at a glance

September 2012
Volume 6, Issue 3
Redesigned
Launder
System Reduces costs,
Improves Performance
Mapsa S. Coop L., a Spanish low-pressure diecaster,
part of the Fagor cooperative group, produces over 9000
aluminium wheels a day from thirty-two casting machines.
Having worked with Pyrotek for several years, the customer
has used a variety of Pyrotek’s products including transport
ladles, ceramic foam filters, thermocouple assemblies,
coatings, riser tubes and graphite.
Mapsa approached Pyrotek
Sales Engineer, Saul Gracia
Villacampa, with concerns
about the launders which
connected their maintenance and reverberatory
furnaces. In order to reduce
heat loss during metal
transfer, they were running
nine gas burners to heat the
metal. This caused several
problems including oxidation of the aluminium,
Burners were costly and
corundum
generation, generated oxides and dross
shortened refractory life,
difficulty with maintenance and significant costs in gas
usage. In addition to these problems, the launder system
was still losing 37°C (67°F) in melt temperature during
transfer.
The customer requested assistance in remedying the
issues while obtaining a flow rate of 5–6 t / hour. After
analysis, it was decided that the launder was oversized,
the current material (concrete) had too much thermal
conductivity and the launder lacked sufficient insulation.
continued on page 6
Missouri Diecaster
adding Eighty jobs
Missouri, USA-based Continental Casting recently
announced a USD$2.6 million capital investment in its
two facilities: Monroe City, Missouri and nearby Palmyra,
Missouri, USA. Continental Casting estimates that eighty
new jobs will be created, forty-three at the Monroe City
facility and thirty-seven at the Palmyra facility.
Producers of aluminium, magnesium and zinc castings,
Continental Casting’s target markets are automotive,
communications, electronics and consumer products.
The investments are a response to several new contracts,
reflecting an increase in demand. If the company meets
job creating and investment criteria, they may be eligible
for a state economic incentive package to help with the
expansion.
This is the second positive
announcement made this
year by the company. In
April,
they
announced
construction of a new
warehouse, as well as the
creation of thirty new jobs.
The expansions are welcome
news to Monroe City which
was still feeling the effects of
the closing of diecaster Pace
Industries back in February
2010. In a press release Image Courtesy of
supporting the expansions, Continental Casting
Missouri Governor, Jay
Nixon said, “Homegrown, Missouri companies like
Continental Casting are creating jobs and growing our
economy.”
Family owned since 1974, Continental Casting currently
employs about 215 people between its two facilities.
Hyundai Translead to Set Up New Aluminium
Diecasting Plant in Tijuana, Mexico
Source: Tijuana Economic Development Corporation (tijuanaedc.org)
Hyundai, the Korean automotive leader maintains its
trust in Tijuana’s competitiveness and announced their
investment in a new MXN$131 million (USD$9.78 million)
aluminium diecasting plant adding nearly 300 new jobs
to the company’s current base of 2300 employees. The
announcement was made by Kenny Lee the company’s
CEO, in a ceremony with representatives of local and state
government, and private sector leaders.
David Mayagoitia stressed that according to the Mexican
Association of Automotive Industry (AMIA) Mexico
exported over 2 million units in 2011, 68% of these
units were sent to the USA. Mayagoitia also said that
in regards to the city’s industry, “We are giving a higher
priority to high-tech auto parts; this is the first step
towards assembly of a complete car in Tijuana.”
The new plant’s construction will start in July 2012 and it
is expected to reach its full capacity on January 2014. It
will produce 900,000 units of three automotive parts such
as engine blocks, engine cylinder heads, and transmission
cases.
Courtesy: www.infomine.com
Heated Refractory Trough System
Improves Safety and Savings
A prominent foundry and Pyrotek customer from
Wisconsin, USA, specializes in casting using
permanent mould, green sand, dry sand and lowpressure casting processes.
Full story, page F2
German Aluminium Producer Builds
Diecasting Plant
Responding to increasing demand for chassis parts
for the automotive industry, Trimet Aluminium
AG, Germany’s largest aluminium producer, is
constructing a new diecasting facility in Harzgerode,
Germany.
Full story, page F2
Better Fluxes Reduce Metal Loss in Dross
A large USA green sand foundry, producing large
tank castings as well as small high volume castings,
was generating around 115,000 lb (52,160 kg) of
dross a year from its three automatic moulding lines.
Full story, page F3
Ask the Expert...Best Practice in Pump
Maintenance
Garry Morgan, Metaullics Systems Sales Engineer for
Pyrotek, answers questions on pump maintenance
and provides guidance on best practice.
Full story, page F4
PRECISION CASTPARTS CORP. BROADENS
AEROSTRUCTURES CAPABILITIES WITH THE
ACQUISITION OF KLUNE
Precision Castparts Corporation (PCC) has agreed to
acquire Klune Industries (“Klune”), a manufacturer
of complex aluminium, nickel, titanium, and steel
aerostructures.
Full story, page F5
Re-engineered Dosing Tube Reduces
Maintenance costs, Increases Savings
A large Italian high pressure diecaster has been a
Pyrotek customer since 2008. Equipped with fifteen
Striko Westofen furnaces, the customer was looking
for a better solution for their dosing tubes.
Full story, page F5
Kenny Lee mentioned Tijuana was competing for this project
with Monterrey, Mexico and Montgomery, Alabama, USA.
