AJO-3-21-epaper

Special: Aluminium
Extrusion industry
Interview with SMS group
Castool clean-out block
for efficient cleaning
of liner walls
Integrated process model
for inductive billet heating
AWW starts operating
a new extrusion press
CRU launches Emissions
Analysis Tool
© SMS group
BMW Group sources
aluminium produced
using solar energy
Volume 97 · March 2021
International Journal for Industry, Research and Application3

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Phone: +43 7722 806-0
Fax: +43 7722 806-1530
info@hertwich.com
www.hertwich.com

e d i t o r i a l
Volker Karow
Chefredakteur
Editor in Chief
Low-Carbon-Labels
haben Hochkonjunktur
Trade boom for
low-carbon labels
Eine nachhaltige Wertschöpfung, eine energie-
und ressourceneffiziente Produktion, die
Reduzierung des ökologischen Fußabdrucks,
der Aufbau einer Kreislaufwirtschaft – dies
alles sind seit vielen Jahren zentrale Schlagworte,
die auf die Herausforderungen im
Kampf gegen die globale Klimaerwärmung
verweisen. Kaum eine Firmenmeldung, die
eine Investitionsmaßnahme zum Gegenstand
hat, kommt ohne den Hinweis auf die damit
verbundene Einsparung von CO 2 -Emissionen
aus. Gelegentlich fragt sich der geneigte
Leser, ob es auch betriebswirtschaftliche
Gründe für eine geplante Produktionsausweitung
oder Anlagenmodernisierung gibt.
Dieses Phänomen kann industrieweit beobachtet
werden, nicht nur in der Aluminiumindustrie.
In der dem Verfasser dieser Zeilen
etwas vertrauteren Branche fällt allerdings
auf, dass die letzten Monate von einer besonderen
Kreativität geprägt sind, mit der Hüttenproduzenten
„grünes“ Aluminium propagieren
– insbesondere unter dem Schlagwort
„low carbon aluminium“, kohlenstoffarmes
Aluminium. Die Liste der Unternehmen, die
ihr Hüttenaluminium mit speziellen Low-Carbon-Labels
versehen, wird länger und länger:
Alcoa vermarktet EcoLum, Rio Tinto Renew-
Al, Hydro hat Reduxa im Angebot, Century
verkauft seit kurzem Natur-Al, Rusal bietet
Allow an, das mit Wasserkraft in Sibirien hergestellt
wird, EGA liefert an BMW CelestiAL,
das mit Solarstrom erzeugt wird, und Rio Tinto
hat obendrein noch ein Nachhaltigkeits-
Label, Start, angekündigt. Sicherlich werden
weitere kohlenstoffarme Marken diese Aufzählung
in nächster Zeit ergänzen.
Im Grunde ist nichts dagegen einzuwenden,
wenn im Wettbewerb stehende Produzenten
mit solchen Labels auf die kohlenstoffarme
Produktion von Aluminium hinweisen
und versuchen, dafür einen Premium-Aufschlag
einzufordern. Andere Branchen wie
die Stromwirtschaft vermarkten ihren Ökostrom
auch mit speziellen Tarifen. Und
schließlich nutzen die Kundenindustrien, allen
voran die Automobilbranche, das CO 2 -
arm und nachhaltigkeits-zertifizierte Aluminium,
um die Klimabilanz ihrer Produkte
aufzubessern. Ob sich ein solcher Premium-
Aufschlag aber für ein Metall, dessen Preisbildung
an den globalen Rohstoffbörsen erfolgt,
in nennenswertem Umfang erfolgreich
durchsetzen lässt, bleibt abzuwarten.
Klar ist auch, dass ein Low-Carbon-Label
kein neuer Beitrag im Kampf gegen den Klimawandel
ist. Das mit erneuerbarer Energie,
meist Wasserkraft, so erzeugte Metall wird in
aller Regel in Aluminiumhütten produziert,
die seit vielen Jahren, meist Jahrzehnten diese
Aluminium“qualität“ produzieren.
Sustainable value creation, energy- and resource-efficient
production, the reduction of
the ecological footprint, the creation of a cyclic
economy – for many years all these have
been catchwords that highlight the challenges
in the fight against global climate warming.
Hardly a single company report that deals with
investment measures appears without a reference
to the related saving of carbon dioxide
emissions. Occasionally a reader so inclined
might wonder whether there are also business
management reasons for a planned production
increase or plant modernization.
This phenomenon can be observed throughout
industry, not just in the aluminium industry.
In the branch most familiar to the author
of these lines, however, it is striking that the
last few months have been characterized by
the particular creativity with which smelter
producers are promoting ‘green’ aluminium,
especially under the slogan ‘low-carbon aluminium’.
The list of companies that have
endowed their smelter aluminium with special
low-carbon labels is growing longer and
longer: Alcoa markets EcoLum, Rio Tinto RenewAl,
Hydro has Reduxa in its range, Century
recently began selling Natur-Al, Rusal
offers Allow which is made in Siberia with
hydroelectric power, EGA supplies CelestiAl
to BMW, which is made using solar power,
and Rio Tinto has on top of that announced
yet another sustainability label, Start. Further
low-carbon brands will certain be added to
that list before long.
Basically there are no grounds for objection
if competing producers refer to the lowcarbon
production of aluminium with such
labels and seek to claim a premium surcharge
for them. Other sectors too, such as the electricity
industry, market their eco-power at
special rates. And finally the customer industries,
with the automobile industry at the forefront,
use low CO 2 and sustainability-certified
aluminium to improve the climate balance
of their products. But whether such a
premium surcharge for a metal whose pricing
is determined by the global raw materials
exchanges will succeed on a significant scale,
remains to be seen.
It is also clear that a low-carbon label offers
no new contribution or approach to the
fight against climate change. The metal produced
using renewable energy, water power
in most cases, is as a rule produced in aluminium
smelters which have already been producing
these aluminium ‘grades’ for many
years, in most cases decades.
ALUMINIUM · 3/2021

i n h a l t
Editorial
Low-Carbon-Labels haben Hochkonjunktur
Trade boom for low-carbon labels.................................................... 3
Aktuelles • News in Brief • Event 6
Wirtschaft • Economics
14
Aluminium im Monatsrückblick...................................................... 10
Produktionsdaten der deutschen Aluminiumindustrie ......................... 11
LME issues discussion paper on future market structure.....................12
Growing demand for sustainable aluminium solutions at sea...............13
New US presidency – more trade tariff questions..............................14
Rio Tinto launches ‘Start’: the first sustainability label for aluminium....15
North American industry records major sustainability gains.................16
CRU launches Emissions Analysis Tool..............................................17
20
Pioneer solution can eliminate use of permanent bauxite tailing dams ..18
Schweizer Alu-Branche meldet deutlichen Produktionsrückgang .......... 19
BMW Group bezieht mit Solarstrom hergestelltes Aluminium
BMW Group sources aluminium produced using solar energy ............. 20
BMW Group, Tetra Pak and Schüco
raise concerns over Atewa-sourced bauxite..................................... 24
ALUMINIUM-StrangpressINDUSTRie
ALUMINIUM Extrusion INDUSTRY
26
Interview mit T. Winterfeldt, Geschäftsbereichsleiter Schmiedetechnik,
und H. Hoppe, Vertriebsleiter Strangpressen bei der SMS group
Interview with T. Winterfeldt, manager of the Forging Technology business
and H. Hoppe, head of Sales for Extrusion Presses in SMS group... 26
Castool clean-out block for efficient cleaning of the liner wall ............32
Multidirektionale Gabelstapler für sicheres
und effizientes Bolzenhandling • Multidirectional
forklifts for safe and efficient billet handling................................... 34
AWW nimmt neue Strangpresse in Betrieb
AWW starts operating a new extrusion press................................... 36
Latest News
www.alu-web.de/en
36
Hydro completes ASI certification of its European extrusion plants •
Vimetco Extrusion a supplier for sophisticated industries • extrutec
awarded new order from Turkey • Dubal Holding acquires majority
stake in extrusion company • Hindalco to set up an extrusion plant
in Silvassa • Auto extrusion applications: some recent highlights ...38-39
Aluminium extrusions address auto industry challenges......................40
Tri Metalurji works closely with Turkish aluminium extrusion industry....41
ALUMINIUM · 3/2021

C o n t e n t s
Danieli Breda: New 40-MN extrusion press for PMS Aluminium...........42
Integriertes Prozessmodell für die induktive Bolzenerwärmung
Integrated process model for inductive billet heating.........................43
Technologie • Technology
Jiangzhong launches installation of
Italpresse’s largest ever die-casting machine ....................................48
Automated billet casting lines in the aluminium industry................... 49
Pioneering research into aluminium
grain refiner efficiency back in business ..........................................50
42
Storvik’s furnace tending tools – the optimal solution for casthouses... 51
Flexible crane logistics for a press shop.......................................... 52
Huissel betreibt Schuler-Presse neuester Bauart
Huissel operates Schuler press of latest design .................................54
Industria Metalli – mit Hochdruck in die Gussteilbearbeitung
Industria Metalli – pressing ahead with the machining of castings.......56
Doppelte Standzeit durch geringen Verschleiß
Tool life doubled thanks to low wear..............................................60
GM launches USD100m expansion for transmissions production •
New Nissan SUV based on closed-loop recycled aluminium.................62
52
Forschung • Research
Besser kleben im Leichtbau: Projekt
GoHybrid optimiert Hybridverbindungen..........................................63
Schwingfestigkeit hybrid gefügter Materialverbindungen:
Fraunhofer LBF ermittelt hohes Potenzial für Leichtbau
Fatigue strength of hybrid joined steel-aluminium structures:
Fraunhofer LBF identifies high potential for lightweight design...........64
56
C o m pa n y N e w s W o r l d w i d e
Aluminium smelting industry .........................................................66
On the move...............................................................................66
Bauxite and alumina activities....................................................... 66
Recycling and secondary smelting.................................................. 67
Downstream activities.................................................................. 67
Suppliers....................................................................................69
Dokumentation • Documentation
Vorschau, Impressum • Imprint, Preview..........................................82
Lieferverzeichnis • Suppliers Directory...... 70-81
Inserenten dieser Ausgabe
List of advertisers
Drache GmbH, Germany 35
extrutec GmbH, Germany 33
Hertwich Engineering GmbH, Austria 2
Lasco Umformtechnik GmbH, Germany 19
Ria Cast House Engineering
GmbH, Germany 47
Scheuch GmbH, Austria 7
Storvik AS, Norway 49
Tri Metalurji AS, Turkey 39
ALUMINIUM · 3/2021

a k t u e l l e s
Step-G baut neues Logistik-Verteilzentrum in Hettstedt
© Step-G
Step-G, Hersteller von Alu-Strangpressprofilen
in Deutschland, Belgien und
China, hat am Standort Hettstedt mit
dem Bau eines neuen Logistik-Verteilzentrums
begonnen.
Mit dem neuen Verteilzentrums für die Traditionsmarke
Bug Aluminium-Systeme bündelt
Step-G interne Abläufe von der Weiterverarbeitung
bis hin zum Versand und richtet sich
damit besser auf Kundenanforderungen aus.
Der Standort Hettstedt wurde 2019 übernommen.
Seitdem wurden umfassende Sanierungs-
sowie Modernisierungsarbeiten in An-
Die Modernisierung in Halle II des Bug Logistik-Verteilzentrums ist in vollem Gange
lagen, Infrastruktur und Gebäude durchgeführt.
Diese Investitionen sorgen dafür, dass
der Standort bestens für den Aufbau des Lo-
gistikverteilzentrums für die Bug Aluminium-
Systeme gerüstet ist.
Der Schwerpunkt liegt in der zentralen
Bündelung der Weiterverarbeitung, der Lagerung
und dem Versand von Fensterbankund
Dachsystemen. Mit der Verlagerung von
einzelnen Weiterverarbeitungs- und Logistikprozessen
vom Bolzen bis zum Kunden von
bisherigen Standort Vogt nach Hettstedt sollen
die Partner und Kunden von Bug profitieren.
So agiere die Weiterverarbeitung für die Systemprofile
an zentraler Stelle und sei dadurch
unabhängig.
Durch die Vereinfachung von Prozessen
und Abläufen ergänzt um die Erhöhung von
Lagerbeständen und einer effizienten Transportabwicklung
wird die Lieferfähigkeit deutlich
erhöht, Lieferzeiten werden verkürzt.
Die zentrale Erschließung von Weiterverarbeitung
und Lager am Standort Hettstedt sowie
dem weiteren Aufbau und der Inbetriebnahme
der Anlagen erfolgt schrittweise. Die
Umstellung werde ab der zweiten Jahreshälfte
erfolgen, teilt Step-G mit. Ab dann werde
damit begonnen, die Kunden von Bug Aluminium-Systeme
direkt vom Bug Logistikverteilzentrum
in Hettstedt zu beliefern.
Neuer Geschäftsführer bei Hertwich Engineering
Die Hertwich Engineering GmbH in
Braunau, Österreich, hat mit Gerold
Keune seit 1. Oktober 2020 einen neuen
Geschäftsführer, der zudem die Aufgabe
des Vertriebsleiters übernimmt.
Diplomingenieur Keune, zuvor verantwortlich
für Vertrieb und Abwicklung bei KHD,
werde mit seiner über 25-jährigen Erfahrung
im internationalen Maschinen- und Anlagenbau
besondere Schwerpunkte auf den Ausbau
der Technologieführerschaft von Hertwich
Engineering sowie auf verstärkte Internationalisierungs-
und Service-Aktivitäten legen,
heißt es in einer Unternehmensmitteilung der
Muttergesellschaft SMS group.
Als einer der Innovationsführer in Recyclingtechnologien
für Aluminiumschrott und
Anlagen in der Aluminiumindustrie präsentiert
Hertwich Engineering regelmäßig Neuentwicklungen
und Verbesserungen vorhandener
Produkte.
Gerold Keune im Hertwich-Werk vor einer der
leistungsfähigsten Ultraschallprüfanlagen mit
AA-Prüfqualität und intuitiven Bedienfunktionen
© Hertwich
ALUMINIUM · 3/2021

n e w s i n b r i e f
Rusal to acquire insolvent Aluminium Rheinfelden
Russia’s aluminium flagship Rusal has
agreed to acquire the business and assets
of Aluminium Rheinfelden out of insolvency.
Aluminium Rheinfelden is one of Germany’s
leading manufacturers of aluminium alloys,
semis and carbon-based components and a
major supplier to the global automotive industry.
The company’s track record of innovation
and R&D, combined with its technical
expertise (Aluminium Rheinfelden owns over
70 patents) and deep connections into the
automotive sector, will help strengthen Rusal’s
position as the supplier of choice to its
international network of automotive customers.
The transaction is expected to deliver
strong commercial synergies by matching Aluminium
Rheinfelden’s high-end niche product
focus with Rusal’s global scale low-carbon
aluminium alloy production.
As part of its long term growth strategy,
Rusal intends to rebuild the Aluminium Rheinfelden
businesses and restore the majority of
existing roles, unlocking the potential of its
R&D platform to deliver a new generation of
sustainable aluminium solutions that can be
produced on an industrial level in combination
with Rusal’s smelters. The company aims
to grow Aluminium Rheinfelden’s alloys production
back to 30,000 tonnes of output on
an annual basis.
The takeover is subject to approval by
the German Federal Ministry for Economic
Affairs and Energy and the German Federal
Cartel Office.
Aluminium Rheinfelden most recently
employed a total of 264 people and achieved
an annual turnover of 159 million euros in
2019. The company‘s history dates back to
1898, when the first aluminium smelter on
German soil was built in Rheinfelden, directly
on the Swiss border.
Century Aluminium and Glencore
to supply low-carbon Natur-Al to HAI
Century Aluminium has finalized the
sale of 150,000 tonnes of brand-named
‘Natur-Al’ aluminium over five years
to Austrian firm Hammerer Aluminium
Industries (HAI). Natur-Al products are
made with energy from 100% renewable
sources (hydro energy) at Century’s
Norðurál Grundartangi plant in Iceland.
The product line was officially launched
in 2020. The aluminium will be supplied
to HAI by Glencore.
Natur-Al aluminium has direct CO 2 levels below
2t of CO 2 /t Al – one of the lowest carbon
footprints in the world for the metal. The total
CO 2 footprint is 4t of CO 2 /t Al, less than
one quarter of the industry average, stresses
Century. Achieving these levels requires strict
adherence to the highest standards in the
sourcing of bauxite and alumina, the exclusive
use of ‘green’ energy from hydroelectric
and geothermal sources, and seamless operation
of the production process.
Referring to the first major sale of Natur-
Al, Century boss Michael Bless commented:
“We firmly believe that the Natur-Al lowcarbon
product allows Century and our customers
to contribute towards a better, greener
future. The use of aluminium instead of
steel, or other heavier metals, in manufacturing
has already delivered significant reductions
in CO 2 emissions; an excellent example
is the increased fuel efficiency in automobiles
with significant aluminium content.
Natur-Al offers a way for manufacturers to
further lighten their carbon footprint.”
HAI CEO Rob van Gils commented: “We
are delighted about this partnership that will
secure the supply of aluminium produced with
one of the lowest CO 2 footprints available.
As a recycler and remelter the CO 2 content
of the primary aluminium we buy has a tremendous
impact on our overall footprint. This
supply agreement is a clear statement that
HAI group is not compromising on our commitment
to sustainability. Combining Natur-
Al aluminium with our recycled materials will
allow us to produce billets at less than two
tonnes of CO 2 per tonne of metal. It underlines
our ambition to contribute to a better
future and that aluminium is part of the solution
for the ambitions of the EU Green
Deal.”
Robin Scheiner, Glencore’s head of Alumina
and Aluminium, commented: “We are
proud to support our long-standing partners
in the manufacture and supply of high quality,
low-carbon aluminium. Our commitment
to sourcing and supplying sustainable aluminium
will be enhanced through our membership
of the Aluminium Stewardship Initiative
(ASI). Each of us has a role to play in the
energy and mobility transition. At Glencore
over half the aluminium we supply is low-carbon,
a key element in our ambition to be net
zero by 2050.”
Norðurál Grundartangi is ASI certified
for the responsible production, sourcing and
stewardship of aluminium. All CO 2 emissions
are audited by independent third parties. ■
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www.scheuch-components.com
ALUMINIUM · 3/2021

E v e n t
ALUMINIUM-Messe auf September verschoben
Die für den 18. bis 20. Mai 2021 in Düsseldorf
geplante Branchenleitmesse ALU-
MINIUM wird auf den 28. bis 30. September
verschoben. Der Veranstalter Reed
Exhibitions hat diese Entscheidung in
Hinblick auf den anhaltenden Verlauf der
Covid-19-Pandemie nach Gesprächen mit
Ausstellern und Partnern getroffen. Auch
die Unsicherheiten rund um Reiserestriktionen
waren wegen des internationalen
Charakters der Messe ausschlaggebend.
Pandemie eingebrochen sind, brauchen wir
den Austausch, um wichtige Themen zu diskutieren
und Impulse für den Neustart setzen“,
so Baader weiter. So sieht das auch der
Branchenverband European Aluminium: „Die
Aluminiumindustrie konzentriert sich noch
immer auf die Überwindung der Krise. Zusätzlich
stehen wir vor der Herausforderung,
die Transformation zu einer klimaneutralen
und kreislauforientierten Wirtschaft in Europa
weiter vorantreiben. Eine ALUMINIUM in
angepasstem Format kann dazu einen wichtigen
Beitrag leisten“, sagt Gerd Götz, Director
General von European Aluminium.
„Wir sind zuversichtlich, mit dem neuen Termin
optimale Bedingungen für eine sichere
Veranstaltung und mehr Planungssicherheit
für unsere Aussteller und Besucher schaffen
zu können“, erläutert Benedikt Binder-Krieglstein,
Vorsitzender der Geschäftsführung des
Veranstalters Reed Exhibitions Deutschland,
die Ende Januar getroffene Entscheidung. „Die
weiter unklaren Pandemie-Entwicklungen
und Rahmenbedingungen haben uns zu einer
Neubewertung der Lage veranlasst. Für uns
steht an erster Stelle, die gesundheitlichen
aber auch wirtschaftlichen Risiken für alle
Teilnehmer zu minimieren und unnötige Kosten
zu vermeiden.“
Entsprechend wird auch der in Kooperation
mit dem Gesamtverband der Aluminiumindustrie
(GDA) ausgerichtete Kongress auf
den Septembertermin verschoben. Im Fokus
der Messe und des Kongressprogramms stehen
unter anderem die Zukunftsperspektiven
der Aluminiumindustrie, die Digitalisierung
der Wertschöpfungskette, eine nachhaltige
Mobilität und der Green Deal. „Die gesamte
Aluminiumindustrie steht vor einem zukunftsweisenden
Wandel. Wir werden der Branche
im September die Plattform bieten, um den
wichtigen Herausforderungen zu begegnen
und den Werkstoff Aluminium als Schlüsselmaterial
der Zukunft zu positionieren. Dabei
prüfen wir auch, wie wir physische und digitale
Komponenten ideal miteinander kombinieren
können. Mit der Veranstaltung im
September werden wir darüber hinaus einen
Ausblick auf die zukünftige Ausrichtung und
die Themen der darauffolgenden ALUMINI-
UM 2022 geben“, sagt Binder-Krieglstein.
„Es ist für uns wichtig, mit der Veranstaltung
im September erneut Anlauf zu nehmen
und unserer Industrie mit der ALUMINIUM
eine prominente Bühne für den Branchendialog
zu bieten“, ergänzt GDA-Geschäftsführer
Marius Baader. „Wir benötigen diese
Plattform dringend. Nachdem unsere Märkte
im vergangenen Jahr aufgrund der Corona-
ALUMINIUM Show postponed to September
ALUMINIUM, the world’s leading trade
fair for the aluminium industry, scheduled
for 18-20 May 2021, in Düsseldorf,
Germany, has been rescheduled to 28-30
September. Organizer Reed Exhibitions
made this decision in view of the ongoing
Covid-19 pandemic after discussions with
exhibitors and partners. Uncertainties
surrounding travel restrictions were also
a deciding factor due to the international
nature of the trade fair.
Benedikt Binder-Krieglstein, CEO of Reed
Exhibitions Deutschland GmbH, says: “We
are confident that the new dates will provide
us with the ability to ensure a safer event and
provide our exhibitors and visitors more time
to plan their attendance. The still unclear
developments of the pandemic and general
uncertainty have prompted us to reassess the
situation. For us, the priority is to minimize
the health and economic risks to all participants
and to avoid unnecessary costs.”
Accordingly, the congress, organized in
partnership with the German aluminium association
GDA, will be postponed to the September.
The focus of the trade fair and the
congress programme will include the future
prospects of the aluminium industry, the
digitization of the value chain, sustainable
mobility and the Green Deal. “The entire aluminium
industry is facing a transformation,”
says Binder-Krieglstein, adding: “In September,
we will provide the industry with the
platform to address these important challenges
and position aluminium as a key material of
the future. In doing so, we will also examine
how we can ideally combine physical and
digital components. With the September 2021
event, we will also provide an outlook on
the future direction and topics of the subsequent
ALUMINIUM 2022.”
GDA’s managing director Marius Baader
says: “It is important for us to take another
run-up with the event in September and to
offer our industry a prominent stage for industry
dialogue with ALUMINIUM. We urgently
need this platform. After our markets
collapsed last year due to the Coronavirus
pandemic, we need the exchange to discuss
important topics and propel the industry forward.”
This is also the view of European Aluminium:
“The aluminium industry is still focused
on overcoming the crisis. In addition,
we face the challenge of continuing to drive
the transformation to a climate-neutral and
circular economy in Europe. ALUMINIUM
in an adapted format can make an important
contribution to this, says Gerd Götz, director
general of European Aluminium.
© Reed Exhibitions
ALUMINIUM · 3/2021

n e w s i n b r i e f
Constellium plans to increase its recycling capacity in Europe
Constellium SE is in the advanced planning
stages of an investment to increase
its recycling capacity in Europe. This project
will be focused on using recycled material
to provide slabs for the company’s
automotive and packaging businesses in
Europe. The investment is expected to
add a minimum of 60,000 tonnes of annual
capacity to Constellium’s current
recycling footprint, which is already one
of the largest in the world.
Constellium expects to finalize the scope
and location of the project by the end of this
year, which will be dependent upon finalizing
engineering and obtaining required permits.
Start of production is expected to begin within
two years of when construction begins.
“An investment in expanding our recycling
capacity is a strong demonstration of our
commitment to sustainability. I expect this will
be a meaningful contributor to both our financial
and ESG (editor’s note: Environmental,
Social and Governance) objectives over
time,” said Constellium CEO Jean-Marc Germain.
“Furthermore, aluminium is at the epicentre
of several sustainability mega-trends
across our packaging, automotive, and transportation
end markets. As a result, our customers
are increasingly demanding products
that are sustainably and responsibly produced.
We expect this investment will provide
opportunities for Constellium to expand
its low-carbon product offerings to meet customer
needs,” he added.
The inherently sustainable
attributes of aluminium
are driving increased
demand for advanced
aluminium solutions produced
by Constellium.
In packaging, aluminium
cans are the most recycled
beverage containers, infinitely
reborn in a closed
loop process that has
them back on the shelf
in 60 days. In automotive
and transport, aluminium
helps advance
‘greener’ mobility by improving
fuel economy,
reducing CO 2 emissions,
increasing electric vehicle
range and improving
safety.
Recycling scrap is critical
to the aluminium life cycle. Using scrap
reduces the need for primary aluminium and
therefore minimizes waste, avoids resource
depletion, and lowers greenhouse gas emissions
across a product’s life cycle. Using scrap
aluminium is also more energy efficient and
has a lower environmental impact than primary
aluminium.
Constellium actively recycles more than
560,000 tonnes of externally sourced aluminium
scrap per year. On average, recycled
aluminium accounted for 38% of the
company’s product content in 2019. Of this,
With more than 560,000 tpy of externally sourced aluminium
scrap, Constellium is one of the largest recyclers
18%-points was post-consumer scrap (generated
at the end-of-life phase of finished
goods), and 20%-points was pre-consumer
production scrap (generated downstream from
Constellium’s operations). Constellium does
not consider that recycled content should be
singled out as the only relevant indicator for
the environmental performance of aluminium
products. “We prefer to focus on a product’s
end-of-life recycling, to ensure that
valuable resources are reliably and efficiently
collected and recycled,” Constellium stated
in its 2019 Sustainability Report.
© Constellium
Deposit Return Scheme threatens aluminium industry in UK
The UK’s thriving aluminium industry,
which employs more than 20,000 people
nationwide, would be facing an annual
production shortfall of 4.7 billion units
and the very real possibility of plant closures
if the UK adopts a flat rate deposit
return scheme (DRS).
This is one of the key findings from the Aluminium
Packaging Recycling Organisation
(Alupro), which has launched an extensive
new report assessing the implications of a
poorly designed national scheme. Developed
in partnership with independent think-tank
London Economics, alongside experts from
across the UK packaging sector, the document
analyses the environmental and economic
implications of implementing a flat rate versus
a variable rate deposit fee.
Aiming to tackle plastic pollution, increase
recycling rates, improve recyclate quality and
minimise litter, England, Wales and Northern
Ireland’s long-awaited DRS is expected to
come into force in 2023. The scheme will see
a deposit value added to the price of a beverage
product in store, which will be refunded
to the customer when empty packaging is
returned to a designated collection point.
Alupro notes that, while a variable rate
fee would see containers allocated with a deposit
value based on container size, a flat rate
model would apply a fixed fee to all beverage
containers. This unsophisticated approach
could see customers charged an additional
£4.80 for a 24-can multipack (on top of product
purchase price) compared to just 80p for
a 2 litre plastic bottle, which research suggests
would result in 60% of shoppers opting
for larger, cheaper, but much less sustainable
plastic alternatives – resulting in an immediate
decline in demand of around 11% for
easy-to-recycle aluminium cans. (KS) ■
Latest News
www.alu-web.de/en
ALUMINIUM · 3/2021

