates
Aluminium (Emal) smelter currently
under construction at Taweelah in
Abu Dhabi. The plant will be ready to
receive the first batch of molten metal
from the Emal smelter and commence
commercial production in 2010.
Adbic is an industrial development
and investment company created to facilitate the expansion of sustainable industrial activity in Abu Dhabi through
the development of industrial clusters,
the first such model in the UAE. Midal
Cables, which has over 30 years’ experience in this field, will provide the
technology and expertise for the project
as well as investment capital.
N
The Author
The author, Dipl.-Ing. R. P. Pawlek
is founder of TS+C, Technical Info
Services and Consulting, Sierre
(Switzerland), a new service for the
primary aluminium industry. He is also
the publisher of the standard works
Alumina Refineries and Producers of
the World and Primary Aluminium
Smelters and Producers of the World.
These reference works are continually
updated, and contain useful technical and economic information on all
alumina refineries and primary aluminium smelters of the world. They
are available as loose-leaf files and/or
CD-roms from the Aluminium-Verlag,
Marketing & Kommunikation GmbH
in Düsseldorf as well as by online ordering via www.aluweb.de (Alu-Bookshop) from Giesel Verlag GmbH.
Industrieofen + Stranggieß - Technik GmbH
Bachstr. 51
D-46149 Oberhausen / Germany
+ 49 (0) 208 62914-0
www.ist-engineering.de
Competence and Experience in
Modern Furnace Technology
I S T - Your Competent Partner
Engineering, Supervision, and
Turn-key Projects for
Melting / Casting Furnaces
and DC Casting Machines
Visit us: ALUMINIUM 2008 in Essen, hall 6 A46
ALUMINIUM · 9/2008
131
RESEARCH
How to obtain quality profile surfaces
Die design solutions to avoid weld streaks
P. A. Bevilacqua Fazzini, St. Bellotti, M. Rompato; Italy
As everyone knows, this is the age
of light metals and nowadays extruded aluminium sections are used
in many different fields (e. g. automotive, architecture and components).
Consequently, the quality standards
demanded are continually becoming stricter. The customer’s demand
for ‘perfect sections’ compel extrusion die makers to analyze process
defects and look for design solutions
that minimize imperfections. Good
extrusion product quality is based on
the satisfaction of five basic requirements:
1. good surface finish
2. good transverse and longitudinal
weld seams (the latter only in
hollow shapes)
3. conformity with the specified
mechanical properties
4. conformity with the specified
section dimensional tolerances
5. product integrity.
If even one of these requirements is
missed, the extrusion is considered
out of specification and rejected.
Many variables affect the extrusion
process and it is therefore difficult to
establish the causes of a production
defect. Furthermore, some parameters are interdependent and if one is
changed, others too will change and
in turn still others will be affected. In
practice a ‘domino effect’ takes place,
making it difficult to determine the
relation between cause and effect,
because the same imperfection can be
produced by from different combinations of variables.
In the present case study the focus is on the surface damage associated with the longitudinal weld seams
produced when hollow shapes are
132
Fig. 1: A clear central streak, illustrating a
typical fault in an extruded section
formed. The streaks (Fig. 1) that appear on sections after post-extrusion
processes (cooling and anodizing) are
the problem. These imperfections are
caused by metallurgical phenomena
that arise at longitudinal weld seams.
During extrusion the aluminium
phase is always solid (superplastic
condition) and union between the
aluminium flows is assured by a solid
welding mechanism. To obtain a good
joint the mean stress must reach values such that the grains come closer
together than 2 to 3 nm; this distance
in fact permits electrons from adjacent atoms to be shared, and a good
metal-to-metal weld bond is therefore
formed. Many parameters influence
this mechanism: the material (alloy composition, temperature, flow
stress, strain and strain rate), welding
chamber geometry and dimensions,
hydrostatic pressure and contact time
of the flows, etc.
Obviously, solid welding is accompanied by many phenomena,
such as change of grain orientation
and dimensions, formation of micro
cracks, Mg2Si precipitation zones and
β-AlFeSi accumulation points which
create regions with different metallurgical composition (Fig. 2). The surface
streaks appear because these areas
react to post-extrusion processes in a
different way.
Many people have studied longitudinal welding paying attention only
or predominantly to the mechanical
characteristics, while underestimating the aesthetic problem. In reality the two are directly connected,
because metallurgical homogenization guarantees good mechanical
Compes
This report is the summary of a
survey by Compes s.p.a. R&D office in collaboration with Pandolfo
Alluminio. The aim of this study
was to develop die design solutions for the production of extruded sections without longitudinal
weld streaks.
Fig. 2: Under the microscope areas of different metallurgical composition are clearly
visible
properties and a perfect surface.
The literature mentions various
‘weld criteria’ (e. g. Donati-Tomesani
{1}, Akeret {2}, Piwnik-Plata {3}, Burqui-Huber {4}, Maier {5}, Jo-Lee-Kim
{6}) that should ensure good longitudinal welding if they are satisfied.
All these rules are correct, but too
complex to be used in everyday die
design, because they are based on
production process data (for example
aluminium flow stress or pressure on
the die surface). However, a single parameter recurs in every criterion: the
mean stress on the aluminium in the
welding chamber. Thus, it can be said
that if the hydrostatic pressure in the
welding chamber increases, the weld
quality is better and the profile streaks
disappear.
The aim of the present research
was to verify this proposition and
find design solutions that ensure a hydrostatic pressure increase, therefore
leading to sections without streaks.
Research plan
The first step was to identify a die
project in which the extrusions were
affected by longitudinal welding
streaks. Pandolfo Alluminio supplied
a continuous façade section (Fig. 3)
affected by this problem and experimental data about two different die
designs (one called ‘Original’ and the
other called the ‘Remake’, in which
the welding chamber height is increased by 10 mm).
©
ALUMINIUM · 9/2008
www.
alu-bookshop.de
EINSCHLÄGIGE FACHLITERATUR
AUSSCHLIESSLICH RUND UM
NE-METALLE
ALLES AUS EINER HAND
SUCHEN, FINDEN, BESTELLEN
Giesel Verlag GmbH
Postfach 120158
D-30907 Isernhagen
Tel. +49 511 7304-122
Fax +49 511 7304-157
www.giesel.de · [email protected]
RESEARCH
Fig. 3: Continuous façade section chosen for the study
Fig. 4: On the left, the longitudinal weld streak on the ‘Original’ section is clear; on the
right, the line on the ‘Remake’ section is less visible, but still present
On the basis of the ‘Original’ project
a number of new die designs were
developed:
• ‘Pear web’ (the central web was
designed as ‘pear’ shaped)
• ‘Blade web’ (the central web was
designed as ‘blade’ shaped)
• ‘New chamber’ (the welding
chamber profile was modified)
• ‘Convergent’ (ports and welding
chamber form a convergent pipe)
• ‘High chamber’ (the welding
chamber height was increased
Process parameters
Billet temperature
450°C
Equipment temperature
450°C
Main ram velocity
9.72 mm/s
Material equipment
H13
Tab. 1: Process parameters used for simulations
by 20 mm)
• ‘Divergent’ (ports and welding
chamber form a divergent pipe)
• ‘Eight webs’ (the central web was
replaced by two webs).
All these geometries were tested with
FEM simulation software (Tab. 1) to
understand the project behaviour
and to measure the mean stress in the
welding chamber.
The hydrostatic pressure value
is calculated as the average of point
measurements (considering one point
every 5 mm in each direction). The
standard deviation is used to estimate
the pressure distribution in the welding chamber: it is uniform, if the variable tends towards zero.
Results
At first sight (Tab. 2) it is clear that
only three versions show an
Die version
Mean stress
increase in welding chamber
Standard
mean stress, while all the othMPa Δ%
deviation
ers produce the opposite effect.
Original
220.51
16.20
The ‘Remake’ version results in a
Remake
221.76 +0.6
15.63
slight mean stress increase (0.6%)
Pear web
218.77 -0.8
16.48
which is not enough to eliminate
Blade web
218.73 -0.8
13.55
the streak. This was demonstratNew chamber 228.81 +3.8
15.51
ed by extrusion tests: on a section
Convergent
218.94 -0.7
14.06
extruded with the ‘Original’ die,
High chamber 234.00 +6.1
16.89
the weld streak is clear; on one
Divergent
216.98 -1.6
14.33
produced with the ‘Remake’ die,
Eight webs
213.06 -3.4
16.09
the streak is not so pronounced,
but is still present (Fig. 4).
Tab. 2: Mean stress simulation results
134
Metallurgical analyses too confirmed
this evolution: in the second extrusion
there is a lower concentration of precipitation (Fig. 5).
The ‘High chamber’ design is the
best, in fact increasing the pressure
by 6%. Looking at the FEM images
(Fig. 6) it can be seen that there is
the same colour shade for ‘Original’
and ‘Remake’, but the ‘High chamber’
design produces a more intensely coloured result.
The other successful design was
the ‘New chamber’, because the pressure is increased substantially (+3.8%)
(Fig. 7) and because the distribution
is more homogeneous (the standard
deviation decreases).
From the structural point of view
the simulation results show that the
maximum stress does not undergo
significant changes. As expected, a
higher displacement is found in designs where the mandrel anchorage
has been modified (‘New chamber’
and ‘Divergent’: the central web is
longer; ‘Remake’ and ‘High chamber’:
the central web is shorter).
The ‘Eight webs’ solution gives no
advantage: the data are in line with the
other designs.
The working die temperature was
the same for all the tests.
To check the results a new die design (called ‘Verify’) was developed,
which is a fusion between the ‘High
chamber’ and ‘New chamber’ versions.
The FEM results agree with those
expected: the mean stress increased
by 11% (value: 243.77 MPa, standard
deviation: 15.35), the temperature and
maximum stress were about equal
and the displacement was the highest
measured.
Unfortunately, experimental data
about the last design (‘Verify’) are not
yet available at the time of writing.
Conclusions
In conclusion it can be said that the
mean stress in the welding chamber
increases if its volume increases.
In addition, if the welding chamber
volume increases, so also does the
contact time between the aluminium
flows (another parameter that occurs
in various ‘weld criteria’) and this
ALUMINIUM · 9/2008
RESEARCH
Fig. 5: Under the microscope the ‘Original’ section (on the left) shows more precipitation
compared with the ‘Remake’ section (on the right)
helps to improve the situation.
In other words, to obtain sections
without weld streaks the welding
chamber must be sufficiently large.
The drawback is that the mandrel
displacement is then greater, and this
may lead to fatigue or die life problems.
The other important result is that
the ‘Eight webs’ design was useless
because the mean stress decreased,
producing two lines instead of one
on the section surface. In reality, with
this die design the aluminium flows
change completely, and it is therefore
impossible know, by the use of simulations, if the metallurgical phenomena would be different and the lines
might disappear.
This research raises a new question: what happens if
the welding chamber
pressure is homogeneous? Is the longitudinal welding better?
Or is this parameter
not relevant?
Bibliography
Fig. 6: From left to right the mean stress increases: the blue
shade is always more full
Fig. 7: In the ‘New chamber’ design (on the right) the colour
tone is higher compared with the ‘Original’ (on the left)
ALUMINIUM · 9/2008
K. Laue, H. Stenger, ‘Extrusion’, 1981, American
society for metals
T. Sheppard, ‘Extrusion
of aluminium alloys’,
1999, Kluwer Academic
Publishers
{1} L. Donati, ‘Modellazioni FEM e verifiche
sperimentali di processi
di estrusione di leghe di
alluminio per la determinazione delle caratteristiche meccaniche delle
saldature e della qualità
superficiale’, 2004, Università politecnica delle
Marche
{1} L. Donati, L. Tomesani, ‘Simulation of
welding conditions in porthole die extrusion’, 2002, Amst conference; published
on ‘Advanced manufacturing systems and
technology’ (N. 437)
{1} L. Donati, L. Tomesani, ‘The prediction
of seam welds quality in aluminium extrusion’, 2004, Journal of materials processing
technology
{1} L. Donati, L. Tomesani, ‘Evaluation of
a new finite element method (FEM) criterion for seam welds quality prediction in
aluminum extruded profiles’, 2004, Proceedings: eighth international aluminum
extrusion technology seminar. (Vol. II),
Aluminum Extruders Association
{2} R. Akeret, ‘Extrusion welds – quality
aspects are now center stage’, 1992, Proceedings: fifth international aluminum
extrusion technology seminar. (Vol. I),
Aluminum Extruders Association
{3} M. Plata, J. Piwnik, ‘Theoretical and experimental analysis of seam weld formation in hot extrusion of aluminium alloys’,
2000, Proceedings: seventh international
aluminium extrusion technology seminar.