However, Hyundai’s positive experience in the city for over
twenty years, competitive costs, and the support received
from local governments were important factors that played
a significant role in the choice of Tijuana over the others.
David Mayagoitia, President of Tijuana Economic Development Corporation, expressed that this new plant will
increase the automotive industry base of fifty-one plants
operating in the city that employ over 15,000 people. The
new project will be a milestone in Hyundai’s history due
to the fact that it represents almost half of the company’s
actual investment in Tijuana, “we are deeply honored to be
part of this state and this city,” said Kenny Lee.
at a glance
Hyundai facility in Tijuana, Mexico. Image courtesy of Tijuana
Economic Development Corporation.
As the automobile export market continues moving
forward, more corporations will find competitive
advantages in Tijuana’s operating platform which
combines high-skilled workforce, immediate market
access, fifty years of manufacturing experience and a
wealth of resources.
Eight Toyota Manufacturing Facilities
Recognized by the U.S. EPA for Improved
Environmental Performance
The U.S. Environmental Protection Agency (EPA) has
recognized eight Toyota manufacturing sites in North
America for achieving a 10% reduction in energy
intensity through its ENERGY STAR Challenge For
Industry program.
Full story, page F6
F2
Heated Refractory
Trough System Improves
Safety and Savings
A prominent foundry and Pyrotek customer
from Wisconsin, USA, specializes in casting using permanent mould, green sand,
dry sand and low-pressure casting processes. Producing castings for a wide variety of
industries, the company has been in business for over a century. As part of recent
capital investments, they installed two new
dosing furnaces in the tilt pour permanent
mould casting area. The furnaces utilised
a small trough to transfer the metal from Previous customer trough system was
the furnace to the pour cup, with each fur- dangerous and costly
nace feeding two tilt pour machines. This
required the trough to transition from one tilt pour machine to the other; however, the
trough required a constant gas fired flame to maintain metal temperature.
The customer had two main concerns with their current system: the first concern was
the safety issues of the continuous flame required on the launder; the second concern
was the cost of the gas to sustain the flame.
Through a continuing positive relationship with Pyrotek Sales Engineer Terry Mueller,
the customer discussed their concerns about their current launder system. After
understanding the customer’s requirements, Mueller turned to Pyrotek’s technical
resources for assistance in designing a new system.
With the help of Dennis Sanders, Pyrotek Foundry Project Engineer, Mueller developed
a covered heated launder system. This system utilises electric cartridge heaters
inserted in slots at the back surface of the precast refractory liner. The underside
of the launder includes a bayonet mount
thermocouple, maintaining contact with
the bottom of the refractory, allowing
a simple control system to regulate the
temperature of the refractory. The launder
was designed to maintain a temperature
of 1200°F (650°C) inside the covered
launder. If repairs are ever required, the
refractory is precast and can be easily
replaced as one piece to minimise
downtime.
Results of the new system are very
positive. The customer has been able
to eliminate the gas burners, improving
safety and reducing the cost of operating
this casting cell. Moreover, with the gas
savings, payback is expected in nine
months.
New launder system improving
customer performance
www.pyrotek.info/launder
ASCO Signs Contract with
Bombardier Shorts to Supply
Aluminium Floor Structure Beams
Source: PRWeb (www.prweb.com/releases/2012/7/prweb9675985.htm)
Asco, proven specialist from design to
manufacturing of high lift devices and
complex precision mechanical subassemblies for the aerospace industry, has
signed a long term contract with Bombardier Aerospace Belfast to supply aluminium floor structure beams. The parts
will equip several fuselage sections of
Bombardier aircraft, including the CRJ700/900/1000, the Global and Challenger families, and the Learjet 70/75.
The parts will be manufactured in Asco
Asco Deutschland, the site will manufacture
Deutschland, center of excellence aluminium floor beams for Bombardier Shorts.
for both extrusion milling and large Image courtesy of PRWeb.com
structural aluminium parts of the Asco
group in Europe, located in Gedern, Germany. As sole source provider, Asco has been
awarded this build to print work package, comprising 200 different part numbers, for
multiple years.
Under the contract award, the Asco group extends its work share on components for
Bombardier Belfast and Asco Deutschland further consolidates its position as complex
mechanical assembler and manufacturer for extrusion milled and large structure
aluminium parts.
The contract confirms a proven relationship of confidence and trust between Asco and
Bombardier Shorts, including Asco’s material (Otto Fuchs KG) and treatments (AERnnova/NMFE) long term partners.
Casting Machine
Manufacturer
Builds Plant in
China
Sanji Opens
Squeeze Casting
Technical
Centre
Hong Kong-based L.K. Group held a
ceremony to announce the building
of a USD$10 million plant in Phoenix
Lake Industrial Park, Yongchuan District,
Chongquing, China. L.K., a market
leader in the production of diecasting
machines since 1999, produces cold
and hot chamber diecasting machines,
injection machines and CNC machines.
They have more than ten wholly-owned
subsidiaries in various cities in China.
Chinese casting equipment manufacturer
Suzhou Sanji Foundry Equipment Co.
Ltd. (Sanji), has opened a 20,000 ft2
(1860 m2) squeeze casting technical
centre at its operations centre in Suzhou,
China. The technical centre is available
for manufacturers to develop and
evaluate light aluminium alloy squeeze
cast prototype components up to 30 kg
(66 lb).