W i r t s c h a f t
Aluminium im Monatsrückblick
Ein Service der TRIMET Aluminium SE
Im Januar legte die Aluminium 3-Monatsnotierung
an der Londoner Metallbörse
nach der Rallye zum Jahresende
erstmal eine Verschnaufpause ein. Der
Aluminiumpreis notierte in einer Spanne
von USD 2.075/t bis USD 1.945/t
und schloss auf ähnlichem Niveau wie
im Dezember, bei circa USD 1.980/t.
Positive Zahlen aus dem verarbeitenden
Gewerbe in den USA, China und Europa
unterstützen weiterhin den Preis für das
Leichtmetall. Somit trafen die Gewinnmitnahmen
institutioneller Anleger auf
ein starkes Kaufinteresse physischer
Marktteilnehmer. Ein weiterer Grund für
die zwischenzeitlichen Kurskorrekturen
war der starke US-Dollar. Der Euro notierte
im Monatsverlauf zwischen 1,23 und
1,19 US-Dollar.
Die Marktprämie für P1020 Masseln (verzollt,
in warehouse Rotterdam) zeigte
sich im Januar unbeeindruckt von der
anhaltenden Backwardation zwischen
Januar und Februar sowie dem Anstieg
der LME registrierten Lagerbestände für
Aluminium um rund 80.000 Tonnen. Im
Monatsverlauf notierte die Marktprämie
bei USD 155/t. Das zeigt, wie stark die
physische Nachfrage auch weiterhin ist.
Auf- bzw. Abschlag für 3-Monatstermin
Letzte 6 Durchschnittswerte LME
Januar 2021 1,02 Euro
Dezember 2020 9,05 Euro
November 2020 11,29 Euro
Oktober 2020 14,46 Euro
September 2020 32,20 Euro
August 2020 31,85 Euro
2012 2013
2014 2015 2016 2017 2018 2019 2020
0
50
–50
Aluminium High Grade, Kasse
Letzte 6 Durchschnittswerte LME 2.500
Januar 2021 1.646,44 Euro
Dezember 2020 1.658,71 Euro
November 2020 1.631,78 Euro
Oktober 2020 1.531,07 Euro
September 2020 1.479,88 Euro
August 2020 1.466,58 Euro
2012 2013
2014 2015 2016 2017 2018 2019 2020
2.000
1.500
1.000
Aluminium Lagerbestände
Letzte 6 Monatsendwerte LME
6.000
Januar 2021 1.431.050 t.
Dezember 2020 1.345.800 t.
November 2020 1.374.025 t.
Oktober 2020 1.462.925 t.
September 2020 1.466.925 t.
August 2020 1.554.375 t.
2012 2013
2014 2015 2016 2017 2018 2019 2020
5.000
4.000
3.000
2.000
1.000
0
Alle Angaben auf dieser Seite sind unverbindlich.
Quelle: TRIMET Aluminium SE, weitere Informationen unter www.trimet.de.
Kennen Sie schon unser Monatsrückblick als Video-Podcast? www.trimet.eu/de/service/monatsrueckblick
Gemeinsam sind wir stärker | Gemeinsam gegen Corona. Bitte bleiben Sie gesund!
10 ALUMINIUM · 3/2021

W i r t s c h a f t
Produktionsdaten der deutschen Aluminiumindustrie
Primäraluminium Sekundäraluminium Walzprodukte > 0,2 mm Press- & Ziehprodukte**
Produktion
(in 1.000 t)
+/-
in % *
Produktion
(in 1.000 t)
+/-
in % *
Produktion
(in 1.000 t)
+/-
in % *
Produktion
(in 1.000 t)
Dez 44,5 3,3 Q4 17 186,4 6,8 144,3 11,1 24,7 -7,2
+/-
in % *
Jan 20 44,9 2,7 Q1 18 198,7 1,0 157,6 7,3 45,9 -10,9
Feb 42,6 8,8 Q2 199,8 4,6 176,2 13,4 46,2 -6,1
Mär 45,4 5,8 Q3 182,2 -3,6 180,9 6,9 46,9 -0,8
Apr 44,3 6,5 Q4 18 181,0 -2,9 159,9 4,0 38,9 -16,4
Mai 45,5 6,0 Q1 19 187,9 -5,4 143,8 -22,9 34,1 -27,3
Juni 43,4 5,9 Q2 170,0 -14,9 136,0 -19,1 35,0 -14,2
Juli 45,3 6,4 Q3 173,6 -4,7 139,6 -27,4 39,4 -15,2
Aug 44,6 4,0 Q4 19 160,4 -11,4 141,1 -22,7 39,4 -10,4
Sep 42,9 3,7 Q1 20 163,0 -13,3 165,6 -5,9 46,4 5,9
Okt 44,0 2,3 Q2 92,7 -45,5 165,7 -7,8 48,5 10,6
Nov 42,2 0,0 Q3 141,5 -18,5 174,2 -0,6 48,5 19,1
Dez 43,8 -1,6 Q4 20 151,2 -5,7 137,6 -4,6 29,9 21,2
* gegenüber dem Vorjahresmonat bzw. Vorjahresquartal für den Bereich Sekundäraluminium
** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
Sekundäraluminium
Walzprodukte > 0,2 mm
Press- und Ziehprodukte
ALUMINIUM · 3/2021 11

e c o n o m i c s
LME issues discussion paper on future market structure
The London Metal Exchange (LME) has
issued a discussion paper on market structure,
putting forward a set of proposals
designed to enable the Exchange to modernize
and adapt to emerging trends and
evolving customer needs. The proposals
aim to achieve increased transparency
and a structurally fairer and more efficient
marketplace. They also take account
of the rapidly increasing digitization
across commodity trading and the physical
metals industry more broadly.
LME CEO Matthew Chamberlain explained:
“As we set out in the 2017 Strategic Pathway,
it is vital that the LME continues to adapt to
serve its diverse trading
community as effectively
as possible.
Three years on, it is
clear that a desire for
greater transparency
and fairness, and increasing
digitization
across commodities
trading, require us to
consider changes to
some elements of the
LME’s structure. The
LME has an important
role to play in responding
to these trends, a
nd we believe it is the
right time to consider
the future development
of our market
in order to secure its
long-term sustainability
and growth and maintain the highest
standards in our broader ecosystem.”
The discussion paper considers several
changes to the LME, which are focused on
four main topics as set out in detail below:
• The Ring and reference prices
• Enhancing liquidity in the market
• The potential benefits of moving to a
realized variation margin methodology
• The possible introduction of additional
disclosures and policies to strengthen
market conduct.
The discussion paper also identifies key
features which the LME wishes to protect and
maintain – such as its date structure – and this
balance is reflective of the Exchange’s commitment
to the principles set out in its 2017
Strategic Pathway: serving the physical market,
ensuring fairness, increasing user choice
and maximising trading efficiency.
The Ring and reference pricing
The Ring, LME‘s open-outcry trading floor in pre-Covid era. Its days are numbered.
The LME believes it is the right time to consider
the permanent closure of the Ring and
a move to an electronic pricing structure. This
shift is expected to benefit the market by
broadening direct participation during the
price discovery periods and increasing overall
transparency.
Chamberlain commented: “The Ring is
a greatly treasured aspect of the LME’s rich
144-year history, and its closure is not a decision
we or our market will take lightly. However,
the LME has stood the test of time precisely
because of its ability to adapt to the
evolution of market dynamics and trading
behaviour.”
He continued: “For the last ten months,
the Ring had to be temporarily closed due
to the global Covid-19 pandemic. We have
been clear that we will not use the pandemic
as a pretext to close the Ring, and we remain
committed to this; however, it is fair to observe
that this period of electronic pricing has
served the market well, with consistently high
volumes of activity in the pricing window,
easily observable by all stakeholders, and
more participants with direct access.”
“Given the data, and our industry’s continued
move towards digitization and greater
transparency, we believe it is now time to
consider the long-term future of pricing at
the LME – with the intention of providing cer-
tainty, which will allow all customers to make
their future business decisions with confidence.”
Enhancing liquidity
The second set of proposals put forward are
designed to bring greater liquidity to the central
electronic venue, which is by nature the
most transparent marketplace and enables
the broadest participation. The proposals specifically
focus on incentivising electronic trading
on the member-to-member market in the
following ways:
• Increasing fees for inter-office memberto-member
trades, while reducing fees for
electronic member-tomember
trades
• Introducing the Enhanced
Transparency
Cross – which combines
the flexibility of
the inter-office market
with the transparency
of the electronic market,
by allowing members
to bilaterally
negotiate trades preexecution
and then to
transact or ‘cross’ any
proposed trades in the
electronic market, at
the lower electronic
fee
• Potentially introducing
block rules and a
liquidity provider programme.
Adrian Farnham, LME Clear chief executive,
noted: “Crucially, the LME believes
that these steps will further strengthen and
protect its unique date structure. By bringing
electronic displayed liquidity to a broader
range of trading dates, it will be even easier
for market users to take advantage of the
flexibility of the LME’s daily delivery structure.”
He continued: “Furthermore, the LME is
committed to providing the right balance
between maximizing transparency and fair
access while ensuring that customers – particularly
in the physical market – retain their
freedom to choose how to do business with
their LME member. The LME does not propose
to make any changes to its memberto-client
trading structure, which benefits
physical customers by enabling bespoke and
© LME
12 ALUMINIUM · 3/2021

e c o n o m i c s
flexible bilateral trade negotiations to take
place.”
Margin methodology
The move from a Discounted Contingent
Variation Margin” (CVM) methodology to
one of Realized Variation Margin” (RVM)
was first considered in the 2017 Strategic P
athway, where the decision was made to keep
the potential change under ongoing review.
This discussion paper highlights the increased
focus on the regulatory capital costs associated
with CVM and explores the potential
benefits of moving to an RVM methodology,
which include an increase in trading efficiency,
greater standardization and the removal
of some barriers to entry to the LME’s
market.
However, the discussion paper also notes
the central importance of credit provision
in the LME ecosystem, and understands the
view of many observers that such provi-
sion is easier under the current CVM structure.
Given the finely balanced nature of this
debate, the discussion paper invites views on
the relative merits of CVM and RVM, so that
an appropriate roadmap can be developed.
Market conduct
Finally, the discussion paper considers the introduction
of potential additional disclosures
and policies to strengthen market conduct,
such as in relation to stocks and the movement
of physical metal. The discussion paper
explores a regulatory news service for stock
warranting or cancellations. It also considers
some form of disclosure obligation for certain
physical transactions, above a specific size,
by those trading on the LME. The paper also
explores regular reporting of OTC positions
or rules to limit any one party’s ability to acquire
significant holdings of new or remaining
warrants.
Next steps
The LME invites feedback on all topics within
the discussion paper from market participants
and broader stakeholders until 19 March
2021. The LME aims to provide feedback and
next steps before the end of the second quarter
this year.
LME chairman Gay Huey Evans OBE (Order
of the British Empire) concluded: “The
LME has a strong history of engagement with
its market, and is committed to fully discussing
these topics with all stakeholders before
making any proposals on implementation. We
encourage feedback from across our industry
on our proposed path forward.”
The Discussion Paper on Market Structure
and related materials, including the LME’s
Strategic Pathway 2017, can be found at
www.lme.com/News/LME-Strategic-
Pathway#tabIndex=0
■
Growing demand for sustainable aluminium solutions at sea
Stricter environmental requirements and
increased focus on sustainability in the
maritime industry have boosted demand
for innovative aluminium solutions.
“We see the maritime industry has increased
its focus on sustainable products, material
selection and design in recent years. Electric
ferries carry heavy batteries and need lighter
materials. The CO 2 footprint in the industry
needs to be reduced and recycling
of material has therefore gained
traction. Aluminium is a good fit,”
says Thomas B. Svendsen, market
manager at Hydro.
Since 2015, Hydro has delivered
cost-effective and customized
aluminium products for
cruise ships, mega-yachts, defence
vessels, passenger ferries, and
leisure craft, as well as offshore
vessels and installations. Hydro
expects to deliver nearly 8,000
tonnes of aluminium to the maritime industry
in 2021.
In recent years, Hydro has collaborated
with the shipbuilding industry to discover new
ways to include aluminium in their vessels.
“The immediate environmental focus in the
maritime industry is related to direct emissions.
But we also see increased focus on material
usage as well,” says Svendsen.
Greener maritime industry
with greener materials
The introduction of stricter environmental
requirements for international shipping by
the International Maritime Organization has
resulted in an expected growing demand for
Hydro is collaborating with the shipbuilding industry to
discover new ways to include aluminium in their vessels
environmental and climate technology in the
years to come. One of the biggest industry
challenges today is that products designed
and produced are too difficult or expensive
to take apart and recycle when they are no
longer in use. Hydro has extensive experience
in developing cost-effective, efficient
and strong solutions for the marine industry.
“We supply aluminium extrusions and aluminium
sheet for vessels that are strong yet
light and corrosion-resistant, making them i
deal materials for marine applications. Hydro
is working systematically to increase the knowledge
in the market about the advantages of
aluminium and we see more customers coming
to us for support,” says Svendsen.
He adds that by using aluminium, it is
also possible to cut the weight
to about 50% compared to steel
while maintaining the necessary
strength. Moreover, aluminium
has a density around one-third
that of steel or copper, making it
one of the lightest commercially
available metals. The resultant
© iStock / Debove Sophie
high strength-to-weight ratio
makes it an important structural
material, allowing increased payloads
or fuel savings for transport
industries.
The demand for sustainable solutions is
expected to grow in the next couple of years
and Hydro is working on several upcoming
projects. A push from both consumers and
governments, together with increased focus
across the maritime industry, is expected to
lift demand for innovative solutions at sea. ■
ALUMINIUM · 3/2021 13

e c o n o m i c s
New US presidency – more trade tariff questions
In January, the Aluminum Association
released a series of policy documents
outlining priorities to support a strong
US aluminium industry. The Presidential
Policy Brief: Recommendations for a
strong U.S. aluminum industry includes
several recommendations for the new
Biden administration and Congress to
support a growing and vibrant aluminium
sector in the USA. An addendum to the
industry’s overarching Aluminum Agenda
released in 2019, the brief includes key
policy goals in the areas of the Energy,
Environment, Infrastructure, Recycling
and Trade.
tion Agency. Smart climate change policy
should work to reduce emissions at home while
avoiding jobs ‘leakage’ to overseas countries
with more lax environmental enforcement.
Infrastructure: The US aluminium industry
strongly supports increased public and private
infrastructure investment and incentives
for operational efficiencies and sustainable
material choices. The aluminium industry has
a role to play in electric grid modernization,
electric vehicle infrastructure, public transportation,
construction and recycling system
revitalization.
Recycling: While the aluminium used for
cars, buildings and similar industrial applications
is typically recycled at rates exceeding
90%, aluminium used in consumer applications
is recycled at far lower rates, which is
bad for the economy and the environment.
The Aluminum Association supports policies
such as a recycling infrastructure fund and
well-designed container deposit programs to
increase consumer recycling.
Trade: The single biggest threat to US
aluminium remains unfairly subsidized overcapacity
in China. Strong, targeted trade enforcement
is vital to the domestic aluminium
industry’s ability to compete on a marketbased,
level playing field. The Aluminum Association
supports renewed cooperation with
traditional trading partners and allies to address
this persistent issue.
Last year, the Aluminum Association released
economic data showing largely steady
job numbers and economic impact for the
aluminium industry in the USA over the
last decade. In total, the US aluminium industry
supports nearly 660,000 total jobs
(166,000 direct) and nearly USD172 billion
in total economic output (USD70bn direct).
Modelling through Q3 2020 suggested that
Covid-19 driven economic disruptions likely
reduced jobs and output by about 11%.
“Among the many lessons of the past year
is just how essential American manufacturing
is to a strong and healthy country,” added
Dobbins. “We are ready to roll up our sleeves
“We congratulate President Biden and look
forward to working with him and his team
in the coming months and years,” said Tom
Dobbins, president and CEO of the Aluminum
Association. “During this challenging
time for our nation, it is critically important
that we all work together toward renewal
and recovery. A strong and growing domestic
aluminium industry can play a role in the
American comeback story.”
During the presidential election campaign,
on a visit to Wisconsin Aluminum Foundry
in Manitowoc, Wisconsin, President Biden
noted how aluminium is a key part of future
infrastructure development in the USA, for
example in addressing climate change, saying
“That means American aluminium for infrastructure,
including for developing more wind
and solar power.”
The Presidential Policy Brief further details
on how these ambitions can be realized
through smart and constructive public policy:
Energy: As a lightweight, durable and infinitely
recyclable material, aluminium is part
of a suite of solutions for 21 st century energy
challenges. Both Congress, the Biden administration
and state governments have an opportunity
to reduce greenhouse gas emissions
through research and investment in production,
recycling and use of aluminium.
Environment: Aluminium producers have
voluntarily worked to reduce their environmental
impact and to cut greenhouse gas emissions
from North American primary production
by nearly half since 1991, work previously
recognized by the Environmental Protec-
The Aluminum Association represents aluminium
production and jobs in the US, ranging from primary
production through value added products to recycling,
as well as suppliers to the industry.
During a presidential campaign visit to Wisconsin Aluminum Foundry in Manitowoc, Wisconsin,
President Biden stressed how aluminium is a key part of future infrastructure development in the USA
and do our part as aluminium producers, recyclers
and fabricators. We look forward to
working with policymakers to grow goodpaying
manufacturing jobs while building a
more sustainable world.”
American Metal Manufacturers
and Users call for removal of tariffs
The Coalition of American Metal Manufacturers
and Users (CAMMU), representing more
than 30,000 US manufacturing companies
and over one million American workers, sent
a letter to President Biden requesting the immediate
termination of the Section 232 tariffs
on steel and aluminium imports imposed
under the Trump administration. These tariffs
have damaged US consuming industries that
employ more than 6.8 million workers, compared
to 140,000 in the US steel industry.
They also feed current supply shortages and
high prices at a time when US manufacturers
face significant challenges due to the Covid-
19 pandemic.
CAMMU urged the President to consider
how the tariffs have damaged small, familyowned
manufacturers while also fracturing
14 ALUMINIUM · 3/2021

e c o n o m i c s
relations with overseas trading partners and
impacting US manufacturers’ ability to compete
globally. The letter concludes that the
US should now end counterproductive trade
policies and remove the Section 232 steel and
aluminium tariffs, and focus instead on re-engaging
with trading partners in a coordinated
response to address the root cause of global
oversupply in steel and aluminium – excess
capacity in China.
Shutdowns likely if tariffs removed?
Another industry group takes a polarized view
and supports maintaining the tariffs. The American
Primary Aluminum Association, which
represents Century Aluminum and Magnitude
7 Metals, said in a letter to President Biden that
remaining US smelters will likely be forced to
close if the 10% import tariffs are removed.
The group believes global subsidized overcapacity
continues to prejudice US industry
regardless of whether the imports come from
trade allies or strategic competitors.
Legacy and new proposals
The Trump administration left a legacy of disrupted
US trade policy in the name of better
deals, launching a protracted trade war with
China, imposing tariffs on US allies, and renegotiating
major trade agreements.
President Biden proposes a combination of
stronger domestic investment and better coordination
with allies as part of a sensible rational
global trade policy. The priority is to reestablish
an intelligent approach to foreign
trade policy based on considered economic
analysis and a strategy that ensures a level
playing field for the American worker to compete
internationally, a White House spokesperson
offered. Biden promises to focus on
domestic priorities to boost US competitiveness,
to implement federal ‘Buy American’
policies to favour domestic producers; to
maintain environmental protections, and to
counter irresponsible trading practices, particularly
from China.
Foreign policy and trade
The aim is to unite with major US allies, such
as the EU, in a common front against China.
But with Biden making no promises on ending
existing tariffs on EU products, this could
be a challenge. A recent EU-China investment
treaty could also undermine Washington’s
dialogue with Brussels. Negotiations on closer
trade ties with other countries, for example
the UK post-Brexit will continue apace.
The European Union’s ambassador to the
US, Stavros Lambrinidis, called on President
Biden’s administration to immediately lift tariffs
imposed on steel and aluminium imports
from the EU and to work to settle a longstanding
dispute over aircraft subsidies for
aircraft manufacturers Airbus and Boeing. In
this respect, the USA had announced at the
end of 2020 that it would impose additional
tariffs on French and German aero parts including
fuselage and wing assemblies.
Lambrinidis stressed that Brussels was
ready to work with the USA to strengthen the
transatlantic trade relationship, in the context
of worldwide trade and common international
issues. He said Brussels was ready to immediately
lift its own retaliatory tariffs if the US
removed the Section 232 tariffs on steel and
aluminium. Doing so would provide a big boost
to many sectors in both regions, he added.
Biden reinstates key tariffs
Early moves suggest the Biden administration
is inclined to maintain the current substantial
tariffs, imposed on imported foreign metals to
protect domestic industry. The decision will
please unions but disappoint manufacturers
arguing that tariffs raise costs.
Notably, President Biden reinstated tariffs
on aluminium exported from the United Arab
Emirates, reversing President Trump’s decision
to lift them on his last day in office. The
decision appeared to have been motivated by
political rather than economic considerations
and based on foreign policy issues unrelated
to trade.
In March 2018, Trump imposed a 10% tariff
on aluminium imports from a variety of countries,
including the UAE, saying their metal
exports had put American aluminium producers
out of business and therefore threatened
national security. He subsequently exempted
aluminium from Argentina, Australia, Canada
and Mexico and, just hours before his term
ended, lifted the tariffs on the UAE.
Biden recently said the concerns that had
initially driven the tariffs still existed – imports
from the UAE may still displace domestic
production, and thereby threaten to impair
US national security. The UAE is one of the
world’s largest aluminium exporters, enjoying
an abundant petroleum supply that keeps production
costs low.
The White House concluded that US data
showed a fall of 25% in aluminium imports
from the UAE after the tariff, matched by a
rise of 22% in domestic aluminium production
through 2019, before the coronavirus
pandemic began.
Ken Stanford, contributing editor
Rio Tinto launches ‘Start’: the first sustainability label for aluminium
Today’s consumers want to know more
about the products they buy. A wide variety
of brands, notably food products,
already provide information on nutrition
and country of origin, for example through
barcodes and packaging labels. But what
about the materials that cars, cans, buildings
and smart phones are made of? How
do we create transparency around the
responsible materials the metals industry
produces? Also, what is the gold standard
for sustainability in this sector?
In February, Rio Tinto and CRU partnered together
to deliver an event – ‘Start’ Empowering
Aluminium – a discussion platform for a new
standard in the aluminium industry. Through
this, customers and their end users can achieve
their climate change targets by understanding
how the aluminium they are purchasing is sustainably
sourced and produced, through data,
traceability, and transparency in assurance.
Rio Tinto stresses that aluminium can be
the material of choice for end users when it is
produced sustainably. A leader in sustainable
aluminium products, the company has developed
a ground-breaking technology solution
to afford confidence for customers and their
end users in their purchasing decisions.
The on-line forum staged in February comprised
a topical discussion on sustainability led
by industry thought leaders, and a live Q&A.
Responsible aluminium with ‘Start’
Rio Tinto’s chief commercial officer for Singapore,
Simon Trott, and Tolga Egrilmezer,
vice-president, Sales and Marketing, UK were
joined by Anheuser-Busch InBev’s Jon Hoffmeister,
vice-president of Packaging Procurement
and Sustainability, North America and
Schneider Electric’s Aamir Paul, country president,
USA in a series of presentations, a fireside
chat and a questions session – facilitated
by CRU’s Eoin Dinsmore, head of Primary and
ALUMINIUM · 3/2021 15