(Vol. I), Aluminum Extruders Association
{4} Bourqui, A. Huber, C. Moulin, A. Brunetti, Alcan, M. Plata, Y. Krähenbühl, MTD,
‘Improved weld seam quality using 3d fem
simulation in correlation with practice’,
2002, The first EAA extruders division
congress
{5} B. Meier, „Werkzeuggestaltung und
Werkstofffluss“, 1989, in: Journal „Baumyartner“ ed. „Strangpressen“ DGM Informationsgesellschaft
{6} H. H. Jo, C. S. Jeong, S. K. Lee, B. M. Kim,
‘Determination of welding pressure in the
non-steady-state porthole die extrusion of
improved al7003 hollow section tubes’,
2003, Journal of materials processing technology (N. 139)
{6} H. H. Jo, S. K. Lee, S. B. Lee, B. M. Kim,
‘Prediction of welding pressure in the
non-steady state porthole die extrusion of
al7003 tubes’, 2002, International journal
of machine tools and manufacture (N. 22)
Authors
Eng. Pietro Alfredo Bevilacqua Fazzini,
Co.m.p.es SpA, Italy
Eng. Stefano Bellotti, Co.m.p.es SpA, Italy
Eng. Marco Rompato, Pandolfo Alluminio
SpA, Italy
Compes will be an exhibitor at
Hall 3, Stand K30
www.compes.com
135
V E R A N S TA LT U N G E N
AMB – Internationale Ausstellung
für Metallbearbeitung
9 to 13 September 2008, Stuttgart, GER
AMB, the highly traditional exhibition
for the metal working and processing
industry, will be held for the first time
in 2008 at the new Stuttgart trade fair
centre next door to Stuttgart airport
with the support of the German Engineering Federation (VDMA) and the
Association of German Machine Tool
Manufacturers (VDW). Exhibitors from
all over the world will present their
products and services on an area of
105,200 m2 in nine exhibition halls divided into special sections. The fair is
an ideal place to socialize international
business relations in the following areas: metal cutting machine tools, physiochemical process machine tools, precision tools, measuring systems, quality
assurance, robots, tooling systems, tool
handling systems, software and engineering, as well as parts, components
and accessories.
Further information:
Landesmesse Stuttgart GmbH
Tel: +49 (0)711 18560 0
[email protected]
www.messe-stuttgart.de
11. Aachener Dienstleistungsforum
10. bis 11. September 2008, Aachen
Das Forum steht unter dem Motto „Industrielle Dienstleistungen: Differenzierend – Modularisiert – Preiswürdig“
und bietet eine Kombination aus Fachtagung und Fachmesse. In zahlreichen
Vorträgen (u. a. Wert- und Preisorientierung interner Dienstleistungen am
Beispiel der Instandhaltung; Alunorf
GmbH) werden Teilnehmern praxisnahe Informationen zum Thema wettbewerbsfähiger und effizienter Dienstleistungen vermittelt. Darüber hinaus
werden dem Publikum im Rahmen einer Messe intelligente Lösungen durch
ausstellende Firmen präsentiert.
Weitere Infos:
Forschungsinstitut für Rationalisierung e. V. an der RWTH Aachen
Tel: +49 (0)241 47705 246
[email protected]
www.fir.rwth-aachen.de
risierung des Gefüges können Werkstoffe heute nicht maßgeschneidert
entwickelt werden. Die Metallographie bzw. die Materialographie, die
der ganzen Bandbreite der modernen
Werkstoffe gerecht wird, liefert diese
Charakterisierung. Konstruktion und
Fertigung, Prüfung und Qualitätssicherung, Forschung und Schadensanalyse brauchen dieses Werkzeug, um
qualitative und quantitave Aussagen
über die Werkstoffeigenschaften zu
erhalten. Die Methoden und Geräte
entwickeln sich ständig weiter. Die
jährliche Metallographie-Tagung mit
ihrer umfassenden Ausstellung ist der
Schauplatz der Neuerungen und der
Treffpunkt der Metallographen, die
sich über neueste Erfahrungen austauschen.
Weitere Infos:
Deutsche Gesellschaft für Materialkunde e. V., Niels Parusel
Tel: +49 (0)69 75306 757
[email protected]
www.dgm.de/metallographie
Werkstoffkompetenz in NRW
17. bis 18. September 2008, Rheinbach
Die Veranstaltung präsentiert neue
Ansätze und realisierte Produkte aus
verschiedenen Werkstoffwelten. In den
Vorträgen und anhand der gezeigten
Exponate wird das Anwendungspotenzial neuer Werkstoffe dargestellt, das
Spannungsfeld Werkstoffe und Nachhaltigkeit beleuchtet sowie spezielle
Werkstoffe für innovative Produkte
vorgestellt. Das Thema Verbundlösungen steht ebenfalls auf dem Plan. Renommierte Firmen wie Bayer Material
Science und die SGL Group haben ihre
Teilnahme zugesagt. Darüber hinaus
sind u. a. vertreten: das Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung IFAM (Bremen), das Ford Forschungszentrum
Aachen. Das Programm findet sich
unter www.werkstoffkompetenz.de.
Weitere Infos:
Werkstoffzentrum Rheinbach GmbH
Tel: +49 (0)2226 169810
[email protected]
www.werkstoffkompetenz.de
42. Metallographie-Tagung
11th Intl Conference on Aluminium
Alloys
17. bis 19. September 2008, Jena
22 to 26 September 2008, Aachen, GER
Ohne eine professionelle Charakte-
More than 500 participants are ex-
136
pected to attend the ICAA11 conference. Anyone related to science and
research in aluminium and its alloys or
applying and developing conventional
and/or advanced technologies and applications will be present to discuss
most recent results and new developments. The traditionally strong link to
the industrial community is established
by the Aluminium 2008 fair held in
parallel in Essen where new products
and technologies will be presented on
an industrial scale. The ICAA11 covers both areas – fundamental science
and established technologies, also
expressed by the excellent keynote
presentations from both areas. It offers
a unique insight into global development and current focus on aluminium
research and technology, including indepth understanding of conventional
and advanced aluminium alloys and
related processes.
Deutsche Gesellschaft für Materialkunde e. V.
Tel: +49 (0)69 75306 747
[email protected]
www.dgm.de/icaa11
5. BMBF-Forum für Nachhaltigkeit
23. bis 25. September 2008, Berlin
Forschung für Nachhaltigkeit ist Innovationstreiber. Ob in der Produktion,
bei der Verteilung und Nutzung von Gütern, im Verkehrswesen, bei der Bereitstellung und Verwendung von Energie
– überall wird versucht, mit geringeren
Umweltbelastungen einen größeren
Nutzen für den Menschen zu erwirtschaften. Ziel des 5. BMBF-Forums ist
die Stärkung der Zusammenarbeit von
Politik, Wissenschaft und Wirtschaft
zur Schaffung nachhaltiger Innovationen. Im Fokus stehen Diskussionen
über den aktuellen Forschungsstand,
über die Zusammenarbeit von Politik,
Wirtschaft und Forschungsgemeinden
sowie über zukünftige Forschungsprioritäten. In rund 40 Sessions und
Workshops beschäftigen sich über 400
Teilnehmer mit Projekten, Ideen und
Herangehensweisen und deren Beitrag
zur nachhaltigen Entwicklung.
Weitere Infos:
VDI Technologiezentrum GmbH
Tel: +49 (0)211 6214 665
[email protected]
www.fona.de
©
ALUMINIUM · 9/2008
ER
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www.giesel.de · [email protected]
.
FlyMYP_D BWH
EVENTS
Wire China
23 to 26 September 2008, Shanghai
Given the success of the previous two
editions – Wire China 2006 attracted
615 exhibitors, among which 271 were
international exhibitors – as well as the
era of strong demand in wire and cable
and great opportunities along with the
fast growing wire and cable industry
in East China, the 2008 wire China fair
will continue to be an indicator of the
latest trend in China’s wire and cable
industry.
Messe Düsseldorf
Tel: +49 (0)211 4560 466
[email protected]
[email protected]
17th Aachen Colloquium ‘Automobile
and Engine Technoloy’
6. bis 8. Oktober 2008, Aachen, GER
The Aachen Colloquium has become
the largest automotive and engine
technology congress in Europe and
the increasing number of participants
shows the existing interest of the automotive and supplier industry. In 2007,
the organizers welcomed 1,800 participants from 25 countries. The congress
will provide a wide range of technical
presentations addressing current challenges of the vehicle and powertrain
industry. Programme related test vehicles, prototypes and aggregates from
participating companies and institutions will be presented on the ika test
track. The technical exhibition is the
second essential part of the Aachen
Colloquium. The traditional banquet
in historical buildings of Aachen will
offer culinary and musical delights.
Tel: +49 (0)241 80 256 00
www.aachener-kolloquium.de
Aluminium-2008 / Alumico
8 to 10 October 2008, Moscow, RU
The event is dedicated to the entire
spectrum of the global aluminium industry and will provide an overview of
the production, processing, manufacturing and products. It offers the opportunity to suppliers of raw materials,
plant machinery, equipment, semi-finished and finished products and services to present their latest equipment,
technologies, and innovations. New
products for the aerospace, automo-
138
tive, transportation, construction,
packaging, electronics and other enduser industries will also be in focus.
For companies with direct interests in
the Russian aluminium technology and
products market, the exhibition offers
a good opportunity to meet real buyers
face to face and to promote real business relations.
MVK Intl Exhibition Co.
Tel: +7 495 995 0595
[email protected]
www.alumico.ru
Materialica
14. bis 16. Oktober 2008, München
Materialica ist die internationale Fachmesse für Werkstoffanwendungen,
Oberflächen und Product Engineering.
Innovative technologische Entwicklungen sind entscheidende Faktoren
für internationales Wachstum sowie
globale Wettbewerbsfähigkeit. Neue
Technologien brauchen zudem den
branchen- und prozessübergreifenden
Dialog. Nur so entwickeln sich aus
neuen Ideen marktreife Innovationen.
Das stellen insgesamt sieben Fachkonferenzen vom 14. bis 16. Oktober 2008
auf dem Gelände der Neuen Messe
München unter Beweis. Über 100 Experten aus Industrie und Wissenschaft
referieren über Leichtbau, Materialund Produktinnovationen, neueste
Herstellungs- und Verfahrensweisen,
Beschichtungs- und Klebtechniken,
Nanotechnologie, Technologietransfer
und Einsatzmöglichkeiten sowie über
aktuelle Forschungserkenntnisse aus
den verschiedensten Bereichen des
Product Engineerings. Parallel dazu
findet die Materialica 2008 statt, auf
der internationale Aussteller ihr Leistungsprogramm präsentieren.
Weitere Infos:
Neue Messe München
Tel.: +49 (0)89 322 991 22
[email protected]
www.materialica.de
Fortbildung
Ermüdungsverhalten metallischer Werkstoffe,
29. Sept. bis 1. Okt. 2008, Siegen
DGM Deutsche Gesellschaft für Materialkunde e.V., Tel: +49 (0)69 75306 757,
[email protected], www.dgm.de
Kleben – Grundlagen, Technologie, Anwendungen,
29. Sept. bis 1. Okt. 2008, Ismaning
IFF GmbH, Tel: +49 (0)89 969989 0, [email protected], www.iff-gmbh.de
Lager optimieren, 30. Sept. bis 1. Okt. 2008, Regensburg
OTTI Ostbayer. Technologie-Transfer-Institut, Tel: +49 (0)941 29688 36,
[email protected], www.otti.de
Zarges Sachkundigen-Seminar für Leitern, Tritte und Fahrgerüste,
7. Oktober 2008, Berlin; 8. Oktober 2008, Gera
Zarges GmbH, Tel: +49 (0)881 687 203, www.zarges.de
Effektive Arbeitsvorbereitung für kleine und mittlere Unternehmen,
8. bis 9. Oktober 2008, Linz; 18. bis 19. November 2008, Regensburg
OTTI Ostbayer. Technologie-Transfer-Institut, Tel: +49 (0)941 29688 36,
[email protected], www.otti.de
Schweißtechnische Problemfälle, 14. bis 15. Oktober 2008, Braunschweig
DGM Deutsche Gesellschaft für Materialkunde e.V., Tel: +49 (0)69 75306 757,
[email protected], www.dgm.de
Europäische Werkstoffnormung, 16. Oktober 2008, Ismaning/M.