German
Aluminium
Producer Builds
Diecasting Plant
Responding to increasing demand for
chassis parts for the automotive industry,
Trimet Aluminium AG, Germany’s largest
aluminium producer, is constructing a
new diecasting facility in Harzgerode,
Germany. Built in cooperation with BMW,
two casting sites, two processing lines and
an x-ray inspection station will support the
production of castings for the new BMW
5 Series.
The EUR€13 million (USD$16.4 million)
expansion is the continuation of the
company’s investment of over EUR€160
million (USD$200 million) in their
automotive part manufacturing over the
past decade.
“The current investment will advance our
production technology further, strengthen
the location and create new jobs,” says
Thomas Reuther, Executive Vice-President
over Trimet’s Automotive Industry segment.
In addition to the expansion, the company
plans on purchasing two more diecasting
machines: one for the Harzgerode site
and one for their Sömmerda site. The
Harzgerode expansion is scheduled for
completion in early-2013.
A privately held company, Sanji
produces light-alloy diecasting machines
including a range of fourteen, horizontal
cold-chamber, vertical injection squeeze
casting machines.
SCH-350A Horizontal Squeeze Diecasting
Machine. Image courtesy of Sanji.
Sanji describes squeeze casting as
“a modified diecasting process that
minimises turbulence during injection
of liquid aluminium into reusable steel
moulds, producing extremely highquality components that can develop
excellent mechanical properties after
heat treatment.”
“This is a very proud day for Sanji,” stated
president Shanxin Xu. “Establishing
the technical centre lets companies
prototype high-quality, near-net shape
castings, while allowing Sanji to spotlight
our casting technologies to companies
around the world.”
The technical centre includes five indirect
squeeze casting machines ranging in size
from 350–2000 tonnes, each with its
own melting furnace.
Better Fluxes Reduce Metal
Loss in Dross
PYROFLUX
A large USA green sand foundry, producing large tank castings as well as small high
volume castings, was generating around 115,000 lbs (52,160 kg) of dross a year from
its three automatic moulding lines. The dross was approximately 75% recoverable
aluminium; the customer only received 1/3 of their purchase price from the dross
recycler. This meant significant potential savings in retaining recoverable aluminium
were lost with the dross skimmed off from their furnaces and ladles annually.
However, the customer had a larger concern: a critical large tank process using alloy
356 where there was apprehension over strontium loss in the castings as a result of past
fluxing practices. As a result of that past experience, the customer only used a cover
flux in the bath to control dross generation. This resulted in the high aluminium content
dross, but was felt to be necessary to avoid failure of any large tank castings due to
concern that flux was taking out strontium from the melt.
Solution
Pyrotek Sales Engineer, Paul Carlstrom, worked with the
customer to understand their situation, and then reviewed
the application with Jim Nook, Pyrotek USA Flux Manager.
They determined, based on the customer’s current dross
practices and their understanding of the customer’s
process, that Pyroflux 355, a sodium-free flux, would be
most appropriate.
Proceeding on an extended timeline with a control test,
Paul along with the local Pyrotek flux distributor were both
present at the beginning of the trial to train operators in
proper flux addition and dross removal techniques. The
first load of dross processed during the Pyroflux 355 trial
was shipped out with the results convincing the customer
that they had retained approximately 2000 more pounds
(900 kg) of aluminium metal from their typical 8000 lb
(3600 kg) dross shipment. Based on the results another
order for Pyroflux 355 was placed with similar results seen
over three additional dross reclamation shipments. In
each case, the aluminium recovery was under 50% from
dross treated with Pyroflux 355 verses at or over 75% on
average with their previous cover flux.
New Equipment
for U.S. Aluminum
Castings
U.S. Aluminum Castings, located in Entiat,
Washington, USA, recently announced
installation of a new permanent mould
casting machine and three new vertical
machining centers. A business unit
of Philadelphia, Pennsylvania, USAbased Advanced Metals Group, the
investment is part of plans to increase
its production capability in support of
domestic and international customers in
the aerospace, aviation, heavy trucking,
marine and military industries. They
manufacture aluminium castings using a
variety of casting processes including nobake, permanent mould, lost foam and
green sand. The company also has three
other foundries: Ross Aluminum Castings
in Sidney, Ohio, USA; Mabry Castings,
Beaumont, Texas, USA; and Oberdorfer
LLC, Syracuse, New York, USA.
Metal-rich dross drains profits
The annual savings potential was based on the average results of the first four dross
shipments over a 3-1/2 month period. Subtracting the costs of the Pyroflux 355, the
customer will save over an estimated USD$30,000 annually.
This project also strengthened the relationship with the customer, who is now exploring
with Pyrotek other ways to save money and improve performance. Special thanks go to
Jim Nook for his technical assistance and expertise.
www.pyrotek.info/pyroflux
BMW Group and Toyota Motor
Corporation Agree to Further
Strengthen Collaboration
Companies Sign Memorandum of Understanding Aimed
at Collaboration in Four Technological Fields
Source: Toyota (pressroom.toyota.com)
Akio Toyoda, President of Toyota Motor Corporation (TMC), met recently with Norbert
Reithofer, Chairman of the Board of Management of BMW AG, at the BMW Group
headquarters in Munich, Germany, to announce the planned expansion of their existing
cooperation initiated in December last year. The two companies signed a memorandum
of understanding (MoU) aimed at a long-term strategic collaboration in four fields: joint
development of a fuel cell system; joint development of architecture and components for
a future sports vehicle; collaboration on powertrain electrification; and joint research and
development on lightweight technologies. Also, Reithofer and Toyoda signed a joint statement to reconfirm their companies' shared
intention to strengthen the long-term, strategic collaboration between them. Reithofer said, "We aim to further strengthen our competitive position in sustainable future
technologies. We signed an MoU to this effect…Toyota and the BMW Group share the
same strategic vision of sustainable individual future mobility. Together we have a great
opportunity to continue leading our industry through this transformation." Toyoda added, "BMW and Toyota both want to make ever-better cars. We respect each other.
