December 2024
Georg Fischer AG is evaluating what to do with GF Casting Solutions
A strategic reorganisation of the Georg Fischer group has landed its precision CNC machine business in the wide portfolio of the United Grinding Group. Georg Fischer AG is evaluating “all strategic options” for GF Casting Solutions, a collection of 13 metal casting operations in Germany, Austria, Romania, Switzerland and China that is one of the four vertical businesses that comprise the global organisation.
Xpeng starts series production with 16 000 ton giga/mega press
The launch of the world’s first 16 000 ton press in series production was a significant milestone for the automotive industry, especially for the electric vehicle manufacturer Xpeng who have just launched its AI vehicle the P7+, demonstrating how innovative manufacturing technologies can be used to produce vehicles even more efficiently and cost-effectively.
Everything is in crisis, except the craft of war
Rheinmetall continues to benefit greatly from the armaments boom resulting from the wars that are currently taking place around the world. Germany’s largest arms company is sitting on a record backlog of orders. At the end of June, this was valued at 48.6 billion euros. The company supplies not only Germany but also other NATO countries.
Thyssenkrupp suffers billions in losses and reacts
German industrial giant Thyssenkrupp has reported a massive annual loss for the second year running, as it battles challenges including a crisis in its historic steel division. The conglomerate, whose products range from steel to submarines, booked a loss of 1.5 billion euros ($1.6 billion) for the 2023-24 financial year, after a loss of over two billion euros the previous year.
New initiative to ‘green’ ship recycling
Bimco has launched a Ship Recycling Alliance to help accelerate safe and environmentally sound recycling of ships. The alliance will coordinate the voices of the ship recycling industry and the shipping industry and help facilitate the global implementation of the Hong Kong International Convention for the Safe and Environmentally Sound Recycling of Ships (HKC).
Japanese steel giants apply for government subsidy to go green
Two of the largest integrated steel producers in Japan, Nippon Steel and JFE Steel, have applied for government funding allocated through the new Green Transformation Promotion Act (GX) to advance research and development in decarbonising operations. The two mills were among many companies in the targeted sectors of iron and steel, chemicals, pulp and paper, and cement that had applied for investment support.
Harz Guss Zorge (HGZ) has been sold to a US investor
The GMH Group subsidiary Harz Guss Zorge (HGZ) has been sold to the US investor Hugh Aiken it has been announced. GMH wants to devote more time to its core businesses. GMH Gruppe is one of the largest privately managed metalworking companies in Europe. Under its umbrella we combine the expertise of 20 medium-sized companies in the steel, forging and foundry industry.
SMS group and SSAB advancing together in the green steel revolution
One of the world’s most powerful electric arc furnaces is SSAB’s strategic unit for green steel production. This EAF, currently under construction by SMS for SSAB’s Oxelösund steel plant in Sweden, will be equipped with the most advanced medium-voltage digital power feeding system. The MMC system is critical for maintaining the quality of the power grid.
China ups steel output, while other nations cut back
The world’s steel mills produced 151.2 million metric tons of crude steel in October, marking a 0.4 per cent increase compared with October of last year. Compared with the prior month, global output rose by 7.6 million metric tons, or 5.3 per cent. China was responsible for 4.8 million metric tons of that September-to-October boost, or 63 per cent of the overall rise in production.
The role of steel scrap in the circular economy
David Busstra, Commercial Manager Circularity, at Tata Steel Nederland, explores sustainable trends in steel production: “As the global steel industry strives to reduce its carbon footprint, EAF technology, which largely uses steel scrap as feedstock, is expected to gain more prominence. These furnaces are more energy-efficient and produce lower CO2 emissions compared to traditional blast furnace methods.”
October 2024
Voxeljet assembling the world’s largest 3D printer for sand
This printer is dedicated to a collaboration with GE Vernova and aims to support the US energy transition to sustainable and renewable sources. With a build envelope of approximately 70 square metres, the VX9000 will be used to print moulds for wind and water turbine castings. A giant step towards a new scale in additive manufacturing.
HA-International appoints Gordon McNeilage as its Regional Vice President of the Americas
In October 2023 HA-International announced that it had appointed Gordon McNeilage to the position of CEO, effective January 1st, 2024. Gordon succeeded Mike Feehan, who had this to say: “Gordon joined HAI in 2023 and has led the commercial team as VP of Sales and Marketing.
A Chinese company just ‘gigacast’ an entire underbody: Here’s why that might be a bad thing
Large component casting, also known as megacasting, or gigacasting if you’re Tesla, is hot right now, and a major milestone has just been reached. Chinese automaker Chery Auto has cast an entire underbody using a 13 000-ton dual-injection press, and while the result is nothing short of impressive, there are a few good reasons why you probably shouldn’t want a one-piece cast underbody on your car.
Reuters says US manufacturers are to be hit by soaring property insurance costs
Did you know that the foundry industry in the US is currently facing a major challenge with soaring property insurance costs? US manufacturers are facing skyrocketing property and casualty insurance costs, with some premiums expected to double or even triple. According to Reuters, US manufacturers are feeling the impact of these high insurance costs.
Calderys invests in a major single-site greenfield plant in India
Calderys has reached a significant milestone in its global growth strategy with the commencement earlier this year of a project in the state of Odisha, India. This project will be the world’s largest single-site greenfield plant dedicated to refractories and steel casting fluxes. It represents a strategic move from Calderys to expand its product range.
Borbet GmbH acquires wheel manufacturer Dymag
Borbet GmbH acquires wheel manufacturer DymagDymag Technologies Ltd, a new wholly-owned subsidiary of Borbet GmbH – a leading global manufacturer of light alloy wheels – has acquired the trade and assets of Dymag Group Ltd, a manufacturer and developer of carbon rims for cars and motorcycles that was founded in 1974 and is based in Chippenham, the UK.
The quest to make iron and steel production more sustainable
Making iron produces huge amounts of carbon emissions, but a Tufts University, Massachusetts, US chemist thinks there is a better way. Instead of using coal-derived coke in the process of smelting iron ore, he proposes substituting hydrogen-rich ammonia, which would drastically reduce the carbon footprint for the widespread industrial process, and finding a way to make it commercially viable.
Study finds metals actually get stronger when hot
The unexpected finding could be important for designing spacecraft shielding or in high-speed machining applications. Metals get softer when they are heated, which is how blacksmiths can form iron into complex shapes by heating it red hot. And anyone who compares a copper wire with a steel coat hanger will quickly discern that copper is much more pliable than steel.
US to control export of metal Additive Manufacturing technologies
The US Bureau of Industry and Security (BIS), a government entity focused on export control and treaty compliance, has issued a ruling regarding the exportation of advanced manufacturing technologies, including Additive Manufacturing equipment and software.
Europe’s automakers are increasingly vocal about the challenges they face in meeting the EU’s stringent decarbonisation targets
Europe’s automakers are increasingly vocal about the challenges they face in meeting the EU’s stringent decarbonisation targets, citing growing concerns over economic uncertainty, consumer reluctance to adopt electric vehicles (EVs) and shrinking production margins, according to Fastmarkets website.
Nano Dimension agrees to buy Desktop Metal for as little as $135 million. Also announces deal to acquire Markforged for $115 million
The combined Nano Dimension-Desktop Metal-Markforged company would have revenue of $340 million based on fiscal year 2023. The Israeli 3D printer maker plans to purchase the American company that has seen its valuation plummet since reaching more than $5 billion in 2021.
Accelerating product development in investment casting
Customers for investment castings appreciate the precision and detail the process provides, but keep asking for more. In response, foundries are implementing new techniques and technologies that cut lead time and costs while improving quality and expanding capabilities. Here’s a look at what’s new and what’s coming.
Federacciai addresses key challenges for future of steel
The situation with the scrap shortage in Italy and Europe will get worse. The growing share of electric arc furnace (EAF) steel production in the EU and globally will lead to an increase in demand for this raw material, especially for high-quality steel. This was stated by Antonio Gozzi, President of the Italian steelmakers’ association Federacciai, during the organisation’s annual meeting.
August 2024
WFO acknowledges Best Young Foundry Researchers and Early Career Professionals 2024
The foundry industry was able to meet some of the best young foundry researchers identified in USA, Finland, Japan, Spain, China, India and Germany through a competition organized by The WFO (World Foundry Organisation). The WFO announced the 2024 Best Young, Foundry Professionals as a result of the final stage of the Young Researchers Conference that took place in Germany in June 2024.
South Africa a major transit hub for illegal bullion exports
Swissaid has shone the spotlight on South Africa for its role as a major transit hub for illegal bullion exports from the region with over $35 billion (R657 billion) worth of gold smuggled out of Africa. Switzerland-based Swissaid runs development policy projects and raw materials is a focus area.
Swiss Steel Group relies on precise data for sustainable steel production from scrap
The Swiss Steel Group, one of the market-leading producers of steel on the electric arc furnace route, emphasises the importance of precise data in sustainable steel production. With over 2.2 million tons of scrap processed each year, the company is not only one of the largest recycling companies in Europe, but also a pioneer in the production of green steel.
Saint Gobain PAM switches to induction technology – with ABP Induction
Switch to induction: 62% less CO2, 80% less water consumption. It is a milestone for Saint Gobain PAM, a lighthouse project for the French industry, and a showcase project for ABP Induction: In Foug, France, an old cupola furnace system is being decommissioned and replaced by a more climate-friendly induction furnace system from ABP Induction.
US Army foundry completes multi-ton casting using multiple 3D printed sand mould components
The US Army’s Rock Island Arsenal-Joint Manufacturing and Technology Centre reported it completed the largest pour of molten metal in at least two decades – 7 125 lbs. or more than 3.5 tons – in June 2024, at the manufacturing centre in Rock Island, IL. The completed casting consists of 16 separate pieces that form a “pintle system” for a Pennsylvania lock and dam project by the US Army Corps of Engineers.
Tesla abandons revolutionary gigacasting manufacturing process – report
A new technique from Tesla designed to drastically cut vehicle manufacturing time and cost is said to have been scrapped, adding to the latest drama from the electric-car company. Tesla has reportedly taken a step back from a new manufacturing technique which has been widely touted as being revolutionary for the automotive industry.
BMW Group makes further investment in Plant Landshut
BMW Group Plant Landshut is continuing to ramp up production capacity – by expanding the manufacturing facilities for the central housing of the highly integrated electric drive unit to be fitted in Neue Klasse models. The BMW Group is investing a further €200 million to this end, bringing the total channelled into the German factory site since 2020 to around €1 billion.
Scrap metal collector found attempting to dismantle bomb in scrap yard
A scrap metal collector was allegedly found with a mortar bomb in a scrap yard in Phoenix north-west of Durban, KwaZulu-Natal, according to an IOL News report. In a statement released by Reaction Unit South Africa (RUSA), it was said that the bomb was brought to the scrapyard by a patron who was found attempting to disassemble it.