Beuth Verlag GmbH, Tel: +49 (0)30 2601 2518, [email protected],
www.beuth.de/seminare
ALUMINIUM · 9/2008
PAT E N T E
Patentblatt Juli 2008
Sputtertarget aus einer Al-Legierung
und Verfahren zu dessen Herstellung. Kabushiki Kaisha Kobe Seiko Sho,
Kobe-shi, Hyogo 651-8585, JP; Kobelco
Research Institute, Inc., Kobe-shiHyogo
651-0073, JP. (C23C 14/34, EPA 1932940,
EP-AT: 14.11.2007)
Verfahren zur Herstellung eines plattierten Al-Ti-Verbundmaterials sowie Verwendung eines derartigen
Verbundmaterials. Trierer Walzwerk
GmbH, 54295 Trier, DE. (B23K 20/04,
PS 102 58 943, AT: 17.12.2002)
Verfahren zur Herstellung von Flugzeugstrukturelementen aus Al-Si-MgLegierung. Alcan Rhenalu, Courbevoie,
FR. (C22F 1/05, EP 1 143 027, EP-AT:
03.04.2001)
Al-Cu-Dünnfilmsputterprozess mit hohem Durchsatz auf einem schmalen
Kontakt-Via. International Business Machines Corp., Armonk, N.Y., US; Kabushiki Kaisha Toshiba, Kawasaki, Kanagawa,
JP; Qimonda AG, 81739 München, DE.
(H01L 21/285; C23C 14/18, PS 699 37
317, EP 0954015, EP-AT: 21.04.1999)
Nach dem Heißtauchverfahren mit
einer Legierung auf Zn-Al-Basis beschichtetes Stahlprodukt mit hervorragender Biegebearbeitbarkeit und Herstellungsverfahren dafür. Nippon Steel
Corporation, Tokyo 100-8071, JP. (C23C
2/06, EPA 1930463, EP-AT: 01.09.2005)
Nanokohlenstoff/Aluminium-Verbundwerkstoff, Herstellungsverfahren dafür und Plattierungsflüssigkeit zur
Verwendung bei dem Verfahren. Nissan Motor Company Ltd, Kanagawa-kuYokohama-shi, Kanagawa 221-0023, JP;
Koura, Nobuyuki, JP. (C25D 15/02, EPA
1930481, EP-AT: 16.06.2006)
Elektrolysezelle für die Herstellung
von Aluminium mit Vorrichtungen zum
Verringern des Spannungsabfalls. Alcan International Ltd, MontrealQuebec
H3A 3G2, CA. (C25C 3/16, EPA 1927679,
EP-AT: 22.11.2006)
Elektrolyt zur galvanischen Abscheidung von Aluminium aus aprotischen
Lösungsmitteln in einer Galvanisiertrommel. Aluminal Oberflächentechnik
GmbH & Co. KG, 56412 Montabaur-Heiligenroth, DE. (C25D 3/44, EPA 1927680,
EP-AT: 29.11.2006)
Oberflächenbehandlungsverfahren für
mit Flussmittel hartgelöteten Aluminium-Wärmetauscher. Nippon Paint Co.,
Ltd., Osaka, JP; Denso Corp., Kariya, Aichi, JP. (F28F 13/18, PS 60 2005 001 592,
EP 1624274, EP-AT: 27.07.2005)
ALUMINIUM · 9/2008
Verfahren zum Beschichten von Aluminium- und Magnesium-Druckgusskörpern mit einer kataphoretischen
Elektrotauchlackierungsschicht und mit
diesem Verfahren hergestellte Aluminium- und Magnesium-Druckgusskörper. Benseler Sachsen GmbH & Co. KG,
09669 Frankenberg, DE. (C25D 11/18, PS
100 25 643, AT: 24.05.2000)
Beizverfahren und Beizprodukt für
Aluminium. Henkel AG & Co. KGaA,
40589 Düsseldorf, DE. (C23G 1/22, OS
10 2004 004 140, AT: 28.01.2004)
Glänzende Beschichtungen für Aluminium- oder Stahloberflächen und
deren Herstellung. Daimler AG, 70327
Stuttgart, DE. (C23C 30/00, OS 10 2007
004 570, AT: 30.01.2007)
Verwendung einer Eisen-Chrom-Aluminium-Legierung mit hoher Lebensdauer und geringen Änderungen im
Warmwiderstand. ThyssenKrupp VDM
GmbH, 58791 Werdohl, DE. (C22C 38/18,
OS 10 2007 005 154, AT: 29.01.2007)
Aluminium-Oberflächenbearbeitungsprozess und Aluminium-Verbundwerkstoffmaterial. Jatco Ltd, Fuji, Shizuoka,
JP. (C23C 8/36, OS 10 2008 004 883, AT:
17.01.2008)
Form aus einer Kupfer-Aluminium-Legierung zum Herstellen von Flaschen.
Saint-Gobain Emballage, Courbevoie, FR.
(C03B 9/48, PS 698 24 483, EP 0879796,
EP-AT: 19.05.1998)
Einteiliger Stahl-Aluminium-Ring für
eine mittels Wirbelstrom betätigte
Reibkupplung. Horton, Inc., Roseville,
Minn., US. (F16D 27/112, PS 698 27 237,
EP 0960289, EP-AT: 11.02.1998)
Zelle für die Aluminium-Herstellung mit
drainierfähiger Kathode. Moltech Invent S.A., Luxemburg/Luxembourg, LU.
(C25C 3/08, PS 698 37 966, EP 0996773,
EP-AT: 07.07.1998)
Verfahren zum Reinigen und Wiedereinschmelzen von in feiner Form vorliegenden verunreinigten Leichtmetallen
und Leichtmetall-Legierungen. Magontec GmbH, 46240 Bottrop, DE. (C22C
3/00, PS 101 28 335, AT: 12.06.2001)
Verfahren zur Herstellung von Blechen
oder Blechteilen aus Leichtmetall sowie Kraftfahrzeugbauteil aus Magnesium oder eine Magnesiumlegierung.
Volkswagen AG, 38440 Wolfsburg, DE.
(B21C 35/03, OS 10 2007 002 322, AT:
16.01.2007)
Runde Aluminium-Grillpfanne für HolzKohle-Grill/Gasgrill. Holczinger, Jürgen,
88444 Ummendorf, DE. (A47J 37/07, GM
20 2004 009 404, AT: 14.06.2004)
Verfahren zum Leichtmetall-Legierungs-Sintern. Schwäbische Hüttenwerke Automotive GmbH & Co. KG,
73433 Aalen, DE. (C22C 1/04, EP 1 709
209, EP-AT: 26.11.2004)
Chromfreie Konversionsbehandlung
von Aluminium. Henkel AG & Co.
KGaA, 40589 Düsseldorf, DE. (C23C
22/78, PS 594 03 473, EP 0700452, EPAT: 17.05.1994)
Verfahren und Vorrichtung zum Spritzgießen von Leichtmetall. Kabushiki
Kaisha Kobe Seiko Sho, Kobe, Hyogo, JP.
(B22D 17/30, PS 600 35 147, EP 1046445
(86) EP-AT: 19.04.2000)
Chromfreies Verfahren zur No-rinse
Behandlung von Aluminium und seinen Legierungen sowie hierfür geeignete wässrige Badlösungen. Henkel
AG & Co. KGaA, 40589 Düsseldorf, DE.
(C23C 22/36, PS 595 02 263, EP 0754251,
EP-AT: 31.03.1995)
Leichtmetall-Gussteil. DRM Druckguß
GmbH, 36179 Bebra, DE. (F16S 5/00, GM
202 20 492, AT: 19.04.2002)
©
Verfahren zur Herstellung einer inerten Anode zur Herstellung von Aluminium in einer Schmelzflusselektrolysezelle. Aluminium Pechiney, Voreppe, FR. (C25C 3/12, EP 1 601 820, EP-AT:
10.03.2004)
Drehtrommelofenwerke zum Aufschmelzen von Aluminium, mit Sortierung und Rückgewinnung von Schlacke. Hitech S.r.l., Nocera Inferiore, IT.
(F27D 3/14, PS 603 14 780, EP 1608926,
EP-AT: 30.12.2003)
Wärmebeständige Magnesium-Gusslegierung. Aisin Seiki K.K., Kariya, Aichi,
JP. (C22C 23/02, PS 60 2004 009 260, EP
1526188, EP-AT: 05.08.2004)
ALUMINIUM veröffentlicht unter
dieser Rubrik regelmäßig einen Überblick über wichtige, den Werkstoff
Aluminium betreffende Patente. Die
ausführlichen Patentblätter und auch
weiterführende Informationen dazu
stehen der Redaktion nicht zur Verfügung. Interessenten können diese
beziehen oder einsehen bei der
Mitteldeutschen Informations-, Patent-, Online-Service GmbH (mipo),
Julius-Ebeling-Str. 6,
D-06112 Halle an der Saale,
Tel. 0345/29398-0
Fax 0345/29398-40,
www.mipo.de
Die Gesellschaft bietet darüber hinaus
weitere „Patent“-Dienstleistungen an.
139
LITERATURSERVICE
Verfahren zur Herstellung von Gussteilen aus Leichtmetall-Legierungen
mit Kühlung vor dem Pressen. Process
Conception Ingenierie S.A., Meudon,
FR. (C22F 1/04, EP 1 213 367, EP-AT:
16.11.2001)
Magnesium-Legierung mit verbesserter Kombination der mechanischen
Eigenschaften und des Korrosionsverhaltens. Acrostak Corp., Winterthur,
CH. (C22C 23/06, EPA 1835042, EP-AT:
18.03.2006)
Verfahren zur Herstellung von Calciumaluminaten ausgehend von Aluminiumschlacken-Rückständen. Alcan International Ltd., Montreal, Quebec, CA;
31025273 Quebec Inc., Quebec, CA.
(C04B 35/44, PS 694 15 033, EP 0720592,
EP-AT: 19.09.1994)
Zusammensetzung und Verfahren zur
Behandlung von Magnesiumlegierungen. Universite Pierre et Marie Curie,
Paris, FR. (C23C 22/57, EP 1 390 565,
EP-AT: 31.05.2002)
Deckfolie für eine Blisterpackung. Glaxo Group Ltd, Greenford, Middlesex UB6
ONN, GB; Alcan Technology & Management Ltd., 8212 Neuhausen am Rheinfall,
CH. (B32B 15/16, EPA 1928654, EP-AT:
26.09.2006)
Verbundprofil mit einem Tragkörper
aus Leichtmetallwerkstoff sowie einem
Profilband und Verfahren zum Herstellen des Verbundprofils. Alcan Technology & Management AG, Neuhausen am
Rheinfall, CH. (B60M 1/30; B21C 23/22,
PS 10 2005 004 547, AT: 31.01.2005)
Verfahren zur Herstellung eines aus
einem Verbundwerkstoff hergestellten Formwerkzeugs. Alcoa Inc., Pittsburgh, PA 15212-5858, US. (B32B 15/08,
EPA 1928653, EP-AT: 25.09.2006)
Sputtertarget aus einer Al-Ni-La-Legierung und Verfahren zu dessen Herstellung. Kabushiki Kaisha Kobe Seiko Sho,
Kobe-shi,Hyogo 651-8585, JP; Kobelco
Research Institute , Inc., Kobe-shiHyogo
651-0073, JP. (C23C 14/34, EPA 1923479,
EP-AT: 14.11.2007)
Aktiviertes Erdalkalimetall, insbesondere Magnesium, zur Herstellung von
Organo-Erdalkalimetall-Verbindungen.
Chemetall GmbH, 60487 Frankfurt am
Main, DE. (C07C 29/70, EPA 1924542,
EP-AT: 01.09.2006)
Bordstück aus Metall für Fensterbänke.
Hermann Gutmann Werke GmbH, 91781
Weißenburg, DE. (E06B 1/70, GM 202 20
306, AT: 18.04.2002)
Profil für eine Stoßstange eines Fahrzeuges, Haltewerkzeug und Rohrprofil
dafür sowie Verfahren zur Herstellung
des Profils. Alcan Technology & Management AG, Neuhausen am Rheinfall,
CH. (B60R 19/18, OS 10 2006 062 294,
AT: 27.12.2006
Verbundprofil und Verfahren zur Herstellung eines Verbundprofils. Alcoa
Aluminium Deutschland, Inc., 58642
Iserlohn, DE. (E06B 3/263, EPA 1932998,
EP-AT: 08.12.2006
Auflageprofil für Fensterbänke o. dgl.
