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).
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.