That is why we already can take the next step together." He went on to say, "Toyota is strong
in environment-friendly hybrids and fuel cells…I believe BMW's strength is developing
sports cars. I get so excited thinking about the cars that will result from this relationship." In March 2012, the BMW Group and TMC signed a binding agreement on collaborative
research in the field of next-generation lithium-ion battery cells. In addition, the BMW
Group and Toyota Motor Europe entered into a contract in December last year, under which
the BMW Group will supply highly efficient 1.6 litre and 2.0 litre diesel engines to Toyota
Motor Europe starting in 2014. The MoU represents the companies' agreement in December last year to identify and discuss
other possible collaborative projects. industry events
october 2012
8–10 October
NADCA’s Die Casting Congress
Indianapolis, IN, USA
http://www.diecasting.org/congress/
exposition/
VISIT PYROTEK IN STAND #1024
21–25 October
43rd National AFI Conference
Sydney, Australia
https://wired.ivvy.com/event/
HT4WNP/
november 2012
8–10 November
Japan Die Casting Show 2012
Yokohama, Japan
http://www.diecasting.or.jp/index.php
VISIT PYROTEK IN STAND B-37
december 2012
Entiat, Washington, USA Plant
Courtesy of U.S. Aluminum Castings
(www.us-castings.com)
Dry dross increases yield
F3
13–15 December
Alucast 2012
Greater Noida (Delhi NCR), India
http://www.alucast2012.com
VISIT PYROTEK IN HALL 1, STAND C8
Grede to Supply New General
Motors Truck Platform
Source: Grede Holding LLC (grede.com)
Grede Holdings LLC announced that it has secured approximately USD$150 of vehicle
content with various tier one suppliers for General Motors’ (GM) upcoming K2XX truck
platform. The K2XX platform includes the Chevy Silverado, Tahoe and Suburban along
with the GMC Sierra and Yukon, plus the Cadillac Escalade vehicle programs.
Grede will produce safety-critical components including brake calipers, control
arms and differential carriers and cases at its foundry facilities in Wisconsin, Virginia,
Minnesota, Alabama, USA; and Mexico. These parts will be sent to various tier one
suppliers in North America, who will assemble them into components and systems
for General Motors. The K2XX truck platform will be assembled by GM at its facilities
in Arlington, Texas, USA; Fort Wayne, Indiana, USA; Flint, Michigan, USA; and Silao,
Mexico, with volumes approaching one million trucks per year.
“We are very excited about expanding our relationship with General Motors and the
tier one suppliers for this platform, which is one of the top selling in North America
year-in-and-year-out,” said Tony Lovell, Vice President of Global Sales and Marketing at
Grede. “We have a long-standing relationship with General Motors and supplied similar
content on the predecessor T900 platform.”
F4
PRECISION CASTPARTS CORP. BROADENS
MACHINING CAPABILITIES WITH THE
ACQUISITION OF BUSINESSES FROM
HEROUX-DEVTEK
Source: Precision Castparts Corp. (www.precast.com)
Precision Castparts Corporation (PCC) has agreed to acquire certain aerostructures
business units and McSwain Manufacturing from Heroux-Devtek Inc.
Heroux-Devtek’s aerostructures operations manufacture a wide variety of components
and assemblies from aluminium, aluminium-lithium, and titanium, such as bulkheads,
wing ribs, spars, frames, and engine mounts. The aerostructures operations include
Progressive Machine in Arlington, Texas, USA, as well as plants in Dorval (Montreal),
Canada, and Queretaro, Mexico. McSwain, headquartered in Cincinnati, Ohio, USA,
specializes in turning, milling, and drilling, and has developed a strong presence in
components for gas turbine and mining applications. These four facilities employ a total
of 440 people.
“The acquisition of these operations continues to move us much farther down the road
toward strategically building a more cohesive, far-reaching aerostructures business
within our Fastener Products segment,” said Mark Donegan, Chairman and CEO of
PCC. “In addition to serving our current customer base, Heroux-Devtek strengthens
our presence with such key customers as Lockheed, Bombardier, and Gulfstream. The
acquisition significantly enhances our ability to machine longer aircraft ribs and spars,
as well as larger forged components such as our titanium bulkheads from Grafton,
which we can then supply directly to our OEM customers. These businesses provide us
with the advanced, state-of-the-art machining capability that will continue to help drive
our top- and bottom-line growth.”
The cash acquisitions, which will be treated as the acquisitions of assets for tax
purposes, will be immediately accretive to earnings. Subject to regulatory approvals,
the transactions are expected to be completed during the second quarter of fiscal 2013.
The aerostructures businesses will be reported as part of the Fastener Products segment,
while McSwain will become part of the Forged Products segment.