Aleris Aluminium Vogt GmbH, 88267
R. Coquard, M. Loretz, D. Baillis
Conductive Heat Transfer in Metallic/Ceramic Open-Cell
Foams
Advanced Engineering Materials 2008, 10, No. 4, pp. 323-337
During the last decade, solid foams which are characterized by
a relatively high porosity (> 80%), have known a strong development. Indeed, they allow envisaging a substantial improvement of the performance of standard materials in numerous
technological fields. Notably, metallic and ceramic foams exhibit thermal, mechanical and exchange properties, which make
them very interesting in lots of applications requiring multifunctionality. To illustrate this, we can cite a non-exhaustive list
of functions for which they are usually used: ultra light panels,
energy absorbing structures, heat dissipation media, electrodes
for electric battery, ultra-sound deflector, carrying structure for
catalyst, medical prosthesis, heat exchanger. In most of these
applications, the knowledge of the thermal transport properties is of primary importance for the dimensioning of the structures. At ambient temperature, the heat transfer in solid foams
is dominated by thermal conduction. To quantify the magnitude
of heat conduction, one generally uses the effective conductivity kc which implies that the two-phase material behaves like
a homogeneous conductive medium. This assumption is rigorously valid when the size of the pores is much lower than the
dimensions of the materials, which is the case in solid foams.
The effective conductivity depends on the porosity of the foam,
140
Vogt, DE. (E06B 1/70, GM 20 2008 004
379, AT: 28.03.2008)
Vorrichtung zum Fügen von mindestens zwei Bauteilen aus artverschiedenen Werkstoffen. Hydro Aluminium
Deutschland GmbH, 51149 Köln, DE.
(B23K 20/12, GM 20 2005 021 318, AT:
28.04.2005)
Gießform zur Herstellung eines Kastenkolbens. Mahle GmbH, 70376 Stuttgart, DE. (B22D 15/02, PS 500 14 483, EP
1218130, EP-AT: 21.03.2000)
Al-Kunststoff-Fenster mit Klebebandfixierung. Hermann Gutmann Werke
AG, 91781 Weißenburg, DE. (E06B 3/30,
EPA 1 923 532, EP-AT: 28.09.2007)
Gebauter, flüssigkeitsgekühlter Kolben. Mahle International GmbH, 70376
Stuttgart, DE. (F02F 3/00, EPA 1922478,
EP-AT: 02.09.2006)
Kühlschmierstoff für die wässrige Zerspanung von aluminiumlegiertem Magnesium. Henkel AG & Co. KGaA, 40589
Düsseldorf, DE. (C10M 133/00, OS 10
2007 004 325, AT: 23.01.2007)
Strangpressen mit Abschrecken von
Aluminiumlegierungen vom Typ 6020.
Alcoa Inc., Pittsburgh, PA 15212-5858,
US. (C22F 1/04, EPA 1926838, EP-AT:
30.08.2006)
Verfahren zur Herstellung von MetallMatrix-Verbundwerkstoffen.
Mahle
GmbH, 70376 Stuttgart, DE. (B22D 17/00,
PS 50 2004 004 318, EP 1680246, EP-AT:
16.10.2004)
the morphology of the material and on the properties of the
two-phases. It is particularly difficult to estimate in solid foams
due to the complexity of the geometry encountered and to the
large difference between the thermal conductivity of fluid and
solid phases. 11 figs., 2 tables, 26 sources.
ALUMINIUM 9 (2008)
Werkstoffe, Aluminiumschaum
S. Hirsekorn, U. Rabe, D. Bruche, J. Maurer, W. Arnold, N. Grov,
T. Kinzler
Prüfung von Nicht-Eisen-Metall-Druckgusskomponenten.
Detektion und Bewertung oberflächennaher Porosität mit
Hochfrequenzultraschall
MP Materials Testing 50 (2008) 4, S. 206-215
Im Automobilbau werden zunehmend Druckgusserzeugnisse
aus NE-Metallen als Sicherheitsbauteile eingesetzt, die zu
100% zerstörungsfrei geprüft werden müssen. Auch zur kostengünstigen Optimierung der Herstellungsprozesse sind vor einer Bearbeitung zerstörungsfreie Prüfungen der Gussteile erforderlich. Prozessbedingt weisen Druckgussteile innere Volumendefizite (Poren und Lunker) auf. Diese können abhängig
von ihrer Lage im Bauteil sowie von der Art, Beschaffenheit
und Beanspruchung (zum Beispiel statische oder dynamische
Belastung) des Bauteils Auswirkungen auf Festigkeit, Druckdichtheit und Oberflächenbeschaffenheit haben. Zur Detektion
ALUMINIUM · 9/2008
LITERATURE SERVICE
und Charakterisierung fertigungsbedingter Poren und Lunker
in oberflächennahen Zonen (0,5 bis 2 mm Tiefe) von Druckgussteilen komplizierter Form wurde ein Verfahren mit hochfrequenten Ultraschallrückstreusignalen entwickelt. 17 Abb., 1
Tab., 23 Qu.
ALUMINIUM 9 (2008)
Materialprüfung
G. Müller, J. Böhmert, F. Bergner, K. van Ouytsel, I. Dolbnya
Investigation of the Damage around a Crack Tip in Metals
using Small Angle X-Ray Scattering
MP Materials Testing 50 (2008) 4, pp. 191-198
Structural materials, such as ferritic and austenitic steels and
aluminium alloys, as used in the nuclear and aircraft industry,
are subjected to external stresses which may lead to the nucleation of cracks. The damage zone ahead of a crack tip introduced
as a result of static deformation was investigated in an Al-2024
and Al-6013 alloy, and in a 10 CrMo9 10 reference steel by
means of small angle X-ray scattering. A robust parameter, the
anisotropy parameter, describing the damage region was developed. Further damage parameters were explored. The data,
supported by electron microscopy investigations, point to large
oriented dislocation networks. Finite element calculations show
a good correspondence in the shape and size of the damage
zone. 10 figs, 2 tables, 24 sources.
ALUMINIUM 9 (2008)
S. Sayer, V. Ceyhun
Influence of Pin Structure on Micro-structure and Mechanical
Properties of Friction Stir Welded AA 6063 (AlMgSi 0.5)
Aluminum Alloy
In this study, AA 6063 (AlMgSi0.5) aluminium alloy plates were
welded by a solid state welding procedure, friction stir welding
(FSW). The influence of pin structure on the microstructure of
the weld region and the mechanical properties of the joints were
studied. It has been seen that the helical structure on pinscrew
has an effective role on the formation of a zigzag line in the
weld region. While rather long and uninterrupted zigzag lines
in the weld region are obtained when right helical pinscrew
is used, left helical pinscrew gave rise to shorter zigzag lines.
While the zigzag line has no effect on the mechanical properties
of the as-welded joint, heat treatment after the welding (PWHT)
procedure seriously affects the strength of the joint due to the
zigzag line formed in the weld region. The mechanical strength
decreases with right helical pinscrew in PWHT, whereas, left
helical pinscrew causes an increase in mechanical strength. 7
figs., 1 table, 14 sources.
ALUMINIUM 9 (2008)
Metallkunde, Reibrührschweißen
E. Solórzano, M.A. Rodriguez-Perez, J.A. de Saja
Thermal Conductivity of Cellular Metals Measured by the
Transient Plane Sour Method
Cellular metals combine the advantages of a metal (strong, hard,
tough, conductive both electrically and thermally, etc) with the
functional properties of a foam (lightweight and adjustable
properties by selecting the density). Because of this, metal foams
are interesting in a number of engineering applications such as
structural panels, energy absorption devices, acoustic damping
panels, compact heat exchangers, etc. Particularly, the thermal
transport properties of metal foams are attractive in a wide collection of applications, from thermal insulation to heat transfer,
being also important for the later processing of the metal matrix,
for instance in the thermal treatments of the base alloy. In the
last 10 years the fabrication routes to produce aluminium foams
have been deeply studied and continuously improved. Never-
ALUMINIUM · 9/2008
theless, these materials are often non homogeneous materials,
characterized by a density gradient related to both the presence
of an outer skin and the presence of internal defects (big pores,
wide cell-size distributions, fractured cell walls and cell-wall
corrugations and misalignments. These deviations from homogeneity affect the physical properties and as a consequence an
important aspect of aluminium foaming technology is to have
experimental techniques able to characterise the in-homogeneity. 7 figs., 2 tables, 26 sources.
ALUMINIUM 9 (2008)
A. Karaaslan, I. Kaya, H. Atapek
Tensile Strength and Impact Toughness of an AA 7075T6 Alloy. Effects of Aging Temperature and Time During
Retrogression Treatment
In this study retrogression and aging treatment have been applied to the samples of an aluminium alloy AA 7075-T6. The
retrogression treatment has been performed with different temperatures and times and then aging treatment has been applied
at 130°C for 12 hours. By determining the effects of the retrogression treatment temperatures and times on the samples, the
microstructral and also mechanical changes in AA 7075-T6 alloy have been examined. All microstructures have been investigated by scanning electron microscopy (SEM). Additionally, the
mechanical properties have been determined by the notched
impact test and the tensile test. 3 figs., 1 table, 8 sources.
ALUMINIUM 9 (2008)
Werkstoffe, Metallkunde
K.-D. Liss, A. Stark, A. Bartels, H. Clemens, Th. Buslaps, D.
Phelan, L. A. Yeoh
Directional Atomic Rearrangements During Transformations
Between the α- and γ-Phases in Titanium Aluminides
Phase transitions and their attendant atomic rearrangement
processes in polycrystalline substances are most important
for tailoring the physical properties of modern engineering
materials. Multiphase alloys, such as γ-TiAl based intermetallics possess distinguished mechanical properties depending
on their thermo-mechanical treatment history and thus their
microstructure. Not surprisingly, both fundamental and industry-related research has been undertaken to find optimal
process parameters. As these metallurgical investigations are
often obtained off-situ, little is known about the kinetics of the
phase transition, nor the path of atomic rearrangements. Here
we report on novel, in-situ time resolved 2D diffraction and
microscopy measurements which were conducted at elevated
temperatures. The transition from α2-Ti3Al to γ-TiAl has been
followed in both reciprocal and real space and is found to appear homogeneously over the bulk and to occur through an
oriented rearrangement of atoms. At higher temperatures, the
transition reverses and starts to grow slowly and stepwise from
the grain boundaries into irregular shapes which impinge leading to grain refinement. 3 figs., 24 sources.
ALUMINIUM 9 (2008)
Metallkunde, Zweistofflegierungen
Y. Boonyongmaneerat, C. D. Dunand
Ni-Mo-Cr Foams Processed by Casting Replication of Sodium
Aluminate Preforms
Advanced Engineering Materials 2008, 10, No. 4, pp 379-383
The casting replication method, where a liquid metal is infiltrated in a bed of space-holder powders which are subsequently
removed by dissolution, has been used primarily for aluminium
and magnesium foams, because the low melting points of these
metals allows the use of inexpensive salts with high water solubility, such as NaCl. There is interest in using the replica- ©
141
LITERATURSERVICE
tion casting method for metals with higher melting temperature
with greater strength at ambient and elevated temperature. In
particular, Ni-base superalloy foams are attractive for applications where creep, oxidation and corrosion resistance are
needed together with a low density and high specific area, e.g.
for structural applications in engines, and as catalyst support
and heat exchangers. However, creating Ni-superalloy foams
by casting replication necessitates a space-holder material with
high melting point and chemical inertness with the melt. These
requirements are usually incompatible with that of high solubility in aqueous Solutions needed for easy removal, so that to
date no such material has been identified in the metallic foam
literature. 5 figs., 20 sources.
ALUMINIUM 9 (2008)
diative properties of dispersed media. Some of them consider
the porous structure equivalent to a random arrangement of
particles of given shapes and use the Mie theory or the geometric optics laws. Other methods are based on reflectance and
transmittance measurements of the medium and use the inverse
method. Finally, another approach consists in realising Monte
Carlo simulation at the local microscopic scale and taking into
account the complex morphology of the porous medium. If, in
these former studies, the architecture of the porous medium was
taken from a model shape, recent studies use the real structure
re-construction using the X-ray tomography technique. However, Monte Carlo simulations in tomographed samples require
a huge computational effort, and should be restricted to the
study of some Special aspects such as the detailed effect of the
architecture. 8 figs., 9 tables, 19 sources.
ALUMINIUM 9 (2008)
Th. Fiedler, A. Öchsner, I.V. Belova, G.E. Murch
Recent Advances in the Prediction of the Thermal Properties
of Syntactic Metallic Hollow Sphere Structures
Metallic hollow sphere structures (MHSS) are a new group of
cellular metals characterized by easily reproducible geometry
and therefore consistent mechanical and physical properties.