European foundry industry records third consecutive month of growth
In March 2024, the European Foundry Industry Sentiment Indicator (FISI) experienced another increase, up to 95.8 index points, says the European Foundry Federation (EFF, formerly CAEF). This development reflects the third consecutive increase for the FISI, the index experiences an increase of 1.8 points, settling at 95.8 compared to 94.0 in the previous month.
June 2024
Metal casting with 3D printing
During the 2024 AMUG Conference, David Moodie of Foundry Lab and Cameron Peahl from Eaton Additive Manufacturing Center of Excellence discussed using new technology in manufacturing, particularly in die-cast metal production. Moodie shared his experience as a startup founder, highlighting the challenges of producing diecast metal, including the need for a fast and efficient system.
Chemex celebrates 50 years
From its beginnings in 1974 to its current technical solutions, the company can look back on an impressive success story. Starting out as a supplier to Friedrich-Carl-Hütte in Delligsen, Germany also known as ‘Carlshütte’, the former Chemex GmbH has developed into a leading specialist for feeding technology under the umbrella of Hüttenes-Albertus.
Israeli company Magnus Metal raises Series B Funding to transform metal part casting with its revolutionary Digital Casting technology
Magnus Metal has developed the Digital Casting, which blends the benefits taken from both Additive Manufacturing (AM) and traditional casting, while avoiding the typical associated deficiencies. This enables a streamlined supply-chain, digital inventory and remote manufacturing hubs.
Scrap metal smuggling could cripple East Africa’s infrastructure
On 11 January 2022, Nairobi was plunged into darkness after Kenya Power lost supply along the Kiambere-Embakasi high voltage transmission power line. Vandals in search of scrap metal had removed cross beams on the angle towers, causing the towers to collapse.
Project set to develop aluminium shape casting for aerospace components
A project aimed at developing geometrically complex castings using aluminium shape casting has been awarded £2.07 million of grant funding from the Aerospace Technology Institute (ATI) programme. According to Kirkbymoorside, North Yorkshire, UK headquartered Sylatech, aluminium shape casting for aerospace components is under exploited due to concerns over process and product consistency, plus mechanical performance.
AFS announces 2024 casting of the year competition winner
A Midwestern corporate-member iron foundry with a reputation for producing complex castings has been crowned winner of the prestigious 2024 AFS/Casting Source Casting of the Year competition. St. Marys Foundry (St. Marys, Ohio) captured the overall title in this year’s contest, which attracted submissions of remarkable castings from metalcasters throughout North America.
New radar solution for level measurement of liquid metal
OndoSense is expanding its portfolio in the metal industry. The German radar specialist has developed a sensor solution for the level measurement of molten metal with unprecedented precision and stability. The robust and low-maintenance radar system reliably measures steel, aluminium, or copper levels at temperatures up to 1 600 degrees, even in the presence of dust, fumes, smoke, vibrations, or sparks.
Synthetic diamonds grow in liquid metal at ambient pressure
The usual way of manufacturing synthetic diamonds involves applying huge pressures to carbon at high temperatures. Now, however, researchers at the Institute for Basic Science (IBS) in Korea have shown that while high temperatures are still a prerequisite, it is possible to make polycrystalline diamond film at standard pressures. The new technique could revolutionise diamond manufacturing, they say.
Making steel with electricity
MIT spinout Boston Metal is commercialising a new method for making steel and other metals, to help clean up the emissions-intensive industry. Steel is one of the most useful materials on the planet. A backbone of modern life, it’s used in skyscrapers, cars, airplanes, bridges, and more. Unfortunately, steelmaking is an extremely dirty process.
April 2024
ASK chemicals group announces Luiz Totti as new CEO
ASK Chemicals Group, one of the world’s leading suppliers of foundry chemicals and a global supplier of high-performance industrial resins, announces Luiz Totti as the new CEO of the Group, effective immediately. Luiz Totti has been with ASK Chemicals for more than 11 years, having demonstrated remarkable leadership and vision during his tenure with the company.
MetlSaw integrates with the Inductotherm Group
MetlSaw Systems is set to leverage the extensive resources and global network of the Inductotherm Group with the announcement that it has been acquired by Inductotherm. This partnership aims to enhance MetlSaw’s capabilities in providing innovative sawing solutions, while expanding its reach to new markets and industries worldwide.
Metso to discontinue its foundry operations in Prerov, Czech Republic
After a careful evaluation of future options for its foundry in Prerov, Czech Republic, Metso has decided to discontinue operations at the site. The decision is based on fundamental changes in the market environment, which have negatively impacted the foundry’s competitiveness.
ABP Induction: 120 years of induction furnace construction and 95 years on the Dortmund site
ABP Induction is celebrating two special events this year. 120 years ago, the first induction furnace was built by the predecessor company ASEA. And for 95 years, industrial furnace construction has been based at the Dortmund, Germany site under the same roof as ABP Induction and its predecessor companies.
SSAB launches world’s first emission-free steel powder
SSAB is today launching the world’s first emission-free steel powder for commercial deliveries, made of recycled SSAB Zero steel. The product will create opportunities for customers to 3D print their unique designs in steel produced without fossil carbon dioxide emissions. The powder combines the properties of SSAB’s high-strength steel with the light structural possibilities of 3D printing.
VDMA Metallurgy: Till Schreiter takes over chairmanship of the board of the specialist association
The VDMA Metallurgy board has elected Till Schreiter, CEO of ABP Induction Systems GmbH, as the new Chairman with immediate effect. Schreiter succeeds Dr Ioannis Ioannidis, who retired from his active career at the Frech Group at the end of 2023 and thus also relinquishes the chairmanship of the specialist association.
Bruker acquires Japanese technology leader in research Raman microscopy
Bruker Corporation has announced the acquisition of Nanophoton Corporation, a pioneer focused on advanced research Raman microscopy systems. Headquartered in Osaka, Nanophoton offers a broad portfolio of advanced Raman microscopes, serving academic and industrial research customers, primarily in Japan. This acquisition fills a gap in Bruker’s molecular microscopy portfolio.
Canada will require melt and pour information for steel imports
Global Affairs Canada announced that Canada will make its steel supply chain more transparent by collecting and publishing more information on steel imports, notably on “country of melt and pour” information. As part of a phased-in approach, steel importers now have the option under Global Affairs Canada’s Steel Import Monitoring Programme to provide country of melt and pour information to the Canada Border Services Agency through customs declarations.
Refractories manufacturer Rath acquires 33% stake in Avanee Refsol India
The Rath Group has announced it has acquired 33% stake in Avanee Refsol India as part of its Evolution 2030+ strategic growth plan. Production is being set up in Visakhapatnam (state of Andhra Pradesh) together with the partners of Avanee Refsol. Production is scheduled to start at the beginning of 2025. An annual capacity of 20 000 tons of refractory products is projected in a two-stage plan.
German aluminium industry: More common sense needed in economic policy
The statement comes alongside Aluminium Deutschland’s concern that over-regulation, high energy costs, and economic recession could impact Germany’s future as an industrial location for aluminium – calling for more “common sense” in economic policy developments going forward.
Aluminium beverage can recycling in 2021 at a new record level of 76%
Aluminium beverage can recycling achieved a new record level of 570 000 tons, saving 4.7 million tons of CO2eq. The latest report by Metal Packaging Europe and European Aluminium shows that the overall recycling rate for aluminium beverage cans in the European Union, United Kingdom, Switzerland, Norway and Iceland went up by 3.2% to a new record level of 76.1%.
Iron foundry aims to reduce natural gas consumption by 25% using heat recovery
The Danish iron foundry, BIRN, aims to reduce its natural gas consumption by around 25 per cent by this year. The reason is the recirculation from two new heat recovery plants that utilise the excess heat from parts of BIRN’s production to heat the rest of the company. BIRN has invested in two new heat recovery systems that retain heat in parts of the iron foundry’s production facilities.
Striking gold: BHP overtakes Glencore as world’s most valuable Mining, Metals & Minerals brand
This year, more than half of the brands in the ranking of the world’s most valuable and strongest Mining, Metals & Minerals brands witnessed an increase in brand value, according to new data from Brand Finance, the world’s leading brand valuation consultancy. This year, 11 brands from the US, China, and South Korea entered the ranking.
Researchers demonstrate rapid 3D printing with liquid metal
Their new technique can produce furniture-sized aluminium parts in only minutes. MIT researchers have developed an additive manufacturing technique that can print rapidly with liquid metal, producing large-scale parts like table legs and chair frames in a matter of minutes. Their technique, called liquid metal printing (LMP), involves depositing molten aluminium along a predefined path into a bed of tiny glass beads. The aluminium quickly hardens into a 3D structure.
February 2024
The Bright World of Metals expands global network to include ANKIROS/TURKCAST and ALUEXPO
The Messe Düsseldorf Group expands its global network in the growth market Türkiye winning over three powerful new events for its global metal trade fair portfolio with the leading Eurasian metallurgy, foundry and aluminium trade fairs – ANKIROS/TURKCAST and ALUEXPO.
Otto Junker to celebrate its 100th anniversary
Otto Junker, a German company specialising in developing systems for metallurgical processes and refining metals, can reflect positively on its performance in 2023. Having made a convincing impression at trade shows, formed new partnerships and received innovative orders, the business is looking to further expand its role in the technology industry.
LK Dreampress 16 000 ton die-casting machine unveiled
LK has launched its Dreampress 16 000 ton die-casting machine. This unveiling marked a historic milestone in the world of die-casting and manufacturing, as the Dreampress 16 000T sets new industry standards, reaffirming LK’s position as one of the global leader in the field die-casting machinery, in the wake of the successful launch of the Dreampress 12 000T in 2022.
Advantages of sand reclamation
In the world of foundry operations, sand reclamation plays a pivotal role in the pursuit of cost-efficiency, environmental sustainability, and improved product quality. One critical innovation in this field is the Simpson Pro-Claim®, a cutting-edge sand reclamation system that has been making waves due to impressive fiscal impacts. Let us explore how the Simpson Pro-Claim is transforming the landscape of sand reclamation.
Hüttenes-Albertus’ CEO Christoph Koch gives his views on the many current challenges such as high energy costs, overwhelming bureaucracy and production migration in Germany
“We have far too many regulations. Germany will only remain viable for the future if the government finally stops this bureaucratic madness.” He also gave his views on the many current challenges such as high energy costs, overwhelming bureaucracy and production migration in Germany.
Planning begins on development centre in sustainable casting for increased competitiveness for the Swedish manufacturing industry
Through a letter of intent between RISE and Volvo Cars, the Volvo Group and Scania, work has begun on the planning of a national centre for sustainable casting for new sustainable materials, technologies and processes in the manufacturing industry. The background to the initiative is the development that is taking place in high-pressure die-casting, so called, Mega-casting.
EU has extended its suspension of tariffs on US products, in the context of the steel and aluminium, as part of the Section 232 dispute
Customs duties are suspended until 31 March 2025. The EU has suspended duties on US products until 31 March 2025, in the context of the steel and aluminium dispute. This is stated in the message of the European Commission.