e c o n o m i c s
Products, Aluminium,
and introduced
by Paramita Das,
Rio Tinto’s general
manager, Marketing
and Development
Aluminium.
The thrust of the
proceedings centred
on a new standard
in transparency and
traceability for the
aluminium industry
set by Rio Tinto with
its launch of Start, a
type of ‘nutrition label’
for responsible
Latest Michelob Ultra
beer cans, developed
through a partnership
aluminium.
between Anheuser-Busch
Start will help InBev and Rio Tinto
customers meet the
demand from consumers for transparency on
where and how the products they purchase are
made. It aims to empower end-users to make
informed choices about the products they buy,
enabling them to contribute to a sustainable
future, and to differentiate between end products
based on their environmental, social and
governance credentials. In practice, customers
will receive a digital sustainability label –
similar to a nutrition label included on food
and drink packaging – using secure blockchain
technology.
A blockchain is essentially a digital ledger
© Anheuser-Busch InBev
of transactions that is duplicated and distributed
across the entire network of computer systems
on the blockchain. This provides a system
of recording information in a way that
makes it difficult or impossible to change,
hack, or cheat the system.
It will provide key information about the
site where the aluminium was responsibly produced,
covering ten criteria: carbon footprint;
water use; recycled content; energy sources;
community investment; safety performance;
diversity in leadership; business integrity;
regulatory compliance, and transparency.
Rio Tinto Aluminium chief executive Alf
Barrios said: “Start is a significant step forward
for the aluminium industry as the first offering
of this kind, which sets a new standard
on transparency, traceability and responsible
production from mine to market. Our vision
is that our customers can showcase the sustainability
of the aluminium they purchase
from Rio Tinto to their consumers, delivering
full value from our responsible production.”
The Start sustainability label is now available
for aluminium purchased from Rio Tinto’s
managed operations globally. Through Start,
Rio Tinto will also provide technical expertise
through a sustainability advisory service
and support for customers looking to build
their sustainability offerings, benchmark and
improve performance, support sourcing goals
and access to green financing.
Start will continue to build on existing
ecosystems for assurance and provide a transparent
assessment of market impact and insights
across key criteria of Rio Tinto’s aluminium
business. It will incorporate dynamic
and evolving metrics to reflect the company’s
climate change-based targets up to 2030 and
2050.
Rio Tinto Aluminium: ‘Start’ sets a new
metal industry sustainability standard on
transparency, traceability and responsible
production – from mine to market
Rio Tinto as a global industry leader in responsible
aluminium production, prides itself
on its green, sustainable credentials. Across
its aluminium operations worldwide, the company’s
GHG emissions intensity is 60% lower
than the industrial average, according to Rio
Tinto.
Ken Stanford, contributing editor
© Rio Tinto
North American industry records major sustainability gains
A new peer-reviewed life-cycle assessment
(LCA) study reveals a major decline
in energy demand and greenhouse gas
emissions for primary aluminium production
in the US and Canada. The study
covers all life cycle impacts, from production
through semi-fabrication.
These findings were revealed from a multiyear
life-cycle assessment (LCA) study released
by the Aluminum Association examining
the environmental impact of modern
aluminium production. The study reviewed
the 2010 production year and incorporates
data from 25 companies, representing 95% of
primary metal production and the majority of
the industry in North America.
Key findings
The study shows the tremendous energy and
emissions savings made by the aluminium industry
in the US and Canada. For example,
energy demand to produce new (primary)
aluminium is down more than a quarter since
1995 and the industry’s carbon footprint is
down nearly 40%. This is equivalent to 37
million barrels of oil saved per year. Furthermore,
“we are also using more renewable
hydropower than ever before – 75% today
versus 63% in 1991,” says the study.
Aluminium production in North America
is more sustainable today than at any time in
history. The industry undertook a voluntary
effort with the EPA in 1992 to reduce perfluorocarbon
(PFC) emissions. The program
was extremely successful and has reduced
PFCs by 85%.
The industry has also improved its technology
with computerized process controls to
produce aluminium ever more efficiently.
Increasing aluminium usage helps off-set
many of the environmental impact of aluminium
production. Aluminium can improve
the fuel efficiency of vehicles through lightweighting,
increase energy efficiency in buildings
and limit carbon footprint of consumer
goods like beverage containers. A 2009 study
showed that the light-weighting of passenger
vehicles with aluminium off-set fully 92% of
the industry’s overall greenhouse gas emissions.
And coated aluminium roofs reflect up
to 95% of sunlight, dramatically increasing
building energy efficiency.
Increased recycling is another great way to
save energy and drive the metal’s sustainability
advantage. Producing recycled aluminium
reduces energy demand by 92% compared to
making primary aluminium. This means that
a 10% increase in end-of-life recycling rates
decreases primary energy demand and greenhouse
gas emissions by 15%. Aluminium is an
ideal material for recycling because the metal
can be recycled over and over again without
any loss in quality.
Ken Stanford, contributing editor
16 ALUMINIUM · 3/2021

e c o n o m i c s
CRU launches Emissions Analysis Tool
CRU Group, the global mining and
metals business intelligence company,
has announced a one-stop global GHG
emissions data shop, cradle to product
– the CRU Emissions Analysis Tool.
CRU data in this service is calculated according
to the GHG Protocol Corporate Accounting
and Reporting Standard. It differs from
the self-published emissions by asset owners
only because it is completely standardized
and comparable across assets. While asset
owners’ individual reporting requirements or
preferences lead to reported numbers lacking
absolute comparability from one to another,
CRU provides a completely independent likefor-like
assessment across the board. CRU’s
data set allows for impartial benchmarking by
bringing transparency and comparability.
Such data allows for governments, industry,
financial and consumer bodies to quickly
and confidently benchmark and make informed
data-driven decisions as the global
challenge of decarbonising our commodities
comes to the fore.
With a deep understanding of commodity
extraction and processing costs, CRU has been
evaluating emissions data alongside costs of
production since the EU Emissions Trading
Scheme was launched on New Years’ Day in
2005. Its data set has since been extended to
encompass all major steel- and aluminiumproducing
assets globally, covering 1,100 assets
and an estimated 3 gigatons or 5-6% of
Scope 1 and 2 global greenhouse gas (GHG)
emissions. Although CRU already includes
some important Scope 3 categories, CRU will
add to these copper, nickel and nitrogen fertiliser
coverage in the coming months. The data
matters as miners, metals and fertiliser producers
work with their stakeholders to rise to
the collective challenge of decarbonising their
supply chains, tackling climate change and
adhering to ESG standards.
Lavan Mahadeva, Research director at
CRU, said: “There are so many complex components
and ways of aggregating data that,
though highly accurate, the basis of reported
emissions can differ significantly. That has
generated the need for like-for-like, plant-byplant
and even process-by-process comparisons
for GHG emissions that enable industry
participants to more clearly plot their path to
decarbonisation, evaluate peers and supply
chain partners. As sustainability and emissions
reduction are pushed by governments around
the world ahead of COP26, the CRU data are
Q. What is the coverage?
We include all large mines, plants and
smelters that produce these commodities
along a supply chain from mine to factory gate.
This would capture all major exporters and all
major suppliers of seaborne sales. Future data
includes all important new projects likely to
come online.
CRU’s Emission Analysis Tool enables a comparison of the differences in emissions
according to power source for aluminium smelters. Data: CRU Aluminium Cost model
well placed to inform that global endeavour.”
Chris Houlden, head of Analysis at CRU,
added: “Mining, metals and fertiliser industries
are interconnected and essential, but decarbonising
challenges remain significant. In
rising to these, producers and their stakeholders
will need to reference a granular and standardised
data set that aids both policy- and decision-making.
This information gap through
supply chains is one CRU can fill now. As we
look to prioritise decarbonisation it is vital to
start with transparent data and to use it constructively
to facilitate change.”
Questions & Answers
Q. For which commodities can greenhouse
gas emissions curves be plotted?
A. Currently the fully interactive GHG
emissions tool can be plotted and tabulated
for bauxite, alumina, aluminium, iron ore,
metallurgical coal and steel. GHG emissions
can be compared by site, producer, geography,
type of process and production volume
over time (with forward looking projections).
Q. How do we know the data is accurate?
A. CRU have verified its input data with a
significant proportion of industry participants,
and whilst differences to reported data have
been found in many cases they are readily
explained by differences in methodology / interpretation
allowable under the rules. Moreover,
differences between public sources and
EAT output will reflect our work on standardisation,
are not a question of right and wrong
and merely serve to illuminate the need for
an independent level playing field.
Q. What is your methodology for calculation
and how does this reflect published data?
A. A high level of consistency and accuracy
is achieved by our Cost experts modelling production,
costs and emissions all together and
reconciling with published data on all three.
They estimate at a highly granular process
level, assessing inputs and outputs and so efficiency
and net emissions of each process.
One set of sources of emission data are
company sustainability reports and associated
technical documentation, as well as Government
Portals (e.g. EU ETS). There are many
different frameworks to disclose environmental
data in reports so an understanding of
these compared to the CRU methodology is
required to reconcile them.
The third source is from the companies
themselves. We engage directly with the owners
and operators of these mines and request
key data. Moreover, as subscribers to this
data already, many of them flag anything that
looks slightly off. We then investigate this
and make adjustments where necessary. This
means our data can continuously improve.
We align most closely to the GHG Protocol,
by far the most established methodology
for quantifying emissions across the entire
mining and minerals sector.
■
© CRU Group
ALUMINIUM · 3/2021 17

e c o n o m i c s
Pioneer solution can eliminate
use of permanent bauxite tailing dams
© Hydro
A new solution for storing dried tailings
from Hydro’s bauxite mine in Brazil replaces
the need for raising and building
new dams, improving safety and environmental
performances.
Hydro has invested around USD5.5 million
in the testing stage of the methodology that
allows for the final disposal of tailings in areas
already mined, and has received an operating
license from Semas, the Pará State Secretariat
for the Environment and Sustainability at the
end of 2020.
“Hydro is committed to driving sustainability
in the aluminium industry. This challenge
has driven our efforts to pursue practices
that can eliminate the need for new permanent
tailings storage dams in bauxite mining,”
says John Thuestad, Hydro’s executive VP
for the Bauxite & Alumina business.
Hydro’s project is a pioneer in the sector
and has been in testing since July 2019 at
the Mineração Paragominas bauxite mine in
the northern state of Pará. The methodology
eliminates the need for continuous construction
of new permanent tailings dams, or even
the need to add layers to existing structures,
by applying the methodology known as
Tailings Dry Backfill, which deposits inert dry
tailings in areas already mined.
This stage of testing is being carried out
with permanent monitoring and follow-up
by environmental agencies and following the
technical standards of Conama, the National
Environmental Council. The application of
this methodology in Brazil is an important
step in terms of sustainability in the industry,
increasing operational safety and significantly
advancing work to reduce Hydro’s environmental
footprint.
About Tailings Dry Backfill
The Tailings Dry Backfill technology allows
inert tailings from bauxite mining to be returned
to the already open and mined areas,
preceding the rehabilitation process, instead
The Paragominas bauxite mine in Brazil
of being deposited in separate, permanent
storage areas.
After drying in temporary storage for 60
days, the bauxite tailings are put back into
the mined areas, which are later rehabilitated
and reforested. This will further reduce
the environmental footprint of bauxite mining
and increase operational safety. The tailings
from bauxite mining are chemically and
physically similar to what was removed during
the mining process. Therefore, it is returned
to nature without any impact to the environment.
Before testing the method in Paragominas,
Hydro carried out technical studies and detailed
planning. In July 2019, after obtaining
authorization from the environmental agency,
Hydro began the field-testing phase. The
tests have been carried out in different seasons,
continuously monitored by the project’s
technical team and detailed reports are regularly
forwarded to the environmental authorities.
After one year of testing, the results are
generating positive results in relation to the
environment, operational safety and within
forecast costs.
Rehabilitation of mined areas
Mineração Paragominas is committed to applying
the best environmental practices and
continuously invests in the rehabilitation
of mined areas. In the recovery
of these areas, the original form of the
soil is reproduced, with the addition of
organic matter. Then, the land is prepared
to receive the seedlings that will
restore the vegetation coverage.
Since the reforestation programme
was launched in 2009, Mineração Paragominas
has already accounted for an
area of 2,300 hectares in the recovery
process. On average, 200,000 seedlings
of native species are produced
per year in the Mineração Paragominas
nursery.
To improve the rehabilitation
process, Hydro is part of the Brazil-
Norway Biodiversity Research Consortium
(BRC), which brings together
researchers from the Federal University
of Pará, the Federal Rural University
of the Amazon, the Emílio Goeldi
Museum, the University of Oslo and
Hydro professionals in Brazil, seeking
the best alternatives for reforestation
and monitoring of mined areas.
Current dam systems
at Mineração Paragominas
Mineração Paragominas has two dam systems
for bauxite waste storage. Both systems
use a tailings disposal methodology based on
the alternate operation of their reservoirs,
allowing the tailings to dry out in each reservoir
by combining drainage and evaporation,
which results in tailings with a minimum
solid content of 60 percent.
■
18 ALUMINIUM · 3/2021

W i r t s c h a f t
Schweizer Aluminiumindustrie meldet
deutlichen Produktionsrückgang in 2020
Das Jahr 2020 begann für die Schweizer
Aluminiumindustrie ausgesprochen gut.
Die Auslastung bewegte sich bei einigen
Mitgliedsfirmen des Branchenverbandes
alu.ch sogar auf Rekordniveau. Im
Frühjahr bremste die Pandemie diesen
positiven Trend jedoch jäh aus. Im dritten
Quartal sorgte die rasch gestiegene
Nachfrage in wichtigen Anwendermärkten
wie der Automobilindustrie zwar
für eine moderate Erholung. Insgesamt
betrachtet brach die Produktion der
Schweizer Walz- und Presswerke in
2020 jedoch gegenüber dem Vorjahr um
17 Prozent auf 189.200 Tonnen ein.
Mit dem harten Lockdown zur Eindämmung
der Pandemie wurden ab Mitte März Werke
teils vorübergehend stillgelegt, teils der
Betrieb auf Kurzarbeit umgestellt. Mit Betriebsschließungen
und Produktionskürzungen
auf Kundenseite kam der Absatz für die
Schweizer Alubranche in wichtigen Märkten
vollständig zum Erliegen, bspw. im Transportwesen
(besonders in der Luftfahrt), im
Maschinenbau, in der Elektroindustrie.
Ab Mai stieg die Nachfrage besonders aus
der Autoindustrie wieder an und sorgte für
eine bessere Auslastung. Nach der Sommerpause
hatte sich die Auftragssituation in den
meisten Anwendermärkten für die Schweizer
Alu-Banche auf moderat gutem Niveau
normalisiert. Auch die erst weichen und
dann zunehmend verschärften Teil-Lockdowns
in Europa seit dem Herbst wirkten
sich in der gesamten Schweizer Aluminiumbranche
nicht wieder außergewöhnlich
negativ auf die Produktionen aus.
Sogar aus dem Maschinenbau konnten
im letzten Quartal 2020 wieder Aufträge
verbucht werden, so für Gesundheitseinrichtungen
wie Impfzentren. Anhaltend positiv
verlief die konjunkturelle Entwicklung
in der Bauindustrie. Hier kam es schon im
Frühjahr für die Schweizer Hersteller und
Systemanbieter von Fassaden, Fenstern und
Gebäudeteilen aus Aluminium zu keinen
größeren Auslastungsproblemen.
Trotz dieser positiven Entwicklungen in
Teilen der Aluminiumindustrie verzeichnet
der Branchenverband alu.ch, in dem 57
Aluminiumverarbeiter zusammengeschlossen
sind, ein Jahresergebnis mit deutlichen
Einbußen: Pandemiebedingt ging die Produktion
der Walz- und Presswerke in der
Schweiz 2020 gegenüber dem Vorjahr um
17 Prozent auf 189.200 Tonnen zurück.
Dank der Möglichkeiten von Kurzarbeit
und Überbrückungskrediten des Bundes, innerbetrieblich
geglückter Umstellungen auf
Homeoffice und laufender Optimierungsprozesse,
sah sich kein Mitgliedsunternehmen
des Branchenverbandes 2020 zu Entlassungen
im größeren Ausmaß gezwungen.
Auch unter den schwierigen Rahmenbedingungen
wurden vielerorts neue innovative
Produktentwicklungen vorangetrieben.
Durch stabile eigene finanzielle Rücklagen
gelang es einigen Mitgliedsfirmen zudem,
auch in diesem schwierigen Jahr die
geplanten Investitionen zur Stärkung und
Erneuerung ihrer Schweizer Produktionsstandorte
umzusetzen.
Ausblick ungewiss
Laut einer Umfrage unter den Vorstandsmitgliedern
des alu.ch wird für dieses Jahr
mit einer leichten Erholung der Produktionsauslastung
gerechnet – jedoch mit stark
volatilen Entwicklungen, in Abhängigkeit
von den verschiedenen Maßnahmen zur
Pandemie-Eindämmung. Trotz der Erholung
im Automobilsektor blicken führende Vertreter
der Schweizer Aluminiumindustrie
skeptisch auf die künftige Entwicklung des
für die Branche ebenfalls wichtigen Volumensegments
Bau.
Durch die Corona-Geschehnisse in ganz
Europa und angesichts harter Lockdowns
wie in Deutschland in den letzten Monaten
wird im ersten Quartal 2021 nochmals
mit einem deutlichen Rückgang gerechnet.
Viele Kunden mussten wieder schließen
oder Kurzarbeit anmelden. Die Absatzchancen
für die exportorientierte Branche
sinken damit wieder und bleiben ungewiss.
Insgesamt sind der Verdrängungswettbewerb,
Margendruck und Preiskampf für die
Schweizer Alu-Branche in der Pandemie
noch härter geworden, etwa durch Billigimporte
aus China und Überkapazitäten
wie in der Luftfahrt. alu.ch-Geschäftsführer
Marcel Menet dazu: „Auf dem internationalen
Parkett werden sich nur diejenigen
Schweizer aluminiumverarbeitenden Unternehmen
behaupten können, die auch in
diesem schwierigem Umfeld weiterhin Innovationen
bieten und Investitionen in neue
Technologien dazu treffen können.“ ■
Die beste
Qualität ist
oberstes Ziel
– seit 1863
Aktuelle
Anwendungsgebiete:
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LASCO Umformtechnik GmbH
Hahnweg 139 96450 Coburg
Deutschland
Tel +49 9561 642-0
ALUMINIUM · 3/2021
LASCO.COM

© BMW / EGA
Die BMW Group bezieht ab sofort Aluminium,
für dessen Herstellung Strom
aus Sonnenenergie zum Einsatz kommt.
Für den Autobauer ein wichtiger Schritt,
mit dem das Unternehmensziel erreicht
werden soll, die CO 2 -Emissionen im Lieferantennetzwerk
bis 2030 um 20 Prozent
zu senken. Da die Herstellung von Aluminium
sehr energieintensiv ist, hat der
Einsatz von regenerativer Energie, wie
Solarstrom, erhebliches Potenzial bei der
Reduzierung der CO 2 -Emissionen. Daher
plant die BMW Group auch langfristig,
mit erneuerbaren Energiequellen hergestelltes
Aluminium zu beziehen. In den
nächsten zehn Jahren sollen so rund 2,5
Mio. Tonnen CO 2 -Emissionen eingespart
werden. Das entspricht ca. drei Prozent
der selbst gesetzten CO 2 -Ziele für das
Lieferantennetzwerk.
„Wir gehen beim Thema Nachhaltigkeit voran
und setzen unsere Nachhaltigkeitsziele
konsequent um“, sagt Andreas Wendt, Vorstand
der BMW AG für Einkauf und Lieferantennetzwerk,
und fährt fort: „Über 50 Prozent
der CO 2 -Ziele, die wir uns bis 2030 für
das Lieferantennetzwerk gesetzt haben, können
wir allein durch den Einsatz von Grünstrom
erreichen. Die Verwendung von Solarstrom
für die Produktion von Aluminium ist
ein großer Schritt in diese Richtung.“
Das mit Solarstrom hergestellte Aluminium
kommt von Emirates Global Aluminium
(EGA) aus den Vereinigten Arabischen Emiraten
und wird in der Leichtmetallgießerei
im BMW-Werk Landshut zu Karosserie- und
Antriebskomponenten weiterverarbeitet, wie
sie auch für Elektroantriebe benötigt werden.
Mit 43.000 Tonnen im Wert eines dreistelli-
BMW Group bezieht mit Solarstrom
hergestelltes Aluminium
BMW Group sources aluminium
produced using solar energy
BMW Group will begin sourcing aluminium
produced using solar electricity with
immediate effect. This marks an milestone
on the road to the company’s goal
of lowering CO 2 emissions in its supplier
network by 20% by 2030. Since producing
aluminium is highly energy-intensive,
the use of renewable energy, such as solar
electricity, offers considerable potential
for reducing CO 2 emissions. That is why
BMW Group also plans to source aluminium
produced with ‘green’ power in the
long term – enabling it to avoid some 2.5
million tonnes of CO 2 emissions over the
next ten years. This is equivalent to about
3% of the CO 2 targets the company has
set for its supplier network.
“We aspire to lead the way in sustainability
and implement our sustainability goals in a
systematic manner. We will be able to meet
over 50% of our CO 2 targets for the supplier
network, just by using green power. The use
of solar electricity for producing aluminium is
a major step in this direction,” says Andreas
Wendt, member of the board of management
of BMW AG responsible for Purchasing and
Supplier Network.
The aluminium produced using solar power
is delivered by Emirates Global Aluminium
(EGA) in the UAE and processed in the light
metal foundry at BMW Group Plant Landshut
to manufacture body and drive train components,
including those needed for electric drive
trains. Sourcing 43,000 tonnes of solar alu-
minium valued in the three-digit million euros
will supply nearly half the annual requirements
of the light metal foundry at Plant
Landshut.
With the trend toward e-mobility,
CO 2 -free value creation in the life
cycle of cars gains further importance
BMW points out that the share of CO 2 emissions
in the life cycle of a vehicle is shifting
significantly to upstream value creation in the
supplier network as the trend toward e-mobility
increases. In an electrified vehicle, CO 2
emissions from the use phase are much lower,
but producing battery cells or aluminium is
very energy-intensive. Without corrective
measures, CO 2 emissions per vehicle in BMW
Group supply chain would increase by more
than a third by 2030. The company not only
wants to stop this trend, but also reverse it
– and even lower CO 2 emissions per vehicle
by 20% from 2019 levels.
The carmaker has therefore already agreed
with suppliers for its current fifth-generation
battery cells that they will only use renewable
power for producing battery cells. By sourcing
aluminium produced with solar electricity,
BMW Group is now taking the next logical
step.
The carmaker stresses that the use of the
lightweight metal aluminium is increasingly
important for electric vehicles to compensate
for the heavy weight of the batteries in e-vehicles.
On the other hand, producing aluminium
20 ALUMINIUM · 3/2021

e c o n o m i c s
lich geringer, während andererseits die Herstellung
von Batteriezellen oder Aluminium
sehr energieintensiv ist. So würden ohne Gegenmaßnahmen
die CO 2 -Emissionen je Fahrzeug
in der Lieferkette der BMW Group bis
2030 um mehr als ein Drittel steigen. Diesen
Trend will das Unternehmen nicht nur stoppen,
sondern sogar umkehren und die CO 2 -
Emission je Fahrzeug verglichen mit 2019
sogar um 20 Prozent senken.
Mit den Lieferanten für die Batteriezellen
der aktuellen, fünften Generation hat BMW
daher bereits vereinbart, dass für die Produktion
der Batteriezellen ausschließlich erneuerbare
Energien verwendet wird. Mit dem
Bezug von Aluminium, das mittels Solareneris
known to be very energy-intensive. BMW
argues that generating the electricity needed
to produce primary aluminium is alone responsible
for about 60% of the global aluminium
industry’s greenhouse gas emissions.
The use of solar electricity is therefore an effective
lever for reducing the CO 2 emissions
associated with aluminium smelting.
Solar park in the desert supplies
power for aluminium production
BMW Group already has a long-standing supply
relationship with primary aluminium producer
EGA. EGA has now become the first
company in the world to also use solar electricity
for commercial production of aluminium,
which it will initially supply exclusively
to BMW Group. EGA sources the electricity
used to produce ‘solar aluminium’ (marketed
under the brand name CelestiAL) from the
Mohammed Bin Rashid Al Maktoum Solar
Park in the desert outside of Dubai, which,
in the final stage of development, is set to become
the world’s largest solar park.
It is operated by the Dubai Electricity and
Water Authority, which has the electricity it
produces sustainably certified by third parties,
ensuring that it can supply EGA with power
that is traceable and transparent.
Abdulnasser Bin Kalban, CEO of EGA,
says: “We are delighted to have BMW Group
as our first customer for low-carbon CelestiAL
aluminium from EGA. Aluminium is light,
strong and infinitely recyclable. That is why it
plays such an important role in the development
of a more sustainable society and in making
modern life possible. But how sustainably
the aluminium is produced is also important.
Solar aluminium is a step in the right direction
– it uses a natural and abundant source of
energy in our desert environment to produce
a metal that is vital to the future of our
planet.”
Ein Mitarbeiter in der Leichtmetallgießerei prüft die gelieferten Aluminiummasseln
An employee at the light metal foundry checks the delivered aluminium ingots
gen Millionen-Euro-Betrags deckt der Bezug
des Solaraluminiums nahezu die Hälfte des
jährlichen Bedarfs der Landshuter Leichtmetallgießerei
ab.
Mit Trend zur E-Mobilität gewinnt
CO 2 -freie Wertschöpfung im Lebenszyklus
von Autos weiter an Bedeutung
BMW verweist darauf, dass sich der Anteil der
CO 2 -Emissionen im Lebenszyklus eines Fahrzeugs
mit zunehmendem Trend zur E-Mobilität
deutlich auf die vorgelagerte Wertschöpfung
im Lieferantennetzwerk verschiebt. Bei
einem elektrifizierten Fahrzeug seien die
CO 2 -Emissionen in der Nutzungsphase deut-
© BMW
Light metal foundry in Landshut –
honoured for innovative and
sustainable production processes
The light metal foundry is the largest production
unit at the Landshut plant and the company’s
only European manufacturing facility
for light metal casting. Last year, the more
than 1,600 employees at the foundry produced
a total of 2.9 million cast components.
The scope of production includes engine components
such as cylinder heads and crankcases,
components for electric drive trains and
structural components for vehicle bodies.
The light metal foundry is one of the most ➝
Einschmelzen der Masseln im Werk Landshut
Melting of the ingots in the Landshut Plant
© BMW
ALUMINIUM · 3/2021 21