Precision Castparts Corporation is a worldwide, diversified manufacturer of complex
metal components and products. It serves the aerospace, power, and general industrial
markets. PCC is the market leader in manufacturing large, complex structural investment
castings, airfoil castings, forged components, and highly engineered, critical fasteners
for aerospace applications. In addition, the company is the leading producer of airfoil
castings for the industrial gas turbine market. PCC manufactures extruded seamless pipe,
fittings, forgings, and clad products for power generation and oil & gas applications;
commercial and military airframe aerostructures; and metal alloys and other materials
to the casting and forging industries.
Nevada repair and casting
centre undertakes USD$4 million
renovation
Source: Chromalloy (chromalloy.wordpress.com)
Chromalloy’s engine component repair, manufacturing and casting centre in Carson
City, Nevada, USA, is undertaking a USD$4 million renovation and modernisation to
expand capacity and enable the operation to deliver parts in record time for the industry.
The project will add an additional casting furnace and other new equipment to the
superalloy component foundry, as well as better utilise space in a new Lean design that
will improve flow and accelerate throughput.
“We are expanding the breadth and level of services for our customers worldwide,” said
Nat Love, General Manager. “The Arrowhead facility is being completely renovated as
we continue delivering repairs and parts to our customers. When completed, the new
foundry and manufacturing and repair areas within the factory will significantly expand
capacity while allowing us to offer market-leading turnaround times.”
The renovation and expansion will result in “a vertically integrated business that provides
every gas turbine engine component repair service, from advanced coatings to finished
foundry castings to new manufactured parts ready for installation,” Love said.
Chromalloy’s 192,000 ft2 (17,800 m2)
Arrowhead operation—one of four
operations within the Nevada business
enterprise—provides turbine component
repairs and castings for aerospace
and aeroderivative engines that power
military and commercial aircraft, marine
fleets and electric plants in the energy
industry. Customers include major
commercial air carriers, the U.S. military
and utility companies.
Chromalloy manufactures aerospace engine
components. Image courtesy of Chromalloy.
With the installation of a new, higher
capacity foundry furnace, that will bring
to a total of thirteen superalloy investment casting furnaces at the facility. The operation
currently services approximately 15,000 components each year—and that capacity will
grow by 33% after the modernisation is complete, Love said.
“The renovation is being driven by a modern, new Lean factory layout to ensure efficient
work flow and work processes,” he added. The renovation and modernisation project
will be completed during the first quarter of 2013. At that time a grand opening will be
held for customers.
ask the expert...
Best Practice in Pump Maintenance
Garry Morgan,
Metaullics Systems
Sales Engineer,
Pyrotek Inc., Solon,
Ohio, USA
Most pump users understand the
necessities of basic maintenance.
However, some confusion can remain
on required frequency, maintenance
priorities and best practice. Here Garry
Morgan, Metaullics Systems Sales
Engineer for Pyrotek, answers questions
on pump maintenance and provides
guidance on best practice.
Why is it important to regularly maintenance pumps? What happens if you
don't?
I followed the parts (shafts, impellers
and posts) used by two companies that
use our J-50 pumps. Both run the same
number of J-50 pumps and have about
the same size furnaces. Pump speeds
were within 15 rpm of each other.
One company didn't have a planned
maintenance schedule for pump
repairs. They operated the pumps until
they failed. The other company had a
planned maintenance schedule with
pumps pulled on a weekly, monthly and
bimonthly schedule. The company with
the planned maintenance schedule
used 50% fewer shafts and impellers
and 60% fewer posts.
What are some best practices for
scheduling pump maintenance?
Some maintenance staff use repair tags.
When a pump is pulled out of service by
an operator / mechanic, they place this tag
on the pump to identify what part failed
on the pump (such as injection plug,
tube, etc.). Since each pump can require
a variety of different maintenance, some
maintenance departments also place
labelled pictures of each pump in the
maintenance area to help new operators
identify which pump they are using. To
most operators, a pump is just a pump.
What basic maintenance must be performed every week, month, two months?
Pump wells need to be skimmed a couple
times a shift to keep dross from building
up around the pump shaft. Dross can
reach extreme temperatures and cause
excess wear on the shaft at the metal level.
Gas injection pumps need to be checked
weekly to ensure there is no magnesium
chloride buildup in the discharge,
which could reduce circulation and
melt rates. Magnesium chloride can
form when chlorine is used at low metal
temperatures.
Posts and pump shafts should be checked
monthly. If worn below half their original
diameter, the pump should be pulled and
the posts and shaft cleaned and wrapped
using Frakset cement and fibreglass tape.
This process is much like wrapping a
baseball bat handle. Always start about 2
inches (5 cm) above the top of the worn
area and extend 2 inches (5 cm) below
Metaullics
repaired. I've seen both process work,
but the part life on the second (layer by
layer) method seems to last longer.
Pump bases should be inspected every
couple months for damage (chipping
or cracks) to both the top and bottom
bearing rings. Bases should also be
inspected at this time for any cracks in
the graphite.
Repaired J-50 Pump after 60 days of service
the worn area to ensure a strong bond for
the repair.
It's important to clean the graphite area
to be repaired very thoroughly (a wire
grinder wheel or wire brush work best),
and wipe down the graphite with a wet
cloth to remove the dust before starting
to wrap the part. Apply a 1/4 inch (0.64
mm) thick layer of Frakset to the graphite
starting a couple of inches above the
worn area and extending 2 inches (5 cm)
below. Using the fibreglass tape, wrap
the graphite using the same principle
you use to wrap a baseball bat. Work the
fibreglass tape into the cement during
the wrapping process, making sure to
keep the tape pulled tight at all times.