Bühler to deliver four Carat 920 mega-casting cells to Duoli in China
Chinese car parts supplier Duoli Technology and Swiss technology company Bühler Group have signed a new contract for the delivery of four new Carat 920 mega-casting cells. The deal represents one of the largest single orders for Bühler Group’s mega-casting business and is testament to the accelerating trend towards the production of large structural car parts for electric vehicles.
ABK Pressenbau und Automation develops hydraulic trimming press for mega-castings
German supplier ABK Pressenbau und Automation, working with Aulbach Trimming Technology, has developed a hydraulic trimming press for ‘mega-cast’ parts. Mega-casting, or giga-casting, is the high-pressure die-casting process now emerging for producing large-dimension, unitary components for automotive structures.
New IAI study reveals environmental benefits of increased global aluminium can recycling
A new study on recycling of aluminium cans has identified that 60 million tons of CO2e per annum could be saved through effective global recycling of used beverage cans by 2030. The study was commissioned by the International Aluminium Institute and co-funded by Emirates Global Aluminium, Crown Holdings, Australian Aluminium Council and Novelis.
Aston University receives EPSRC grant to improve liquid metal casting
The mathematical method aims to help prevent lightweight aluminium alloys corroding – or oxidating – very quickly when first exposed to air. The researchers said that, within the transportation sector, steel is gradually being replaced by ‘functionalised energy-efficient lighter alloys’, with the aim of lessening the CO2 emissions of the metallurgy industry.
New 3D printer uses liquid metal to print furniture and other large objects
Researchers from MIT have developed a new kind of 3D printer that squirts out liquid metal to rapidly produce big objects like components for furniture. The system deposits molten aluminium through a path of tiny glass beads not unlike a mould. To demonstrate, the team created sturdy parts like chair legs.
Japan’s SLIM lands on Moon with help from metal Additive Manufacturing
The Japan Aerospace Exploration Agency (JAXA)’s Smart Lander for Investigating Moon (SLIM) has landed on the moon, making Japan only the fifth nation to successfully reach the lunar surface. Playing an essential role in protecting the spacecraft from the impact of the lunar landing, metal Additive Manufacturing was used to produce the shock absorber structures found on the tip of each leg.
GF Casting Solutions showcases their high-pressure die-casting capabilities
The automotive casting industry is in transformation. Driven by advancing technology, components become bigger and bigger. Big castings offer numerous advantages, including cost and time savings in vehicle production, integration of functionality, and the reduction of overall vehicle weight. New vehicle architectures open doors for innovative ideas and even more development projects.
Metso invests EUR 8 million on a DRI smelting furnace pilot facility
Supporting decarbonisation of the iron and steel industry. Metso is expanding its testing capabilities by investing EUR 8 million to build a state-of-the-art DRI (direct reduced iron) Smelting Furnace pilot facility. The pilot plant will be constructed in Pori, Finland, where Metso has one of its major R&D Centres serving the minerals and metals industry.
analytica and ceramitec 2024 in parallel – added value for exhibitors and visitors
From April 9 to 12, 2024, analytica, the world’s leading trade fair for laboratory technology, analysis and biotechnology, and ceramitec, the world’s leading trade fair for the ceramics industry, will be held in parallel at the Munich Exhibition Center. That will create added value for exhibitors and visitors at both events, as the entire value chain from material development to analytical precision will be covered.
New name for European foundry association
The European Foundry Association, CAEF, marked a transformative milestone at its annual council meeting, held recently in Sofia, Bulgaria. The meeting, attended by representatives from leading foundry associations across Europe, sees the adoption of critical decisions made to reshape the association’s future.
December 2023
Tesla is working with multiple 3D printed sand casting companies
Tesla is trying to master the art of casting large, complex car parts in one go. If it succeeds, it will change how cars are made, making it faster and cheaper to produce electric vehicles (EVs). According to a Reuters report, five people familiar with Tesla’s plans revealed that the company aims to revolutionise the traditional, complicated, time-consuming, and expensive process of creating large components.
General Motors acquires Tesla 3D printed mould supplier Tooling & Equipment International
General Motors (GM) has recently acquired Tooling & Equipment International (TEI), a significant supplier to Tesla in the area of gigacasting, a process for casting large car body parts in one piece. This move is seen as a strategic effort by GM to enhance its manufacturing efficiency and compete more effectively with Tesla.
Toyota will adopt Tesla-style cast bodies that might be impossible to fix
Toyota has reportedly demonstrated a prototype production line for a cast car chassis, made by a process sometimes referred to as “gigacasting.” The new manufacturing technique may offer significant production advantages, but could hand consumers the short end of the stick when it comes to the castings’ repairability.
voxeljet and Loramendi jointly developed a fully-automated serial additive production solution for inorganic 3D printed cores as part of the Industrialisation of Core Printing (ICP) cooperation project
voxeljet showcases its next-gen 3D printers VJET X in action at BMW group. With 10x faster performance, the new 3D printers are integrated into a fully automated additive production line.
Ford, Hyundai test Tesla supplier’s Giga Press
Tesla has pioneered the use of massive casting machines known as Giga Presses to make large single pieces of vehicle underbodies. Idra, the Italian aluminium casting machine manufacturer and Tesla supplier, has added Ford, Hyundai and another European company to its customer base as more automakers explore this manufacturing technique.
Japan International Cooperation Agency (JICA) supports skills development – inaugurates Kimura Foundry’s Casting Training Course in Bengaluru
Japan International Cooperation Agency (JICA) is supporting the skill development programme in the Indian casting industry through the launch of the Kimura Foundry Casting Training Course at Karnataka German Technical Training Institute (KGTTI) Bengaluru.
SMS group to build new electric arc furnace for SSAB for fossil-free steel production
SMS group has secured the contract from Nordic steelmaker SSAB to engineer, deliver and construct a new electric arc furnace (EAF) for steelmaking at SSAB’s site in Oxelösund, Sweden. The scope of supply includes a 190-ton Alternate Current-Electric Arc Furnace (AC-EAF) capable of processing various raw materials, including fossil-free Direct Reduced Iron (DRI) or Hot Briquetted Iron (HBI), and scrap.
The 75th World Foundry Congress (WFC 2024)
The 75th World Foundry Congress (WFC 2024), hosted by the World Foundry Organisation (WFO), will be held in Deyang, China from 25 to 30 October 2024. The conference will take place in the Deyang Wende International Convention and Exhibition Centre, Sichuan, China. The World Foundry Congress is held every two years.
Ferrous scrap consumption declining in 2023
Trade group BIR says even China, where steel output was up in the first half of the year, is melting less scrap, according to a report in Recycling Today. Global steelmaking and ferrous scrap recycling figures for the first half of this year portrayed a tepid market when presented to attendees of the Bureau of International Recycling (BIR) Ferrous Division session in October in Abu Dhabi, United Arab Emirates.
Ceba and Kanthal in strategic partnership for the green shift – focus on electric ladle and tundish preheaters
The steel and metal industry’s quest to decarbonise production requires new solutions for heating processes such as ladle and tundish preheating. A new strategic partnership between Kanthal, a global leader in industrial heating technology, and Ceba, an expert in equipment for ladle and tundish preheating and drying, aims to offer sustainable electric solutions for these processes, advancing the green technology shift.
Secondary copper production based on scrap infeed has risen by 7.5 per cent year on year nine months into 2023
The ICSG’s (International Copper Study Group) report covering September 2023 says secondary copper production based on scrap infeed has risen by 7.5 per cent year on year nine months into 2023, according to a report in Recycling Today. According to ICSG, that rate of increase is above that for global primary refined copper production, which rose by about 4.8 per cent in the first nine months of 2023.
The 16 largest pig iron producing countries
According to Yahoo Finance South Africa sits at number 16 in the ranking. Production of pig iron in 2022 was 2.4 million metric tons. South Africa produced 17.5% less pig iron in 2022 as compared to 2021. This is mainly due to the inefficiency of the state-owned railway operator. Most of the iron ore and coal in the country is transported by rail and so producers had to hire trucks to transport raw material, leading to an increase in the cost of logistics.
Acetarc acquires the assets of A1 Roper
In August, molten metal pouring and handling specialist Acetarc acquired the assets of A1 Roper, the latter company having ceased trading at the end of February 2023. The move signals the end of a rivalry between the two companies that dates back to the early 1970s when Acetarc was “the new kid on the block” in terms of foundry ladle suppliers.
October 2023
Toyota gigacasting prototype cuts production from hours to minutes
Die casting tech aims to streamline assembly in preparation for EV shift. Toyota Motor showed off a prototype of its new gigacasting equipment that can make a third of a car body in about three minutes, a development that will be key to its plans to ramp up electric-vehicle production profitably in the coming years.
How the BMW Group uses ExOne binder jetting technology to virtually eliminate emissions at its Landshut Light Metal Foundry
The company is using 4 ExOne Exerial systems to cast the Series 3 engine cores. It is no secret that the BMW Group is a major first adopter of multiple AM technologies. A few weeks ago, the company revealed that it is using voxeljet’s VJET X technology, streamlining highly automated core and mould production.
Tesla reinvents car making with quiet breakthrough
Tesla has combined a series of innovations to make a technological breakthrough that could transform the way it makes electric vehicles and help Elon Musk achieve his aim of halving production costs, five people familiar with the move said, according to a Norihiko Shirouzu Reuters report in September 2023.
Robots vs. CNC for automated metal additive manufacturing
3D scanning aids robotic removal of AM part supports. The use of metal additive manufacturing has revolutionised the manufacturing industry, allowing for the creation of complex and intricate parts in a faster and more cost-effective manner. However, essential post-processing of these parts introduces time and financial constraints to the overall cost-per-part that can negate the benefits of AM altogether.
The future of work with AI-driven cobots beyond automation
Imagine a world where work is not bound by limits, where humans and artificial intelligence join forces to create a new era of productivity. Welcome to the realm of AI-driven cobots – the future of work. These collaborative robots are revolutionising the way we think about automation.
CAEF Report: European foundry industry faces headwinds as index declines in August 2023
The European Foundry Industry Sentiment Indicator (FISI) has recorded a decline, marking a shift from the positive trend observed in July 2023. With a decrease of 3.2 index points, the index now stands at 96.0, down from 99.2 last month. Currently, a key challenge facing the European foundry industry is the shortage of new orders.
Rheinmetall wins three-digit million-euro order to supply structural parts for a fully electric vehicle made by a premium automaker
Technology group Rheinmetall has won a new order from the automotive industry worth a low three-digit million euro amount for structural components. The highly complex castings will be used in a fully electric platform of a well-known international car manufacturer in the premium segment.
Recycling of refractory materials avoids 800 000 tons of CO2
In the European research project ReSoURCE, experts from nine different companies and institutes are working together to develop sustainable solutions for the recycling of refractory materials. The German project partners are primarily providing laser know-how.
