Constellium’s Muscle Shoals facility receives Department of Defense grant to increase casting capacity

Constellium, Muscle Shoals, AL, announces that its facility has been selected by the U.S. Department of Defense (DoD) for a $23 million investment under Title III of the Defense Production Act to rebuild its Direct Chill aluminum casting center.

The funding was awarded via the Defense Production Act Investments (DPAI) Program, overseen by the Manufacturing Capability Expansion and Investment Program (MCEIP) in the Office of the Assistant Secretary of Defense for Industrial Base Policy. Constellium will use the funds to install state-of-the-art casting equipment on the site of a dismantled casting center, adding up to 300 million pounds of annual casting capacity. With this added capacity, the plant expects to increase its recycled input, reduce its use of primary metal, and provide the U.S. industrial base with an additional, self-reliant domestic source of supply for aluminum rolling ingot.

“This investment under the Defense Production Act will enable our industry to meet the rapidly increasing demand for the aluminum products needed not only for our national security but also necessary for the overall U.S. manufacturing sector and a healthy economy,” commented Buddy Stemple, President of Constellium Muscle Shoals. “We are very excited to have this opportunity to partner with the DoD to help strengthen our industrial base.”

Constellium Muscle Shoals is a major aluminum sheet supplier for the packaging and automotive markets. The plant has the capacity to produce over 1 billion pounds per year of finished aluminum coils. Muscle Shoals also operates a world-class recycling center able to recycle the equivalent of 20 billion aluminum cans per year.

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Seco Vacuum delivers Vector Furnace to major automotive supplier in Mexico

Seco Vacuum, Meadville, PA, announces that an international Tier 1 automotive supplier headquartered in the USA has ordered a Vector vacuum furnace for one of their facilities in Mexico.

The Vector 15VP furnace is capable of a variety of thermal processes. Its hot zone measures 36x36x48 inches (900x900x1200 mm) and has a 3,300 lb. (1500 kg) capacity. It features convection heating and a mechanical vacuum pump system, meeting or exceeding the specifications necessary for the production line’s brazing process.

Typically, SECO/VACUUM furnaces are custom-engineered; however, this particular furnace was fabricated ahead of time as a stock item to meet the contingency of a customer requesting immediate delivery. This strategic move allowed the heat treat partner to quickly and seamlessly ramp up production capacity. Additionally, if production demand shifts, the new Vector vacuum furnace can be easily repurposed for other heat treat processes, offering significant versatility.

“We built this furnace to be ready to be shipped and put into operation very quickly, which is just the solution they were looking for,” said SECO/VACUUM Managing Director Piotr Zawistowski.

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Solar Atmospheres awarded Lockheed Martin space systems approval

Solar Atmospheres, Greenville, SC, has announced that it has been awarded Lockheed Martin Space Systems approval. With this approval, now all five Solar Atmospheres facilities are an option for our customers with Lockheed Martin requirements for thermal processing services.

Steve Prout, President of Solar Atmospheres’ Greenville facility states: “We are proud to once again provide our customers in the Southeastern U.S. with another regional option for aerospace and defense thermal processes, saving them time and money while continuing to deliver the high level of quality required.”

With the ability to support vacuum thermal processing needs ranging from development cycles to 50,000 pound loads at temperatures of up to 2400°F, Solar Atmospheres provides AS9100 and Nadcap quality accredited heat treatments, providing our customers with the confidence their product is being processed as specified.

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One Minute Mentor: Vacuum Furnaces

Driven by the development of new tool steels—which were property-wise tailor made for applications such as aluminum die casting, drilling, and tools and dies for the plastic industry—but also due to rising dimensions of the tools, the demands on vacuum-hardening technology have changed in recent decades. One of the most important considerations that must be met is the accomplishment of highest dimensional stability with optimal microstructural properties and minimal change of the surface of the workpieces. Minimizing exposure to air during the heat treatment by reducing the quantity of oxygen in a heat treatment furnace, as with creating a vacuum, is an excellent method for preventing changes in surface appearance and chemical composition.

For more information, click on the link below (subscription required). Then scroll to Figure 14. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014  https://doi.org/10.31399/asm.hb.v04d.a0005958

Harper Furnace Technology enables high performance silicon anodes

Harper Furnace Technology, Buffalo, NY, announced the development of high temperature thermal process solutions to enable production at several silicon anode battery material companies in 2024. Silicon anode material offers significantly higher specific capacity than traditional graphite anode materials enabling higher power density, faster charge times and smaller carbon footprint than current batteries. 

 

Harper has entered engineering design and equipment supply contracts for pilot and production scale equipment with its USA-based customers, many of whom are funded in part by grants from the U.S. Department of Energy. The Harper technology includes indirect electrically heated, continuous rotary, vertical and horizontal conveyor furnace systems for each customer’s unique thermochemical processes. The Harper furnaces include tight control of the process atmosphere enabling safe and reliable continuous operation, are rated for temperatures between 800˚C and 1,800˚C and will have capacity up to 1,000 metric tons per year. Beyond the pilot-scale equipment projects, Harper is actively engineering the next generation of equipment solutions for these customers whose commercial scale plants will require capacity of 20,000 – 40,000 metric tons per year for the electric vehicle (EV) market.