There are two ways to approach the next
step. Some plants repeat this wrapping
procedure until the part is back to its
normal size, while others put the part
in the drying oven and let the cement
and tape dry, then apply the next layer,
continuing this processes until the part is
How much more life can I get out of a
regularly maintained pump?
Depending on the quality of the repairs
and how closely repair schedules are
followed, you can see a 20–30%
average improvement over running the
pumps to failure.
Is operator training important for pump
maintenance?
I find that companies who consistently
have the lower annualized pump
costs also have high quality operator
training guidelines. Operators are
trained to recognise when a pump is
not operating correctly and how to fix
the problem.
What support does Pyrotek provide?
In addition to full pump installation and
start-up support, Pyrotek has a trained
staff of technical support ranging from
field service technicians to mechanical
and electrical engineers located
close to most customers. In addition,
Metaullics pump sales engineers do
a range of on-site operator and staff
training.
www.pyrotek.info/metaullics
Waukesha Foundry Celebrates
Centennial
Specialisation Was Key to Success
Source: Waukesha Foundry (waukeshafoundry.com)
Throughout its 100-year history, Waukesha Foundry has adapted its product line and
business focus to meet industry demand. Once a maker of cast aluminium cookware,
the foundry is now a sophisticated manufacturer of high alloy castings for the aerospace,
automotive, defense, petrochemical and food processing equipment markets.
Founded in 1912 by Corwin C. “C.C.” Smith, the company originally produced brass
castings. By 1915, the foundry introduced nickel because Smith saw an increased need
from food manufacturing clients for non-galling alloys that improved sanitation. By the
mid 1930s, Waukesha Foundry was the largest producer of nickel alloy in the country.
As such, the company’s namesake Waukesha Metal was “famous” both nationally
and internationally. An early newspaper article from 1936 boasts, “All the ice cream
counters made in this country contain parts made of the firm’s alloy.” That statement
remains true today.
During the Great Depression, Waukesha Foundry entered the cast aluminium cookware
business; it was short lived but highly successful during lean manufacturing years. A
pump business was added and in full swing by 1940 catering to food, chemicals, oil,
cosmetics, and pharmaceuticals industries. R&D and metallurgical labs were started in
1940 and 1942 respectively to develop new products and alloys, specifically in stainless
steel which became popular and had widespread use by the 1950s. The company
continued to expand and was owned by various investment companies throughout the
next several decades. Today, the company is owned by Facilitator Capital, FCF Partners,
of Milwaukee, Wisconsin, USA.
“2012 has been an exciting year for Waukesha Foundry,” said Ken Kurek, the foundry’s
President and CEO. “We are celebrating our past while making a major investment in
our future,” referring to a USD$2.2 million capital investment in foundry equipment and
office renovation.
Other significant developments in 2012 include:
•Restructured its union agreement with a Pay For Skill program
•Developed a partnership with French tool shop, Groupe Allio
•Secured a major order from Japan Aeroforge / Kobe Steel
•Implemented an ERP system within a six month timeframe
•Launched a five year, USD$25,000 scholarship program for University of WisconsinMadison College of Engineering & Applied Science students
•Increased participation at international trade shows
Kurek is managing an aggressive growth strategy, having increased sales by 40% over
the last two years. Browsing through the company archives, Kurek noted similarities
between the early business and today. “The company was always proud to be on the
cutting edge of technology for its time.”
PRECISION CASTPARTS CORP. BROADENS
AEROSTRUCTURES CAPABILITIES WITH
THE ACQUISITION OF KLUNE
Source: Precision Castparts Corp. (precast.com)
Precision Castparts Corporation (PCC) has agreed to acquire Klune Industries (“Klune”),
a manufacturer of complex aluminium, nickel, titanium, and steel aerostructures. Klune
focuses on complex forming, machining, and assembly of aerostructure parts, in addition
to offering significant expertise in a range of cold-formed sheet metal components. The
company, which operates facilities in North Hollywood, California, USA; Spanish Fork,
Utah, USA; and Kent, Washington, USA, employs approximately 740 employees.
“Like Centra and Primus before that, Klune expands our reach into the widely
fragmented aerostructures market,” said Mark Donegan, Chairman and CEO of PCC.
“Klune also offers significant synergies with our existing operations. Klune’s sheet metal
and fabrication capabilities will be a major addition to our aerostructures product
offering. The company purchases castings, forgings, and fasteners, which can now be
supplied internally, and their expertise in machining castings adds to the capabilities
of our aerostructures companies. The Klune facilities in California and Washington are
located very close to existing PCC aerostructures plants, enabling us to gain operational
and geographical leverage. And, from a top-line perspective, Klune’s product line will
significantly increase our dollar content on the Boeing 787, and they have solid positions
on other major aircraft platforms, such as the Boeing 737 and Gulfstream G650.”
The cash acquisition will be immediately accretive to earnings. Subject to regulatory
approvals, the transaction is expected to be completed during the second quarter of
fiscal 2013, after which Klune’s results will be reported as part of the Fastener Products
segment.