Well-known advantages of cellular metals are their excellent
ability for energy adsorption, good damping behaviour, sound
absorption, excellent heat insulation and a high specific stiffness. The combination of these properties opens a wide field of
potential multi-functional applications. The high thermal insulation capability of hollow sphere structure has been addressed
in a US Patent by Schneider and coworkers. Baumeister and
colleagues investigated the linear thermal expansion coefficient
of corundum based hollow sphere composites (HSC) using thermomechanical analysis. They found that the thermal behaviour
of HSC is mainly governed by the epoxy resin. Lu and Kou conducted a comprehensive numerical and experimental study
based on unit cells of homogeneous hollow sphere structures.
However, only automatically generated finite element meshes
were used. This approach does not allow the consideration of
different material combinations. 8 figs., 30 sources.
ALUMINIUM 9 (2008)
Werkstoffe, Metallkunde
M. Loretz, E. Maire, D. Baillis
Analytical Modelling of the Radiative Properties of Metallic
Foams: Contribution of X-Ray Tomography
Solid foams and notably metallic and ceramic foams exhibit
thermal, mechanical and exchange properties that make them
very interesting in various applications such as burners, electrodes for electric battery, high temperature spatial insulation,
heat exchangers, etc. In most of these applications, the knowledge of the thermo-physical properties is of primary importance
for the dimensioning of structures. However, these properties,
and especially the radiative properties, are directly related to
the foam microstructure. In order to optimize the thermal efficiency of such materials it is thus necessary to understand how
the microstructure affects the radiative properties.
It is particularly difficult to estimate radiative heat transfer in solid foams due to the complexity of the architecture in
these materials. Several methods are used to predict the ra-
B. Rieth
SMS Meer – A broad product range for the aluminium
industry
ALUMINIUM 84 (2008) 7/8, S. 50-54
Within the SMS Group, one of the world’s leading metallurgical
plant engineering concerns, the SMS Meer is mainly known for
tube and section rolling plants and forging aggregates. Besides
such equipment directed at the needs of the steel industry, the
company supplies a wide range of highly specialized equipment for many processing steps in the aluminium and copper
industries. In all these fields of activity SMS Meer has a store
of experience accumulated over years from the construction
of numerous plants. By continual innovation the company has
developed into the world market leader for most of its products.
This also applies in the aluminium sector, in which it is successfully active as a competent partner for the planning, engineering, production, assembly, commissioning and servicing of
equipment for melting through to semis production. In this, the
company’s aim is always to supply the customer with a plant
that gives him competitive advantages. The article is supplemented with an interview with Joachim Schönbeck, Member
of the Board of SMS GmbH and President of the Board of SMS
Meer GmbH, explaining the company’s strategy and market
prospects. 7 photos.
ALUMINIUM 9 (2008)
Strangpressen
Horizontal-Stranggussanlage zur Herstellung von
Walzbarren und Plattenvormaterial
ALUMINIUM 84 (2008) 7/8, S. 55
Eine Neuentwicklung der HPI High Performance Industrietechnik ermöglicht es, großformatige Querschnitte durch horizontalen Strangguss herzustellen. Auf dem „SuperSizeCaster“
können im Einzelstrangverfahren großformatige Querschnitte
wie Walzbarren, Stromschienen und Plattenvormaterial gegossen werden. Die wesentlichen Vorteile dieser Technologie sind
unter anderem: große Flexibilität, geringe Kokillenkosten, da
nur eine Kokille benötigt wird (plus eine Ersatzkokille), hervorragende Geradheit der Barren, da diese quasi schwebend
bewegt werden. Artikel dt./engl. 2 Fotos, 1 Tab.
ALUMINIUM 9 (2008)
Walzen
Für Schrifttum zum Thema „Aluminium“ ist der Gesamtverband der Aluminiumindustrie e.V. (GDA)
der kompetente Ansprechpartner. Die hier referierten Beiträge repräsentieren lediglich einen Ausschnitt aus dem umfassenden aktuellen Bestand der GDA-Bibliothek.
Die von der Aluminium-Zentrale seit den dreißiger Jahren kontinuierlich aufgebaute Fach-Bibliothek
wird duch den GDA weitergeführt, ausgebaut und auf die neuen Medien umgestellt. Sie steht allen
Interessenten offen.
Ansprechpartner ist Dr. Karsten Hein, E-Mail: [email protected]
142
ALUMINIUM · 9/2008
International Journal for Industry, Research and Application
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LIEFERVERZEICHNIS
1
Smelting technology
Hüttentechnik
1.1 Raw materials
1.2 Storage facilities for smelting
1.3 Anode production
1.4 Anode rodding
1.4.1 Anode baking
1.4.2 Anode clearing
1.4.3 Fixing of new anodes to the anodes bars
1.5 Casthouse (foundry)
1.6 Casting machines
1.7 Current supply
1.8 Electrolysis cell (pot)
1.9 Potroom
1.10 Laboratory
1.11 Emptying the cathode shell
1.12 Cathode repair shop
1.13 Second-hand plant
1.14 Aluminium alloys
1.15 Storage and transport
1.1 Rohstoffe
1.2 Lagermöglichkeiten in der Hütte
1.3 Anodenherstellung
1.4 Anodenschlägerei
1.4.1 Anodenbrennen
1.4.2 Anodenschlägerei
1.4.3 Befestigen von neuen Anoden an der -stange
1.5 Gießerei
1.6 Gießmaschinen
1.7 Stromversorgung
1.8 Elektrolyseofen
1.9 Elektrolysehalle
1.10 Labor
1.11 Ofenwannenentleeren
1.12 Kathodenreparaturwerkstatt
1.13 Gebrauchtanlagen
1.14 Aluminiumlegierungen
1.15 Lager und Transport
Open top and closed
type baking furnaces
1.1 Raw Materials/Rohstoffe
Raw Materials / Rohstoffe
ALUMINA AND PET COKE SHIPUNLOADERS
Contact: Andreas Haeuser, [email protected]
Offene und geschlossene Ringöfen
1.3 Anode production
TRIMET ALUMINIUM AG
Niederlassung Düsseldorf
Heinrichstr. 155
D-40239 Düsseldorf
Tel.: +49 (0) 211 / 96180-0
Fax: +49 (0) 211 / 96180-60
Internet: www.trimet.de
Anodenherstellung
RIEDHAMMER GmbH
D-90332 Nürnberg
Internet: www.riedhammer.de
see Storage facilities for smelting 1.2
1.2 Storage facilities for
smelting
Lagermöglichkeiten i.d. Hütte
FLSmidth MÖLLER GmbH
Haderslebener Straße 7
D-25421 Pinneberg
Telefon: 04101 788-0
Telefax: 04101 788-115
Internet: www.flsmidthmoeller.com
Kontakt: Herr Dipl.-Ing. Timo Letz
Automatische Feuerungssysteme
RIEDHAMMER GmbH
D-90332 Nürnberg
Internet: www.riedhammer.de
Abgasbehandlung
Conveying systems bulk materials
Förderanlagen für Schüttgüter
(Hüttenaluminiumherstellung)
Internet: www.flsmidthmoeller.com
Unloading/Loading equipment
Entlade-/Beladeeinrichtungen
www.flsmidthmoeller.com
144
Anodenanschlägerei
Auto firing systems
Exhaust gas treatment
Outotec GmbH
Albin-Köbis-Str. 8, D-51147 Köln
Phone: +49 (0) 2203 / 9921-0
www.outotec.com
1.4 Anode rodding
ALSTOM Norway AS
Tel. +47 22 12 70 00
Internet: www.environment.power.alstom.com
Hydraulic presses for prebaked
anodes / Hydraulische Pressen zur
Herstellung von Anoden
LAEIS GmbH
Am Scheerleck 7, L-6868 Wecker, Luxembourg
Phone: +352 27612 0
Fax: +352 27612 109
Internet: www.laeis-gmbh.com
Contact: Dr. Alfred Kaiser
Removal of bath residues from
the surface of spent anodes
Entfernen der Badreste von der Oberfläche der verbrauchten Anoden
GLAMA Maschinenbau GmbH
Hornstraße 19
D-45964 Gladbeck
Telefon 02043 / 9738-0
Telefax 02043 / 9738-50
Transport of finished anode
elements to the pot room
Transport der fertigen Anodenelemente in Elektrolysehalle
Hovestr. 10 . D-48431 Rheine
Telefon + 49 (0) 59 71 58-0
Fax
+ 49 (0) 59 71 58-209
E-Mail [email protected]
Internet www.windhoff.de
ALUMINIUM · 9/2008
LIEFERVERZEICHNIS
1.4.1 Anode baking
Anodenbrennen
Anode charging
Anodenchargieren
SERMAS INDUSTRIE
see Casting Machines 1.6
Anode storage
Anodenlager
SERMAS INDUSTRIE
1.4.2 Anode clearing
Anodenschlägerei
Separation of spent anodes
from the anode bars
Trennen von den Anodenstangen
SERMAS INDUSTRIE
SIGNODE® SYSTEM GMBH
Packaging Equipment
Non-Ferrous Specialist Team DSWE
Magnusstr. 18, 46535 Dinslaken/Germany
Telefon: +49 (0) 2064 / 69-210
Telefax: +49 (0) 2064 / 69-489
Internet: www.signode.com
Contact: Mr. Gerard Laks
Stopinc AG
Bösch 83 a
CH-6331 Hünenberg
Tel. +41/41-785 75 00
Fax +41/41-785 75 01
Internet: www.stopinc.ch
Fixing the nipples to the
anodes by casting in
Befestigen der Nippel mit der
Anode durch Eingießen
SERMAS INDUSTRIE
IMPERIAL-OEL-IMPORT
Bergstraße 11, D 20095 Hamburg
Tel. 040/338533-0, Fax: 040/338533-85
Clay / Tonerde
TRIMET ALUMINIUM AG
Niederlassung Düsseldorf
Heinrichstr. 155
D-40239 Düsseldorf
Tel.: +49 (0) 211 / 96180-0
Fax: +49 (0) 211 / 96180-60
Degassing, filtration and
grain refinement
Entgasung, Filtern, Kornfeinung
1.5 Casthouse (foundry)
Gießerei
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstraße 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
Internet: www.hertwich.com
INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH
Konstantinstraße 1a
D 41238 Mönchengladbach
Telefon +49 (02166) 987990
Telefax +49 (02166) 987996
Internet: www.inotherm-gmbh.de
OTTO JUNKER GmbH
see Extrusion 2
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
Gautschi
Engineering GmbH
see Casting equipment 3.1
Dross skimming of liquid metal
Abkrätzen des Flüssigmetalls
see Anode rodding 1.4
Dross skimming of the melt
Abkrätzen der Schmelze
ALUMINIUM · 9/2008
see Casthouse (foundry) 1.5
Sistem Teknik Ltd. Sti.
DES San. Sit. 102 SOK No: 6/8
Y.Dudullu, TR-34775 Istanbul/Turkey
Tel.: +90 216 420 86 24
Fax: +90 216 420 23 22
Internet: www.sistemteknik.com
Metal treatment in the
holding furnace
Metallbehandlung in Halteöfen
Gautschi
Engineering GmbH
Transfer to the casting furnace
Überführung in Gießofen
GmbH
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
Gautschi
Engineering GmbH
Windhoff Bahn- und
Anlagentechnik GmbH
Transport of liquid metal
to the casthouse
Transport v. Flüssigmetall in Gießereien
MARX GmbH & Co. KG
www.marx-gmbh.de
see Melt operations 4.13
see Casting machines 1.6
Windhoff Bahn- und
Anlagentechnik GmbH
Furnace charging with
molten metal
Treatment of casthouse
off gases
Ofenbeschickung mit Flüssigmetall
see Equipment and accessories 3.1
Schmelz-/Halte- und Gießöfen
Gautschi
Engineering GmbH
Bone ash / Knochenasche
1.4.3 Fixing of new anodes
to the anodes bars
Befestigen von neuen
Anoden a. d. Anodenstange
Melting/holding/casting furnaces
Behandlung der Gießereiabgase
Gautschi
Engineering GmbH
145
LIEFERVERZEICHNIS
Gießmaschinen
Gautschi
Engineering GmbH
OTTO JUNKER GmbH
see Extrusion 2
Pig casting machines (sow casters)
Masselgießmaschine (Sowcaster)
Gautschi
Engineering GmbH
343 Chemin du Stade
38210 Saint Quentin sur Isère
Tel. +33 (0) 476 074 242
Fax +33 (0) 476 936 776
Internet: www.sermas.com
Heat treatment of extrusion
ingot (homogenisation)
Rolling and extrusion ingot
and T-bars
Formatebehandlung (homogenisieren)
Gautschi
Engineering GmbH
Formatgießerei (Walzbarren oder
Pressbolzen oder T-Barren)
Gautschi
Engineering GmbH
IUT Industriell Ugnsteknik AB
see Extrusion 2
see Billet Heating Furnaces 1.5
Wagstaff, Inc.