W i r t s c h a f t
© EGA
Den Strom für die Produktion von Solaraluminium bezieht EGA aus dem
Mohammed Bin Rashid Al Maktoum Solarpark in der Wüste außerhalb von Dubai
The electricity used to produce solar aluminium is sourced from the
Mohammed Bin Rashid Al Maktoum Solar Park in the desert outside of Dubai
gie produziert wird, geht der Autohersteller
nun den nächsten, konsequenten Schritt.
BMW betont, dass der Einsatz des Leichtmetalls
Aluminium für Elektrofahrzeuge zunehmend
wichtig ist, um das hohe Gewicht
der Batterien in den elektrifizierten Fahrzeugen
zu kompensieren. Andererseits ist die
Herstellung von Aluminium bekanntlich sehr
energieintensiv. BMW führt an, dass die Erzeugung
des Stroms für die Herstellung von
Primäraluminium für etwa 60 Prozent der
Treibhausgasemissionen der weltweiten Aluminiumindustrie
verantwortlich ist. Der Einsatz
von Solarstrom sei damit ein wirksamer
Hebel, um die mit der Aluminiumschmelze
verbundenen CO 2 -Emissionen zu reduzieren.
Solarpark in der Wüste liefert
Strom für die Aluminiumproduktion
Mit EGA verbindet BMW Group eine langjährige
Lieferbeziehung für Primäraluminium.
EGA setzt nun als erstes Branchenunternehmen
Solarstrom für die kommerzielle Produktion
von Aluminium ein und liefert dieses
unter der Marke CelestiAL zunächst exklusiv
an die BMW Group. Den Strom für die Produktion
von Solaraluminium bezieht EGA
aus dem Mohammed Bin Rashid Al Maktoum
Solarpark in der Wüste außerhalb von Dubai.
Betreiber des Solarparks, der in der Endausbaustufe
der größte Solarpark der Welt
werden soll, ist die Dubai Electricity and
Water Authority. Sie lässt den nachhaltig erzeugten
Strom durch Dritte zertifizieren und
liefert ihn somit nachverfolgbar und transparent
an EGA.
Abdulnasser Bin Kalban, CEO von EGA,
erklärt: „Wir freuen uns, dass die BMW Group
der erste Kunde für das kohlenstoffarme CelestiAL-Aluminium
von EGA ist. Aluminium
ist leicht, stark und unendlich recycelbar.
Deshalb spielt es eine wichtige Rolle bei der
Entwicklung einer nachhaltigeren Gesellschaft
und macht das moderne Leben erst möglich.
Aber es kommt auch darauf an, wie nachhaltig
Aluminium hergestellt wird. Solaraluminium
ist ein Schritt nach vorne – es nutzt eine natürliche
und reichlich vorhandene Energiequelle
in unserer Wüstenumgebung, um ein Metall
herzustellen, das für die Zukunft unseres Planeten
lebenswichtig ist.“
Landshuter Leichtmetallgießerei
für innovative, nachhaltige
Fertigungsverfahren ausgezeichnet
Die Leichtmetallgießerei ist der größte Promodern
foundries in the world. Its innovative
and sustainable production processes have
won numerous awards. The foundry also
works with shaping sand cores, among other
methods, to manufacture cast parts. The sand
cores are produced using inorganic binders –
making the casting process virtually emissionfree.
Five different casting methods are used
for standard production of cast components.
The most suitable casting method is selected,
depending on the component concept, technological
requirements and production volume.
The foundry was already certified for its
sustainable use of aluminium back in December
2019. It meets the standards of the
Aluminium Stewardship Initiative (ASI), an
international non-profit organization supported
by environmental and industrial associations,
NGOs, aluminium producers and
processing companies. ASI aims to maximize
aluminium’s contribution to a sustainable society
and defines sustainability criteria for an
environmentally and socially responsible aluminium
value chain. Through this initiative,
following an audit by an independent third
party, BMW Group received confirmation that
its light metal foundry handles aluminium in
a conscious and responsible manner.
Responsible use of
natural resources
In addition to using green power to produce
aluminium, BMW Group is also taking additional
steps to safeguard reserves of critical
raw materials. For instance, the carmaker has
set itself the goal of significantly increasing
the percentage of recycled raw materials by
BMW bezieht jährlich 43.000 Tonnen CelestiAL-Solaraluminium und deckt
damit die Hälfte des Bedarfs der Leichtmetallgießerei im Werk Landshut
BMW purchases 43,000 tonnes of CelestiAL solar aluminium
annually, covering half of the need of the light metal foundry
© EGA
22 ALUMINIUM · 3/2021

e c o n o m i c s
duktionsbereich des BMW-Werks Landshut
und die einzige Fertigungsstätte für Leichtmetallguss
der BMW-Gruppe europaweit. Im
vergangenen Jahr fertigten die über 1.600
Beschäftigten der Leichtmetallgießerei rund
2,9 Mio. Gusskomponenten. Zum Produktionsumfang
zählen Motorkomponenten wie
Zylinderköpfe und Kurbelgehäuse, Komponenten
für elektrische Antriebe oder großflächige
Strukturbauteile für die Fahrzeugkarosserie.
Die Leichtmetallgießerei zählt zu den
modernsten Gießereien weltweit. Die innovativen
Fertigungsverfahren sind nachhaltig
und wurden mehrfach ausgezeichnet. Zur
Fertigung der Gussteile arbeitet die Gießerei
unter anderem mit formgebenden Sandkernen.
Die Sandkerne werden mithilfe anorganischer
Bindemittel hergestellt. Beim Gießen
werden so gut wie keine Emissionen freigesetzt.
Für die Serienproduktion der Gusskomponenten
kommen fünf verschiedene Gießverfahren
zum Einsatz. In Abhängigkeit vom
jeweiligen Bauteilkonzept, den technologischen
Anforderungen und dem Produktionsvolumen
wird das jeweils am besten geeignete
Gießverfahren ausgewählt.
Die Gießerei wurde bereits im Dezember
2019 für ihren nachhaltigen Einsatz von Aluminium
zertifiziert. Sie erfüllt die Standards
der Aluminium Stewardship Initiative (ASI),
einer internationalen, gemeinnützigen Organisation,
die von Umwelt- und Industrieverbänden,
NGOs, Aluminium-Produzenten und
-Verarbeitern getragen wird. ASI hat das Ziel,
den Beitrag von Aluminium zu einer nachhaltigen
Gesellschaft zu maximieren, und definiert
Nachhaltigkeitskriterien für eine ökologisch
und sozial verantwortungsvolle Aluminium-Wertschöpfungskette.
Durch diese
Initiative erhielt die BMW Group nach Prüfung
durch eine unabhängige dritte Partei die
Bestätigung, dass die Leichtmetallgießerei einen
bewussten und verantwortungsvollen
Umgang mit dem Werkstoff Aluminium verfolgt.
Verantwortungsvoller Umgang
mit natürlichen Ressourcen
© BMW
BMW Group setzt sich klare Ziele zur CO 2 -Reduktion bis zum Jahr 2030 – erstmals über den
gesamten Lebenszyklus von der Lieferkette über die Produktion bis zum Ende der Nutzungsphase
BMW Group sets clear targets for CO 2 reduction by 2030 – for the first time
across the entire lifecycle from supply chain to production to end of use phase
2030 and using raw materials multiple times
in a circular economy. The use of secondary
material reduces CO 2 emissions substantially
compared to primary materials and also conserves
natural resources. Moreover, BMW
Group is establishing carbon footprint as a new
contract award criterion for its supply chain
and already began implementing this for the
tenders with the biggest carbon footprint in
2020.
These measures are already delivering
results in the BMW iX (power consumption
combined: less than 21 kWh/100 km in the
WLTP test cycle; CO 2 emissions combined:
0 g/km): relying on renewable power to produce
battery cells, in combination with increased
use of secondary material, reduces
CO 2 emissions in the BMW iX supply chain
by 17%, compared to the same vehicle produced
without these measures.
BMW Group aims to have more than seven
million electrified vehicles on the roads by
2030 – two thirds of them fully-electric. For
this order of magnitude, the Purchasing department
is working with suppliers to ensure
not only that the supply chain can manage
the growth in volumes, but also that it can
implement the requirements for sustainable
development. In this way, the Purchasing department
is making a vital contribution to the
company’s transformation towards e-mobility.
■
Neben dem Einsatz von „Grünstrom“ für die
Produktion von Aluminium ergreift die BMW
Group zusätzliche Maßnahmen, um die Bestände
kritischer Rohstoffe zu schützen. So
hat sich der Autohersteller zum Ziel gesetzt,
den Anteil von recycelten Rohstoffen bis 2030
deutlich zu erhöhen und Rohstoffe in einer
Kreislaufwirtschaft mehrfach zu nutzen. Der
Einsatz von Sekundärmaterial reduziert die
CO 2 -Emissionen gegenüber Primärmaterial
deutlich und schont zudem die natürlichen
Ressourcen. Zudem etabliert BMW einen
CO 2 -Footprint als neues Vergabekriterium in
der Lieferkette und hat bereits 2020 begonnen,
dies bei den Ausschreibungen mit dem
größten CO 2 -Fußabdruck umzusetzen.
Beim BMW iX (Stromverbrauch kombiniert:
weniger als 21 kWh/100 km im Testzyklus
WLTP; CO 2 -Emissionen kombiniert:
0 g/km) zeigen diese Maßnahmen bereits
Wirkung: Der Einsatz von erneuerbarer Energie
bei der Herstellung der Batteriezellen
in Kombination mit dem verstärkten Einsatz
von Sekundärmaterial reduziert die CO 2 -
Emissionen in der Lieferkette des BMW iX
um 17 Prozent im Vergleich zum gleichen
Fahrzeug, bei dem diese Maßnahmen nicht
umgesetzt worden wären.
Bis 2030 will die BMW Group mehr als
sieben Millionen elektrifizierte Fahrzeuge auf
die Straßen bringen, davon zwei Drittel vollelektrisch.
Für diese Größenordnung stellt
der Einkauf gemeinsam mit den Lieferanten
sicher, dass zum einen das Volumenwachstum
in der Lieferkette abgebildet werden
kann und zum anderen, dass die Anforderungen
an nachhaltiges Handeln umgesetzt
werden. Damit leistet der BMW-Einkauf einen
wichtigen Beitrag zur Transformation
des Unternehmens hin zur E-Mobilität. ■
ALUMINIUM · 3/2021 23

t e c h n o l o g i e
© A Rocha Ghana
Aerial view of the Atewa Forest
BMW Group, Tetra Pak and Schüco
raise concerns over Atewa-sourced bauxite
Three global manufacturing companies –
BMW Group, Tetra Pak and Schüco International
– have signalled concern over
the use of bauxite sourced from Ghana’s
unique Atewa Forest for aluminium if
mining has catastrophic and irreversible
effects on the people and wildlife that depend
on the forest. More than five million
Ghanaians depend on Atewa Forest as
their source of clean drinking water.
“Saving Atewa Forest from mining should
be an intergenerational priority, and we are
happy and grateful that big businesses in the
aluminium value chain understand the importance
of a healthy forest and the environmental
services it provides,” said Oteng Adjei,
president of the Concerned Citizens of Atewa
Landscape (CCAL), the grassroots movement
advocating against bauxite mining in Atewa
Forest and the recipient of letters from all
three companies. “We appreciate their commitment
to supporting local and international
efforts to secure Atewa Forest against bauxite
mining that is certain to destroy the forest, its
water services and biodiversity.”
BMW Group, Tetra Pak and Schüco International
are all members of the ASI Aluminium
Stewardship Initiative, established to certify
the production and supply of aluminium
including bauxite extraction. The letters from
the companies state:
BMW Group: “Bauxite from the region of
the Atewa Forest needs to be in line with the
Convention on Biological Diversity, the UN-
FCCC Paris Agreement on Climate Change
and Ghana’s voluntary national contributions
towards the UN Sustainable Development
Goals. If this is not the case the BMW Group
will not accept aluminium in its supply chains
that originates bauxite from the Atewa Forest.”
Schüco: “Schüco would oblige our aluminium
suppliers not to supply aluminium derived
from bauxite mined in the Atewa Range
Forest Reserve, and we intend to encourage
other aluminium users to join us in this commitment.”
Tetra Pak: “Sourcing aluminium produced
from bauxite mined in the Atewa Range Forest
Reserve… presents a level of risk that is completely
unacceptable to Tetra Pak. No matter
how high the environmental standards that are
applied, any form of mining at this site will
have an unavoidable destructive impact on
the values inherent in such a natural habitat.”
Campaigners to protect Atewa Forest have
repeatedly stated that purchasing bauxite
mined from in the Atewa Forest would not
meet ASI’s standards and that bauxite mining
in Atewa would threaten species with global
extinction, undermining the Convention on
Biodiversity and the Sustainable Development
Goals, both of which set clear targets to stop
extinctions.
While the companies recognize the government
of Ghana’s desire to develop the aluminium
sector for economic development and
poverty reduction, their letters make clear
their commitments to sustainability. All three
companies pointed to their endorsement of
the ASI’s social and environmental standards,
and said they also want their suppliers to meet
these same standards.
Ghana government plans to establish
an integrated aluminium industry
If bauxite from Atewa becomes part of Ghana’s
aluminium supply, the Ghana Integrated
24 ALUMINIUM · 3/2021

e c o n o m i c s
© A Rocha Ghana
Aluminium Development Corporation (Giadec)
risks outright rejection of all Ghana’s
bauxite and aluminium by responsible aluminium
users such as these.
In 2016, the Ghana government identified
the legally protected Atewa Forest as one of
three sites to mine bauxite to support the repayment
of a USD2 billion infrastructure loan
from the People’s Republic of China. The government
plans to establish an integrated aluminium
industry and to repay the loan with
receipts from processed bauxite.
Extracting bauxite in Atewa would require
‘strip mining’ where the whole surface
layer of soil is removed. This means a total
loss of the forest in the mined areas, along
with all the biodiversity it contains. In 2019,
bulldozers started to clear trees and create
access roads in Atewa Forest, even after a
number of international groups, led by A Rocha,
and local groups, now led by CCAL, had
spent years urging the government to protect
Atewa Forest in perpetuity by converting
it into a national park.
Unlike Ghana’s existing bauxite mine at
Awaso, which locals describe as a ‘desert of
red mud’, Atewa Forest is teeming with life,
home to at least 50 mammal species, more
than 1,000 species of plants, at least 230 species
of birds and more than 570 butterflies –
including species found nowhere else in the
world.
“Incredible biodiversity”
In a recent book, acclaimed biologist and author
Professor E.O. Wilson lists Atewa Forest
as one of the 38 most important places
on Earth that should be set aside for nature’s
benefit.
“Atewa’s incredible biodiversity and the
ecosystem services it provides are priceless,
and the local communities have been very
vocal in their wish to protect this place from
Deforestation from mining
destruction,” said Daryl Bosu of A Rocha
Ghana. “By trying to extract short-term monetary
gain from the forest, the government is
actually driving companies away from doing
business with Ghana. It is time to invest in
Atewa’s long-term protection, not only for the
benefit of Ghanaians, but to the benefit of all
life on Earth, which depends on our forests to
help fight the climate crisis and prevent pandemics.”
In 2016, A Rocha and partners published
a report that showed that protecting Atewa
Forest as a national park and a buffer area
around it – rather than mining it for bauxite
– actually had the highest economic value for
the country over 25 years, with tremendous
benefits to communities both upstream and
down. The forest also harbours the headwaters
of three rivers – the Ayensu, Densu and
Birim – that together provide clean water daily
for over five million people.
The International Union for Conservation
of Nature (IUCN) passed a resolution in November
of 2020 demanding global action to
save Atewa from bauxite mining, joining the
international call to protect this irreplaceable
forest. In addition to providing clean water to
the communities around it, Atewa Forest is
home to the endangered white-naped mangabey;
the critically endangered togo slippery
frog, and the critically endangered Afia Birago
puddle frog, which was discovered in 2017.
“Major multinationals listening to the
voices of communities and publicly throwing
their economic weight behind the campaign to
protect Atewa Forest is a very welcome step
because tackling nature loss is everyone’s business,”
said Alice Ruhweza, director of WWF
Africa Region. “Hopefully, more companies
will quickly follow suit, helping to safeguard
Atewa and sending a clear message that parts
of our natural world are too priceless to be
destroyed for short term profit.” ■
Aluminium - the material of choice.
Visit our website and find out about the latest developments in the
international aluminium industry.
www.alu-web.de/en
ALUMINIUM · 3/2021 25

A L U M I N I U M - S t r a n g p r e s s I N D U S T R i e
© SMS group
„Als Systemlieferant haben wir den
Anspruch, die gesamte Prozesskette zu
beherrschen – auch im Additive Manufacturing“
Interview mit Thomas Winterfeldt,
Geschäftsbereichsleiter Schmiedetechnik,
und Hansjörg Hoppe, Vertriebsleiter
Strangpressen bei der SMS group, über
die Entwicklung und Erweiterung des
Geschäftsbereichs, die Übernahme von
Omav und der Beteiligung an Hydromec,
den ökologischen Fußabdruck im Maschinen-
und Anlagenbau, die Berücksichtigung
digitaler Technologien sowie die
Entwicklung im Bereich Additive Manufacturing.
ALUMINIUM: Herr Winterfeldt, seit drei Jahren
leiten Sie den Bereich Schmiedetechnik
bei der SMS group, zu dem auch das Strangpressgeschäft
gehört. Das letzte ausführliche
Gespräch mit Ihnen liegt rund zwei Jahre zurück.
Wie hat sich der Geschäftsbereich seitdem
entwickelt?
Winterfeldt: Wir haben uns in den vergangenen
Jahren strategisch weiterentwickelt,
sind deutlich internationaler aufgestellt. Wir
haben auf unseren wichtigsten Märkten außerhalb
Europas – in China, den USA und in Indien
– ein umfassendes Netzwerk mit eigenen
Mitarbeiten aufgebaut, um in diesen Regionen
Thomas Winterfeldt: „Wir haben uns in den vergangenen
Jahren strategisch weiterentwickelt,
sind deutlich internationaler aufgestellt.“ / Thomas
Winterfeldt: „In recent years we have developed
further strategically and established ourselves at
a much more international level.”
“As system suppliers we aspire to
the mastery of the entire process chain
– including additive manufacturing”
Interview with Thomas Winterfeldt, manager
of the Forging Technology business
and Hansjörg Hoppe, head of Sales for
Extrusion Presses in SMS group, about
the development and enlargement of the
business area, the takeover of Omav and
the stake in Hydromec, the ecological
footprint in mechanical and plant engineering,
the consideration paid to digital
technologies and developments in the
field of additive manufacturing.
ALUMINIUM: Mr Winterfeldt, for three
years you have headed the Forging Technology
sector in SMS group, which also includes
the extrusion business. The last detailed discussion
we had with you was around two
years ago. How has the business sector developed
since then?
Winterfeldt: In recent years we have developed
further strategically and established
ourselves at a much more international level.
In our most important markets outside Europe
– in China, the USA and India – we have built
up an extensive network with our own staff,
in order to be as close as possible to our customers
in those regions. And besides classical
mechanical and plant engineering we are developing
new business fields, such as digitization
and the Competence Centre for Additive
Manufacturing, in which we also want to grow
substantially with our eyes on aluminium as
well.
ALUMINIUM: The Covid-19 pandemic
has probably thrown business plans overboard
for the SMS group as well, as for other companies
too. What traces has the pandemic left
behind it at SMS?
Winterfeldt: So far we have come through
the pandemic comparatively well. The first
half of 2020 went off relatively unscathed for
SMS group as it did for the forging technology
sector; order intakes continued largely according
to plan until then, but from the summer
onward it became perceptible that projects
came to a halt and order intakes declined.
However, we were able to pick up a lot in our
servicing activities, which are becoming more
and more important for our group and for
Forging Technology. Meanwhile, around onethird
of our contracts relate to servicing, in
other words the classical after-sales business
with replacement parts, repair and modernization
contracts. We seek to establish longterm
agreements with our customers and we
also see on the customer side increasing
readiness to outsource these activities to us
as technology partners, in order to be able to
concentrate completely and fully on their core
business – namely running optimized processes
and manufacturing qualitatively highgrade
products.
ALUMINIUM: For many long years China
was the most important market for SMS
group. Did business in China also help you
last year?
Winterfeldt: Market activities in China
remained to a large extent unaffected by the
pandemic. There, we have seen and are still
seeing lively project activity and are very successful
in China with our forging technology
business. In China we mainly serve customers
producing for technologically demanding
applications in the automotive and aviation
industries, and who turn to SMS as an experienced
and competent project partner.
Hoppe: An example of that is the contract
awarded to us in December by Shandong
Weiqiao Light Metal for a 28-MN direct / indirect
extrusion and tube press. This is a very
special unit with many technological features.
From the third quarter of 2022 the press
will be producing profiles and thin-walled
tubes of aluminium – mainly for demanding
automotive products (for details see box
next double page). The contract was agreed
and signed by our local staff without anyone
having to travel out from Germany, but with
video-conference support.
Winterfeldt: Thanks to our well-established
presence in the various market regions,
despite the travel restrictions we have been
26 ALUMINIUM · 3/2021