Precision Castparts Corporation is a worldwide, diversified manufacturer of complex
metal components and products. It serves the aerospace, power, and general industrial
markets. PCC is the market leader in manufacturing large, complex structural investment
castings, airfoil castings, forged components, and highly engineered, critical fasteners
for aerospace applications. In addition, the company is the leading producer of airfoil
castings for the industrial gas turbine market. PCC manufactures extruded seamless pipe,
fittings, forgings, and clad products for power generation and oil and gas applications;
commercial and military airframe aerostructures; and metal alloys and other materials
to the casting and forging industries.
F5
Product Feature
TOUNETSU® OXIDE REDUCING
HOLDING FURNACE
Oxide Reducing Furnace
®
The Tounetsu® heat source is fully immersed in the molten metal, minimising the
generation of oxides in the furnace. The heaters produce convection currents in the
molten metal, increasing temperature uniformity throughout the melt, lowering the
temperature of the roof of the furnace, and improving the operator environment.
The advanced ceramic heater tubes typically provide a life of four-plus years. The
homogeneous melt temperature provided by the under heat immersion heater
system produces the high melt quality required to cast critical parts with complex
features and strict quality requirements. The Tounetsu under heat design is ideal for
customers producing larger and more expensive castings.
Additional Benefits
•Heater elements are individually
and proportionally controlled to
maximise the element life.
•Furnace design typically provides
for continued operation even with
the failure of one heater.
•Heaters and heater thermocouples
can be replaced without draining
the furnace.
www.pyrotek.info/tounetsu
Reengineered Dosing Tube
Reduces Maintenance costs,
Increases Savings
A large Italian high pressure diecaster
has been a Pyrotek customer since 2008.
Equipped with fifteen Striko Westofen
furnaces, the customer was looking for a
better solution for their dosing tubes. Their
standard two-part (metal cone, ceramic
tube) dosing tubes required significant
maintenance time and handling: old tubes
were packaged and sent to a subcontractor
who would maintenance and reassemble
the pieces.
Working closely to understand the
customer’s requirements, Claudio Cozzi,
Pyrotek Sales Engineer, suggested they use
a single piece cast refractory dosing tube,
made from Pyrocast NZ recenly developed
by Pyrotek’s engineering centre in Blankso,
Czech Republic.
Typical two piece dosing tube
Pyrotek’s single piece cast dosing tube
The single piece dosing tube provides
several benefits to the customer. Foremost, the customer’s maintenance handling is
reduced to simply throwing the tube away; as an added benefit, the refractory tubes are
lighter and easier to handle. This reduction in handling equates to an estimated six hours
of time savings per year. Additionally, the new dosing tubes have a 20% longer lifetime
on average and cost 25% less than the previous dosing tube. Combined, these benefits
add up to an estimated USD$18,000 annual savings for the customer.
www.pyrotek.info/foundry
F6
Schaeffler is Focusing on Innovative
Lightweight Technologies for
Sustainable Mobility in the Future
Lightweight designs as a key technology for sustainable
drive concepts
Source: Schaeffler Technologies AG & Co. KG (schaeffler.com)
Reducing fuel consumption and CO2 emissions are important fields of activity for
developers in the automobile industry. Reducing overall vehicle weight thus reversing the
upward spiral in this area is one of the fields with potential for optimisation. Lightweight
construction will become an elementary technology for sustainable mobility in the
future, not only for conventional drive types, but also for electric vehicle concepts.
Schaeffler is also focusing on innovative lightweight technologies as an important
component for sustainable strategies for reducing CO2.
Selector hubs in transmissions: With its new selector hub made of sheet metal for
example, Schaeffler can now facilitate reductions in weight of up to 25% compared
with a conventional solid sintered metal version. The new two-part design comprising
geometrically-compatible sheet metal half shells can even transmit higher torque than
sintered components after optimization of the design process.
Hybrid design gearshift forks: The intelligent use of mixed constructions is key to
opening up further potential for improving efficiency in manual transmissions. For
example, Schaeffler’s new hybrid gearshift forks, which can replace more traditional and
conventional steel gearshift forks, have bodies made of aluminium. The striker jaw is a
high-precision sheet metal blanked component. During the assembly process, the striker
jaw is precisely aligned in the screw mounting plane and joined to the gearshift fork,
allowing single component tolerances to be compensated. Costly recasting as required
with conventional aluminium gearshift forks is not necessary during the manufacturing
process of Schaeffler’s hybrid gearshift forks. In addition, complex reworking of the
assembly is not necessary. This mixed construction not only reduces the weight of
Schaeffler hybrid gearshift forks compared with that of conventional solutions, but also
makes them more compact. This reduces the design space required.
Redesigned Launder System Reduces Costs, Improves Performance
continued from page 1
SOLUTION
After working with Pyrotek’s engineering centre in Blansko, Czech Republic, Villacampa
proposed a new solution to the customer. Using the existing steelwork, he proposed
a new profile with a variety of speciality designed refractories for various sections of
the launder, depending on their use. By using the old steelwork, there was extra space
to add more insulating board as well as
more backup insulation. In addition, a
new impact bowl was proposed to reduce
metal splashing.
Using calculations, it was estimated that
a change in refractory and insulating
materials would reduce metal heat loss
by 14°C (25°F). In addition, Pyrotek
proposed new launder covers to further
reduce heat loss by 10°C (18°F).