SinterCast breaks four million engine equivalent milestone
SinterCast set a series production all-time high of 4.1 million engine equivalents in June, surpassing the four million engine equivalent milestone for the first time. This followed production of 3.9 million engine equivalents in May, marking an end to the variable production that affected the first four months of the year.
August 2023
Toyota unveils new technology that will change the future of cars
Pioneering the future with the power of technology, centred on innovative battery EV technology and the establishment of a hydrogen business. Toyota Motor Corporation (Toyota) recently held a technical briefing session, “Toyota Technical Workshop,” under the theme “Let’s Change the Future of Cars” and announced a variety of new technologies that will support its transformation into a mobility company.
ASK Chemicals sets out sustainability strategy and goals to reduce environmental impacts
ASK Chemicals Group, a global supplier of high-performance industrial resins and materials, has announced its sustainability strategy and targets. On the way to climate neutrality in 2050, ASK Chemicals will steadily reduce its greenhouse gas emissions, such as by decreasing its Scope 2 emissions by 30% until 2030. As part of its sustainability strategy, the company is continuously working to improve its environmental footprint, for example by implementing closed water cycles.
Are lasers the new standard for brake disc manufacturing?
Avoiding the emissions of fine dust is important, and a cladding process that reduces abrasion may offer the right approach as series testing with automakers are demonstrating now. Foundries and die casters can never be sure where the next process or material challenge will come from, particularly in an automotive industry hooked on the appeal of new consumer products and process technologies – an atmosphere ripe for product and supplier displacement.
Voxeljet launches new cold IOB (Inorganic Binding) 3D printing technology
Voxeljet AG presented a ground-breaking innovation at GIFA 2023: The new cold IOB (Inorganic Binding) 3D printing technology. With this unique process, moulds and cores for the foundry industry can be produced from sand and an inorganic binder without the need for microwave treatment. For voxeljet, this year’s GIFA was all about inorganics. In addition to the joint project ICP (Industrialisation of Core Printing) with Loramendi for BMW, the Bavarian company also presented a new, patent-pending, cold-curing inorganic process technology (cold IOB).
June 2023
Rolls-Royce has completed the first ground tests on its massive UltraFan engine
Rolls-Royce has completed the first ground tests on its massive UltraFan engine, claiming it’s at least 10% more efficient than any other large aero engine in service today. This carbon/titanium beauty will roll out on airliners in the 2030s. The initial demonstrator tests have been completed at the world’s biggest jet engine testbed.
Kanthal and Rath announce strategic partnership to expand sustainable industrial heating technology offerings
Kanthal and Rath have announced a strategic partnership to expand their combined offering in industrial heating technology. Through close collaboration, their offerings will enable industries, such as steel and petrochemical, to make the green shift. Kanthal products focus on industrial electric heating technology and Rath in high-temperature refractory products.
Stratasys, Desktop Metal merger creates industrial 3D printing ‘powerhouse’
3D printing companies Stratasys Ltd and Desktop Metal Inc announced that they have entered into a definitive agreement to combine the companies via an all-stock transaction valued at approximately $1.8 billion. Described by Desktop Metal co-founder and CEO Ric Fulop as a ‘turning point in the next phase of additive manufacturing for mass production.’
e-mobility: Steel and aluminium in a smart material mix
Casting trends in the automotive industry will feature among the crucial focal themes of the world’s leading foundry trade fair GIFA held as part of the Bright World of Metals in Düsseldorf from 12th to 16th June 2023, writes Gerd Krause, Mediakonzept Düsseldorf.
BMW Group has taken factory planning to new heights: Virtual production
The BMW Group has taken factory planning to new heights – setting the latest milestone in the digitalisation of automotive manufacturing. More than two years before the official launch of series production, vehicle manufacturing is already underway in the future plant Debrecen, virtually, at least, as Debrecen is the BMW Group’s first facility to be planned and validated completely virtually.
April 2023
Metallic raw materials – the building blocks of the circular economy
Disrupted supply chains during the Covid pandemic and the dependencies on countries such as China have placed the issue of secure raw material supplies on the agenda. The war in Ukraine and the resulting economic sanctions against Russia have additionally fuelled the debate about supply security and the circular economy.
One of the world’s largest industrial decarbonisation projects gets underway
Germany’s biggest steelmaker has placed an order with SMS, Düsseldorf, for the engineering, delivery and construction of the EUR 1.8 billion facility. The plant will have a capacity of 2.5 million tons of directly reduced iron (DRI) and is scheduled for completion by the end of 2026. The overall project remains subject to European Union approval under state aid provisions.
ASK Chemicals saves 1 200 tons of CO2 through sustainable measures at Wülfrath site
ASK Chemicals, a global supplier of high-performance industrial resins and materials, has implemented successful measures to save gas and electricity at its European flagship plant in Wülfrath, Germany in 2022. Thanks to targeted optimisation measures, the Wülfrath plant has succeeded in saving 5 million kWh of gas and 368 000kWh of electricity.
German scrap exports hit lowest level since 2009
Ferrous scrap exports from Germany decreased significantly in 2022, according to data from the German federal statistics office. In January-December, shipments totalled 7.7 million tons, down 14% on 2021, Kallanish notes. This was the lowest export volume since the economic and financial crisis of 2009, say local experts.
Metso Outotec to continue Prerov foundry operations in Czech Republic
Metso Outotec has concluded the evaluation process of its Prerov foundry in Czech Republic, announced in November 2022. After carefully evaluating multiple options and their implications as well as the market outlook, the company has decided to continue the foundry’s operations.
Laempe Mössner Sinto will demonstrate its complete portfolio at GIFA 2023
Laempe Mössner Sinto GmbH will demonstrate its complete portfolio of solutions for core making technology at GIFA 2023. As a full-service provider, Laempe offers a wide range of products from the design to the construction of turnkey plants: core shooters, including gassing units, core sand mixers, automation and robotics solutions as well as automated visual and quality inspections.
ASK Chemicals presents new developments for more sustainability and efficiency at GIFA 2023
ASK Chemicals, one of the leading suppliers to the global foundry industry, will present its latest innovations for greater sustainability and efficiency from 12 to 16 June 2023 at GIFA 2023. At the industry’s key event the expert for foundry chemicals will present its range of environmentally friendly solutions.
UAE Metallurgy and Foundry Industry poised to grow by over 3 per cent, estimated value to reach nearly $10 billion by 2025
In the backdrop of the accelerated energy transition to achieve the Net Zero goal by 2050 as well as the exponential growth in infrastructure development and construction activities in the UAE, the minerals and metals industry is estimated to grow at a rate of over 3 per cent, touching an estimated value of nearly US$10 billion by 2025.
BMW’s closed-loop recycling of production scrap from casting processes at its light metal foundry in Landshut
Global automaker includes procuring recycled-content materials when describing its sustainability efforts. BMW is pointing to recycling activities at its aluminium foundry in Landshut, Germany, as a reason it is setting and meeting sustainability targets within the automotive industry.
February 2023
Advancing foundry digitalisation: Norican’s Monitizer and ABP’s Digital Services agree to interface their products
Monitizer, part of Norican Group (DISA, Simpson Technologies, Wheelabrator, StrikoWestofen and ItalPresseGauss), and ABP Induction Systems have agreed to build links between their digital systems. The two foundry suppliers will now collaborate to create an interface that will share furnace data from ABP Digital Services with the Monitizer® Suite from Norican.
World’s largest non-contact robot measuring cell inaugurated at Siempelkamp Foundry
Together with its project partners, Zeiss Industrial Quality Solutions, and precision metrology services provider a3Ds, the Siempelkamp Foundry recently presented the world’s largest non-contact robot measuring cell. As a world first, the new robot measuring cell is the special pride of one of the world’s leading hand-casting manufacturer. It allows for the fully automated, non-contact and reliable inspection of finished components up to a weight of 240 tons.
Zimbabwe bans all lithium exports
Is there some resource nationalism starting to take place in Africa? The African continent is seeing a shift in its economic landscape, with Zimbabwe recently banning all raw lithium exports after the government said it was losing €1.7 billion from exporting it as a raw mineral and not processing it into batteries in-country. Lithium is a mineral used as a component in electronic batteries for mostly cars, cellphones and computers.
Barnes Group to increase Scaw’s steelmaking capacity
Barnes Group CEO Doron Barnes, whose company acquired Scaw Metals, together with its Haggie and McKinnon Chain units in May 2018, has announced in an Engineering News article that it is to invest in new steel making plant to increase Scaw’s steelmaking capacity from about 500 000 tons per year to 650 000 tons per year.
WATCH: Tesla releases impressive footage of robot pulling still smoking casting from Giga Press
Tesla has released impressive new footage of one of its robots pulling a still smoking large casting part from one of its Giga Press machines. This new casting approach from Tesla is going to be critical for the future of the company and especially new vehicle programs like the Cybertruck.
Critical replacement castings delivered fast with sand 3D printing
Critical replacement parts and difficult-to-source castings often suffer from the long lead times, most caused by the wait to procure traditional patterns or core boxes. The expensive acquisition of tooling machined from wood or metal for low-volume or one-off pours is often not cost effective.
GF Casting Solutions releases a new show car to demonstrate their capabilities
The reduction of CO2 emission is the key challenge of the global automotive industry. These include alternative drives or the reduction of fuel consumption and emissions in a combustion engine. After several months of part selection, 3D design, building, and several engineering changes, GF Casting Solutions show car is finally ready at their plant in Suzhou, China to be viewed.
December 2022
Call for Papers to be presented at the VDMA Thermprocess Forum in Düsseldorf from 12 to 16 June 2023
The VDMA have sent out an advisory of a Call for Papers to be presented at the VDMA Thermprocess Forum. Contributions on the topics of energy transition, energy-efficiency and sustainable thermoprocessing technology are wanted. 12 to 16 June 2023 will see the world’s leading trade fairs GIFA, METEC, THERPROCESS and NEWCAST open their doors in Düsseldorf, Germany again.
Simpson Technologies joins Norican Group
Acquisition of sand preparation expert complements global offering. The Norican Group, home to DISA, ItalPresseGauss, StrikoWestofen and Wheelabrator, has acquired US-based Simpson Technologies, experts in equipment for the mixing, cooling, handling, reclamation and analysis of sand. The 110-year-old family business is based in Aurora, Illinois, with subsidiaries in Germany and India.
Metso Outotec to evaluate the future of its Prerov foundry in Czech Republic
Due to increased energy and production costs, Metso Outotec is initiating a process to evaluate the options for the future of its foundry in Prerov, Czech Republic. The options include a partial or full divestment of the foundry or a potential closure. The Prerov foundry produces metallic wear parts for Metso Outotec’s mining customers. The foundry is at a logistical disadvantage in supplying customers.