S P E C I A L
A L U M I N I U M E x t r u s i o n I N D U S T R Y
Hansjörg Hoppe: „Wir haben ein Dutzend HybrEx-
Pressen verkauft – in alle Regionen dieser Welt.“ /
Hansjörg Hoppe: „We have sold a dozen HybrEx
presses – all over the world.”
möglichst nahe bei unseren Kunden zu sein.
Und wir bauen uns neben dem klassischen
Maschinen- und Anlagenbau neue Geschäftsfelder
auf, beispielsweise mit Digitalisierung
und dem Kompetenzzentrum Additive Manufacturing,
in dem wir auch mit Blick auf den
Werkstoff Aluminium stark wachsen wollen.
ALUMINIUM: Die Covid-19-Pandemie
hat vermutlich auch bei SMS group Geschäftspläne
etwas über den Haufen geworfen, wie in
anderen Unternehmen auch. Welche Spuren
hat die Pandemie bei SMS hinterlassen?
Winterfeldt: Wir sind bislang vergleichsweise
gut durch die Pandemie gekommen.
Das erste Halbjahr 2020 verlief für die SMS
group wie für den Bereich Schmiedetechnik
relativ störungsfrei, die Auftragseingänge erfolgten
bis dahin weitestgehend nach Plan, ab
Sommer war dann spürbar, dass Projekte angehalten
wurden und die Auftragseingänge ins
Stocken gerieten. Wir haben aber Vieles über
unsere Service-Aktivitäten auffangen können,
die für unsere Gruppe und die Schmiedetechnik
immer wichtiger werden. Inzwischen beziehen
sich rund ein Drittel unserer Aufträge
auf den Service, also das klassische After-
Sales-Geschäft mit Ersatzteil-, Reparatur- und
Modernisierungs-Aufträgen. Wir streben langfristige
Service-Verträge mit den Kunden an
und sehen auf Kundenseite auch die wachsende
Bereitschaft, diese Tätigkeiten an uns
als Technologiepartner auszulagern, um sich
voll und ganz auf das Kerngeschäft zu konzentrieren
– nämlich optimierte Prozesse zu
fahren und qualitativ hochwertige Produkte
herzustellen.
ALUMINIUM: China war lange Jahre der
wohl wichtigste Markt für SMS group. Hat
Ihnen das China-Geschäft auch vergangenes
Jahr geholfen?
Winterfeldt: Die Marktaktivitäten in China
sind von der Pandemie weitgehend unbehelligt
geblieben. Wir sahen und sehen dort
eine rege Projekttätigkeit und sind dort mit
unserem Schmiedetechnik-Geschäft sehr erfolgreich.
Wir bedienen in China vor allem
Kunden, die für technologisch anspruchsvolle
Anwendungen in der Automobil- und
Luftfahrt produzieren und auf SMS group als
erfahrenen und kompetenten Projektpartner
zurückgreifen.
Hoppe: Ein konkretes Beispiel hierfür ist
der im Dezember an uns erteilte Auftrag von
Shandong Weiqiao Light Metal für eine 28-
MN-Direkt / Indirekt-Strang- und Rohrpresse.
Dabei handelt es sich um eine sehr spezielle
Anlage mit vielen technologischen Features.
Die Presse wird ab dem dritten Quartal 2022
Profile und dünnwandige Rohre aus Aluminium
produzieren – hauptsächlich für anable
to reactivate several construction sites
quickly, link up with our experts remotely,
and complete a number of projects. For example
we brought to the acceptance stage a
closed-die forging press with a new drive in
the USA and in China an open-die forging
press, and in India we are continuing with the
commissioning of a wheel-rolling mill.
Hoppe: India’s market too is developing
very well for aluminium projects. We are
represented there by a company of our own,
which is responsible for the engineering and
for project implementation. Meanwhile, we
have been able to sell five aluminium extrusion
presses made in India.
ALUMINIUM: In September 2020 the
SMS group increased its share in Omav from
25 to 100 percent. Since then, the Italian press
manufacturer Hydromec also belongs to the
SMS group by way of a 70-percent share
owned by Omav. What advantages are linked
to those takeovers?
Winterfeldt: Omav offers a broad spectrum
of knowhow-rich products in front of and behind
the extrusion press, which supplement
the portfolio of the SMS group very effectively.
For example, the company has an energyefficient
HP7 high-performance billet furnace
characterized by high thermal efficiency of
75 percent and low average consumption of
less than 18 Nm 3 of natural gas per tonne of
log material. This is achieved in particular by
a preheating zone in which the logs are preheated
by means of the exhaust air of the
combustion zone. In combination with the
spruchsvolle Automotive-Produkte (Details
dazu im Kasten nächste Seite). Den Vertrag
haben unsere Mitarbeiter vor Ort ohne Anreisen
aus Deutschland, aber unterstützt per Videokonferenz
vereinbart und unterzeichnet.
Winterfeldt: Durch unsere starke Präsenz
in den verschiedenen Marktregionen konnten
wir trotz der eingeschränkten Reisemöglichkeiten
auch viele Baustellen schnell reaktivieren,
unsere Experten per Remote zuschalten
und Projekte abwickeln. Wir haben so eine
Gesenkschmiedepresse mit neuem Antrieb in
den USA und in China eine Freiformschmiedepresse
zur Abnahme gebracht sowie in
Indien die Inbetriebnahme eines Räderwalzwerks
fortgeführt.
Hoppe: Auch der indische Markt für Aluminiumprojekte
entwickelt sich sehr gut. Wir
sind dort mit einer eigenen Gesellschaft vertreten,
die das Engineering und die Abwicklung
von Projekten übernimmt. So konnten wir inzwischen
fünf Aluminium-Strangpressen aus
indischer Hand verkaufen.
ALUMINIUM: Im September 2020 hat
SMS group seine Beteiligung an Omav von 25
auf 100 Prozent aufgestockt. Auch der italienische
Pressenbauer Hydromec gehört seitdem
über eine 70%-Beteiligung von Omav
zur SMS group. Welche Vorteile verknüpfen
sich mit diesen Übernahmen?
Winterfeldt: Omav bietet ein breites Spektrum
knowhow-trächtiger Produkte vor und
hinter der Strangpresse an, die das Portfolio
der SMS group sehr gut ergänzen. Das Unternehmen
hat zum Beispiel einen energieeffizienten
HP7-Hochleistungsblockofen, der
sich durch eine hohe Wärmeeffizienz von 75
Prozent und einem niedrigen Durchschnittsverbrauch
von unter 18 Nm 3 Gas je Tonne
Stangenmaterial auszeichnet. Erreicht wird
dies insbesondere durch eine Vorwärmzone,
in der die Stangen mithilfe der Abluft der Verbrennungszone
vorgewärmt werden. In Verbindung
mit den leistungsstarken Induktionsanlagen
der zur SMS Elotherm gehörenden
IAS, beides Unternehmen der SMS group,
können wir die Bolzenerwärmung auch in einer
Linie zusammengeführt anbieten.
Hoppe: Für die Profilkühlung bietet Omav
sehr temperaturgenaue Quench-Systeme an.
Winterfeldt: Und auch beim Bau von
Strangpressen gibt es die Zusammenarbeit
für „SMS-Pressen – Made by Omav“. Ein
gegenseitiger Technologietransfer gestaltet
sich natürlich leichter, je enger die Partner
auch finanziell miteinander verbunden sind.
Die Zusammenarbeit war aber auch in der
Vergangenheit bereits eng – etwa bei der
55-MN-Strangpresslinie für Thöni oder der
45-MN-Strangpresslinie für Constellium in
ALUMINIUM · 3/2021 27

A L U M I N I U M - S t r a n g p r e s s I N D U S T R i e
Singen, die im Sommer 2020 in Betrieb ging.
Bei beiden Linien kommt der Auslauf hinter
der Presse von Omav. Was Omav bisher fehlte,
war ein global aufgestelltes Vertriebsnetzwerk
für das Servicegeschäft. Hier wollen wir unsere
italienischen Freunde stärker einbinden,
was sicher auch zu deren weiteren Unternehmensentwicklung
beiträgt. Unsere Kunden
werden sowohl vom gemeinsamen Angebot
bestehender Produkte als auch vom weltweiten
Service der SMS group profitieren.
Ähnliches gilt auch für die neue Gruppengesellschaft
Hydromec. Das Unternehmen
befindet sich in unmittelbarer Nachbarschaft
zu Omav, mit Werkstätten, die sich ergänzen.
Hydromec ist ein starkes Unternehmen in den
Mit der von SMS group zu liefernden Pesse steigt Shandong Weiqiao in das Geschäft
für stranggepresste Aluminiumprodukte ein (Das Foto zeigt eine baugleiche Presse)
With the press to be supplied by SMS group, Shandong Weiqiao will make a start in the
aluminium extruded products business (Shown in the photo is a press of identical design)
efficient induction units made by IAS GmbH
which belongs to SMS Elotherm, both of them
companies of the SMS group, we can also provide
billet heating in a single line.
Hoppe: For section cooling Omav offers
very temperature-precise quenching systems.
Winterfeldt: And even for the construction
of extrusion presses there is the collaboration
that leads to ‘SMS Presses – Made by
Omav’. Reciprocal technology transfer is naturally
the more easy, the closer the partners
are financially connected with one another.
However, the collaboration was already close
in the past – for example for the 55-MN extrusion
line for Thöni or the 45-MN line for
Constellium in Singen, which began operating
in the summer of 2020. In both extrusion
lines the run-out behind the press came from
Omav. What Omav has lacked until now was
a globally established marketing network for
the services business. Here, we want to involve
our Italian friends in greater depth, which will
certainly also contribute towards their further
company development. Our customers will
benefit both from the conjoint range of existing
products and also from the world-wide
servicing available from SMS group.
The same applies to Hydromec, the new
group company. Hydromec is in the immediate
vicinity of Omav, with workshops that
supplement it. Hydromec is an efficient company
in the fields of closed-die and open-die
forging as well as ring rolling, and was in the
SMS supplies extrusion all-rounder to Shandong Weiqiao
Shandong Weiqiao Light Metal China has placed
an order with SMS group for the supply of a
28-MN direct-indirect extrusion and tube press.
By making this investment in a multifunctional
light-alloy extrusion press, the Chinese company
is entering the business for extruded aluminium
products. Shandong Weiqiao’s first extrusion
press will be erected at the company’s location
in Zouping City, Shandong Province. The product
range will include profiles and thin-walled pipes
made of aluminium and its alloys, primarily for
use in the automotive sector, especially for the
production of e-vehicles. The annual capacity of
the press will be around 10,000 tonnes.
“We are investing in an extrusion press that
meets all our technological requirements. The
flexibility in production and the wide product diversity
give our company a solid foundation for
this new business area. SMS group’s extrusion
technology is the most advanced in its class and
is resource-efficient too,” says Zhang Guoshuai,
technical project manager at Shandong Weiqiao.
The extrusion press is capable of processing
billets with a maximum diameter of 254
mm (10-in) and a length up to 1,200 mm. The
fully automatic circulation of the loose dummy
blocks and the indirect dies is performed by an
auxiliary robot. SMS group is building the extrusion
press for Shandong Weiqiao according to
a proven design with the patented plate-type
press frame, which makes the press structure
much more rigid and thus more sturdy. The
built-in, high-precision linear guides are practically
maintenance-free.
Thanks to the servo drive used for all auxiliary
functions as well as the EcoDraulic concept
that reduces energy consumption, the press
boasts a highly favourable energy balance. All
pumps that are not required during the extrusion
process are switched off via the automatic
start-stop feature.
SMS group’s modular technology and process
control package offers additional possibilities for
optimization. The Cadex/3 system for isothermal
and isobaric direct extrusion calculates the optimum
extrusion speed and billet temperature for
each profile type. This enables a higher surface
quality and material structure of the profile to
be achieved, which also significantly reduces the
scrap rate at the same time. The Picos software
documents all process and product-relevant
data, which can be retrieved for certification
purposes, e.g. for automotive engineering. With
the integrated IBA measuring and analysis system,
fault diagnoses can be performed remotely,
thus reducing downtimes during production.
SMS group will deliver the press in pre-assembled
equipment units to Zouping City, which
will significantly reduce the installation time at
the customer’s site. The acceptance test for the
new press is scheduled for the third quarter of
2022.
28 ALUMINIUM · 3/2021

S P E C I A L
A L U M I N I U M E x t r u s i o n I N D U S T R Y
past a serious competitor for SMS group, at
least in the European market. With Hydromec
we will follow the same successful path as with
Omav in recent years. Now we have the possibility
to serve the global market together
and are in the market as system suppliers,
beginning with the recycling and melting furnaces
made by Hertwich Engineering, also an
SMS group company, through extrusion and
forging machines, and all the way to run-outs
and heat treatment plants.
ALUMINIUM: Energy and resource efficiency
have for years been at the focus of
climate-friendly production. In the aluminium
industry there is nowadays much talk about
low-carbon aluminium. More and more primary
aluminium producers offer low-carbon
aluminium under creative brand names. To
what extent does such a trend also reach the
plant manufacturer SMS group?
Winterfeldt: The issue of carbon footprint
is becoming more and more important in the
project inquiries that we receive. In the steel
industry, that aspect has become highly topical
under the slogan ‘green slabs’. But in the
aluminium sector too, besides the performance-related
technological plant features everything
has revolved around reducing energy
consumption and CO 2 emissions. Here let me
again refer to Hertwich Engineering, which
sets the benchmark with its energy-efficient
melting furnaces for aluminium scrap.
Hoppe: In the extrusion sector, already
years ago we achieved a great leap forward
toward still more energy-efficient production
with our HybrEx press and its electric servomotors.
ALUMINIUM: With conventional presses
too, you can point to numerous implemented
measures that reduce energy consumption and
idle times. Is the specific energy advantage of
the HybrEx still really significant?
Hoppe: We continually carry out energy
measurements on HybrEx presses during everyday
operation, and can therefore confirm
very definitely that the energy advantage of
a HybrEx is considerable. Of course, energy
consumption depends on the products and the
alloys that are processed by such a machine.
However, as a rough average the energy consumption
with a HybrEx is less than 80 kWh
per tonne of profiles. With our conventional
extrusion presses we fluctuate within a window
of about 110 to 115 kWh per tonne. And
even that, compared with the energy consumption
of these machines twenty years ago,
is a clear advantage.
ALUMINIUM: How many HybrEx machines
have you now sold and up to what size
are these presses available?
➝
Bereichen Gesenk- und Freiformschmieden
sowie Ringwalzen und war in der Vergangenheit
ein starker Wettbewerber für SMS group,
zumindest für den europäischen Markt. Wir
werden mit Hydromec den gleichen erfolgreichen
Weg beschreiten wie mit Omav in den
letzten Jahren. Nun haben wir die Möglichkeit,
den Markt global gemeinsam zu bedienen
und sind als Systemlieferant im Markt unterwegs
– von den Recycling- und Schmelzöfen
von Hertwich Engineering, ebenfalls ein Unternehmen
der SMS group, über die Pressund
Schmiedeaggregate bis hin zu den Ausläufen
und Wärmebehandlungsanlagen.
ALUMINIUM: Energie- und Ressourceneffizienz
stehen seit Jahren im Fokus einer
klimaverträglichen Produktion. In der Aluminiumindustrie
ist dieser Tage viel von „Low
Carbon Aluminium“ die Rede – immer mehr
Hüttenproduzenten bieten kohlenstoffarmes
Aluminium unter kreativen Markennamen an.
Inwieweit erreicht ein solcher Trend auch den
Anlagenbauer SMS group?
Winterfeldt: Die Frage nach dem Carbon
Footprint spielt in den Projektanfragen, die
wir erhalten, immer mehr eine Rolle. In der
Stahlindustrie ist dieser Aspekt unter dem
Stichwort „grüne Bramme“ topaktuell. Aber
auch im Aluminiumsektor dreht sich neben
den leistungsbezogenen technologischen Anlagenfeatures
seit Jahren alles darum, den
Energieverbrauch und die CO 2 -Emissionen zu
reduzieren. An dieser Stelle sei hier nochmals
auf Hertwich Engineering hingewiesen, die
mit ihren energieeffizienten Einschmelzöfen
für Aluminiumschrotte Benchmark-Charakter
haben.
SMS group bietet die HybrEx-Pressen bis zu einer Baugröße von 45 MN an
The SMS group supplies HybrEx presses up to 45 MN size
Hoppe: Im Strangpressbereich haben wir
bereits vor Jahren mit der HybrEx-Presse und
ihren elektrischen Servomotoren einen Riesensprung
zu einer noch energieeffizienteren
Produktion gemacht.
ALUMINIUM: Auch bei den konventionellen
Pressen verweisen Sie auf zahlreiche
umgesetzte Maßnahmen, die den Energieverbrauch
und Nebenzeiten senken. Ist der
spezifische Energievorteil der HybrEx noch
wirklich signifikant?
Hoppe: Wir führen kontinuierlich Energiemessungen
an HybrEx-Pressen im Betriebsalltag
durch und können daher sehr gut belegen,
dass der Energievorteil einer HybrEx
erheblich ist. Der Energieverbrauch hängt
natürlich von den Produkten und den Legierungen
ab, die auf einer solchen Maschine
gefahren werden. Aber grob im Durchschnitt
liegt der Energieverbrauch bei einer HybrEx
unter 80 Kilowattstunden je Tonne Profil.
Bei unseren konventionellen Strangpressen
bewegen wir uns in einem Fenster von etwa
110 bis 115 Kilowattstunden je Tonne. Und
auch das ist, gemessen an den Energieverbräuchen
dieser Maschinen von vor zwanzig
Jahren, ein deutlicher Vorteil.
ALUMINIUM: Wie viele HybrEx haben
Sie inzwischen verkauft und bis zu welcher
Baugröße bieten Sie diese Presse an?
Hoppe: Wir haben ein Dutzend HybrEx-
Pressen verkauft – in alle Regionen dieser
Welt. So zum Beispiel eine 40-MN-Presse
für 10-Zöll-Blöcke nach Japan für UACJ und
eine 35-MN-HybrEx für 9-Zoll-Blöcke nach
England, die beide im vergangenen Jahr eine
Endabnahme erhielten. Wir bieten die HybrEx
ALUMINIUM · 3/2021 29

A L U M I N I U M - S t r a n g p r e s s I N D U S T R i e
bis zu einer Baugröße von 45 Meganewton an.
Der limitierende Faktor ist die Baugröße der
Motoren für die Bewegung des Laufholms und
Containers.
ALUMINIUM: Welche Bedeutung hat die
Digitalisierung für Ihren Bereich?
Winterfeldt: Die Berücksichtigung digitaler
Technologien in unseren Maschinen und Anlagen
ist von entscheidender Bedeutung für
eine vorausschauende Analyse des Anlagenzustands,
für die Produktqualität, die Produktionsplanung
und das Energiemanagement.
Es geht darum, Daten in Informationen und
Informationen in Mehrwert für den Kunden
umzuwandeln. Unterstützt werden wir dabei
von unserer Gesellschaft SMS digital, die maßgeschneiderte,
nutzerorientierte Softwarelösungen
entwickelt.
Intuition und langjährige Betriebserfahrung
der Bediener werden künftig nicht mehr
ausreichen, um eine Anlage optimal zu betreiben.
Wir bieten heute modernste Digitalisierungs-Werkzeuge
an, die perfekt auf die
Strangpressen abgestimmt sind und durch ihre
Sensorik und die Auswertung großer Datenmengen
in Echtzeit tiefe Einblicke in die Prozesse
und über den Zustand und das Verhalten
der Anlagenkomponenten ermöglichen.
Der Anlagenbetreiber erhält so Transparenz
und unterstützende Analysen, die es zuvor
nicht gab. Selbst kleinste Abweichungen werden
frühzeitig erkannt oder Fehler können
durch lernende Systeme (Digitalisierung) vermieden
oder dokumentiert werden, bevor sie
entstehen. Das ist auch für die Rückverfolgbarkeit
von fehlerhaften Produkten immens
Hoppe: We have sold a dozen HybrEx
presses – all over the world. For example a
40-MN press for 10-inch billets was delivered
to Japan for UACJ and a 35-MN HybrEx for
9-inch billets to England, both of them achieving
their final acceptance last year. We offer
the HybrEx up to a size of 45 MN. The limiting
factor is the size of the motors for moving
the running beam and container.
ALUMINIUM: How important is digitization
for your sector?
Der HP7-Blockofen von Omav zeichnet sich durch eine hohe Wärmeeffizienz aus
Omav’s HP7 billet furnace is noted for high thermal efficiency
Winterfeldt: Taking account of digital technologies
in our machinery and plant is decisively
important for a proactive analysis of
the plant status, for product quality, for production
planning and for energy management.
It is all about transforming data into information
and information into added value for the
customer. In this we are assisted by our company
SMS digital, which develops tailor-made,
utility-orientated software systems.
In times to come intuition and years of experience
will no longer be sufficient for the
optimum operation of a plant. Today we offer
the most up-to-date digitization tools, which
are perfectly designed for extrusion and
through their sensor systems and the evaluation
of large data volumes in real time, enable
deep insights into the processes and the state
and behaviour of the entire plant components.
In that way the plant operator benefits
from transparency and supportive analyses
which have not been available before. Even
the smallest deviations are recognized at an
early stage, or faults can be avoided by learning
systems (digitization) or documented
before they take place. This is also hugely
important for the back-tracing of defective
products. In the case of aviation products this
has already been a ‘must’ for a long time and
in the automotive industry it will also be the
case in the not too distant future. In the Big
River Steel plant built by SMS in the US, no
coil leaves the plant without all its production
parameters having been documented
and the AI-supported system of the coil released
for marketing.
ALUMINIUM: Would you say a little more
about your software tools?
Hoppe: Take our Picos visualization system
– with this, the press operator can monitor
and control the entire process flow. The
tool visualizes the production specifying the
required process parameters. It shows the
actual values, includes an alarm function and
delivers diagnoses when a fault occurs in the
production flow.
Winterfeldt: The Midis+ technology package
enables the management of all productrelevant
data and increases the overall equipment
effectiveness, so that we cover the whole
of the process chain from the delivery of the
billet to the packaging of the finished product.
Thanks to the recording of numerous parameters
and by clear visualization, the plant operator
easily detects potentials for improving
the performance of his extrusion press.
With SMS Metrics machine data are gathered,
stored and evaluated in real time. Thanks
to transparency, plant operators are able to
expand their process know-how. Evaluations
can be easily prepared on a dashboard browser
and be retrieved worldwide.
Hoppe: We have already been using the
Cadex software for a long time. It enables the
extrusion process to be optimized by means of
thermal simulation. For that, the heat balance
for each billet is calculated so that the material
can be deformed at the optimum billet
and taper temperature.
Winterfeldt: We offer each of our customers
a basic digital package. This is supplemented
by Smart Alarm – a web-based application
for operators, shift managers, maintenance
staff or even plant managers. Smart Alarm
ensures better oversight and better control
in the event of alarms triggered in the plants.
Via long-term storage of historic alarm, data
alarm trends can be calculated that will permit
to detect potential downtimes. The web-based
application was developed by SMS digital.
All these tools help the customer to improve
his plants and processes and offer advantages
in servicing business because we can
also give long-term guarantees about the
availability of the equipment.
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S P E C I A L
A L U M I N I U M E x t r u s i o n I N D U S T R Y
ALUMINIUM: Earlier you mentioned the
building up of new business fields in the context
of additive manufacturing. This also includes
the production of metal powder by a
powder atomization unit. To what extent has
that field developed?
Winterfeldt: With our own powder atomization
plant we have gained knowledge with
which we can already produce various highly
alloyed metal powders. We have been able to
place a unit of that type with our customer
Outokumpu under an ‘Equipment as a Service’
contract model. With plant technology
for atomizing aluminium powder we have developed
an attractive concept and are in talks
with potential customers for conjoint implementation,
so as to be able in the future to
offer units for the production of
high-grade aluminium powder. In
our view this is a most promising
future field because AM offers
new possibilities for the function-optimized
design of components
whose potential
is already bec
o m i n g
evident.
Already
in some
wichtig. Bei Luftfahrt-Produkten ist dies schon
längst ein Muss, und in der Automobilindustrie
wird das auch in nicht allzu ferner Zukunft
kommen. Bei dem von SMS gebauten
Stahlwerk Big River Steel in den USA verlässt
kein Coil das Werk, ohne dass alle Produktionsparameter
dokumentiert sind und das
KI-gestützte System das Coil zum Verkauf
freigibt.
ALUMINIUM: Würden Sie die Software-
Tools näher beschreiben?
Hoppe: Nehmen Sie unser Visualisierungsystem
Picos – damit überwacht und steuert
der Pressenbediener den gesamten Prozessablauf.
Das Werkzeug visualisiert die Produktion
und gibt erforderliche Prozessparameter
vor. Es zeigt die Ist-Werte an, enthält eine
Alarmfunktion und liefert Diagnosen, wenn
es zu einer Fehlfunktion im Produktionsablauf
kommt.
Winterfeldt: Das
Technologiepaket
Midis+ ermöglicht
die Verwaltung aller
produktrelevanten
Daten und steigert
die Gesamtanlageneffektivität,
dabei decken wir die
für mehr Überblick und bessere Kontrolle bei
den Alarmen, die in Anlagen ausgelöst werden.
Durch die langfristige Speicherung historischer
Alarmdaten lassen sich Trends berechnen,
anhand derer sich potenzielle Stillstände
erkennen lassen. Entwickelt wurde die webbasierte
Applikation von SMS digital. All diese
Tools helfen dem Kunden, seine Anlagen
und Prozesse zu verbessern und bieten Vorteile
im Service-Geschäft, weil wir so auch
langjährige Garantien über die Verfügbarkeit
der Anlagen geben können.
ALUMINIUM: Sie erwähnten anfangs den
Aufbau neuer Geschäftsfelder im Bereich
Additive Manufacturing. Dazu zählt auch die
Herstellung von Metallpulver mittels einer
Pulververdüsungsanlage. Wie weit ist dieser
Bereich gediehen?
Winterfeldt: Mit unserer eigenen Pulververdüsungsanlage
haben wir Knowhow aufgebaut,
mit dem wir bereits diverse hochlegierte
Metallpulver herstellen können. Eine solche
Anlage konnten wir bei unserem Kunden Outokumpu
mit einem „Equipment as a Service“-
Vertragsmodell positionieren. Mit Anlagentechnik
zur Verdüsung von Aluminiumpulver
haben wir ein attraktives Konzept entwickelt
und sind in Gesprächen mit potenziellen
Kunden für eine gemeinsame Umsetzung, um
of our plants
gesamte Prozesskette zukünftig auch Anlagen zur Herstellung von
we have created
a number of 3Dprinted
components
with functionoptimized
designs.
As an example a
hydraulic control
block for open-die
von der Anlieferung der
Blöcke bis zur Verpackung
der fertigen Produkte ab.
Durch die Protokollierung
zahlreicher Parameter und
die übersichtliche Visualisierung
erkennt der Betreiber
sehr einfach Potenziale zur
hochwertigem Aluminiumpulver anbieten zu
können. In unseren Augen ist dies ein aussichtsreiches
Zukunftsfeld, weil das Additive
Manufacturing neue Möglichkeiten der funktionsoptimierten
Konstruktion von Bauteilen
bietet, deren Potenzial schon heute sichtbar
wird. Wir haben in einigen unsere Anlagen
bereits einige 3D-gedruckte Teile eingebaut,
forging presses Der 3D-gedruckte Hydraulic-Steuerblock für Leistungssteigerung seiner
die mittels funktionsoptimierte Konstruktion
Anlage.
designt wurden. Als Beispiel ist hier ein Hy-
can be mentioned,
which is control block for open-die forging presses is more Mit SMS-Metrics draulic-Steuerblock für Freiformschmiede-
Freiformschmiedepressen ist kompakter, leichter
und strömungsoptimiert / The 3D-printed hydraulic
more compact,
compact, lighter and flow-optimized werden Maschinendaten
pressen zu nennen, der kompakter, strömungsoptimiert
flow-optimized
and much lighter than the previous control
blocks, which were very complex and expensive
to produce. We have designed a spray
head which is used for the cooling and lubrication
of dies in forging machines. That was
produced completely by the additive method
and was distinguished in 2019 with the German
Design Award.
So, just as we are system suppliers in forging
technology and extrusion lines who can
provide the entire process and all the equipment
components for a line, we also want to
master the entire process chain in the sector
of additive manufacturing technologies.
ALUMINIUM: Mr Winterfeldt, Mr Hoppe,
in Echtzeit erfasst,
gespeichert und ausgewertet. Dank dieser
Transparenz können die Anlagenbetreiber ihr
Prozesswissen erweitern. Die Auswertungen
können in einem Dashboard im Browser einfach
erstellt und weltweit abgerufen werden.
Hoppe: Die Software Cadex setzen wir
schon seit langem ein. Sie ermöglicht eine
Optimierung des Pressvorgangs mithilfe einer
thermischen Simulation. Dazu wird der Wärmehaushalt
für jeden Bolzen berechnet, damit
das Material bei der optimalen Block- und
Tapertemperatur umgeformt werden kann.
Winterfeldt: Ein digitales Basispaket bieten
wir allen unseren Kunden an. Es wird ergänzt
um Smart Alarm – eine webbasierte Anwendung
und deutlich leichter ist als
der bisher sehr aufwändig gefertigte Steuerblock.
Wir haben einen Sprühkopf konstruiert,
der zur Kühlung und Schmierung von Gesenken
in Schmiedeanlagen eingesetzt wird.
Dieser wurde komplett über das Additive Verfahren
hergestellt und 2019 mit dem German
Design Award ausgezeichnet.
So, wie wir in der Schmiedetechnik und
bei Strangpresslinien Systemlieferant sind, der
den gesamten Prozess und alle Anlagenkomponenten
einer Linie anbieten kann, wollen
wir auch im Additive Manufacturing die gesamte
Prozesskette dieser Technologien beherrschen.
ALUMINIUM: Herr Winterfeldt, Herr
many thanks for this discussion. ■
für Bediener, Schichtleiter, Instandhal-
ter oder auch Werksleiter. Smart Alarm sorgt
Hoppe, vielen Dank für das Gespräch. ■
ALUMINIUM · 3/2021 31