3910 N. Flora Rd.
Spokane, WA 99216 USA
+1 509 922 1404 phone
+1 509 924 0241 fax
Internet: www.wagstaff.com
1.8 Electrolysis cell (pot)
Sawing / Sägen
Elektrolyseofen
Calcium silicate boards
Calciumsilikatplatten
Promat GmbH – Techn. Wärmedämmung
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
Pot feeding systems
Beschickungseinrichtungen
für Elektrolysezellen
146
Tapping vehicles
Schöpffahrzeuge
Dry absorption units for
electrolysis exhaust gases
Trockenabsorptionsanlage für
Elektrolyseofenabgase
ALSTOM Norway AS
Tel. +47 22 12 70 00
Anoden Transporteinrichtungen
Gautschi
Engineering GmbH
Anodenwechselmaschine
Anode transport equipment
Vertical semi-continuous DC
casting / Vertikales Stranggießen
Gautschi
Engineering GmbH
Anode changing machine
Internet: www.environment.power.alstom.com
Horizontal continuous casting
Scales / Waagen
Elektrolysehalle
T.T. Tomorrow Technology S.p.A.
Via dell’Artigianato 18
Due Carrare, Padova 35020, Italy
Telefon +39 049 912 8800
Telefax +39 049 912 8888
Contact: Giovanni Magarotto
Crustbreakers / Krustenbrecher
Horizontales Stranggießen
Gautschi
Engineering GmbH
1.9 Potroom
www.flsmidthmoeller.com
HF Measurementtechnology
HF Messtechnik
OPSIS AB
Box 244, S-24402 Furulund, Schweden
Tel. +46 (0) 46-72 25 00, Fax -72 25 01
Internet: www.opsis.se
1.11 Emptying the cathode shell
Ofenwannenentleeren
Cathode bar casting units
Kathodenbarreneingießanlage
1.15 Storage and transport
Lager und Transport
HUBTEX Maschinenbau GmbH & Co. KG
Werner-von-Siemens-Str. 8
D-36041 Fulda
Tel. +49 (0) 661 / 83 82-0
Fax +49 (0) 661 / 83 82-120
Internet: www.hubtex.com
ALUMINIUM · 9/2008
LIEFERVERZEICHNIS
2
Extrusion
Strangpressen
2.1 Extrusion billet preparation
2.1.1 Extrusion billet production
2.2 Extrusion equipment
2.3 Section handling
2.4 Heat treatment
2.5 Measurement and control equipment
2.6 Die preparation and care
2.7 Second-hand extrusion plant
2.8 Consultancy, expert opinion
2.9 Surface finishing of sections
2.10 Machining of sections
2.11 Equipment and accessories
2.12 Services
2.1 Pressbolzenbereitstellung
2.1.1 Pressbolzenherstellung
2.2 Strangpresseinrichtungen
2.3 Profilhandling
2.4 Wärmebehandlung
2.5 Mess- und Regeleinrichtungen
2.6 Werkzeugbereitstellung und -pflege
2.7 Gebrauchte Strangpressanlagen
2.8 Beratung, Gutachten
2.9 Oberflächenveredlung von Profilen
2.10 Profilbearbeitung
2.11 Ausrüstungen und Hilfsmittel
2.12 Dienstleistungen
Billet heating furnaces
Öfen zur Bolzenerwärmung
OTTO JUNKER GmbH
Jägerhausstr. 22
D – 52152 Simmerath
Phone +49 2473 601 0
Fax
+49 2473 601 600
Contact Mr. Teichert / Heat Treatmant Plants
Dr. Menzler / Extrusion Plants
Mr. Donsbach / Foundry Plants
OTTO JUNKER (UK) LTD.
Kingsbury Road, Curdworth
UK - SUTTON COLDFIELD B76 9EE
Phone +44 1675 470551
Fax
+44 1675 470645
Contact Mr. Hall
IUT INDUSTRIELL UGNSTEKNIK AB
Industrivägen 2
SE - 438 92 Härryda
Phone +46 301 508000
Fax
+46 301 30479
Contact Mr. Berge
2.1 Extrusion billet
preparation
Pressbolzenbereitstellung
Packaging Equipment
Telefon: +49 (0) 2064 / 69-210
Telefax: +49 (0) 2064 / 69-489
ALUMINIUM · 9/2008
Hot shears / Warmscheren
OTTO JUNKER GmbH
see Extrusion 2
2.1.1 Extrusion billet
production
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
Internet: www.ias-gmbh.de
Pressbolzenherstellung
Billet transport and storage
equipment
Bolzen-Transport- u. Lagereinricht.
SERMAS INDUSTRIE
See Casting Machines 1.6
2.2 Extrusion equipment
Strangpresseinrichtungen
MARX GmbH & Co. KG
www.marx-gmbh.de
DES San. Sit. 102 SOK No: 6/8
Y.Dudullu, TR-34775 Istanbul/Turkey
Tel.: +90 216 420 86 24
Fax: +90 216 420 23 22
Internet: www.sistemteknik.com
Billet heating units
Anlagen zur Bolzenerwärmung
OTTO JUNKER GmbH
Oilgear Towler GmbH
Im Gotthelf 8
D 65795 Hattersheim
Tel. +49 (0) 6145 3770
Fax +49 (0) 6145 30770
Internet: www.oilgear.de
SMS Meer GmbH
Schloemann Extrusion
Ohlerkirchweg 66
D-41069 Mönchengladbach
Tel. +49 (0) 2161 / 3500
Fax +49 (0) 2161 / 3501667
Internet: www.sms-meer.com
see Extrusion 2
Billet transport and
storage equipment
Bolzen Transport- und
Lagereinrichtungen
OTTO JUNKER GmbH
see Extrusion 2
SMS Meer GmbH
see Extrusion equipment 2.2
147
LIEFERVERZEICHNIS
Extrusion / Strangpressen
Homogenising furnaces
Homogenisieröfen
OTTO JUNKER GmbH
see Extrusion 2
Section cooling
Profilkühlung
OTTO JUNKER GmbH
OTTO JUNKER GmbH
see Extrusion 2
see Extrusion 2
Press control systems
Pressensteuersysteme
Oilgear Towler GmbH
see Extrusion Equipment 2.2
SMS Meer GmbH
Temperature measurement
Temperaturmessung
Packaging equipment
Verpackungseinrichtungen
H+H HERRMANN + HIEBER GMBH
Fördersysteme für Paletten
und schwere Lasten
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 (0) 711 / 9 34 67-0
Fax +49 (0) 711 / 3 46 0911
Internet: www.herrmannhieber.de
Vollert Anlagenbau
GmbH + Co. KG
Stadtseestraße 12
D-74189 Weinsberg
Tel.
+49 (0) 7134 / 52-220
Fax
+49 (0) 7134 / 52-222
Internet www.vollert.de
SMS Meer GmbH
Section saws
Profilsägen
OTTO JUNKER GmbH
see Extrusion 2
SMS Meer GmbH
Section store equipment
Profil-Lagereinrichtungen
SMS Meer GmbH
Puller equipment
Heating and control
equipment for intelligent
billet containers
Ausziehvorrichtungen/Puller
OTTO JUNKER GmbH
see Extrusion 2
Heizungs- und Kontrollausrüstung
für intelligente Blockaufnehmer
SMS Meer GmbH
MARX GmbH & Co. KG
www.marx-gmbh.de
und schwere Lasten
Rechbergstraße 46
Tel. +49 (0) 711 / 9 34 67-0
Fax +49 (0) 711 / 3 46 0911
KASTO Maschinenbau GmbH & Co. KG
Industriestr. 14, D-77855 Achern
Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300
[email protected] / www.kasto.de
Hersteller von Band- und Kreissägemaschinen
sowie Langgut- und Blechlagersystemen
2.3 Section handling
Profilhandling
Packaging Equipment
Telefon: +49 (0) 2064 / 69-210
Telefax: +49 (0) 2064 / 69-489
148
Could not find your „keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
ALUMINIUM · 9/2008
LIEFERVERZEICHNIS
Transport equipment for
extruded sections
Vollert Anlagenbau
GmbH + Co. KG
see Packaging equipment 2.3
Section transport equipment
Profiltransporteinrichtungen
OTTO JUNKER GmbH
see Extrusion 2
Transporteinrichtungen
für Profilabschnitte
und schwere Lasten
Rechbergstraße 46
Tel. +49 (0) 711 / 9 34 67-0
Fax +49 (0) 711 / 3 46 0911
OTTO JUNKER GmbH
see Extrusion 2
Custom designed heat
processing equipment
Kundenspezifische
Wärmebehandlungsanlagen
Homogenisieröfen
SMS Meer GmbH
Vollert Anlagenbau
GmbH + Co. KG
2.4 Heat treatment
Wärmebehandlung
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
Internet: www.unifour.nl
Sales Contact: Paul Overmans
Stackers / Destackers
Stapler / Entstapler
OTTO JUNKER GmbH
see Extrusion 2
OTTO JUNKER GmbH
see Extrusion 2
BSN Thermprozesstechnik GmbH
Kammerbruchstraße 64
D-52152 Simmerath
Tel. 02473-9277-0 · Fax: 02473-9277-111
[email protected] · www.bsn-therm.de
Ofenanlagen zum Wärmebehandeln von Aluminiumlegierungen, Buntmetallen und Stählen
Annealing furnaces
Glühöfen
SMS Meer GmbH
Extrusion
Stretching equipment
Reckeinrichtungen
2.5 Measurement and
control equipment
Strangpressen
OTTO JUNKER GmbH
see Extrusion 2
Mess- und Regeleinrichtungen
Extrusion plant control systems
OTTO JUNKER GmbH
see Extrusion 2
Heat treatment furnaces
Presswerkssteuerungen
Wärmebehandlungsöfen
SMS Meer GmbH
ALUMINIUM · 9/2008
OTTO JUNKER GmbH
see Extrusion 2
SMS Meer GmbH
149
LIEFERVERZEICHNIS
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
Die heating furnaces
2.10 Machining of sections
Profilbearbeitung
Processing of Profiles
Profilbearbeitung
Ageing furnace for extrusions
Auslagerungsöfen für
Strangpressprofile
see Extrusion 2
Werkzeuganwärmöfen
see Extrusion 2
MARX GmbH & Co. KG
www.marx-gmbh.de
Tensai (International) AG
Extal Division
Steinengraben 40
CH-4051 Basel
Telefon +41 (0) 61 284 98 10
Telefax +41 (0) 61 284 98 20
2.11 Equipment and
accessories
Ausrüstungen und
Hilfsmittel
Nijverheidsweg 3
Tel.: +31 315 641352
Fax: +31 315 641852
Inductiv heating equipment
Induktiv beheizte
Erwärmungseinrichtungen
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
Internet: www.ias-gmbh.de
Nijverheidsweg 3
Tel.: +31 315 641352
Fax: +31 315 641852
2.12 Services
Dienstleistungen
see Die preparation and care 2.6
Extrusion dies
Strangpresswerkzeuge
Karmeliterstraße 6
D-52064 Aachen
Telefon: 02 41 / 9 18 - 500
Telefax: 02 41 / 9 18 - 5010
Internet: www.haarmann-gruppe.de
Hardening technology
Härtetechnik
2.7 Second-hand
extrusion plant
Gebr. Strangpressanlagen
Qualiteam International/ExtruPreX
Champs Elyséesweg 17, NL-6213 AA Maastricht
Tel. +31-43-3 25 67 77
Internet: www.extruprex.com
150
E-Mail:
[email protected]
ALUMINIUM · 9/2008
LIEFERVERZEICHNIS
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
Rolling mill technology
Walzwerktechnik
Casting equipment
Rolling bar machining
Rolling bar furnaces
Hot rolling equipment
Strip casting units and accessories
Cold rolling equipment
Thin strip / foil rolling plant
Auxiliary equipment
Adjustment devices
Process technology / Automation technology
Coolant / lubricant preparation
Air extraction systems
Fire extinguishing units
Storage and dispatch
Second-hand rolling equipment
Coil storage systems
Strip Processing Lines
3.0 Rolling mill technology
Walzwerktechnik
SMS Demag Aktiengesellschaft
Eduard-Schloemann-Straße 4
D-40237 Düsseldorf
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
Internet: www.sms-demag.com
Geschäftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstraße 30
D-57271 Hilchenbach-Dahlbruch
Telefon: +49 (0) 2733 29-0
Telefax: +49 (0) 2733 29-2852
Bandanlagen
Walderstraße 51/53
D-40724 Hilden
Telefon: +49 (0) 211 881-5100
Telefax: +49 (0) 211 881-5200
Elektrik + Automation
Ivo-Beucker-Straße 43
D-40237 Düsseldorf
Telefon: +49 (0) 211 881-5895
Telefax: +49 (0) 211 881-775895
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
Gießanlagen
Walzbarrenbearbeitung
Walzbarrenvorbereitung
Warmwalzanlagen
Bandgießanlagen und Zubehör
Kaltwalzanlagen
Feinband-/Folienwalzwerke
Nebeneinrichtungen
Adjustageeinrichtungen
Prozesstechnik / Automatisierungstechnik
Kühl-/Schmiermittel-Aufbereitung
Abluftsysteme
Feuerlöschanlagen
Lagerung und Versand
Gebrauchtanlagen
Coil storage systems
Bandprozesslinien
Melting and holding furnaces
Schmelz- und Warmhalteöfen
Gautschi
Engineering GmbH
Geschäftsbereich Aluminium
Konstanzer Straße 37
Postfach 170
CH 8274 Tägerwilen
Telefon +41/71/6666666
Telefax +41/71/6666688
Kontakt: Stefan Blum, Tel. +41/71/6666621
LOI Thermprocess GmbH
Am Lichtbogen 29
D-45141 Essen
Germany
Telefon +49 (0) 201 / 18 91-1
Telefax +49 (0) 201 / 18 91-321
Internet: www.loi-italimpianti.com
Gießanlagen
Walzbarrenbearbeitung
Band saws / Bandsägen
SMS Meer GmbH
Ohlerkirchweg 66
D-41069 Mönchengladbach
Tel. +49 (0) 2161 / 3500
Fax +49 (0) 2161 / 3501667
Internet: www.sms-meer.com
Slab milling machines
Barrenfräsmaschinen
Metal filters / Metallfilter
Gautschi
Engineering GmbH
Filling level indicators
and controls
Füllstandsanzeiger und -regler
3.1 Casting equipment
3.2 Rolling bar machining
Gautschi
Engineering GmbH
OTTO JUNKER GmbH
SMS Meer GmbH
see Rolling bar machining 3.2
3.3 Rolling bar furnaces
Walzbarrenvorbereitung
see Heat Treatment 2.4
see Extrusion 2
Homogenisieröfen
Wagstaff, Inc.