Iron ore and steel among industries that were hit hard in the last recession
According to data from the last recession iron ore prices, steel production and sales of iron, steel and ferroalloy could be badly affected in another economic downturn. Bloomberg recently updated its prediction on the likelihood of the US experiencing a recession. In July the forecasters at the company had given a 38% chance of a financial crisis, but just three months later this increased to a 100% likelihood.
German SMEs 3D print metal parts ‘economically’
A German business and research group have realised an ambitious goal: to industrialise additive manufacturing – and economically – for both OEMs and SMEs. The Fraunhofer Institutes for Laser Technology (ILT) and Production Technology (IPT), industry partners and RWTH Aachen University launched the BMBF joint project “IDEA – Industrialisation of Digital Engineering and Additive Manufacturing”, three years ago.
Application of reverse engineering in the development of moulds in patternless manufacturing technology
The production of prototype moulds by traditional manufacturing technologies is time-consuming and financially unsustainable. To speed up the manufacturing of prototype moulds various techniques have been developed to produce a mould without using the existing model. One of the hottest techniques that currently used in modern foundries is the method of reverse engineering.
One of the world’s largest white iron foundries is open for business
Capable of producing 18 000 tons of white iron per year and turning out efficient slurry pumps and parts that can weigh up to 27 tons, the new KSB foundry is at the end of a more than a US$100 million capital investment, according to an article in Mining Technology. April 2022 saw the second stage of the large white iron material manufacturing and handling project that GIW Industries, Inc. (now a part of KSB Mining) had begun building in early 2014, end.
Foundry workers given ‘robotic’ glove to improve grip and protect hands
Waupaca Foundry in the US is using an innovative adaptive technology to support workers who manually grind iron castings in the foundry. The “Ironhand” glove is claimed to be the world’s first soft exoskeleton designed for the human hand to improve grip strength and reduce effort. The system was tested at the iron casting foundry’s Etowah, Tennessee casting finishing plant and is currently in trials at the Marinette, Wisconsin ductile iron foundry.
Iron foundry creates WWII Holy Roller tank models using original parts
An iron foundry in London is turning old parts of a WW II-era tank into model replicas to commemorate its history and raise funds for future maintenance. The report in CBC says the mini tanks are made with iron from the Holy Roller M4A2 Sherman Tank, which sits at London’s Victoria Park. “It’s been a labour of love,” said Joe Murray, president of London’s 1st Hussars Association and a retired lieutenant colonel who commanded the regiment from 1996 to 2000.
October 2022
Suppliers feel squeeze as automakers go green
As automakers become greener, suppliers are feeling the pressure of extra costs to meet their needs. The auto industry’s drive to a greener and cleaner future is a treacherous road for companies in its beleaguered supply chain. Only the strong and the shrewd may survive, says Automotive News Europe.
Castings Technology International becomes AMRC partner
Castings Technology International (Cti), has become a new partner of the University of Sheffield Advanced Manufacturing Research Centre (AMRC), recognising the ‘synergy’ between the two organisations and the value it will bring to its customers. Cti is a leading provider of production, innovation, technology, expertise and services to the cast metals sector.
Imerys SA sells off High Temperature Solutions (HTS) business in a transaction valued at approximately Euro 930 million
Platinum Equity has announced that it has entered into exclusive negotiations to acquire Imerys SA’s High Temperature Solutions business (HTS). The proposed transaction, which is subject to the fulfilment of customary closing conditions, including the information and consultation of works councils and other regulatory approvals, is expected to be completed by the end of the year.
New sculpture will commemorate men of iron that worked at Coalbrookdale Foundry
The closure of the Coalbrookdale Foundry marked the end of the cast iron industry in the area that had begun more than three centuries earlier. Now a sculpture is to be unveiled to mark the skills of the workers who triggered the industrial revolution and continued to run the works until just five years ago, says a report in the Shropshire Star.
Steel makers fear deepening crisis from energy crunch as output halted
Spiralling energy costs have forced steel makers to cut output across Europe, threatening mass plant shutdowns some warn could be permanent in a sector that employs more than 300 000 and contributes tens of billions of euros to the region’s economy. Even with four wind turbines and over 50 000 solar panels at its site in eastern Belgium, stainless steel maker Aperam has been forced to halt production as surging energy prices bite.
Researchers succeed in 3D printing one of the strongest stainless steels on the market
Steel is a metal prized for its resistance to corrosion and is used by many sectors in the 3D printing industry. As is stainless steel which is actually an inox, an alloy made of iron, chromium, and a little carbon. But are you familiar with 17-4 precipitation hardening (PH) stainless steel? This particular stainless steel is a metal that’s also known for being extremely hard, in addition to being corrosion resistant.
Rio Tinto, Shougang to collaborate on finding low-carbon solutions in the steel value chain
Diversifed miner Rio Tinto and Chinese steel producer Shougang Group have signed a memorandum of understanding (MoU) to promote research, design and implement low-carbon solutions for the steel value chain. The MoU’s focus areas include low-carbon sintering technology, blast furnace (BF) and basic oxygen furnace (BOF) optimisation, as well as carbon capture and utilisation (CCU).
August 2022
Gibela unveils its 100th train set
Train manufacturer Gibela has celebrated the handover of its 100th train set to the Passenger Rail Agency of South Africa (PRASA) in Dunnottar, Ekurhuleni. The event was lauded as an important milestone in the journey to reinvigorating the country’s rail sector. In 2013, Gibela signed a R51 billion contract to supply PRASA with 600 six-car trains for its Metrorail service. The company also has a contract to deliver post-delivery train maintenance and technical support to PRASA.
South32’s Hillside smelter and Solana work together to introduce sustainable energy in Richards Bay
South32’s Hillside Aluminium operation has partnered with Solana Energy to bring sustainable energy to one of South Africa’s most important commercial hubs. The multi-phased project will see the establishment of renewable solar power infrastructure in the Richards Bay and King Cetshwayo District economic regions.
Tesla gearing up to build Cybertruck, orders motor assembly machines
Tesla will begin full scale production of the Cybertruck more or less exactly one year from now, if everything goes to plan, although preparation for production will begin a long time in advance. There’s a new report out from Germany stating that Tesla just ordered some production machinery (from several German companies) that is apparently intended for Cybertruck production.
Desktop Metal introduces robotic Additive Manufacturing 2.0 digital casting system
Desktop Metal has announced the launch of the ExOne S-Max Flex, a scalable, large-format binder jetting system that 3D prints sand tooling, which foundries use to quickly cast complex metal designs for the aerospace, automotive and energy industries, among others.
What metal casting trends influence the market?
Metal casting trends continue to shape the market and help people improve on previous efforts. Here are several influencing the sector now and are likely to continue doing so for the foreseeable future, writes Emily Newton, the Editor-in-Chief of Revolutionised, a magazine exploring how innovations change our world.
June 2022
Toyota South Africa (TSAM) starts to re-open after intense KZN floods
The company is likely to lose about 45 000 units in production. Toyota South Africa (TSAM) has announced that it’s slowly getting back on its feet after intense floods damaged its Prospecton plant in April, but that 88% of the production vehicles that were on site at the time will be written off. Toyota SA has now resumed some operations at its Prospecton plant near Durban.
Geared for success: Ford now operates 3D printers autonomously, increasing efficiency and reducing cost
Using a mobile robot, Ford operates 3D printers autonomously. The company has filed several patents for the technology in its drive to innovate. Autonomous processes enables the 3D printer to run continuously with no human interaction needed, increasing throughput and reducing cost of custom-printed products.
Researchers unveil a secret of stronger metals
Forming metal into the shapes needed for various purposes can be done in many ways, including casting, machining, rolling, and forging. These processes affect the sizes and shapes of the tiny crystalline grains that make up the bulk metal, whether it be steel, aluminium or other widely used metals and alloys.
ArcelorMittal changes plans on ferrous scrap acquisitions amid Transatlantic trend
Steel companies investing in ferrous scrap suppliers, seeking to utilise more scrap and alternative metallics to reduce carbon emissions in steel production, continues to gain ground. Global steel and mining group ArcelorMittal has said it had acquired several German steel scrap recycling businesses from Alba International Recycling, building on the acquisition of scrap merchant John Lawrie Metals in Scotland in March 2022.
Metallic 3D printing: Series production of automotive parts on the home stretch
“We have succeeded in industrialising and digitalising additive manufacturing (AM) for automotive series production.” With pride, 12 project partners announce that this has been doubly successful with IDAM (Industrialisation and Digitalisation of Additive Manufacturing). Three years ago, the consortium of SMEs, large companies and research institutions started with the common goal of revolutionising metallic 3D printing in the field of automotive series production.
Frech Group acquires aluminium melting furnace manufacturer ZPF
Die casting specialist Frech has acquired the operations of the insolvent ZPF GmbH located in Siegelsbach, Germany. With the newly founded Frech ZPF GmbH, headquartered in Schorndorf, Germany the corporate group will expand its business in thermal processing technology and develop new fields of business for the foundry industry. In addition to classical products for production and processing of aluminium melt, the new subsidiary will also focus on systems for environmental technology.
ABP innovations make it possible for foundry systems to remain competitive for a long time
Foundry and smelting systems typically have a long service life because they are robust and produced in high quality and because they are normally serviced on a regular basis. Therefore, it also makes good economic sense to think about modernisation of the system so as to attain a longer service life and more efficiency also in higher age.
Rampant costs hit Britain’s steelmakers
Steel boss James Brand raises his voice above the roar of metal being funnelled into a foundry furnace as he details how rampant costs have pushed him to raise his prices by 70%, according to Reuters. Yet he says that, despite this hefty hike, his customers in sectors including oil and gas, autos and construction are placing new orders at a record-breaking gallop. His order book has ballooned from the usual 4 to 6 weeks to 6 months.
April 2022
What the ‘beyond unprecedented’ nickel crisis means for businesses
“We have never seen or experienced anything like what is happening with nickel right now,” said Gary Peters, Director at The Metals Warehouse. “In March 2022, the situation hit beyond unprecedented levels, with that material increasing to a price on the London Metal Exchange that had never been seen before as a result of the war that is taking place in Ukraine. It led to trading being ceased and one of the biggest manufacturers of nickel reportedly recording an $8 billion trading loss.”
Paramount Group Mbombe 4 secures orders from five countries
150+ vehicles in production or on-order. Paramount Group, the global aerospace and technology company, has announced that its Mbombe 4 Infantry Combat Vehicle (ICV), has been selected by five sovereign nations to equip their armed forces with the most advanced armoured vehicle innovations and technologies available in the world.
SVI Engineering expands global footprint into Saudi Arabia
Focus on military, security and civilian sectors. SVI Engineering, a specialist manufacturer of armoured products in South Africa, has expanded into Saudi Arabia, where it plans to develop and manufacture a variety of armoured vehicles and military solutions.
BMW Group significantly increases use of low-carbon steel in series production at European plants
The BMW Group continues to reduce CO2 emissions in its supplier network as part of its ambitious ongoing sustainability activities. Steel produced using natural gas or hydrogen and green power, instead of fossil resources like coal, makes a vital contribution to this.