A L U M I N I U M E x t r u s i o n I N D U S T R Y
Castool clean-out block for
efficient cleaning of the liner wall
After each change of alloy, and also after
every shift, a clean-out block should be
used to remove the build-up of oxide skin
from the liner of the container. The cleanout
block is pushed through a heated container
by the dummy block and should
remove all the aluminium left on the inner
bore of the liner after repeated extrusion
cycles. Castool clean-out blocks have
been designed for maximum efficiency in
cleaning the liner wall.
© Castool
Castool clean-out block
A dummy block that is working properly will
leave approximately .005” (.25 mm) of aluminium
on the inside of the liner. The cleanout
block should remove this, having zero
clearance with the liner in the heated condition.
When ordering a clean-out block, it is important
to accurately measure the current bore
of the entire length of the container. Normally
a container may be used for an extended
period, but especially if hard alloys are being
extruded, over time the actual diameter will
increase.
Temperature control of both the container
and dummy block is critical for efficient extrusion.
Taper heating of the billet, however,
makes cooling of the dummy block no longer
necessary. Also, neither clean-out blocks nor
dummy blocks can operate effectively if the
container has become out of round, bellied,
or gouged. Such containers should either be
relined, or replaced.
The Castool clean-out block has been designed
for maximum efficiency in cleaning
the liner wall. The block is long enough to
sit on the billet loader and travel through the
liner smoothly. It is made to be used at room
temperature to make handling safer and to
achieve better dimensional control. The block
is made hollow to reduce weight and wire cut
at both ends to allow it to flex slightly and
retain contact with the liner wall.
Once the customer has supplied the minimum
container liner diameter at room temperature
and the operating temperature of
the liner during operation, Castool applies the
thermal expansion factors for both the liner
and the clean-out block to calculate the best
diameter for the cold clean-out. The Castool
clean-out block is precisely sized to meet the
requirements of each individual container,
and to remove the maximum amount of skull,
without abrading the liner wall.
Alloy skin: The amount of expansion of
the dummy block is carefully calculated and
controlled in order to leave a thin film of alloy,
or ‘skull’, on the liner of the container,
as the dummy block shears the metal during
its forward stroke. The container then has a
residual built-up oxide layer prior to the next
billet being loaded. After billet upset, the
oxide layer of the new billet mixes with the
previous layer left in the container. When the
alloy is changed, there is then a possibility of
contamination. This can result in defects in
surface finish, or in structural properties.
The dummy block should never remove
the skull completely, because it separates the
outer surface of the dummy block from the
liner of the container. If there is no alloy left,
it usually indicates that the dummy block is
not contracting on the return stroke. Scrap
from the skin of the billet being extruded, as
well as blisters and other defects in the product,
will result.
Billet impurities: Through the ongoing
development of metal treatment and casting
technologies, the quality of aluminium
alloy billets is constantly improving.
The outer skin of the billet, however,
is inevitably oxidized, and often also
marred by surface impurities and minor
inclusions.
Aluminium’s property of sticking
to steel causes the oxide skin of the billet to
remain fused to the interior surface of the
container liner during extrusion. It is important
to prevent this layer of tainted alloy from
sliding forward towards the die.
Forming the butt: During the extrusion
stroke, as the billet is pressed through the
container, the flow into die is from the centre
of the billet. Oxides and other impurities from
the skin then collect in front of the dummy
block. Extrusion is stopped before this contaminated
alloy is carried through the die into
the product. It then forms the butt that
adheres to the back of the die stack, and is
discarded.
Use of cold clean-out block:
• When changing from one alloy family to
another (for example 6xxx to 5xxx, or 7xxx
to 2xxx)
• Within an alloy family: as required by
product quality demands
• Within an alloy family (6xxx alloys only):
when changing from a hard 6xxx alloy to a
soft alloy (from 6061 alloy to 6063)
When encountering persistent blister along
the length of extrusion:
• Use cold clean-out block to remove skin
build up in container
• This is just a temporary fix. The real cause
of the problem needs to be addressed (e.g.,
container liner is worn or bellied; there is
stem to container misalignment; or dummy
block is in need of replacement).
Alu-Ject – for clean separation of
the dummy block from the butt
Castool‘s assortment of Alu-Ject lubricants
At the end of each extrusion cycle, the dummy
block must separate cleanly from the butt,
without removing the profile from the die
32 ALUMINIUM · 3/2021

S P E C I A L
A L U M I N I U M E x t r u s i o n I N D U S T R Y
and without breaking the mandrel cone in the
dummy block. Aluminium sticking can be a
serious problem, especially when using softer
alloys, and with larger billets. It is therefore
essential to lubricate both the billet and the
dummy block to make separation easier.
Aluminium alloys stick to steel at or above
400 ºC and becomes more of a problem, the
larger the billet diameter because of the increased
surface area. Therefore, a carefully
measured amount of lubricant is applied on
the billet face to avoid unnecessary costs and
a workplace pollutant.
Castool’s Alu-Ject is a non-pigmented,
water-based lubricant designed for billet end
coating. It is formulated using organo-metallic
compounds which apply a boundary film to
prevent welding of the billet to the dummy
block, providing excellent release characteristics.
Alu-Ject is capable of wetting temperature
as high as 600 ºC (1 112 ºF).
The lubricant is available as a liquid, solid
soap bar or tablet.
Liquid billet lubrication system: Castool
has developed a unique process of application
for a liquid-soluble lubricant to a preheated
extrusion billet
or tool.
The obstacle
to their use is
the Leidenfrost affect, which makes
it difficult to coat a surface hotter
than 600 °C with a water-based
product. This application process
enables improved coverage and reduces
overspray and cost.
Alu-Ject Liquid should be sprayed
to achieve the best
results. Spray application
provides
a uniform film
thickness, which allows lower friction values;
however, the product can be successfully
swab applied. Alu-Ject Liquid does not contain
graphite or boron nitride, is easy to mix
and dilute, and easily applied by automatic
or manual spray equipment, and last but not
least safe to use.
Alu-Ject Stick is a cream-coloured, sodium-based
soap, supplied in the form of solid
soap bars. It does not contain graphite or boron
nitride and has excellent lubricity and
Alu-Ject assemblies
good adhesion. Alu-Ject Stick is used for the
dummy block, billet face, container seal face,
billet and butt shears, etc.
Alu-Ject PB Tablets are a non-pigmented
lubricant in tablet form designed for billet
end coating. It is formulated using organometallic
compounds which apply a boundary
film to prevent welding of the billet to the
dummy block. It provides excellent release
characteristics.
■
Extrusion Technology
at its best
We offer perfect engineering – from the individual component
to the complete system. We advise you on all aspects of
heating, cooling and material handling and find the perfect
technical solution for your application.
extrutec GmbH
Feldstr. 25 | 78345 Moos · Germany
www.extrutec-gmbh.de
Driven by value creating technology

A L U M I N I U M - S t r a n g p r e s s I N D U S T R i e
Multidirektionale Gabelstapler für
sicheres und effizientes Bolzenhandling
Hammerer Aluminium Industries (HAI)
beschäftigt 1.600 Mitarbeiter an acht
Standorten in Europa und deckt die gesamte
Wertschöpfungskette ab – vom
Recycling über die Herstellung von Aluminiumprofilen
bis hin zu fertigen Bauteilen
und Komponenten. In der Unternehmenszentrale
in Ranshofen, Österreich,
sorgen neue Gabelstapler von Combilift
für das sichere und effiziente Handling
von Pressbolzen.
Seit Juli 2020 sind drei multidirektionale Gabelstapler
des irischen Herstellers Combilift
im Einsatz, nachdem Christian Ertl, Gruppenleiter
Transportlogistik Casting, einen Ersatz
für die bisher verwendeten Seitenstapler suchte.
Die hätten, so Ertl, „in der Vergangenheit
nicht gerade durch ihre Zuverlässigkeit geglänzt“.
Daher machten sich Ertl und einige
Staplerfahrer aus den Bereichen Adjustage
und Verladung auf den Weg nach Kärnten, wo
sie ein ähnliches Combilift-Gerät bei einem
Stahlverarbeiter testeten und mit den Mitarbeitern
vor Ort Erfahrungen austauschten.
“Für uns war wichtig, dass die Leute, die
die Geräte bei uns bedienen sollen, in der
Wahl der neuen Stapler mit eingebunden werden”,
so Ertl, “und es war uns schnell klar,
dass wir bei Combilift fündig wurden. Die
Vorteile des Vier-Wege-Prinzips, das Frontund
Seitenstapler vereint, liegen auf der Hand
gegenüber einem konventionellen Seitenstapler.
Die Möglichkeit, die Räder per Knopfdruck
zu drehen und somit die Fahrtrichtung
zu ändern ist von großem Nutzen, vor allem
an der Verpackungsstation, wo sehr beengte
Platzverhältnisse herrschen.”
Zwei Combilift-Fahrzeuge vom Typ
C14000 sowie ein C8000 Modell, alle mit
Dieselantrieb, wurden als die am besten geeigneten
Lösungen für die anspruchsvollen
Bedingungen bei HAI angesehen, wo die
Stapler in einem intensiven Vierschichtbetrieb
arbeiten und jeweils jährlich rund 3.000
Fahrstunden zurücklegen. Die 7.500 Millimeter
langen und 1.200 Millimeter tiefen Bündel
von Pressbolzen, die bis zu 7.000 Kilogramm
wiegen können, müssen sicher und effizient
sowohl innen in der Produktionshalle und der
Verpackungsstation als auch anschließend
außen ins Zwischenlager befördert werden.
Nicht nur in der Verpackungsstation ist
Platz Mangelware – das gleiche gilt für das
Außenlager, wo die Bolzen teils auf Krag-
Multidirectional forklifts for
safe and efficient billet handling
Hammerer Aluminium Industries (HAI)
employs a workforce of 1,600 at its eight
sites in Europe, and the company covers
the entire value chain – from recycling via
the production of aluminium profiles to
finished components. It is now using three
multidirectional forklifts from Combilift,
which ensure the safer and more efficient
handling of extrusion billets at the company’s
headquarter in Ranshofen, Austria.
The trucks from the Irish manufacturer Combilift
have been in operation since July 2020,
replacing the previous sideloaders, which, according
to Christian Ertl, group manager of
transport logistics casting “had not exactly
impressed us with their track record of reliability.”
Ertl and some of his team from HAI’s
finishing and loading division visited a steel
processing plant in another part of Austria
where Combilifts had been in operation for
some time to check out their capabilities and
get the drivers’ opinions.
“We like to involve those who will actually
operate the trucks in the decision making
process,” says Ertl, “and after seeing them in
action we all agreed that Combilift’s products
fitted the bill perfectly. The advantages of the
4-way concept that combines front and side
loading technology are significant compared
to conventional forklifts. The ability to turn
the wheels with just the touch of a button
to change the direction of travel is of great
benefit, particularly in the packing station,
where space is pretty limited.”
Two 14-tonne capacity C14000 models and
an 8-tonne C8000 truck, all diesel powered,
were chosen as the best solutions for the
tough operational requirements at HAI. The
7,500 mm long and 1,200 mm deep bundles
of billets, which can weigh up to 7,000 kg,
need safe and efficient handling inside in the
production area and packing station as well
as stable transport to the interim storage area
outside. They also need to be able to cope
with an intensive 4-shift schedule and clock
up operational hours of around 3,000 a year
per truck.
Space is not only at a premium in the packing
station but elsewhere on the premises, including
the outdoor storage area, where the
billets are stored on cantilever racking up to
a height of 3 metres, as well as the HGV loading
zone. To maximize the available space,
a guided-aisle system was implemented between
the racking, enabling operational aisle
widths to be narrowed down to just 3,620
mm. Telescopic forks, which can reach across
the whole of the trailer bed, were fitted to
the C14000 models to enable loading from
just one side, once again enabling best use of
space.
One of Combilift’s acknowledged strengths
is its ability to customize its products according
to specific individual requirements, and
this was the case at HAI too, to make the daily
tasks of the drivers as straightforward as possible.
Features included in HAI’s fleet include
Die Combilift-Gabelstapler müssen bei HAI bis zu sieben Tonnen schwere Bündel Pressbolzen transportieren
/ At HAI, Combilift forklifts have to handle bundles of billets weighing up to seven tonnes
© HAI
34 ALUMINIUM · 3/2021

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a reversing and fork camera, air conditioning,
hands-free phone and an air-suspension
comfort seat. The high cab position guarantees
maximum safety as it offers a clear overview
of the load, the forks and the direction
of travel.
Ertl sums up: “These robust and powerful
trucks from
Combilift now
ensure an efficient
and more
cost effective operation.
Thanks
to the co-operation
with the
manufacturer as
well as the excellent
advice from
Wiener Staplerund
Fördertechnik,
we were
able to find a
handling solution
that meets
all of our requirements.”
■
armregale bis zu einer Höhe von drei Metern
gelagert werden, sowie für die Lkw-Verladezone.
Um den verfügbaren Platz zu optimieren,
wurde ein Gangführungssystem zwischen
den Regalen implementiert. So konnten Arbeitsgangbreiten
von lediglich 3.620 mm realisiert
werden. Teleskopgabelzinken, die über
Die Combilift-Fahrzeuge arbeiten nach dem Vier-Wege-Prinzip, das Front- und Seitenstapler vereint
/ The 4-way concept of the Combilift trucks combines front and side loading technology
© Combilift
die Gesamtfläche des Anhängers reichen,
wurden an den C14000-Modellen montiert,
um ein einseitiges Verladen zu ermöglichen.
Weitere kundenspezifische Merkmale –
Combilift ist für seine maßgeschneiderte Fertigung
bekannt – tragen dazu bei, die tägliche
Arbeit der Fahrer zu erleichtern. Dazu gehören
unter anderem eine Rückfahrund
Gabelzinkenkamera, Klimaanlage,
Freisprecheinrichtung und ein
luftgefederter Komfortsitz. Die hohe
Position der Fahrerkabine garantiert
höchste Sicherheit, indem sie
den Fahrern einen klaren Überblick
auf die Ladung, die Gabeln und die
Fahrwege bietet.
Das Fazit von Ertl: “Die leistungsstarken
Combilift Stapler garantieren
einen effizienteren und wirtschaftlicheren
Betrieb, und dank der
Zusammenarbeit mit dem Hersteller
sowie der großartigen Beratung
von der Firma Wiener Stapler- und
Fördertechnik konnte eine Handlinglösung
gefunden werden, die alle
unsere Anforderungen erfüllt.” ■
Filterboxes · Ceramic Foam Filters
w w w. d r a c h e - g m b h . d e · m a i l @ d r a c h e - g m b h . d e

A L U M I N I U M - S t r a n g p r e s s I N D U S T R i e
AWW nimmt neue Strangpresse in Betrieb
Trotz Corona-Pandemie haben die Aluminium-Werke
Wutöschingen die erste
Phase ihres Großprojektes AWW 2025
erfolgreich umgesetzt und mit der Inbetriebnahme
der neuen 45-MN-Strangpresslinie
weitere Investitionen an ihren
Standort am Hochrhein angekündigt.
Die Aluminium-Werke Wutöschingen haben
den ersten Teil ihres millionenschweren Investitionsprogramms
AWW 2025 erfolgreich
abgeschlossen. Nach der planmäßigen Inbetriebnahme
der neuen Logistikhalle für Systemkomponenten
im Frühjahr 2020 wurde
die neue Strangpresslinie mit einer 45-MN-
Presse der SMS group Mitte November angefahren.
„Mit der zukunftsweisenden Investition in
eine moderne, energieeffiziente Strangpresslinie
und in die Erweiterung der Weiterverarbeitungs-
und Logistik-Kapazitäten minimieren
wir unseren Ressourceneinsatz und eröffnen
unseren Kunden neue Möglichkeiten für
die Entwicklung und Fertigung materialeinsatzoptimierter
Leichtbaulösungen“, betont
der Vorstandsvorsitzende Frank Aehlen.
Das neue Presswerk ist, so Aehlen, das
„neue Herz und Taktgeber“ des integrierten
Werkverbundes. Durch das neue Werkslayout
kann AWW Synergien fördern und innerbetriebliche
Logistikprozesse optimieren. Mit
der neuen Pressenlinie wird AWW dem Bedarf
an kundenindividuellen Leichtbaulösungen
mit optimiertem Materialeinsatz gerecht –
unter anderem dank einer deutlich höheren
spezifischen Presskraft und einer weiteren
Auffächerung des hauseigenen Legierungsspektrums.
Die offizielle Inbetriebnahme der Strangpresslinie
fand im kleinen Kreis statt, da
AWW seit März letzten Jahres strenge Corona-Maßnahmen
befolgt. Die Einweihungsfeier
soll daher im Laufe dieses Jahres nachgeholt
werden. Aehlen würdigte die herausragenden
Leistungen der Belegschaft und
Projektteilnehmer, die das Projekt unter den
erschwerten Bedingungen fristgerecht zum
Erfolg geführt hatten, und dankte auch den
beteiligten Fremdfirmen. „Bei einem solchen
Großprojekt zählt die Leistung jedes Einzelnen,
genauso wie das reibungslose Zusammenspiel
aller. Wir haben bei diesem Projekt
fast ausschließlich auf langjährig bewährte
Partner gesetzt. Das hat sich über den gesamten
Projektverlauf ausgezahlt, nicht zuletzt
in der aktuellen Krisensituation.“
Der Vorstandsvorsitzende betont, dass die
AWW starts operating
a new extrusion press
Despite the Corona pandemic, Aluminium
Werke Wutöschingen has successfully
implemented the first phase of its
major AWW 2025 project, and following
the commissioning of the new 45-MN extrusion
press line, has announced further
investments at its site on the High Rhine
in Germany.
Aluminium Werke Wutöschingen has successfully
completed the first part of its AWW
2025 investment programme worth millions
of euros. Following the commissioning on
schedule of the new logistics hall for system
components in the spring of 2020, the
new extrusion line with a 45-MN press from
SMS group started operating in November.
“With this forward-looking investment in
a modern, energy-efficient extrusion line and
the extension of the further-processing and
logistical capacities, we are minimizing our
use of resources and opening up for our customers
new possibilities for the development
and production of lightweight construction
solutions that optimize the use of materials,”
emphasizes the chairman of the board, Frank
Aehlen.
According to Aehlen the new extrusion
plant is the “heart and impulse generator”
of the integrated plant association. By virtue
of the new layout of the works AWW can
promote synergies and optimize in-house logistics
processes. With the new press line the
company will be able to meet the demand
for customer-individual lightweight solutions
with optimized material utilization – among
other things thanks to a substantially higher
extrusion load and further diversification of
the in-house alloy spectrum.
The official commissioning of the extrusion
line took place attended by only a small
circle, because since March last year AWW
has been following strict Corona measures.
The opening celebration should therefore
Von links nach rechts: Frank Aehlen (Vorstandsvorsitzender), Thomas Jehle (Leitung Werksplanung
und Instandhaltung), Heiko Maier (Vorstand), Paul Happle (Geschäftsleitung Produktion Pressfabrikate)
From left to right: Frank Aehlen (chairman of the board), Thomas Jehle (director for Plant Planning
and Maintenance), Heiko Maier (board member), Paul Happle (director for Production of Extrusions)
take place during the course of this year.
Aehlen acknowledged the outstanding performance
of the company’s workforce and
the participants in the project, who brought
it to a successful conclusion under the current
difficult conditions, and also thanked
the external companies involved. “In such
a major project the performance of every
individual is just as vital as the frictionless
collaboration of all. In this project we relied
© AWW
36 ALUMINIUM · 3/2021