Do you need more
information?
Melt purification units
Schmelzereinigungsanlagen
E-Mail:
[email protected]
ALUMINIUM · 9/2008
Gautschi
Engineering GmbH
151
LIEFERVERZEICHNIS
Gautschi
Engineering GmbH
OTTO JUNKER GmbH
see Extrusion 2
3.4 Hot rolling equipment
Spools / Haspel
Warmwalzanlagen
see Cold rolling units / complete plants 3.6
see Rolling mill Technology 3.0
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
Hot rolling units /
complete plants
Warmwalzanlagen/Komplettanlagen
Annealing furnaces
Glühöfen
EBNER Industrieofenbau Ges.m.b.H.
Ruflinger Str. 111, A-4060 Leonding
Tel. +43 / 732 / 68 68
Fax +43 / 732 / 68 68-1000
Internet: www.ebner.cc
Gautschi
Engineering GmbH
OTTO JUNKER GmbH
see Extrusion 2
SIEMAG GmbH
Obere Industriestraße 8
D-57250 Netphen
Tel.: +49 (0) 2738 / 21-0
Fax: +49 (0) 2738 / 21-1299
Internet: www.siemag.com
Coil transport systems
Bundtransportsysteme
Vollert Anlagenbau
GmbH + Co. KG
Windhoff Bahn- und
Anlagentechnik GmbH
schwartz GmbH
see Heat treatment 2.4
Drive systems / Antriebe
Bar heating furnaces
3.5 Strip casting units
and accessories
Bandgießanlagen und
Zubehör
Cores & shells for continuous
casting lines
Cores & shells for continuous
casting lines
Bruno Presezzi SpA
Via per Ornago 8
I-20040 Burago Molgora (Mi) – Italy
Tel. +39 039 63502 229
Fax +39 039 6081373
Internet: www.brunopresezzi.com
Contact: Franco Gramaglia
Barrenanwärmanlagen
Revamps, equipments & spare parts
for continuous casting lines
EBNER Industrieofenbau Ges.m.b.H.
see Annealing furnaces 3.3
Gautschi
Engineering GmbH
for continuous casting lines
Rolling mill modernisation
Walzwerksmodernisierung
OTTO JUNKER GmbH
see Extrusion 2
Roller tracks
Twin-roll continuous casting
lines (complete lines)
Rollengänge
Gautschi
Engineering GmbH
Do you need more information?
152
Bruno Presezzi SpA
Via per Ornago 8
Tel. +39 039 63502 229
Fax +39 039 6081373
Twin-roll continuous casting lines
(complete lines)
Bruno Presezzi SpA
Via per Ornago 8
Tel. +39 039 63502 229
Fax +39 039 6081373
ALUMINIUM · 9/2008
LIEFERVERZEICHNIS
3.6 Cold rolling equipment
Kaltwalzanlagen
see Heat Treatment 2.4
Mainzer Landstrasse 16
D-60325 Frankfurt am Main
Tel.: +49 69 97 16 81 48
Fax: +49 69 97 16 82 00
Internet: www.pesmel.com
Coil transport systems
Bundtransportsysteme
Vollert Anlagenbau
GmbH + Co. KG
Heating furnaces / Anwärmöfen
Gautschi
Engineering GmbH
OTTO JUNKER GmbH
see Extrusion 2
Windhoff Bahn- und
Anlagentechnik GmbH
Cold rolling units /
complete plants
Kaltwalzanlagen/Komplettanlagen
SIEMAG GmbH
D-57250 Netphen
Tel.: +49 (0) 2738 / 21-0
Fax: +49 (0) 2738 / 21-1299
Vits Systems GmbH
Winkelsweg 172
D-40764 Langenfeld
Tel.: +49 (0) 2173 / 798-0
Fax: +49 (0) 2173 / 798-244
E-Mail: [email protected], Internet: www.vits.com
Packaging Equipment
Telefon: +49 (0) 2064 / 69-210
Telefax: +49 (0) 2064 / 69-489
Process optimisation systems
Prozessoptimierungssysteme
Drive systems / Antriebe
Gautschi
Engineering GmbH
Coil annealing furnaces
Process simulation
Bundglühöfen
Gautschi
Engineering GmbH
Gautschi
Engineering GmbH
Prozesssimulation
OTTO JUNKER GmbH
see Extrusion 2
Hier könnte Ihr
www.vits.com
see Cold rolling equipment 3.6
ALUMINIUM · 9/2008
BezugsquellenEintrag
stehen.
Rufen Sie an:
Tel. 0511 / 73 04-148
Beate Schaefer
Bruno Presezzi SpA
Via per Ornago 8
Tel. +39 039 63502 229
Fax +39 039 6081373
153
LIEFERVERZEICHNIS
Roll exchange equipment
Walzenwechseleinrichtungen
Trimming equipment
Besäumeinrichtungen
Heating furnaces
Anwärmöfen
Gautschi
Engineering GmbH
OTTO JUNKER GmbH
see Extrusion 2
Vollert Anlagenbau
GmbH + Co. KG
Windhoff Bahn- und
Anlagentechnik GmbH
3.7 Thin strip /
foil rolling plant
Feinband-/Folienwalzwerke
Rolling mill modernization
Walzwerkmodernisierung
Slitting lines-CTL
Längs- und Querteilanlagen
Packaging Equipment
Telefon: +49 (0) 2064 / 69-210
Telefax: +49 (0) 2064 / 69-489
Coil annealing furnaces
Vits Systems GmbH
Winkelsweg 172
D-40764 Langenfeld
Tel.: +49 (0) 2173 / 798-0
Fax: +49 (0) 2173 / 798-244
E-Mail: [email protected], Internet: www.vits.com
Thin strip / foil rolling mills /
complete plant
Feinband- / Folienwalzwerke /
Komplettanlagen
Bundglühöfen
Gautschi
Engineering GmbH
OTTO JUNKER GmbH
Strip shears
see Extrusion 2
Bandscheren
Bruno Presezzi SpA
Via per Ornago 8
Tel. +39 039 63502 229
Fax +39 039 6081373
Rolling mill modernization
schwartz GmbH
see Cold colling equipment 3.6
154
www.vits.com
see Thin strip / foil rolling plant 3.7
Walzwerkmodernisierung
ALUMINIUM · 9/2008
LIEFERVERZEICHNIS
3.9 Adjustment devices
Adjustageeinrichtungen
Process control technology
Prozessleittechnik
Strip flatness measurement
and control equipment
Bandplanheitsmess- und
-regeleinrichtungen
Sheet and plate stretchers
Blech- und Plattenstrecker
SMS Meer GmbH
Unitechnik Cieplik & Poppek AG
D-51674 Wiehl, www.unitechnik.com
ABB Automation Technologies AB
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 342000
Fax: +46 21 340005
Internet: www.abb.com/pressductor
Cable sheathing presses
Kabelummantelungspressen
Wagstaff, Inc.
Strip thickness measurement
and control equipment
SMS Meer GmbH
Banddickenmess- und
-regeleinrichtungen
Cable undulating machines
Kabelwellmaschinen
ABB Automation Technologies AB
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 342000
Fax: +46 21 340005
Internet: www.abb.com/pressductor
SMS Meer GmbH
Transverse cutting units
Querteilanlagen
SERMAS INDUSTRIE
3.11 Coolant / lubricant
preparation
Kühl-/SchmiermittelAufbereitung
Rolling oil recovery and
treatment units
Walzöl-Wiederaufbereitungsanlagen
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
4Production AG
Produktionsoptimierende Lösungen
Adenauerstraße 20, D-52146 Würselen
Tel.: +49 (0) 2405 / 4135-0
[email protected], www.4production.de
SIEMAG GmbH
D-57250 Netphen
Tel.: +49 (0) 2738 / 21-0
Fax: +49 (0) 2738 / 21-1299
ALUMINIUM · 9/2008
Hier könnte Ihr
BezugsquellenEintrag
Filter for rolling oils and
emulsions
Filter für Walzöle und Emulsionen
stehen.
Rufen Sie an:
Tel. 0511 / 73 04-148
Beate Schaefer
155
LIEFERVERZEICHNIS
Rolling oil rectification units
Filtering plants and systems
Walzölrektifikationsanlagen
Filteranlagen und Systeme
3.17 Strip Processing Lines
Bandprozesslinien
Colour Coating Lines
Bandlackierlinien
Industriestr. 9, D-77948 Friesenheim
Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245
Internet: www.danthermfiltration.com
www.bwg-online.com
see Strip Processing Lines 3.17
Lithographic Sheet Lines
3.14 Storage and dispatch
Lagerung und Versand
Mainzer Landstrasse 16
D-60325 Frankfurt am Main
Tel.: +49 69 97 16 81 48
Fax: +49 69 97 16 82 00
Internet: www.pesmel.com
Lithografielinien
www.bwg-online.com
Stretch Levelling Lines
3.12 Air extraction systems
Abluft-Systeme
Exhaust air purification
systems (active)
Abluft-Reinigungssysteme (aktiv)
Streckrichtanlagen
SIEMAG GmbH
D-57250 Netphen
Tel.: +49 (0) 2738 / 21-0
Fax: +49 (0) 2738 / 21-1299
www.bwg-online.com
Strip Annealing Lines
3.16 Coil storage systems
Bandglühlinien
Bundlagersysteme
www.bwg-online.com
SIEMAG GmbH
D-57250 Netphen
Tel.: +49 (0) 2738 / 21-0
Fax: +49 (0) 2738 / 21-1299
Vollert Anlagenbau
GmbH + Co. KG
Strip Processing Lines
Bandprozesslinien
BWG Bergwerk- und WalzwerkMaschinenbau GmbH
Mercatorstraße 74 – 78
D-47051 Duisburg
Tel.: +49 (0) 203-9929-0
Fax: +49 (0) 203-9929-400
Internet: www.bwg-online.com
156
ALUMINIUM · 9/2008
LIEFERVERZEICHNIS
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
Foundry
Gießerei
Work protection and ergonomics
Heat-resistant technology
Conveyor and storage technology
Mould and core production
Mould accessories and accessory materials
Foundry equipment
Casting machines and equipment
Handling technology
Construction and design
Measurement technology and materials testing
Metallic charge materials
Finshing of raw castings
Melt operations
Melt preparation
Melt treatment devices
Control and regulation technology
Environment protection and disposal
Dross recovery
Gussteile
4.2 Heat-resistent technology
Feuerfesttechnik
Refractories
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
Arbeitsschutz und Ergonomie
Feuerfesttechnik
Förder- und Lagertechnik
Form- und Kernherstellung
Formzubehör, Hilfsmittel
Gießereianlagen
Gießmaschinen und Gießeinrichtungen
Handhabungstechnik
Konstruktion und Design
Messtechnik und Materialprüfung
Metallische Einsatzstoffe
Rohgussnachbehandlung
Schmelzbetrieb
Schmelzvorbereitung
Schmelzebehandlungseinrichtungen
Steuerungs- und Regelungstechnik
Umweltschutz und Entsorgung
Schlackenrückgewinnung
Cast parts
4.6 Foundry equipment
Gießereianlagen
Casting machines
Gießmaschinen
and equipment
Gießereimaschinen
und Gießeinrichtungen
Feuerfeststoffe
Promat GmbH – Techn. Wärmedämmung
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
OTTO JUNKER GmbH
see Extrusion 2
Molten Metall Level Control
4.3 Conveyor and storage
technology
Förder- und Lagertechnik
Ostra Hamnen 7
SE-430 91 Hono / Schweden
Tel.: +46 31 764 5520, Fax: +46 31 764 5529
Internet: www.precimeter.com
Sales contact: Jan Strömbeck
Solution annealing furnaces/plant
Lösungsglühöfen/anlagen
Vollert Anlagenbau
GmbH + Co. KG
4.5 Mold accessories and
accessory materials
ERNST REINHARDT GMBH
Postfach 1880, D-78008 VS-Villingen
Tel. 07721/8441-0, Fax 8441-44
Internet: www.Ernst-Reinhardt.com
Wärmebehandlungsöfen
Mould parting agents
Kokillentrennmittel
see Foundry equipment 4.6
Flussmittel
Solvay Fluor GmbH
Hans-Böckler-Allee 20
D-30173 Hannover
Telefon +49 (0) 511 / 857-0
Telefax +49 (0) 511 / 857-2146
Internet: www.solvay-fluor.de
ALUMINIUM · 9/2008
Formzubehör, Hilfmittel
Fluxes
Wagstaff, Inc.