Europe’s carmakers scramble to replace Ukrainian auto parts
Carmakers, including Volkswagen and BMW, are scrambling to find alternative sources of vital parts made in Ukraine from as far afield as China and Mexico as Russia’s invasion halts assembly lines and breaks complex supply chains, according to Reuters. The hunt for new supplies is the latest challenge for an auto industry already reeling from soaring metal and energy prices, supply chains snarled by the pandemic and a shortage of semiconductor chips.
Electron beam welding breakthrough
Adoption of EBW could revolutionise the assembly of thick-walled components for applications including civil nuclear power and chemicals processing industries. Sheffield Forgemasters says it has achieved a breakthrough in the industrialisation of Electron Beam Welding (EBW) for thick-section materials.
Kolhapur foundries feel the heat of Russia-Ukraine conflict
Kolhapur’s famous foundry industry in India is fighting for survival, according to the Times of India. This time, the rapid rise in prices of raw materials due to the war in Ukraine is affecting jobs in this industry. The foundries located in the industrial zones of Kolhapur district are operating at 35% to 50% capacity.
Giga casting and robots: How VW’s Trinity project aims to catch up with Tesla
As Tesla begins production at its German plant this month, rival Volkswagen is weeks away from finalising plans for a 2 billion euro electric-vehicle factory that it hopes will bring it up to speed with its US rival. Tesla says it can already produce a Model Y SUV in 10 hours at its new factory in Gruenheide near Berlin, whereas it can take VW three times as long to make its ID3 full-electric hatchback.
New maker of F1 wheel rims draws on Japanese metalworking history
A Japanese wheel manufacturer with links to a city long famed for its metal processing will supply the wheel rims for all teams competing in the Formula One World Championship for four years starting from this season. BBS Japan Co. is headquartered in Tokyo but has its main factory in Takaoka, Toyama Prefecture, a city known for metal casting since the Edo period (1603-1867).
War complicates aluminium supply chain for Tesla
Tesla and SpaceX CEO Elon Musk has vocally supported Ukraine since Russia began its brutal invasion. But Tesla, like most other large automakers, has ties to at least one Russian supplier. In late 2020, Tesla began procuring aluminium from Rusal, the Russian metals giant founded by sanctioned oligarch Oleg Deripaska, according to invoices obtained by CNBC.
February 2022
Fraunhofer opens new R&D foundry
The Fraunhofer Institute for Foundry, Composite and Processing Technology (IGCV) opened a new metal casting research centre in Garching, Germany where it will explore new moulding materials, sand casting and gravity die-casting processes, as well as simulation technologies. The foundry is part of the new research campus established by Fraunhofer.
How are suppliers strategically dealing with the raw material crisis?
In the current BDG (Bundesverbandes der Deutschen Gießerei-Industrie) report, Thomas Pfeiffer, Member of the Executive Board, Vice President Global Sourcing HA Group, explains how HA is dealing with the current bottlenecks on the raw materials market, which particular strategy makes it possible to remain able to deliver even in times of crisis.
BIONICAST is a Mercedes-Benz registered trademark applied to structural castings
Mercedes-Benz has unveiled the VISION EQXX electric concept car, a highly efficient, sleek concept car capable of exceeding 1 000 kilometres (620 miles) on a single charge with an outstanding energy consumption of less than 10kWh per 100 kilometres (efficiency of more than 6 miles per kWh).
Guangdong Hongtu Technology to develop 12 000 ton die-casting unit
Guangdong Hongtu Technology (GHT), a part supplier to Chinese EV automakers like NIO and XPeng, has announced it will begin developing a 12 000 ton die-casting unit with the help of Tesla supplier LK Technology. Recent responses from representatives at NIO and XPeng hint that they might soon be using GHT’s large, one-piece die-casting machines to manufacture their own EVs.
ASK Chemicals Group opens Mexican plant
ASK Chemicals Group, headquartered in Hilden near Düsseldorf (Germany), has successfully opened their new manufacturing facility in El Carmen, Mexico. With this step, the company is strengthening its position in the North American foundry market and advancing its expansion strategy. Production is starting up with no bake and cold-box binders.
US steelmakers move further into scrap business to feed new mills
US steelmakers are poised to take an even larger role in the US ferrous scrap market in the coming years after a wave of acquisitions in the last year. Fresh off record profits, US mills have made major acquisitions to support a rapid expansion in scrap-intensive melting capacity.
Tesla takes delivery of yet another giant casting machine at Gigafactory Texas
Tesla is taking delivery of yet another giant casting machine, known as a Giga Press, at its Gigafactory Texas as the automaker moves to produce entire car bodies in just a few pieces according to an electrek report. The company acquired several units of the biggest casting machines in the world.
Foundry Lab raises US$8 million to quickly, cheaply create metal castings using a microwave
Remember easy bake ovens? You’d mix up some coloured powder and water until a dough or batter formed, put it in a mould, pop it in the oven and before you knew it – ding! A disgusting treat. Foundry Lab, a New Zealand-based startup with backing from Rocket Lab’s Peter Beck, has figured out how to do something similar, except instead of chemicals and an “oven,” it’s metals and a microwave.
December 2021
Traxtion looks for growth in South African freight rail sector
New investment opportunities are opening up in the African rail sector, and as the continent’s largest private freight operator Traxtion wants to lead the charge. With a commitment from President Cyril Ramaphosa to open South Africa’s rail network to third-party freight operators, Africa’s largest private rail freight operator Traxtion is poised to lead the way.
Rustenburg Engineers & Foundry’s holding company ESG achieves recognition as a Level 2 contributor
Invicta Holdings Limited’s Engineering Solutions Group (ESG) – distributors of engineering consumables, automotive components, technical services and related solutions – has achieved recognition as a Level 2 contributor to Broad-Based Black Economic Empowerment (B-BBEE). ESG has been formally assessed by Ingkwazi, an accredited B-BBEE verification agency.
Scrap dealer jailed after Hawks pick up signal of stolen cellphone tower batteries
A KwaZulu-Natal scrap metal dealer has been jailed for six months after the Hawks recovered stolen cellphone tower batteries in his shop. Scottburgh regional court convicted Albert Ngcameni, 33, of receiving suspected stolen property on Thursday. Hawks spokesperson Capt Simphiwe Mhlongo said Ngcameni was bust in 2020.
Stainless steel castings essential for global infrastructure
Cast stainless steel is gaining rapid traction in infrastructure development and other applications, given its inherent advantages, including high strength-to-weight ratio, corrosion resistance, longer life, and low maintenance costs. This is according to Snehal Jadhav of Global Market Insights.
European industry associations warn against catastrophic impact of Chinese magnesium supply shortage
Europe’s industry associations European Aluminium, Eurofer, ACEA, Eurometaux, industriAll Europe, ECCA, ESTAL, IMA, EUWA, EuroAlliages, CLEPA and Metals Packaging Europe have issued an urgent call for action against the imminent risk of Europe-wide production shutdowns as a consequence of a critical shortage in the supply of magnesium from China.
Fraunhofer IGCV opens new casting technology laboratory
Exactly two years after the foundation stone was laid, the new Casting Technology Laboratory of Fraunhofer IGCV in Garching, Germany was inaugurated on 13 October 2021. Referred to as place for research and cooperation and thus strengthening Germany as a production location, much praise and recognition were expressed during the numerous greetings and celebratory speeches.
Daimler Buses develops mobile 3D printing centre for spare parts
German multinational automotive corporation Daimler AG and its service brand Omniplus have created a mobile 3D printing centre for the decentralised production of spare parts. The mobile container will be in operation at the BusWorld Home (BWH) service centre in Hamburg, and can be transported by truck to any location requiring only electricity and an internet connection to operate.
Desktop Metal completes acquisition of ExOne
Desktop Metal has announced it has successfully completed its acquisition of The ExOne Company following approval by a majority of ExOne’s shareholders. The acquisition reinforces Desktop Metal’s leadership in additive manufacturing (AM) for mass production. ExOne extends Desktop Metal’s product platforms with complementary solutions to create an unparalleled AM portfolio that offers industry-leading technology.
Emirates starts dismantling A380s with specialist recruited for recycling
Middle Eastern carrier Emirates is to recycle a large proportion of parts from its first Airbus A380 following the aircraft’s retirement, just 13 years after delivery. The aircraft (A6-EDA) was delivered to the carrier in July 2008, during a ceremony attended by FlightGlobal. It flew its last commercial service from Singapore to Dubai in March 2020, just as the pandemic began to cripple global air transport.
Metallurgist admits submitting false test results for US Navy subs
The retired director of metallurgy at a Tacoma, Washington-based steel foundry that produced steel casting for Navy subs pleaded guilty to fraud after admitting to faking steel strength test results for decades. A metallurgist in the US state of Washington has pleaded guilty to fraud after she spent decades faking the results of strength tests on steel that was being used to make Navy submarines.
Sculpture plan to mark historic foundry
A sculpture will honour 300 years of industry at a foundry and incorporate real used equipment, if plans are approved. The Coalbrookdale Foundry in Ironbridge closed in 2017 after centuries of metal casting, and the Coke Hearth Improvements Group is proposing to place an anvil, recovered from the site, on the nearby green.
October 2021
ExOne and Fraunhofer IFAM deepen partnership on metal binder development
The ExOne Company and the Fraunhofer Institute for Manufacturing Technology and Advanced Materials (Fraunhofer IFAM) have announced that they are deepening their partnership on binder and materials development projects following the success of CleanFuse metal binder.
Magnesium storm throws up another roadblock for automakers
Widespread closures of magnesium smelters in top producer China due to a clampdown on emissions and shortages of energy have propelled prices of the metal to their highest since 2008, posing another headache for automakers. Magnesium, also widely used in the aerospace industry, is needed to make aluminium alloys for the auto sector, which is already reeling from chip shortages.
3D printing and titanium: A life-changing combination
Additive manufacturing and titanium powder will disrupt medical implant production. 3D printing’s customisation strengths enable the creation of almost any shape using additive manufacturing (AM) technology – even replicating our own skulls. Sandvik’s AM and metal powder specialists are exploring AM’s medical applications potential and preparing for the future of surgical implants.
Smart ring: Installation of sensors during laser-based powder bed fusion holds great potential
A full handbag or bulging trouser pockets – who doesn’t know what it’s like when keys, wallet, and more have to be lugged around. Fraunhofer IGCV has a simple and stylish solution: A smart finger ring with an integrated microchip. This technology, in which the electronics are integrated directly within the 3D printing process, can be used in various ways and offers great potential.
Elon Musk life-size bronze statue in Manhattan mocked online
Social media is a place where beautiful things happen, such as sharing information with family and friends, keeping in touch with loved ones, and posting photos of our daily lives. However, it can also be a scary place because of online bashing and mocking. Tesla CEO Elon Musk is no beginner when it comes to online parody, but he usually posts funny memes and quirky remarks on his infamous Twitter account.