S P E C I A L
A L U M I N I U M E x t r u s i o n I N D U S T R Y
almost exclusively on partners who have
proved their worth over many years. That
has paid dividends over the entire course of
the project, not least in the current crisis situation.”
The chairman stresses that the new extrusion
line is an essential cornerstone of the
future AWW 2025 project, which will be
developed further step by step in the coming
years.
Investment in a billet
casting unit planned
With two casthouses, a slug production unit,
extrusion capacities and facilities for mechanical
further processing and surface finishing,
AWW covers the entire aluminium value
chain – from highly efficient recycling to finished
components.
As the next milestone, the company is now
to invest in optimizing the billet casting unit.
The project includes a new casting machine
and the improvement of operating sequences
in its own billet casthouse. “We are investing
in a modern production facility for high-grade
extrusion billets, mainly made from recycled
material. It that way we will consistently
abide by our sustainability and technological
strategy, and reinforce our metallurgical core
competence,” says Aehlen. The customers
thus benefit in terms of high quality, a stable
in-house value-added chain and low CO 2
emissions.
“With the AWW 2025 investment programme
we will be closing material cycles
locally and to our customers along the shortest
path. In that way we will achieve still
greater value-addition depth and application
breadth, which among other things benefits
our customers by still greater security of supply,”
Aehlen says. By 2025 the “quantum
leap” to an integrated, highly modern aluminium
plant should be completed, adds the
chairman of the board to explain the future
vision of the medium-sized company, which
has been family-owned for five generations.
For more than a hundred years AWW has
been developing and manufacturing innovative
aluminium products for various client
industries in Germany and other countries.
Besides its core markets, namely the building
industry, mechanical and electrical engineering,
medical technology and mobility applications,
with its more than 500 employees
the company also focuses on solutions for
future technologies such as those used in the
field of electro-mobility.
■
Die Inbetriebnahme der neuen Strangpresslinie ist ein weiterer Schritt zu
einem zukunftsfesten Aluminiumwerk / The commissioning of the new
extrusion line is a further step towards a future-proof aluminium plant
neue Strangpresslinie ein wesentlicher Baustein
des Zukunftsprojektes AWW 2025 ist,
das in den kommenden Jahren stufenweise
weiterentwickelt wird.
Investition in Bolzengießerei geplant
AWW umfasst mit zwei Gießereien, einer
Butzenfertigung, Strangpresskapazitäten sowie
Möglichkeiten zur mechanischen Weiterverarbeitung
und Oberflächenveredelung die
gesamte Aluminium-Wertschöpfungskette –
vom hoch effizienten Recycling bis zu fertigen
Komponenten.
Als nächster Meilenstein soll in die Optimierung
der Bolzengießerei investiert werden.
Das Projekt umfasst eine neue Gießanlage
und die Verbesserung von Betriebsabläufen
in der eigenen Bolzengießerei. „Wir investieren
in eine moderne Produktion hochwertiger
Pressbolzen, die hauptsächlich aus
Recyclingmaterial gefertigt werden. So setzen
wir unsere Nachhaltigkeits- und Technologiestrategie
konsequent fort und stärken unsere
metallurgische Kernkompetenz“, betont
Aehlen. Die Kunden profitieren dadurch von
einer hohen Qualität und stabilen Inhouse-
Wertschöpfungsketten sowie niedrigen CO 2 -
Emissionen.
„Mit dem Investitionsprogramm AWW
2025 schließen wir Materialkreisläufe vor Ort
und zu unseren Kunden auf kürzestem Weg.
So erreichen wir eine noch höhere Wertschöpfungstiefe
und Anwendungsbreite, die sich
für unsere Kunden unter anderem durch eine
noch höhere Liefersicherheit auszahlt“, so
Aehlen. Bis 2025 soll der „Quantensprung“
zum integrierten, hoch modernen Aluminiumwerk
abgeschlossen sein, erklärt er die Zukunftsvision
des mittelständischen Familienunternehmens
in fünfter Generation.
AWW entwickelt und fertigt seit über hundert
Jahren innovative Aluminiumprodukte
für unterschiedliche Abnehmerindustrien im
In- und Ausland. Neben den Kernmärkten
Bauindustrie, Maschinenbau, Elektrotechnik
und Medizintechnik setzt das Unternehmen
mit seinen über 500 Mitarbeitern auch auf
Lösungen für Zukunftstechnologien, die in
der Elektromobilität angewandt werden. ■
AWW fertigt seit über 100 Jahren Aluminiumprodukte für unterschiedliche Abnehmerindustrien
AWW has been manufacturing aluminium products for various customer industries for over 100 years
ALUMINIUM · 3/2021 37

A L U M I N I U M - S t r a n g p r e s s I N D U S T R i e
Hydro completes ASI certification of its European extrusion network
© Hydro
All 42 of Hydro’s aluminium extrusion
operations in Europe are now certified
against the ASI Performance Standard,
following certification of its automotive
components plant in the UK. The Performance
Standard recognizes the responsible
production, sourcing and
stewardship of aluminium.
The certification of Hydro Aluminium UK Ltd
Hydro Extrusion reports ASI certification at its 42 European plants
in Gloucester covers the site’s production of
aluminium solutions, including fabrication,
surface treatment and assembly. Fabrication
activities include cutting, stretch bending and
CNC operations. In surface treatment, the
plant boasts one of the main chemical brightening
functions in Europe, which allows it
to manufacture high-gloss anodized finished
parts.
The Gloucester plant offers a wide range
of automotive solutions
for roof rails,
trims and treadplates.
Hydro employs about
150 people at the site,
and some 900 people
in total in the UK.
Most of the employees
are working for Hydro
Extrusions locations in
Bedwas, Birtley, Cheltenham,
Gloucester
and Tibshelf.
In November 2018,
Hydro’s extrusion plant
in Hoogezand, the
Netherlands, became the first extruder in the
world to obtain the ASI PS certification. The
Gloucester plant is now the most recent. In
between, Hydro Extrusions achieved ASI certification
at its 40 other European operations.
ASI is the highest internationally recognized
standard for robust environmental,
social and governance practices across the
aluminium lifecycle of production, use and
recycling. “In combination with the fact that
our carbon footprint is among the lowest of
any aluminium company, ASI certification
provides our customers with the knowledge
that Hydro remains dedicated to sustainability
and responsibility,” says Paul Warton, who
leads the business area Hydro Extrusions.
Hydro already offers two sustainable aluminium
alloys available on the market, the
certified low-carbon products Hydro Reduxa
and Hydro Circal. The first guarantees a
maximum carbon footprint of 4.0 kg CO 2e
per kilogram aluminium during its entire life
cycle, while Hydro Circal contains a traceable
percentage of minimum 75% post-consumer
recycled content.
■
Vimetco Extrusion a
supplier for the most
sophisticated industries
Alro announced that Vimetco Extrusion,
its downstream subsidiary in charge with
the extrusion business, became a supplier
for the most sophisticated industries by
providing high value-added products for
heliport constructions. Thus, Vimetco
Extrusion entered a partnership with
ABC Development Aviation, a company
certified by AACR (The Romanian Civil
Aeronautical Authority) as developer
and installer of aerodrome elements and
infrastructure for developing helideck
platforms made in Romania.
The first beneficiary of the aluminium profiles
platforms produced in Slatina is the heliport
of the County Emergency Hospital in Bistrita,
which now has the necessary landing decks
for helicopters transporting emergency cases.
This avoids heavy road transport, saves precious
time and increases the chances to save
more lives. Moreover, after this successful project’s
implementation at Bistrita, the second
heliport is currently being built at the Bacau
Emergency County Hospital.
Vimetco Extrusion supplies aluminium
profiles and value-added products, such as
connectors for helideck assemblies, developing,
together with ABC Development Aviation,
helidecks made in Romania, with locally
produced materials. In its turn, ABC Development
Aviation certifies the final products
and caters to its proper usage. Following
the completion of the first heliports, two
similar projects are currently in discussions
for the Emergency Clinical Hospital for Children
‘Marie S. Curie’ in Bucharest and for the
Suceava County Emergency Hospital. (RP)
extrutec awarded new
order from Turkey
extrutec delivers the complete new
profile cooling equipment for a planned
28-MN, 8-inch extrusion line for Cansan
Aluminium in Bursa, Turkey.
The order comprises a 2-zone water quenching
section and a high-speed air cooling section,
both integrated in a cooling hood and
corresponding lead-out table. The installation
is planned for mid-2022.
extrutec also delivers the complete new
profile cooling equipment for a planned new
44-MN, 10-inch extrusion line for Cansan Aluminium
in Bursa. This equipment too consists
of a 2-zone water quenching section and a
high-speed air cooling section, both integrated
in one cooling hood and corresponding leadout
table. This installation is planned for the
end of 2021.
Dubal Holding acquires
majority stake in
extrusion company
Dubal Holding, a wholly owned subsidiary
of Investment Corporation of Dubai
has acquired a 60% stake in the aluminium
extrusion company OSE Industries.
The acquisition is aligned to Dubal Holding’s
strategy to expand its industrial footprint in
the region and create value addition in the
38 ALUMINIUM · 3/2021

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downstream sector. Othman Sharif, the president
and chairman of OSE, commented that
the long-term prospect of OSE looks bright.
The company expects a progressively expanding
growth in demand for extrusions from
evolving e-vehicle manufacturers in the next
few years. Established in 2012 as a familyrun
business, OSE commenced commercial
operations in 2015 at Dubai Industrial City,
focusing on the production of multiport extrusion
tubes and precision tubes for applications
in the automotive, HVAC and solar sectors.
(RP)
Hindalco to set up
an extrusion plant
in Silvassa
Auto extrusion applications:
some recent highlights
It is estimated that in 2012 the average
North American passenger vehicle contained
about 27 lb of aluminium extrusions
– with extruded shapes accounting
for about 15 lb of that total and the balance
being rod / bar and pipe / tube.
In 2020, extruded shapes content should
near 35 lb per vehicle- and projections indicate
that number should grow to nearly 45
lb per vehicle by 2025. New vehicles – and
new extrusion applications – launched in the
past few years have certainly validated that
growth outlook.
Although 2020 did not see the launch of
any new, landmark, extrusion-intensive vehicles,
but rather there was certainly continued
growth of often less-visible applications, along
with a range of significant technical design
innovations and materials developments.
Iconic British sports car producer Morgan,
renown for its iconic and timeless design and
Hindalco Industries plans to set up
a 34,000 tpy extrusion plant at Silvassa.
The new plant will serve the
fast-growing market for extruded
aluminium products in India’s western
and southern regions.
The Silvassa plant will be the first of its
kind in India. The fully automated plant
includes three extrusion presses, and it
will enable Hindalco to service premium
customers in the building and construction,
auto and transport, electrical,
consumer and industrial goods sectors.
Commercial production at the plant is
to start in 24 months.
The project signals a step forward in
Hindalco’s downstream strategy. The
company’s intent is to build a larger
value-added product portfolio over the
next few years. This investment indicates
confidence in the economic revival,
which in turn will grow the demand
for downstream value-added products.
Over the few next years Hindalco plans
to double its production capacity from
over 300,000 tpy at present to more
than 600,000 tpy.
The aluminium extrusion market in
India is expected to grow exponentially
– from the current level of 373,000 tpy
to about 850,000 tpy by 2030. The western
and southern regions of the domestic
market account for over 60% of the
extrusion market. The Silvassa facility
will allow Hindalco to serve customers
in these regions with superior quality,
faster service and shorter response
times. (RP)
■
ALUMINIUM · 3/2021 39

A L U M I N I U M - S t r a n g p r e s s I N D U S T R i e
its ash wood construction introduced its new
Plus Four, with a bonded aluminium chassis
replacing the steel ladder frame that had been
in use for 84 years!
Closer to the mainstream,
VW introduced the 8 th generation
of its popular GTI.
Among the changes: a new
aluminium front subframe in
place of the prior steel unit,
resulting in a 7 lb weight
reduction and a more rigid
foundation for the steering
rack and front suspension.
That all contributes to
improved steering response.
In a similar vein, Hyundai
introduced their latest demo
vehicle, the Hyundai RM20e
Sports Car. It is battery powered
and intended to be a
test vehicle to generate data for application to
other Hyundai models. Based on the Veloster,
the RM20e incorporates an extrusion-based
front subframe.
The big extrusion story for 2019 centred
on the launch of the long-awaited mid-engine
C8 Chevrolet Corvette Stingray. While
the engine location is a first for Corvette,
The C8 Corvette structure comprises 40%
aluminium alloy extrusions – mostly 6xxx series alloy
the aluminium-intensive frame is evolutionary,
building on experience gained with special-edition
C6 Corvettes and the aluminium
structure used in total for the 7 th generation.
The updated Jeep Wrangler included ex-
trusion in its chassis for the first time, employing
an extruded 6061 aluminium alloy cross
member. The extruded component helps reduce
critical front-end weight,
is corrosion resistant, and can
provide the durability that Jeep
is known for. This cross-member
application is just the latest
of several that have showed up
in vehicle updates in the last
year or so.
In terms of updates, the
new extrusion-based Multi-
Pro tailgate was launched on
GMC’s Sierra SLT and Denali
models. This feature offers 6-
way functionality, based on
an inner panel and a pivoting
‘flap’ which can function as a
stopper for an extended load,
or a step providing easy access
to the bed. The ‘flap’ is a multi-void hollow
aluminium extrusion that incorporates a nonskid
surface, provides for the pivot and support
mechanisms, and supports a 375 lb load.
Ken Stanford, contributing editor
© Chevrolet
Aluminium extrusions address auto industry challenges
As auto makers maintain their push for
improved fuel economy and reduced
emissions, aluminium – and aluminium
extrusions – continue to deliver technical
solutions and make an important contribution.
Whether by helping car builders
reduce vehicle weight to improve the
efficiency of conventional vehicles, or to
boost the range of electric vehicles, extrusions
play an increasing role.
AEC website tool launched
Aluminum Extruders Council (AEC), the
trade association dedicated to advancing the
effective use of aluminium extrusions in North
America, has launched a new interactive
resource tool on its website that provides a
valuable resource for automotive design engineers.
The interactive web page delivers a
wealth of information on the effective use of
aluminium extrusions in various vehicle components,
systems and subsystems. It provides
overviews, technical information and case
examples of various applications, highlighting
technical details such as alloys, fabrication
methods, performance characteristics and
more. As visitors scroll over an image of a vehicle,
a pop-up box appears to provide infor-
mation on the selected system or component,
offering a link to explore deeper into that particular
application. Currently, the site features
detailed information on vehicle components
including: roof headers, battery boxes, sub
frames, rockers, and cross members.
This interactive tool was designed to disseminate
useful details about aluminium extrusion
in vehicle design, and is intended to
assist automotive designers – from the novice
to the highly experienced – to better understand
aluminium extrusions and how to effectively
employ them in vehicle applications.
AEC says that more modules are being developed
and will be added in the future.
Ideal attributes
“Aluminium extrusions are ideal for helping
to remove weight in vehicle design, but
© AEC
they offer so much more,” said Mark Butterfield,
team chairman at AEC Automotive
and managing director of Magnode, A Shape
Corp. Company. “Aluminium extrusions are
corrosion-resistant with a high strength-toweight
ratio and can deliver a part that can
be complex, produced to tight tolerances
and combines multiple functions to eliminate
parts and be easily assembled. And, they are
fully recyclable. That combination of attributes
has led to an 80% increase in the use of extruded
shapes per vehicle since 2012, and we
project an additional 40 to 50% growth in
per-vehicle usage over the next five years,”
he said.
“We created this site to highlight creative,
and often demanding, extrusion applications,
and to stimulate designers and engineers to
think about how to utilize extrusions for more
components or vehicle systems. The site demonstrates
how extrusions can and are being
used in many ways throughout the vehicle
architecture. We hope this website will be a
go-to reference for automotive engineers
when they have questions relative to employing
aluminium extrusions in their vehicle designs,”
Butterfield continued.
Ken Stanford, contributing editor
40 ALUMINIUM · 3/2021

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In the last two decades, the aluminium
extrusion industry has grown rapidly in
Turkey: production capacity has almost
doubled in the last five years, and business
continuous to flourish with new investments
in extrusion line.
Around 250 companies with over the 450
extrusion lines are in operation today, mainly
for profiles for construction purposes. Due
to the low and medium hardness required for
construction demand, the industry does not
need high-tech extrusion lines. However, especially
in the last ten years, and with the
more demanding requirements from the
automotive industry (regarding mechanical
properties, tolerances, etc.), the extrusion industry
had to choose a
new path for its future
plan.
Around 90 percent
of the extrusion lines in
Turkey are of Chinese
or Taiwanese origin. The
main reasons for this
are favourable investment
costs and fast delivery.
However, these
extrusion lines cannot
fully meet the expectations
of OEMs due to
the lack of capabilities
of the Far East branded
equipment. Therefore,
and due to the pressure
from the OEM market,
extrusion companies had
to decide on the best
way to save their future
plan and join the Champions
League.
Between 2020 and 2022, at least ten new
lines from European suppliers will join the
‘extrusion game’ in Turkey. Nobody expected
such a big investment rally in Turkey. All the
lines are of high technology and energy-efficient
systems. Not only the extrusion press
itself, but also the upstream and downstream
equipment is of high-performing technology.
To meet the expectations of the OEMs,
quenching systems with a high heat transfer
coefficient have been and will be installed,
and the Turkish extrusion industry requires
Tri Metalurji works closely with
Turkish aluminium extrusion industry
E. F. Özdogru, Tri Metalurji
log furnace with very tight temperature tolerances,
high-capacity stretchers and run-out
tables.
To produce profiles for the automotive
industry, temperature control in the log furnace
and speed control of the extrusion press
are mandatory parameters. Furthermore, a
quenching system with a high heat transfer
coefficient is another crucial necessity to produce
profiles with a perfect microstructure
and grain structure to improve the crash
safety and the behaviour in compression and
bending.
While the equipment manufacturers develop
high-quality machines, the aluminium
billet suppliers (let’s say the ‘alloy designers’)
have to develop and integrate their
SEM micrograph of EN AW 6063 microstructure. The image shows α c -AlFeSi and Mg 2 Si particles
alloy composition according to these equipment.
Alloy development is the key point for
extrusion. The requirements and demands of
OEMs are changing; for example, the transport
system is gradually changing from diesel
/ petrol to electric drive and the alloy producers
also need to change their chemistry to
cover these new needs.
Tri Metalurji AS is based in Istanbul and
has over 20 years’ experience in the aluminium
business. The company’s main focus is to
serve the extrusion industry and to develop
and control aluminium alloys and material
characterization. Tri Metalurji is equipped
with a material characterization lab that includes
a scanning electron microscope with
EDS attachment, optical microscopes with
analytical polarisation filters with image processing
software, an optical emission spectrometer,
automatic hardness tester and a
stereo microscope.
There are also atmosphere-controlled heat
treatment furnaces, aluminium anodic oxidation
test equipment (benchtop) and a quench
sensitivity test unit. Tri Metalurji also uses
JMatPro simulation software for alloy development
and process control. The company
has close relations with research institutes
and the industry to support state-funded research
projects.
TRI Metalurji serves
the extrusion industry
in billet and profile
characterization and
fracture analysis, process
control and development
jobs, consultancy
in technical
issues and new investments,
joint research
projects and alloy
development jobs for
specific purposes. The
figure shows a scanning
electron micrograph
of the EN-AW
6063 alloy developed
by Tri Metalurji for a
Turkish customer.
In October 2020,
Tri Metalurji AS was
granted permission to
move to the Istanbul
Tech Zone called Istanbul Teknopark. This
will give a brand-new driving force with a
new research ecosystem for TRI. The company’s
new target is to participate in a research
consortium for joint Horizon Europe
projects.
© Tri Metalurji
Author
Dr Emrah Fahri Özdogru is metallurgical engineer
and managing partner at Tri Metalurji AS, Istanbul,
Turkey
ALUMINIUM · 3/2021 41

A L U M I N I U M - S t r a n g p r e s s I N D U S T R i e
New 40-MN extrusion press for PMS Aluminium
Danieli Breda strengthens its position as a
supplier of high-end extrusion presses in
Turkey. The company PMS Aluminium,
based in Bursa, selected Danieli Breda for
the supply of a new 40-MN, 10-inch front
loading extrusion press.
PMS Aluminium is listed among the 500 Turkish
top exporters, thanks to its annual production
of 60.000 tonnes of flat and extruded
system ESED 4.0, which enables an
average energy savings of 25-30%
• a press control system implementing isothermal
extrusion
• a fully electric billet loader and die change
station, eliminating extra hydraulic systems
and reducing maintenance costs
• wireless tablet control systems for easy
and efficient machine operation, maintenance
and remote service support
© Danieli
The 40-MN press for PSM Aluminium is dedicated to the extrusion of had alloys (the photo shows a similar press)
products, of which 60% is delivered to foreign
markets. PMS Aluminium delivers both aluminium
sheet and extruded profiles, finished
according to customers’ specifications thanks
to its manufacturing facilities.
Latest News
www.alu-web.de/en
Moreover, the in-house die-shop allows to
design and deliver custom-made profiles for
various market segments, such as automotive,
construction, machinery, furniture, industrial
applications, solar power and several
others.
In order to broaden its product portfolio
for the automotive industry, PMS decided
to invest in a new 40-MN extrusion press,
which will be mainly dedicated to the extrusion
of hard alloys. As this type of production
is setting several challenges both in terms of
technical solutions and high-quality demand,
PMS decided to select a well-reputed and
reliable press supplier like Danieli Breda,
which is able to provide high-end technical
solution as well as outstanding project management
and technical services.
The new 40-MN machine will rank among
the biggest extrusion presses in Turkey, featuring
the latest technological innovations
introduced by Danieli Breda, including:
• Danieli Breda’s patented energy saving
• hydraulic pumps and electrical cabinets
pre-installed on skids, for layout optimization
and quick installation.
In order to grant a quick and trouble-free
project development as well as a smooth integration
of plant equipment, Danieli Breda
will also act as project master and coordinate
the activities of the sub-suppliers, making
sure that PMS will match its target in terms
of plant performance and time schedule.
The commissioning of the press is planned
for the autumn 2021.
■
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Integriertes Prozessmodell für
die induktive Bolzenerwärmung
Jan van Treek, Otto Junker GmbH; Simon Künne, Prosik GmbH
Bei Anlagen zur induktiven Bolzenerwärmung
herkömmlicher Bauart werden Andrückthermoelemente
zur Steuerung des
Prozesses verwendet. Mit ihnen wird die
Oberflächentemperatur an verschiedenen
Positionen gemessen und damit die elektrisch
induzierte Leistung geregelt. Diese
Thermoelemente sind jedoch ungenau
und wartungsintensiv. Insbesondere in
radialer Richtung ist nichts über die Temperaturverteilung
im Bolzen bekannt.
Dies führt zu einer schlechten Wiederholgenauigkeit
des Prozesses, was die
Betreiber von Strangpressanlagen immer
wieder vor Probleme stellt.
Die Otto Junker GmbH hat zusammen
mit der Prosik GmbH und der Constellium
Singen GmbH ein integriertes Prozessmodell
entwickelt. Das Modell berechnet anhand
der Leistungsaufnahme der Induktionsspulen
die Verteilung der Leistungsdichte
im Bolzen. Anhand dessen wird
die Temperaturverteilung im Bolzen mittels
Finite-Volumen-Methode ermittelt.
Dieses wird für die optimale Regelung
der elektrischen Leistung verwendet. Mithilfe
dieses digitalen Zwillings kann die
Wiederholgenauigkeit und die Stabilität
des Prozesses verbessert werden.
Bei der Herstellung von Aluminium-Strangpressprofilen
werden gegossene Bolzen unter
hohem Druck durch eine Matrix gepresst.
Durch das Anwärmen der Bolzen vor dem
Pressen werden die dabei erforderlichen
Kräfte möglichst gering gehalten. Aufgrund
der Umformwärme steigt die Materialtemperatur
im Verlauf des Pressens an. Für ein
gleichmäßiges Pressergebnis ist jedoch eine
konstante Temperatur vorteilhaft. Daher werden
die Bolzen so erwärmt, dass sich ein definiertes
Temperaturgefälle entlang der Längsachse
einstellt, der sogenannte „Taper“. Die
induktive Bolzenerwärmung mit kontinuierlicher
IGBT-Leistungsregelung, wie der Otto
Junker JuDyMC ist in diesem Zusammenhang
eine bewährte Technik.
Abb. 1 zeigt eine entsprechende Anlage.
Der Bolzen wird auf einer Transportschale
abgelegt und anschließend in den Ofen gefahren.
In diesem Fall existieren sechs unabhängig
voneinander ansteuerbare Teilspulen.
Die Spulen sind so konstruiert, dass speziell
gefertigte Thermoelemente durch einen Kanal
auf die Oberfläche des Bolzens gedrückt
werden können. Die Anlage wird zur Erwärmung
von Bolzen aus verschiedenen Aluminiumlegierungen
mit einem Durchmesser von
254 mm und einer Länge von max. 1.500
Integrated process model
for inductive billet heating
Jan van Treek, Otto Junker GmbH; Simon Künne, Prosik GmbH
Abb. 1: Anlage zur induktiven Bolzenerwärmung
Conventional induction billet heaters use
retractable thermocouples to control the
process. These measure the surface temperature
at different positions and thus
regulate the electrically induced power.
However, such thermocouples are inaccurate
and require high maintenance.
Especially in the radial direction, nothing is
known about temperature distribution inside
the billet. This leads to poor repeat accuracy
of the process, which is a recurring
problem for operators of extrusion lines.
Otto Junker GmbH in collaboration
with Prosik GmbH and Constellium Singen
GmbH, has developed an integrated
process model which calculates the distribution
of power density in the billet
based on the power consumption of the
mm genutzt. Diese können innerhalb von
ca. 150 s auf bis zu 550 °C erwärmt werden.
Der Bolzen verbleibt nach dem Erwärmen
bis zum Abruf durch die Presse im Ofen und
wird auf Temperatur gehalten. Bei Abruf des
Bolzens wird dieser auf der Tragschale aus
dem Ofen gefahren, vom Manipulator aufgenommen
und zu einer Messstation befördert.
Auch hier wird mit pneumatisch betriebenen
Andrückthermoelementen die Temperatur
des Bolzen erfasst. Liegt diese innerhalb der
vorgeschriebenen Toleranz, wird der Bolzen
zum Pressen freigegeben.
➝
Fig. 1: Inductive billet heater
induction coils. The temperature distribution
throughout the entire billet is then
derived from this with the finite volume
method. This is used to control the electrical
output in an optimal way and enables
the repeatability and stability of the process
to be improved.
To produce aluminium extrusions, cast billets
are forced through a die under high pressure.
By heating the billets before pressing, the
forces required for this can be minimized.
The forming heat causes the temperature of
the material to rise during the pressing process.
However, to ensure a uniform pressing
result, ideally the temperature should remain
constant. The billets are therefore heated in
such a way that an defined temperature gradi-
© Otto Junker
ALUMINIUM · 3/2021 43