 

https://www.harperintl.com/

Solar Atmospheres of Michigan achieves Nadcap accreditation for laboratory

Solar Atmospheres, Chesterfield, MI, has successfully achieved Nadcap AC7101/4 accreditation for their captive metallography laboratory. 

 

The accreditation will allow the Chesterfield plant to continue testing for microhardness, surface contamination, intergranular oxidation and grain size which were all previously completed at the Warren facility. In addition to continued testing capabilities, the addition of new metallographic preparation equipment and metallography software will expand Chesterfield’s R&D capabilities and assist in new product development.

Plant metallurgist Greg Scheuring states, “This was the next step in moving operations from Warren to Chesterfield. To limit downtime and maintain on-time delivery, we gave ourselves a week to make the move and conduct the audit. It was an extremely abbreviated time for such a task but personnel at both facilities pulled together to make it happen. Now the audit is complete with no findings, and we are back up and running. Stellar teamwork all around!”

 

https://solaratm.com/solar-atmospheres-of-michigan-achieves-nadcap-accreditation-for-laboratory/

Quintus cold isostatic press delivered to China’s Lingchuang Special Material Co

Qunitus, Västerås, Sweden, delivered a supersized Cold Isostatic Press (CIP) to China’s Henan Lingchuang Special Material Co. to raise the bar for domestically produced high-quality Isostatic Graphite. 

With its sights set on securing a place as market leader in both product quality and production efficiency, Lingchuang will install a Quintus press model QIC 2.4 x 4.5 – 2000 to maximize operation and output capabilities. The press itself is setting new standards, with its world’slargest vessel dimension—2400 mm x 4500 mm (7.87’ x 14.7’)—along with a new energy management system that offers energy savings of more than 30 percent compared to conventional intensifier solutions.

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One Minute Mentor: Indirectly heated fluidized-bed furnace

Most fluidized-bed furnaces are used at temperatures below 1095 °C (2000 °F), although some manufacturers have furnaces capable of treating components to temperatures through 1205 °C (2200 °F). Initially, the gas flows upward through the permeable base to agitate the particles as the pressure is gradually increased. (b) Eventually, the gas flow is sufficient to lift the small particles of refractory materials and to transform the particle movement into a violent turbulent motion.

In the early 1980s, this furnace technology seemed to be on the right track as an alternative to salt bath technology, showing similar advantages and applications but without the environmental hazard of salt compounds, waste disposal, recycling of salts, and so on. Nowadays it can be concluded that salt bath technology was partially substituted by vacuum technology, but especially for bainitic hardening (austempering processes), salt baths are still commonly used and show a slightly growing tendency, whereas fluidized beds are hardly used any more.

This temperature limitation is related to the wear and tear on the retort materials at high temperatures, which was one of the reasons for the reduced interest in this furnace type after the initial hype.

For more information, click on the link below (subscription required). Then scroll to Figure 8.

R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014, https://doi.org/10.31399/asm.hb.v04d.a0005958

Lindberg/MPH completes roller hearth furnace system for the energy industry

Lindberg/MPH, Mich., announced the installation of a roller hearth furnace system for a manufacturer of products used in the energy industry. The heat treat system is comprised of two box furnaces with quench tanks, a dual directional load transfer car, four companion draw batch ovens, and two stationary load/unload tables.

The maximum operating temperature of the box furnaces is 1850°F and they are designed for nitrogen-based atmosphere applications. The load space dimensions of the box furnaces are 48” W x 96” D x 36” H, and the internal chambers are larger to provide clearance for baskets or fixtures. A snake chain pusher assembly is used by each furnace to transfer the loads from the chamber to the quench elevator deck.

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Wisconsin Oven to ship three custom conveyor ovens to the molded-fiber industry

Wisconsin Oven, East Troy, is scheduled to ship three custom dryers to a manufacturer in the molded-fiber industry. The ovens will be used for drying thick-walled paper pulp molded fiber packaging material used in a variety of products. Molded fiber packaging is made of 100% recycled materials, making them an environmentally friendly solution for companies looking to use sustainable packaging and reduce their environmental impact.

These paper pulp drying conveyor ovens are designed with four temperature zones, and each has the sufficient capability to remove 850 pounds of water per hour from the molded pulp. The ovens feature a maximum temperature rating of 500°. The work chamber dimensions are 8’ W x 120’ L x 1’ H. A total of twelve personnel access doors with explosion relief latches are located on the sides of each unit. Each unit also has stainless steel sheet metal and structure on the wet end to reduce corrosion.

The conveyor ovens are designed with top-down and bottom-up airflow to maximize the drying rate of the paper pulp shapes. The flat wire belt continuous conveyor system uses a variable frequency drive that is adjustable from 0-3 FPM. Emergency stop buttons are located at the load and unload sections of each oven for operator safety.

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