3D printing turns 40 – but which process is best suited to your requirements?
In 1981, Japanese inventor Hideo Kodama created a first-of-its-kind rapid-prototyping device that used UV lights to harden polymers and create three-dimensional forms reports Jennifer Johnson. Kodama’s technology was never properly commercialised, although the US inventor Chuck Hull used similar principles in a process he called “stereolithography”.
Researchers explore laser beam shaping to improve metal 3D printing
While laser-based 3D printing techniques have revolutionised the production of metal parts by greatly expanding design complexity, the laser beams traditionally used in metal printing have drawbacks that can lead to defects and poor mechanical performance.
GE Renewable Energy, Fraunhofer IGCV and voxeljet AG plan to develop world’s largest sand binder jetting 3D printer for offshore wind turbines
Project to accelerate and optimise the production of a key casting components of the GE Haliade-X offshore turbine. Highly complex components are installed in the nacelles of offshore wind turbines. A suitable production method is the additive manufacturing of sand moulds for metal casting.
New alloying process benefits aluminium casting – and more
The manufacturing value of tungsten alloys is found in their corrosion resistance against molten metal and high thermal conductivity for chill mould casting processing of aluminium. Yet, because it is a heavy metal, with a density comparable to gold, tungsten is highly valued for tool manufacturing and for shielding from alpha and gamma radiation.
August 2021
Newly patented manufacturing process of a tungsten alloy enables additive manufacturing of complex components
Tungsten alloys (WNiFe / WNiCu) are used because of their corrosion resistance against molten metal and high thermal conductivity for chill-mould casting processing of aluminium. Yet, also in tool manufacture and for shielding from alpha and gamma radiation, the heavy metal with its density comparable to gold is indispensable. However, at around 3 400°C, tungsten has the highest melting point of all chemical elements and is therefore very difficult to work with.
ASK Chemicals launches ASK Online Academy
ASK Chemicals, a foundry chemicals and materials supplier, has launched its ASK Online Academy programme on 30 June 30 2021. With ASK Online Academy, ASK Chemicals offers the foundry industry an additional channel to gain in-depth expert knowledge and the latest insights into its solutions in foundry chemistry, feeding technology and metallurgy. ASK Online Academy can be seen as a virtual spin-off of ASK Casting Academy, an in-person event.
Lowering the pressure on die-casting development
Diecasting has earned considerable attention from industrial designers in recent years, regarding finished products and consequently production systems. This is mainly the outgrowth of those designers’ efforts to develop lighter versions of standard products, in automotive manufacturing most obviously. Those efforts led to the development of structural castings and drivetrain parts designed in aluminium alloys, for volume production.
Toyota Industries Corporation and Siemens cooperate on digital transformation for die-casting
AI predicts abnormalities in aluminium die-casting products. To support their goal of manufacturing quality parts, Toyota Industries Corporation and Siemens have cooperated to develop artificial intelligence (AI) that can predict product abnormalities in aluminium die-casting, a key process in automotive air conditioning compressor production. The development is one of the world’s first to use defect prediction AI for die-casting.
LK Group introduces the world’s first 9 000T giant die-casting machine
Two years after the world’s first 6 000T die-casting machine was launched by the LK Group the company has achieved another remarkable milestone this year by building the world’s first 9 000T machine. The new model is named Dreampress and the clamping force is 9 000 tons, which is the largest die-casting machine in the world. In December 2019, LK Group launched the world’s largest 6 000T ultra-large intelligent die-casting unit to the market.
Tesla’s superior engineering cuts costs, giving company new option to stoke demand
The company also continues to produce at capacity, amid persisting global challenges and record demand for electric cars. Tesla reported $1.14 billion in (GAAP) net income for Q2 – the first time it has surpassed $1 billion. This is among a revenue of $11.96 billion, mostly made by selling cars. Overall automotive revenues amounted to $10.21 billion, of which only $354 million came from sales of regulatory credits – less than in any other year.
Fast and cost-effective: Process-safe additive manufacturing of titanium components in the aerospace industry
With the project “EasyTitan”, the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM in Dresden has launched a project for the rapid and process-reliable manufacturing of light-metal components in aerospace. Together with the space management of the German Aerospace Center e.V. (DLR), filament-based metal printing processes are to be optimised under reduced gravity conditions.
Lubricants for large-scale die-casting
“The expanding scope of automotive emissions regulations is pressuring automakers and their suppliers, one result of which is designers and manufacturers’ focus on ‘light-weighting’ new vehicles. Their goal is to reduce overall vehicle weight to improve fuel economy and range by introducing a growing number of hybrid and electric vehicles,” says Mark Cross, the global business development director for die-casting at Quaker Houghton.
Two German firms have developed a process that allows a casting or other component to be secured ready for machining, while at the same time checking it for accuracy of form and position before machining starts
Two German firms, 5-axis vertical machining center manufacturer Wenzler (Heller group) and workholding equipment specialist Roemheld, have developed a process that allows a casting or other component to be secured ready for machining, while at the same time checking it for accuracy of form and position before machining starts.
AGC Ceramics and voxeljet develop 3D printing ceramics for investment casting shells and cores
In a joint tailoring project, Japanese ceramics expert AGC Ceramics Co. and voxeljet AG have qualified the high-performance ceramic material Brightorb for 3D printing. In addition to potential applications in the production of structural components and works of art, the material is particularly suitable for 3D printing of highly complex moulds and cores for metal casting. Brightorb was developed on a VX1000 with a build volume of 1 000mm x 600mm x 500mm.
June 2021
Big Ben bell foundry plan approved by government
Plans to redevelop the foundry where Big Ben was cast have been given the green light by the government. Decision has drawn wave of criticism from culture and heritage professionals, accusing government of ‘money-grabbing philistinism’. The plans for a boutique hotel had already been approved by Tower Hamlets Council, but the communities secretary decided to call them in, taking the decision out of the council’s hands.
Castings Technology International casts large titanium pump casting
Castings Technology International (Cti) said it recently produced the largest single component ever cast by the company in commercially pure titanium and probably the largest titanium part poured into a ceramic mould. With an envelope of 1 000mm square by 600mm high and requiring over 1.2 tons of metal to be melted, the casting showcases several novel casting techniques developed in-house at Cti.
Sheffield Forgemasters adopts pioneering Cobot
Sheffield Forgemasters has adopted pioneering collaborative robotic (Cobot) assistance for Foundry operatives. The firm is are one of the first foundries in the world to employ the 6A10 Grinding Cobot, from French firm RB3D, which works with operators of heavy grinders to stabilise and take the weight of the grinder, amplify its operational pressure and dramatically reduce the level of vibrations for the operator.
ExOne acquires 3DP Tooling Technology
The binder-jet printing specialist acquired Freshmade 3D, developers of a method for creating moulds and tooling from 3D printed sand forms infiltrated and coated using a patented technology. ExOne, a developer and supplier of binder-jet additive manufacturing technology, acquired the assets of Freshmade 3D, an Ohio, USA business with a patented method for creating tooling from sand forms 3D printed on ExOne machines.
Enable Manufacturing unveils new vacuum additive casting process for cheaper metal parts
UK-based metal 3D printing service Enable Manufacturing has announced the launch of its new Vacuum Additive Casting process which it claims can manufacture metal parts at a fraction of the cost of direct 3D metal printing. Like the other additive casting processes offered by Enable Manufacturing, the process is based on a hybrid approach to 3D printing moulds and patterns for casting parts, but also uses a vacuum casting technique to draw the metal into fine structures.
Iron ore rebounds as China mills churn out steel at record pace
Iron ore futures climbed back above $200 a ton as soaring steel production in China showed there’s no sign of the industry cooling despite government attempts to rein in output from last year’s record of over one billion tons, as reported by Reuters. Crude steel output in April rose to 97.9 million tons to hit monthly and daily run rate records. The robust pace of production also lifted the year-to-date tally to 375 million tons, a 16% jump compared to same period last year.
China puts Australia on notice with push to diversify iron ore
Beijing threw the spotlight on trade tensions with its top commodities supplier, Australia, after the government’s economic planning agency said it’s looking to diversify China’s supply of iron ore. Chinese firms should boost domestic exploration for the steel-making input, widen their sources of imports, and explore overseas ore resources, the National Development and Reform Commission said at its monthly briefing.
Surge in prices of raw materials casts shadow
The prices of raw materials used to make almost everything are skyrocketing, and the upward trajectory looks set to continue as the world economy roars back to life. From steel and copper to corn and lumber, commodities started 2021 with a bang, surging to levels not seen for years. The rally threatens to raise the cost of goods from the lunchtime sandwich to gleaming skyscrapers. It’s also lit the fuse on the massive reflation trade that’s gripped markets this year and pushed up inflation expectations.
April 2021
O.M.LER srl offers innovative decoring solutions
During the last few years O.M.LER’s management, technical and sales staff, felt it was essential to offer something new to their clients. So, then, during the past year of COVID-19 lockdown, O.M.LER personnel have worked hard and diligently to launch into new markets, and with this develop new and innovative decoring solutions.
Zimbabwe says Tsingshan of China plans iron ore mine, steel plant to begin from May
A fluorite and limestone production plant will also soon be set up, Information Minister Monica Mutsvangwa said. Tsingshan Holdings Group Co., the world’s top producer of nickel and stainless steel, will start construction on an iron ore mine and a carbon steel plant in Zimbabwe in May, according to a senior government official.
Ford and ExOne seek to patent high-speed 3DP for aluminium
The automaker and additive manufacturing specialist have co-developed a binder-jet and sintering process for aluminium 6061, pointing the way to high-speed production of light-weight, complex parts with densities greater than 99%. Ford Motor Co. and The ExOne Co. are seeking to patent a 3D printing process for automotive aluminium alloy 6061 they co-developed, involving a binder-jet process and sintering which they claim, “delivers properties comparable to die-casting.”
International Aluminium Institute releases global aluminium industry 2050 climate pathways
Aluminium industry aims to reduce emissions by 80% by 2050. The International Aluminium Institute (IAI) has today published the most comprehensive greenhouse gas emissions reductions pathways available to the aluminium sector over the next three decades. The pathways are based on the IAI’s unrivalled data and leading analysis of the global aluminium industry.
IDRA secures first order for an 8 000 ton die-casting cell
The machine with the unbelievable clamping force of 8 000 ton is to be delivered for the manufacture of large structural parts. The die-cast parts will be chassis parts for larger vehicles such as pick-ups, small trucks and SUVs. Tesla has placed an order for the world’s first 8 000 ton casting machine, which is expected to be key to produce the Cybertruck pick-up truck.
Voxeljet shipped 131 000 3D printed parts in 2020, that’s 750 tons!