Schröder KG
Schmierstofftechnik
Postfach 1170
D-57251
Freudenberg
Tel. 02734/7071
Fax 02734/20784
www.schroeder-schmierstoffe.de
157
LIEFERVERZEICHNIS
Melting furnaces
4.8 Handling technology
Schmelzöfen
Handhabungstechnik
Vollert Anlagenbau
GmbH + Co. KG
Manipulators
Manipulatoren
SERMAS INDUSTRIE
4.9 Construction and
Design
Konstruktion und Design
THERMCON OVENS BV
see Extrusion 2
ALERIS Recycling (German Works) GmbH
Aluminiumstraße 3
Telefon +49 (0) 2181/16 45 0
Telefax +49 (0) 2181/16 45 100
Internet: www.aleris-recycling.com
Pre alloys / Vorlegierungen
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-43
Fax: +49 (0) 211 / 50 13 97
Internet: www.bloomeng.com
Sales Contact: Klaus Rixen
Gautschi
Engineering GmbH
METALLHANDELSGESELLSCHAFT
SCHOOF & HASLACHER MBH & CO. KG
Postfach 600714, D 81207 München
Telefon 089/829133-0
Telefax 089/8201154
Internet: www.metallhandelsgesellschaft.de
Recycling / Recycling
4.11 Metallic charge
materials
Metallische Einsatzstoffe
Scholz AG
Am Bahnhof
D-73457 Essingen
Tel. +49 (0) 7365-84-0
Fax +49 (0) 7365-1481
Internet: www.scholz-ag.de
Aluminium alloys
Aluminiumlegierungen
TRIMET ALUMINIUM AG
Niederlassung Gelsenkirchen
Am Stadthafen 51-65
D-45681 Gelsenkirchen
Tel.: +49 (0) 209 / 94089-0
Fax: +49 (0) 209 / 94089-60
MARX GmbH & Co. KG
Lilienthalstr. 6-18
D-58638 Iserhohn
Tel.: +49 (0) 2371 / 2105-0, Fax: -11
Internet: www.marx-gmbh.de
TRIMET ALUMINIUM AG
Niederlassung Harzgerode
Aluminiumallee 1
06493 Harzgerode
Tel.: 039484 / 50-0
Fax: 039484 / 50-100
Holding furnaces
Warmhalteöfen
4.13 Melt operations
Schmelzbetrieb
METALLHÜTTENWERKE BRUCH GMBH
Postfach 10 06 29
D-44006 Dortmund
Telefon +49 (0) 231 / 8 59 81-121
Telefax +49 (0) 231 / 8 59 81-124
Internet: www.bruch.de
METALLHANDELSGESELLSCHAFT
SCHOOF & HASLACHER MBH & CO. KG
Postfach 600714, D 81207 München
Telefon 089/829133-0
Telefax 089/8201154
Internet: www.metallhandelsgesellschaft.de
158
OTTO JUNKER GmbH
see Extrusion 2
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-43
Fax: +49 (0) 211 / 50 13 97
Internet: www.bloomeng.com
Sales Contact: Klaus Rixen
Gautschi
Engineering GmbH
ALUMINIUM · 9/2008
LIEFERVERZEICHNIS
4.16 Control and
regulation technology
Flue gas cleaning
Rauchgasreinigung
Steuerungs- und
Regelungstechnik
Gautschi
Engineering GmbH
HCL measurements
HCL Messungen
OPSIS AB
Box 244, S-24402 Furulund, Schweden
Tel. +46 (0) 46-72 25 00, Fax -72 25 01
Internet: www.opsis.se
Industriestr. 9, D-77948 Friesenheim
Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245
Internet: www.danthermfiltration.com
4.18 Dross recovery
Schlackenrückgewinnung
OTTO JUNKER UK
see Extrusion 2
4.17 Environment protection
and disposal
Umweltschutz und
Entsorgung
4.19 Cast parts / Gussteile
4.14 Melt preparation
Schmelzvorbereitung
Dust removal / Entstaubung
OTTO JUNKER GmbH
see Extrusion 2
Degassing, filtration
Entgasung, Filtration
GmbH
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: http://www.drache-gmbh.de
Gautschi
Engineering GmbH
NEOTECHNIK GmbH
Entstaubungsanlagen
Postfach 110261, D-33662 Bielefeld
Tel. 05205/7503-0, Fax 05205/7503-77
[email protected], www.neotechnik.com
TRIMET ALUMINIUM AG
Niederlassung Harzgerode
Aluminiumallee 1
06493 Harzgerode
Tel.: 039484 / 50-0
Fax: 039484 / 50-100
Do you need more information?
Melt treatment agents
Schmelzebehandlungsmittel
Gautschi
Engineering GmbH
4.15 Melt treatment devices
Schmelzbehandlungseinrichtungen
OTTO JUNKER GmbH
see Extrusion 2
Metaullics Systems Europe B.V.
Ebweg 14
NL-2991 LT Barendrecht
Tel. +31-180/590890
Fax +31-180/551040
Internet: www.metaullics.com
ALUMINIUM · 9/2008
5
Materials and Recycling
Werkstoffe und Recycling
Alu-web.de
der ALUMINIUMBranchentreff.
Haben Sie schon Ihren
Basiseintrag bestellt?
Nein, dann sofort anrufen:
0511/73 04-142
Stefan Schwichtenberg
Granulated aluminium
Aluminiumgranulate
ECKA Granulate Austria GmbH
Bürmooser Landesstraße 19
A-5113 St. Georgen/Salzburg
Telefon +43 6272 2919-12
Telefax +43 6272 8439
Kontakt: Ditmar Klein
159
LIEFERVERZEICHNIS
6
Machining and Application
Bearbeitung und Anwendung
Machining of aluminium
Joining / Fügen
Aluminiumbearbeitung
KGaA
Haarmann Holding GmbH Henkel
siehe Prozesse für die Oberflächentechnik 6.1
6.1 Surface treatment
processes
Prozesse für die
Oberflächenbehandlung
Pretreatment before coating
Vorbehandlung vor der Beschichtung
Thermische Beschichtung
Adhesive bonding / Verkleben
Ausrüstung für Schmiedeund Fließpresstechnik
Hydraulic Presses
Hydraulische Pressen
LASCO Umformtechnik GmbH
Hahnweg 139, D-96450 Coburg
Tel. +49 (0) 9561 642-0
Fax +49 (0) 9561 642-333
Internet: www.lasco.com
Henkel KGaA
Thermal coating
Henkel KGaA
D-40191 Düsseldorf
Tel. +49 (0) 211 / 797-30 00
Fax +49 (0) 211 / 798-36 36
Internet: www.henkel-technologies.com
6.3 Equipment for forging
and impact extrusion
Berolina Metallspritztechnik
Wesnigk GmbH
Pappelhain 30
D-15378 Hennickendorf
Tel.: +49 (0) 33434 / 46060
Fax: +49 (0) 33434 / 46701
Internet: www.metallspritztechnik.de
Henkel KGaA
8
Literature
Literatur
Technikcal literature
Fachliteratur
Taschenbuch des Metallhandels
Fundamentals of Extrusion Technology
Giesel Verlag GmbH
Verlag für Fachmedien
Ein Unternehmen der Klett-Gruppe
Rehkamp 3 · 30916 Isernhagen
Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157
Internet: www.alu-bookshop.de.
6.2 Semi products
Anodising / Anodisation
Henkel KGaA
Halbzeuge
Wires / Drähte
Technical journals
Fachzeitschriften
Cleaning / Reinigung
Henkel KGaA
DRAHTWERK ELISENTAL
W. Erdmann GmbH & Co.
Werdohler Str. 40, D-58809 Neuenrade
Postfach 12 60, D-58804 Neuenrade
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044
Internet: www.elisental.de
E-Mail:
[email protected]
160
Giesel Verlag GmbH
Ein Unternehmen der Klett-Gruppe
Rehkamp 3 · 30916 Isernhagen
Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157
ALUMINIUM · 9/2008
IMPRESSUM / IMPRINT
International
ALUMINIUM
Journal
84. Jahrgang 1.1.2008
Redaktion / Editorial office
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Chefredakteur, Editor in Chief
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Tel: +49(0)2225 8359 643
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Hüttenindustrie und Recycling
Dipl.-Ing. Bernhard Rieth
Walzwerkstechnik und Bandverarbeitung
Verlag / Publishing house
Giesel Verlag GmbH, Verlag für Fachmedien, Unternehmen der Klett-Gruppe, Postfach 120158, 30907 Isernhagen; Rehkamp
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ALUMINIUM · 9/2008
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USA, Canada, Africa, U.A.E. etc.
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United Kingdom
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161
VORSCHAU / PREVIEW
IM NÄCHSTEN HEFT
IN THE NEXT ISSUE
Special:
Die internationale Walzwerksindustrie
Special:
The international rolling mill industry
Walzen, Bandguss, Bandbehandlung – neue Projekte
und Technologien, Maschinen und Ausrüstungen,
unter anderem:
Rolling, strip casting, strip treatment – new rolling
plant projects, technologies, machinery and equipment, including:
• Novelis stärkt deutsche Standorte
• Längenexakte Materialverfolgung in Bandanlagen
• Novelis strengthens German locations
• Exact material tracking in strip processing lines
Weitere Themen
Other topics
• Moderne Planungstechnologie optimiert
Produktionsprozesse
• Körperschallgedämpftes Aluminium-Walzhalbzeug
für die Außenarchitektur
• Schweißen von Aluminiumblech
• Aluminium in der Kunst
• Advanced planning and scheduling software for
optimizing production processes
• Sound-deadening aluminium sheet in exterior
architecture
• Welding of aluminium sheet
• Latest international news from the industry
• Aktuelles aus der Branche, Kurzberichte
Research
• Friction-assisted indirect extrusion: physical
models and main processes
Erscheinungstermin:
2. Oktober 2008
Anzeigenschluss:
17. September 2008
Redaktionsschluss: 16. September 2008
Date of publication:
2 October 2008
Advertisement deadline: 17 September 2008
Editorial deadline:
16 September 2008
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ALUMINIUM · 9/2008
Gautschi™
Furnace
& casting
Furnace
& casting
systemssystems
for the
aluminium industry
•Melting and Holding Furnaces
•Casting Systems
•Heat Treatment Plants
•Process Control Equipment
•Casthouse Auxilliaries
•Integrated Plant Design
•Modernisation & up-grading
•Engineering Services
•Project Management
•After Sales Services
Pusher Type Furnaces
Gautschi Engineering GmbH
Konstanzer Str.37
8274 Taegerwilen
Switzerland
Tel. +41-71- 6666 666
Fax +41-71- 6666 677
www.gautschi-engineering.com
[email protected]
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