The first part of the project was approved
New launder system refractories reduced heat loss
and moved forward. With its new
refractories, the redesigned launder system
has been installed and has significantly improved the customer’s performance, foremost
reducing melt temperature loss by 19°C (34°F). They now only require the burners for a
short time to preheat the launder line, significantly reducing gas consumption and the
accompanying costs. Oxidation, dross and corundum build-up were all significantly
reduced and both maintenance and safety were improved.
Mapsa is very satisfied with the results and is now moving forward with the next part of
the project, installing new launder covers to further reduce heat loss. Recognition go to
Pavel Skotak, Ales Blaha and the rest of Pyrotek’s Engineering Centre in Blansko, Czech
Republic for help with the design of the launders and covers. Special thanks also to
Evaristo Zoco, José Ignacio Sáinz de Murieta and Eduardo Gárate, technical team from
Mapsa, for their support and help to carry out this project as well as collecting data for
this article.
www.pyrotek.info/launder
The simple assembly process means the hybrid design can easily be manufactured all
over the world. These hybrid gearshift forks are already in volume production with one
customer and other volume production applications are set to follow.
Shift mass: Reductions in weight and design space can also be made with shift masses,
while simultaneously allowing increases in driving comfort. Conventional shift masses
comprise a steel component with a high mass. They generate mass inertia thereby
balancing out force peaks and vibrations that occur during gearshift operations.
Schaeffler offers two solutions here with optimised mass. The mass of Schaeffler’s i²
shift mass module has been reduced by up to 70% compared with that of conventional
components. However, the i² shift mass module’s lower inertia level is increased using
a gearbox. A two-stage planetary gearbox that enables very high ratios forms the core of
this gearshift module. A slipping clutch reduces the load on the plastic gear teeth during
overloading thereby helping to ensure a long operating life.
Schaeffler’s lightweight shift mass involves using another approach by improving the
distribution of weight of conventional shift masses. Fitting the actual mass on the outer
end of the lightweight carrier ensures optimum utilisation of the lever action provided.
The lightweight carrier is made of aluminium or plastic in conjunction with a steel
gearshift lever for transmitting the gearshift force.
“Schaeffler’s new lightweight concepts enable reductions in weight of up to 1.2 kg
(2.6 lb) to be made in transmissions,” explains Pascal Kohtes, Product Developer at
Schaeffler. “Lightweight constructions often not only have an effect on the components
themselves, but also initiate significant positive secondary effects for the vehicle as
a whole. These range from advantages in driving dynamics and reducing weight to
cutting fuel consumption and CO2 emissions. Lightweight constructions are therefore a
specialist area with a strategic focus that will dominate mobility in the future.”
Publisher
Pyrotek Inc.
9503 E. Montgomery Avenue, Spokane Valley, WA 99206 USA
www.pyrotek.info
Contact-Linda Ingle
email—editor@improvingperformance.com
This document is for information purposes only. The information contained in this
document has been compiled from sources believed to be reliable. While every effort
has been made to ensure that the information is correct and that the views are sound,
Aluminium Insight cannot be made liable for any loss, no matter how it may arise.
Aluminium Insight is produced by Pyrotek Inc. for its customers.
Copyright 2012. All rights reserved.
Please send your comments and suggestions for content for future issues to:
comments@improvingperformance.com
Eight Toyota Manufacturing
Facilities Recognised by the U.S.
EPA for Improved Environmental
Performance
Source: Toyota (pressroom.toyota.com)
The U.S. Environmental Protection Agency (EPA) has recognised eight Toyota
manufacturing sites in North America for achieving a 10% reduction in energy intensity
through its ENERGY STAR Challenge For Industry program. Collectively, these eight sites
have reduced energy intensity by nearly 24% from baseline.
Energy intensity is measured relative to efficiency improvements in process and
equipment.
The ENERGY STAR Challenge For Industry program is only awarded to individual
industrial sites. To gain recognition, the site’s company must be an ENERGY STAR
partner. Earlier this year, Toyota Motor Engineering & Manufacturing North America,
Inc. (TEMA) received its eighth consecutive ENERGY STAR Sustained Excellence Award
for its continued leadership in protecting the environment through energy efficiency and
management.
“Thanks to the efforts of our team members, Toyota has reduced our total energy use per
vehicle over the last five years as we achieved greater energy efficiency across North
America,” said TEMA Executive Vice President Steve St. Angelo. “This demonstrates that
when good ideas are shared, great things can happen as we continuously identify new
opportunities to reduce energy consumption while improving our processes.”
The eight Toyota facilities recognized by the EPA include: Bodine Aluminum (Jackson,
Tennessee, USA, and St. Louis, Missouri, USA); Toyota Motor Manufacturing, Huntsville,
Alabama, USA; Toyota Motor Manufacturing Canada (Cambridge and Woodstock,
Ontario); Toyota Motor Manufacturing, Princeton, Indiana, USA; Toyota Motor
Manufacturing, San Antonio, Texas, USA; and Toyota Motor Manufacturing, Buffalo,
West Virginia, USA.
Several examples of reduction in energy intensity include: lighting efficiency, innovative
lighting technology, hot water boiler linkage, and paint booth HVAC system. These
resulted in an energy reduction from established baselines of 13.8–36%.
Since 2006, Toyota’s U.S. manufacturing operations have received eighteen Energy Star
Plant Awards from the U.S. EPA, recognizing each plant’s energy performance over the
past year and scoring in the top 25% of its industry.