Sand (and plastic) binder jetting 3D printer vendor voxeljet also operates as a major service provider. In 2020, its service activities have delivered an impressive 131 000 3D printed parts, which if stacked would measure 604 metres in height (based on the average build platform of all 3D printers operated in the company’s European Service Centre). That’s not all. The total machine runtime to produce these parts was 32 000 hours, which is 1 333 days or 3.7 years of printing.
Wohlers Report 2021 finds 7.5% growth in additive manufacturing industry despite pandemic
Wohlers Associates, Inc. has announced the publication of Wohlers Report 2021. This marks the 26th year of publishing the industry-leading annual report on additive manufacturing (AM) and 3D printing. The study provides trends, perspectives, and forecasts as a tool for decision making, education, and knowledge acceleration. The report gives readers new to AM a comprehensive understanding of the technology and industry.
Viking Analytics and pour-tech AB sign contract to provide AI operators to iron foundries
Viking Analytics, a Swedish startup in advanced analytics solutions for predictive operations, and pour-tech AB, a specialist in automatic pouring systems, announced a partnership to offer AI operators to iron foundries. Viking Analytics notes that its solution, named EASYpour, uses data analytics and machine learning algorithms developed to automatically adjust the pouring process. This improves product quality, enables faster production, and reduces costs.
Heinz Nelissen announces his retirement
On 30 June 2021, Heinz Nelissen will retire after 31 years of successful service to the Foseco and Vesuvius group of companies. Heinz Nelissen was instrumental in the development and expansion of Foseco and Vesuvius, first as product manager for non-ferrous products, then for Foseco as sales manager of the foundry non-ferrous business unit. ““In my 31 years in the foundry industry, I have met many great people, faced many challenges and implemented many ideas together with colleagues and customers.”
Larger die-casting machines revolutionise body-in-white production
Bühler is expanding its portfolio with the launch of Carat 560 and Carat 610, and the recently announced Carat 840 to meet the trends for larger and more complex parts. “Structural components have clearly gained in importance in the automotive industry over the last years, with a trend towards even larger parts. This presents a clear opportunity for the die-casting industry,” says Cornel Mendler, Managing Director Die Casting.
Foundry-Skills launches free video wiki for prospective foundrymen
Trainees, students, onboarding newcomers and career changers, casting buyers, design engineers and lecturers in foundry technology will find a modern access to expert knowledge in addition to literature. Foundry-Skills is a new, free video wiki with thousands of foundry-specific short videos spread across more than 45 categories. From sand casting to investment casting, from hand moulding to quality assurance, from aluminium to zinc.
Elkem’s long term goal is to achieve carbon-neutral metal production
Currently, Elkem is conducting a feasibility study for the establishment of carbon capture at the Norwegian smelters. Elkem, one of the world’s leading suppliers of silicon-based advanced materials, has a broad and comprehensive approach to the work of reducing emissions and contributing to a sustainable future. Recently, the company was rated among the world’s leading on climate transparency and action by CDP.
Malaysia sets ferrous scrap tariff at 15 per cent
Nation’s steelmakers had been urging an export ban or restriction. The Malaysian government reportedly has finalised its system to impose a 15 per cent duty on ferrous scrap exports, enacting a policy favoured by that nation’s steel industry. A March 19 online news report by S&P Global Platts says a Malaysian government gazette entry on that day points to the March 25 enactment of the 15 per cent duty on outbound shipments for scrap with the Harmonised System.
Plansee Group becomes majority shareholder in Ceratizit Group
Austria’s Plansee Group has reported that as of March 1, 2021, it holds the majority interest in the carbide tool production company Ceratizit SA, headquartered in Mamer, Luxembourg. Formed in 2002 as the result of a merger between Plansee Tizit and Cerametal, Plansee Group’s share in Ceratizit initially accounted for 50%. The parties have agreed to keep the extent of the acquired interest and any financial details confidential.
Audi and EOS expand range of metal 3D printing applications
Audi and EOS development partnership has reached a new milestone: Audi has moved entirely to additive manufacturing for selected tool segments for hot forming at its Metal 3D Printing Centre – conventional production methods are no longer used in these cases. The premium manufacturer leverages the EOS M 400 system for 3D printing.
Rio Tinto and Amaero collaborate on aluminium-scandium alloy for AM
Under the agreement, Rio Tinto will deliver alloy billets made of responsibly-produced, low-carbon aluminium from its hydro-powered Canadian smelters and high-purity scandium oxide from its Rio Tinto Fer et Titane (RTFT) metallurgical complex in Sorel-Tracy, Quebec, Canada. The billets will be processed by Amaero into powder for additive manufacturing (AM) and offered to the market for high temperature applications.
VW accelerates move away from internal combustion engines
Germany’s Volkswagen has announced that it is accelerating its move away from the internal combustion engine, expecting fully-electric vehicles to make up more than 70% of its European sales by 2030, a marked difference to the previously-anticipated target of 35%. By the same year, VW is hoping for electric to make up over half of its sales in the United States and China.
Novelis debuts new aluminium solution category for automaker
Novelis Inc. has unveiled its strongest automotive aluminium product to date, Novelis AdvanzTM 7UHS-s701. The technologically advanced, ultra-high-strength material is now available commercially to the global automotive industry. The product offers lightweighting potential of up to 40% over existing ultra-high strength, hot-formed steel solutions. It is designed for safety-critical structural applications in passenger vehicles that require high in-service strengths.
Volvo to be fully electric by 2030 and carbon neutral by 2040
The Volvo Group, headquartered in Gothenburg, Sweden, reports that it is accelerating its electrification movement and plans to be fully electric by 2030. The car manufacturer reports that it was the first established car maker to commit to all-out electrification back in 2017 and that demand would decide when exactly the group would leave the internal combustion engine behind altogether. Volvo now sees demand for its electrified cars increasing rapidly.
February 2021
Assmang declares force majeure on ferro-manganese production in South Africa
Mining and metals producer Assmang has declared force majeure on its medium-carbon ferro-manganese production in South Africa, a source told Fastmarkets recently. Assmang produces refined ferro-manganese at its Cato Ridge Alloys plant in the eastern province of KwaZulu-Natal and halted production last week. The force majeure declaration was made in the first week of 2021.
Ford Mustang won’t be discontinued even though SUVs, trucks sell much better
A few years ago, the Ford Motor Company in the USA made a rather controversial decision. The Blue Oval decided to pull the plug on passenger cars in favour of sport utility vehicles and trucks. Thanks to hindsight, now we can all agree that Ford did the right thing by discontinuing the Fiesta, Focus, Taurus, and the Fusion, although the latter will come back as a fancy wagon inspired by the Subaru Outback.
From foundry to stovetop: Le Creuset cast iron pots
The coveted heavy-duty, Skittles-coloured enamelled pots, pans, and kettles evoke ambitious Sunday feasts and an iconic French timelessness. Produced in a tiny working-class town far from the lights of Paris since 1925, Le Creuset products have gone global, making their way to kitchens around the world, from Japan to the United States.
Why is cast iron the best material for casserole dishes – and what about stainless steel, copper and aluminium?
Stainless steel is a non-reactive material which can go into the dishwasher, and which is lighter than traditional cast iron. “The problem with stainless steel is that it has terrible heat conductivity. It heats up slowly and unevenly compared to other materials,” says Justin Kowbel, co-founder of Borough Kitchen. “If the flame hits a certain point, you get hot patches.”
New economic forecast from AFS projects strong growth in 2021
The US metalcasting industry is projected to grow at a rate of 19.7% in 2021, according to a new report published by the American Foundry Society (AFS). This and other vital business intelligence was released in the biannual AFS Metalcasting Forecast & Trends, which provides a targeted economic outlook to foundries, industry suppliers, and others who must understand analysts’ projections for the short- and long-term future of the metalcasting industry.
Rio Tinto’s new aluminium alloys to support recycling by die-casters
Rio Tinto is introducing a new family of unique aluminium alloys designed to allow diecasters to increase their use of recycled content in the production of automotive parts, delivering improvements on both environmental footprint and production costs. The company’s new high-quality alloy series has been developed for high pressure vacuum diecasters to mix with their own scrap and recycled cleaned crushed wheels.
Tesla trying to make real cars with unibody casting like toy cars are made
Tesla has not given up on its dream of manufacturing cars by creating the entire body of the vehicle with a single-piece casting. Elon Musk recently tweeted: “With our giant casting machines, we are literally trying to make full-size cars in the same way that toy cars are made.” Just like toy cars are manufactured using a complete body diecast, Tesla is trying to bring the same concept to real-world car manufacturing.
Management buyout of Castings Technology International
The management team of Castings Technology International (CTI) and the University of Sheffield have agreed a management buyout of the company. Taking effect from 19 January 2021, ownership of CTI has transferred to the company’s existing management team, which will take sole ownership of the company and operate it as a privately-run business.
Trimet Aluminium SE develops a new aluminium alloy for crash-relevant components
Trimet Aluminium SE has developed a new aluminium alloy for crash-relevant components. The wrought alloy trimal-53 is suitable for structural components with high strength and excellent deformation capacity. The aluminium specialist thus now supplies a material for which there is a growing need, particularly in the vehicle manufacturing sector. The new Trimet alloy meets every major carmaker’s need for light-metal materials to produce safety-related vehicle components.
Porsche unveils new electric drive housing from 3D printing and additive manufacturing
Porsche has unveiled its first-ever electric drive housing created entirely using 3D printing and additive manufacturing technology. According to the German carmaker, 3D printing and its latest additive laser fusion process are opening new possibilities in creating high-stress components for low-volume series production.
GM investing $71 Million in two Ohio manufacturing plants
Company allocates $39 million to Toledo transmission plant and $32 million to Defiance casting plant, further strengthening its manufacturing presence in Ohio. Late last year General Motors announced plans to invest $71 million into two Ohio manufacturing facilities, including $39 million at its Toledo transmission plant and $32 million at its Defiance casting plant.
Attendee registration opens for Virtual Metalcasting Congress 2021
Professionals across the entire metalcasting supply chain can now register for the virtual conference and trade show, Metalcasting Congress 2021. Streaming live online and on demand 12 to 21 April 2021, the first-ever virtual Metalcasting Congress will offer attendees the same quality presentations and business intelligence they’ve come to expect from North America’s premier foundry industry event.
Ferrous scrap metal traders benefit from high prices
Sustained demand and substantially higher prices for scrap export during the final weeks of 2020 meant a bright New Year for traders. The cost of shipments of HMS 80/20 heavy steel scrap from northern Europe to Turkey soared from around US$293 per ton in November 2020 to US$399 in December and then hit US$432 early in early January 2021 before easing off later in the month.
Scrapping planes in a pandemic isn’t easy
A ‘double whammy’ of low demand and high prices is hitting the aerospace metals sector, according to experts at a recent webinar on the aviation sector. But, the Argus Media event heard, there are signs of a rebound in demand from China – especially ‘good demand’ for stainless steel, as reported by Recycling International. The global market for recycled aircraft parts is expected to be worth around US$6 billion (EUR4.9 billion) by 2022.