A L U M I N I U M - S t r a n g p r e s s I N D U S T R i e
Die konventionelle Fahrweise
und ihre Schwachstellen
Abb. 2 zeigt den Verlauf der elektrischen
Leistungsaufnahme, der gemessenen Temperatur
und des Sollwerts für eine Teilspule bei
Abb. 2: Konventionelle Prozessführung
konventioneller Fahrweise. Nach dem ersten
Erreichen des Sollwertes nach etwa 100 s wird
die elektrische Leistung reduziert und der
im Rezept festgelegte Überziehwert einmalig
angefahren. Aufgrund des Skin-Effektes [1]
wird über 90 Prozent der Leistung in den
äußeren 20 mm des Bolzens induziert. Der
entstehende radiale Temperaturgradient wird
durch Wärmeleitung mit der Zeit ausgeglichen.
Dies führt anfangs bei ausgeschalteter
Spule zu einem starken Abfall der Oberflächentemperatur.
Diese wird nun mithilfe eines
Zweipunktreglers nahe der Solltemperatur
gehalten. Der zeitliche Abstand zweier Heizvorgänge
wird als Indikator dafür verwendet,
wann der Bolzen gleichmäßig durchwärmt
und damit abrufbereit ist. Diese Regelung führt
selbst bei einer idealen Temperaturmessung
je nach Entnahmezeitpunkt des Bolzens zu
einer Gleichmäßigkeit von bestenfalls ±5 K.
Die gemessene Temperatur ist jedoch nicht
ideal, sondern fehlerbehaftet. Die Bolzen
weisen teilweise sehr unterschiedliche Oberflächenbeschaffenheiten
auf. Das Spektrum
reicht von einer blanken Oberfläche bis hin
zu Bolzen mit einer ausgeprägten Gusshaut.
Um die Gusshaut zu durchdringen, müssen
die Thermoelemente mit hoher Kraft auf die
Oberfläche gedrückt werden. Durch die erforderliche
hohe Anpresskraft wird die mechanische
Belastbarkeit der Thermoelemente
erreicht, die Spitzen müssen aufgrund von
Verschleiß regelmäßig gewartet werden. Dennoch
ist die Kontaktierung aufgrund der unterschiedlichen
Bolzenoberflächen und teilweise
mangelnder Wartung ungleichmäßig.
Dies wirkt sich zusammen mit dem hohen
Wärmeabfluss durch die Thermoelemente
negativ auf die Qualität der Messung aus [2].
Daher sind in der Praxis teils deutlich höhere
Temperaturtoleranzen zu beobachten. Die
Thermoelemente müssen regelmäßig ausgebaut
und angeschliffen werden. Außerdem
neigen sie zu einem starken Driftverhalten.
Fig. 2: Conventional process control
Entwicklung des integrierten
Prozessmodells
Die Otto Junker GmbH hat zusammen mit
der Prosik GmbH und der Constellium Singen
GmbH ein integriertes Prozessmodell
entwickelt, das die angeführten Schwachstellen
beseitigt. Ein integriertes Prozessmodell
läuft entweder auf der SPS der Anlage oder
auf einem Industrie-PC, der direkt mit der
SPS und dem MMI kommuniziert. Es ist in
der Lage, den Prozess in Echtzeit zu simulieren,
sodass die Ergebnisse der Simulation zur
Steuerung desselben genutzt werden können
(Digital Twin). Die Simulation der induktiven
Erwärmung eines Bolzens mithilfe der Finite-
Elemente-Methode (FEM) ist Stand der Technik
[3]. Aufgrund der hohen erforderlichen
Rechenleistung ist eine direkte Nutzung von
FEM-Simulationen im Sinne eines integrierten
Prozessmodells jedoch nicht sinnvoll möglich.
Daher wurde im ersten Schritt ein empient
is established along the longitudinal axis.
This is known as a ‘taper’. Inductive billet heating
with continuous power control with IGBT
as the Otto Junker JuDyMC has proved to be
an effective technique in this regard.
Fig. 1 shows a typical example of such
a system. The billet is placed in a transport
trough and then advanced into the furnace.
In this example, there are six independently
controllable coil sections. The coils are designed
so that purpose-built thermocouples
can be pressed through a channel onto the
surface of the billet. The system is used to
heat billets made of various aluminium alloys
with a diameter of 254 mm and a maximum
length of 1,500 mm. These can be heated to
550 °C in approx. 150 s.
After heating, the billet remains in the
furnace and is kept at the desired temperature
until it is called off by the press. When
the billet is called off, it is moved out of the
furnace in the transport trough, picked up by
the manipulator and taken to a measuring
station. Here again, pneumatically operated
retractable thermocouples are used to measure
the temperature of the billet. If it is within
the specified tolerance range, the billet is
released for pressing.
Conventional operating mode
and associated weaknesses
Fig. 2 shows the curve of the electrical power
consumption, the measured temperature and
the setpoint for a coil section operated in the
conventional manner. After the setpoint has
been reached for the first time after about
100 s, the electrical power is reduced and the
temperature head specified in the recipe is
approached once. Due to the skin effect [1],
over 90% of the power is induced in the outer
20 mm of the billet. Over time, the resulting
radial temperature gradient is compensated
by heat conduction. Initially, this leads to a
Abb. 3: Komponenten und Informationsflüsse des integrierten Prozessmodells
Fig. 3: Elements and information flows of the integrated process model
44 ALUMINIUM · 3/2021

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A L U M I N I U M E x t r u s i o n I N D U S T R Y
Abb. 4: Schalenelement des FVM-Modells mit den
berücksichtigten Wärmeströmen und -quellen
Fig. 4: Shell element of the FVM model with
the considered heat flows and sources
sharp drop in surface temperature when the
coil is switched off. The billet is now kept
near the setpoint temperature by a two-point
controller. The time interval between two
heating processes indicates when the billet
has reached an even temperature throughout
and is thus ready for pressing. Even with an
ideal temperature measurement, this control
results in a uniformity of at best ±5 K depending
on when the billet is called up.
However, the measured temperature is not
ideal and is subject to error. Some of the billets
have very different surface finishes. Billets
can have anything from a smooth surface
to a pronounced cast skin. To penetrate the
cast skin, the thermocouples must be pressed
onto the surface with great force. This great
force causes mechanical wear on the measuring
tips, resulting in regular maintenance
The degree of contact nevertheless remains
uneven due to the varying surfaces of the billets
and, in some cases, lack of maintenance.
This, together with the marked dissipation of
heat via the thermocouples, impairs the quality
of the measurement [2]. As a result, much
higher temperature tolerances are sometimes
observed in practice. The thermocouples need
to be dismounted and their tips ground at
regular intervals. They also tend to exhibit severe
drift behaviour.
risches Modell für die Verteilung der Leistungsdichte
im Bolzen entwickelt. Dieses basiert
auf zuvor durchgeführten FEM-Simulationen,
bei denen die unterschiedlichen Betriebszustände
der Anlage untersucht worden
sind. Dies schließt insbesondere verschiedene
Kombinationen von aktiven und ausgeschalteten
Spulen, sowie unterschiedlich lange
Bolzen ein. Die Einbettung des Prozessmodells
in die Steuerungslandschaft ist in Abb.
3 dargestellt. Anhand der Leistungsaufnahme
der Spulen wird mit dem vereinfachten Modell
die Verteilung der Leistungsdichte ermittelt
und an ein Finite-Volumen-Modell (FVM)
übergeben.
Dieses berechnet daraus unter Berücksichtigung
der Wärmeleitung und der Oberflächenverluste
die Temperaturverteilung im
Bolzen. Ein Schalenelement des Bolzens ist
in Abb. 4 dargestellt. Die induzierte Leistung
wird als Quellterm Ǭsl berücksichtigt. Ǭλx,
Ǭλr und Ǭsu bilden die Wärmeströme aufgrund
von Wärmeleitung entlang der Längsachse,
des Radius und des Umfangs ab. Mit
Ǭα werden die Oberflächenverluste aufgrund
freier Konvektion bezeichnet.
Fig. 5: Model-based process control
Steuerung des Prozesses
durch das Modell
Die mithilfe des FVM-Modells berechnete
Temperaturverteilung T(xrt) wird an die Regelung
übergeben. Die berechnet daraus die
Sollwerte für die elektrische Leistungsaufnahme
der Spulen. Der resultierende Prozessverlauf
ist in Abb. 5 dargestellt. Zunächst wird
die Oberflächentemperatur auf den erlaubten
Überziehwert geregelt. Dabei wird kontinuierlich
auch die mittlere Temperatur, die aufgrund
der Simulation nun bekannt ist, betrachtet.
Nähert sich diese dem Sollwert an, wird
die Regelung umgeschaltet, sodass die mittlere
Temperatur auf den Sollwert geregelt wird.
Im Vergleich zum konventionellen Prozess
aus Abb. 2 zeigt sich, dass die Temperaturgleichmäßigkeit
aufgrund der gleichmäßigeren
Beheizung besser ist. In der Abbildung
wird die erste Teilspule betrachtet, bei der
die Verluste wegen der Stirnfläche des Bolzens
besonders hoch sind. Daher liegt die
Oberflächentemperatur hier über dem Sollwert.
Diese Tatsache wird bei der konventionellen
Fahrweise nicht berücksichtigt. ➝
Abb. 5: Modellgestützte Prozessführung
Developing an integrated
process model
Otto Junker GmbH, together with Prosik
GmbH and Constellium Singen GmbH, has
developed an integrated process model which
eliminates these deficiencies. This integrated
process model runs either on the induction
heater’s PLC or on an industrial PC that communicates
directly with the PLC and the HMI.
Since it is capable of simulating the process in
Abb. 6: Vergleich von gemessenen und berechneten Temperaturen im Bolzen
Fig. 6: Comparison of measured and calculated temperatures in the billet
ALUMINIUM · 3/2021 45

A L U M I N I U M - S t r a n g p r e s s I N D U S T R i e
Durch die Kenntnis der mittleren Temperatur
kann besser beurteilt werden, wann der
Bolzen abrufbereit ist. Mithilfe des digitalen
Zwillings kann auch die Überziehtemperatur
besser ausgenutzt und somit der Durchsatz
leicht gesteigert werden. Ist die anfängliche
Temperatur des Bolzens bekannt, kommt das
Modell im Prozess ohne die wartungsintensiven
Thermoelemente aus. Dies ist insbesondere
in der letzten belegten Spule nützlich,
wenn der Bolzen nicht lang genug ist, um von
den Andrückelementen erreicht zu werden.
Gute Übereinstimmung mit Messwerten
Zur Validierung des Modells wird ein spezieller
Messbolzen verwendet. Dieser ist mit
insgesamt 13 Mantelthermoelementen bestückt,
die durch Bohrungen in unterschiedlichen
Tiefen angebracht sind. Für jede Spule
wird die Kerntemperatur des Bolzens, sowie
die Temperatur im Abstand von 25 mm zur
Oberfläche gemessen. Das dreizehnte Element
befindet sich im Kern des Bolzens mit einem
Abstand von 25 mm zur Stirnseite. Abb. 6
zeigt exemplarisch die Auswertung für eine
Teilspule. Die Indizes 0, 25 und K stehen für
die Messung an der Oberfläche, in 25 mm
Abstand zur Oberfläche beziehungsweise im
Kern. Kurven mit dem Index TC sind entweder
durch die Andrückelemente oder durch
die eingebohrten Thermoelemente gemessen.
Die durchgezogenen Kurven mit dem Index
M stehen für die an der entsprechenden Stelle
modellierten Temperaturen. Diese stimmen
gut mit den gemessenen Temperaturen überein.
Insbesondere im ausgeglichenen Zustand
ab 120 s sind die Abweichungen minimal.
Verbesserung der
Temperaturgleichmäßigkeit
Mit der Entwicklung des integrierten Prozessmodells
wurde das Ziel verfolgt, die Temperaturgleichmäßigkeit
des Prozesses zu verbessern.
In Abb. 7 sind die an der Messstation
vor der Presse gemessenen Werte für eine
Abfolge von je 20 Bolzen mit Modell und mit
konventioneller Fahrweise gegenübergestellt.
Durch die Verwendung des integrierten Prozessmodells
hat sich die Reproduzierbarkeit
verbessert. Insbesondere spielen beim Betrieb
mit Modell die äußeren Randbedingungen wie
die Oberfläche des Bolzens oder der Zustand
der Thermoelemente keine große Rolle. Die
verbesserte Gleichmäßigkeit wird dauerhaft
erreicht. Darüber hinaus wird ein stabilerer
Prozessablauf erzielt, da im herkömmlichen
Betrieb fehlerhafte Temperaturmessungen
Störungen in der Anlage verursachen können.
Mittelfristig sollen die Andrückthermoelemente
wegfallen und durch eine weniger
aufwändige Methode zur Bestimmung der Anfangstemperatur
des Bolzens ersetzt werden.
Dies reduziert den Wartungsaufwand und die
Betriebskosten der Anlage. Der Prozess wird
Stand heute schon „blind“ betrieben. Da die
Andrückelemente an der Pilotanlage bereits
vorhanden waren, werden sie als zusätzliche
Sicherheit noch zur Überwachung genutzt.
Zusammenfassung
Durch den Einsatz des integrierten Prozessmodells
werden mehrere Aspekte verbessert.
Durch die Reduktion der Ausgleichszeit wird
ein höherer Durchsatz erreicht. Die Prozess-
Abb. 7: Temperaturgleichmäßigkeit an der Messstation für die beiden Fahrweisen
Fig. 7: Temperature uniformity at the measuring station for both operating modes
sicherheit steigt aufgrund zuverlässigerer
Temperaturdaten. Anhand dieser Daten können
durch die neue Regelstrategie langfristig
enge Temperaturtoleranzen auch unter ungünstigen
Bedingungen garantiert werden.
Zugleich sinkt der Wartungsaufwand durch
die bisher verwendeten Thermoelemente.
Bisher wurden nur die Auswirkungen auf
die reine Erwärmung des Bolzens untersucht.
Speziell das Zusammenwirken mit der Strangpresse,
die nun noch homogeneres Einsatzgut
zur Verfügung gestellt bekommt und damit
am optimalen Betriebspunkt arbeiten kann,
wurde noch nicht betrachtet. Auch in diesem
Zusammenhang sind weitere Verbesserungen
des Gesamtprozesses und damit am Produkt
zu erwarten.
Literatur
[1] J.D. Jackson, Classical Electrodynamics, 2 nd Edition.
Wiley 1975.
[2] D. Körtvélyessy und L. Körtvélyessy: Thermoelement
Praxis, 4. Auflage. Vulkan-Verlag GmbH,
2015.
[3] B. Aschendorf, FEM bei elektrischen Antrieben
1. Vieweg + Teubner Verlag, 2014. ■
real time, the results can be used to control
the actual process (digital twin). Simulating
the inductive heating of a billet with the finite
element method (FEM) is current practice [3].
However, due to the high computing power
required, it is not feasible to use FEM simulations
directly in the sense of an integrated
process model.
Therefore, in a first step, an empirical model
for the distribution of power density in
the billet was developed. This is based on
previous FEM simulations used to study the
different operating states of the system. In
particular, the model includes different combinations
of activated and deactivated coils,
as well as billets of different lengths. Fig. 3
illustrates how the process model is embedded
in the control architecture. Based on the
power consumption of the coils, the distribution
of power density is calculated using the
simplified model and transferred to an Finite
Volume Model (FVM).
This calculates the temperature distribution
in the billet, taking heat conduction and
surface losses into account. A shell element
of the billet is shown in Fig. 4. The induced
power is considered as the source term Ǭsl.
Ǭλx, Ǭλr and Ǭsu depict the heat flows due
to thermal conduction along the longitudinal
axis, radius, and circumference. Ǭα denotes
the surface losses due to free convection.
Controlling the process with the model
The temperature distribution T(xrt) calculated
with the aid of the FVM model is transferred
to the control system. This calculates
the setpoints for the electrical power consumption
of the coils. The resulting process
sequence is shown in Fig. 5. To start with, the
surface temperature is adjusted to the permissible
temperature head. The mean tem-
46 ALUMINIUM · 3/2021

S P E C I A L
A L U M I N I U M E x t r u s i o n I N D U S T R Y
perature, now known from the simulation, is
also observed continuously. When this approaches
the setpoint, the control is switched
over so that the mean temperature is brought
to the setpoint.
Compared to the conventional process
shown in Fig. 2, it can be seen that temperature
uniformity is improved due to the more
consistent heating. In the figure, the first coil
section is considered, where losses are particularly
high due to the front face of the billet.
Consequently, the surface temperature
here is higher than the setpoint. This fact is
not accounted for in the conventional manner
of operation.
By knowing the mean temperature, it is
easier to determine when the billet is ready
to be called off. This digital twin also allows
the temperature head to be better utilized,
thus slightly increasing throughput. If the
initial temperature of the billet is known, the
in-process model can do without the highmaintenance
thermocouples. This is especially
useful in the last occupied coil when the billet
is too short to cover the complete coil and
be reached by the retractable thermocouples.
Close match with measured values
A special measuring billet is used to validate
the model. This is fitted with a total of 13
sheathed thermocouples embedded in bores
at different depths. For each coil, the core
temperature of the billet is measured, as well
as the temperature 25 mm away from the surface.
The thirteenth thermocouple is located
in the core of the billet 25 mm away from the
face end. Fig. 6 shows an example of the results
for a coil section. The indices 0, 25 and
K denote the measurement on the surface, at
a distance of 25 mm from the surface and in
the core, respectively. Curves with the index
TC are measured either by the retractable
thermocouples or by the embedded thermocouples.
The solid curves with the index M
denote the temperatures modelled at the
corresponding point. These are very close to
the measured temperatures. Especially in the
equalized state from 120 s onwards, the deviations
are minimal.
Improved temperature uniformity
The integrated process model was developed
with the aim of improving the temperature
uniformity of the process. Fig. 7 shows a comparison
of consequent measurements of 20
billets at the measuring station when operated
with the model and in conventional operating
mode. Using the integrated process model has
improved repeatability. Especially external
constraints, such as the surface of the billet
or the condition of the thermocouples, do not
play a major role when the system is operated
with the model. The uniformity so improved
is achieved permanently. In addition, the process
is more stable than with the conventional
manner of operation where incorrect temperature
measurements may cause malfunctions.
In the mid-term, the retractable thermocouples
will be dispensed with and replaced
by a less complex method for measuring the
initial billet temperature. This will reduce the
maintenance effort required and cut operating
costs. As of today, the process is already
being operated ‘blind’. Since the retractable
thermocouples were already fitted in the pilot
plant, they are still used as an additional
safeguard for monitoring purposes.
Summary
By using the integrated process model, several
aspects are improved. By reducing the
equalization time, a higher throughput is
achieved. Process reliability is increased
thanks to more reliable temperature data.
Based on this data, the new control strategy
can guarantee narrow temperature tolerances
in the long term, even under unfavourable
conditions. At the same time, the necessary
maintenance work is reduced because thermocouples
are no longer required.
So far, only the effects on heating the billet
have been investigated. In particular, interaction
with the extrusion press, which is
now supplied with even more homogeneous
feedstock and can thus work at the optimum
operating point, has not yet been considered.
Further improvements to the overall process
and thus to the product are also to be
expected in this regard.
Bibliography
[1] J.D. Jackson, Classical Electrodynamics,
2 nd Edition. Wiley 1975.
[2] D. Körtvélyessy und L. Körtvélyessy, Thermoelement
Praxis, 4. Auflage. Vulkan-Verlag GmbH,
2015.
[3] B. Aschendorf, FEM bei elektrischen Antrieben
1. Vieweg + Teubner Verlag, 2014. ■

t e c h n o l o g y
Jiangzhong launches installation of
Italpresse’s largest ever die-casting machine
Nantong Jiangzhong Photoelectricity Co.,
Ltd (Jiangzhong) has officially launched
its latest project: the installation of an
Italpresse Gauss TF5700 high-pressure
die casting (HPDC) machine. The project
launch ceremony on 1 February followed
the contract signed at the end of 2020.
With its huge 3500 x 3500 mm platens, the
TF5700’s closing force of 5,700 tonnes makes
the machine the ideal solution for large-part
production. Once installed, the TF5700, to be
built at Italpresse Gauss’ Italian headquarters,
will be the first one deployed in China.
Established in 1992, Jiangzhong specializes
in the production of die-cast aluminium parts
for lifts and escalators. In 2020, it produced
16,000 tonnes of die-castings for brands like
Schindler, Mitsubishi, Otis, Hitachi and Hyundai.
“The future of our company depends on
advanced, smart and digitally enabled equipment,”
said Xu Yinglong, chairman of Jiangzhong.
“The TF5700 will help us with larger
parts for our traditional escalator market and
will also open up new markets for us in producing
large structural parts for automotive
or even high-speed railway. We are seeing
a 25% increase in our annual output, so we
expect the new machine to help us maintain
or exceed our current growth rate.”
The foundry already operates five 3,000-
tonne die-casting machines and numerous other
smaller and medium-sized die-casting units.
Three of Jiangzhong’s large machines come
from Italpresse Gauss, with the first installed
over a decade ago. “Italpresse die-casting machines
offer reliability, stable performance
and high output, and are supported by good
after sales service,” explains Yinglong. “Our
relationship with Italpresse started in 2005.
Since then, we have bought one 3000-tonne
die-casting machine and two 3300-tonne die
casting machines, which have been great for
us.”
Compared to toggle-based designs, Italpresse
Gauss’s TF (toggle-free) range of highpressure
die-casting machines offer a smaller
machine footprint, greater rigidity and fewer
wear parts for improved reliability and performance.
Though it can produce very large
components, the TF5700’s compact dimensions
mean that the machine will easily fit
into Jiangzhong’s existing factory. The fact
that it is fully digitally enabled also supports
Jiangzhong’s need for smart technology.
“We trust Italpresse’s HPDC technology,
very stable performance and compact design,”
© Italpresse Gauss
Flexible and solid
for greater productivity
• TF‘s high repeatability increases plant
productivity and reduces scrap rate.
• Thanks to four independent nuts, the TF
die casting machine is able to compensate
for geometrical imperfection of the die
and its thermal expansion, adapting to
different working conditions.
• Enhanced hydraulic system provides
greater reliability and uptime at your site.
Rock-steady, rigid and solid performance
ensures consistent production and ontime
delivery of high quality castings to
your customers.
• Reduced footprint with the same closing
force as the toggle machines ensures
optimization of space at your foundry.
said Yinglong. “To suit our current workshop,
we wanted a lean and smart machine, and
the TF 5700 is exactly right. Real-time data is
also very important to us, and will help us to
monitor the whole die-casting process.”
Also attending the official opening ceremony
were Mario Cincotta, CEO of Italpresse
Gauss, and Peter Holm Larsen, head
of Aluminium activities for Norican Group.
Mario said: “This is a hugely important and
exciting milestone for both organizations. In
being one the first organizations to order our
new TF5700 – not just in China, but in the
world – Nantong Jiangzhong Photoelectricity
Co., Ltd. has shown both its pioneering spirit
and its trust in us to make ‘new possibilities’
happen.”
Jiangzhong has also purchased a Westomat
3100 from StrikoWestofen to integrate
seamlessly with the machine.
■
48 ALUMINIUM · 3/2021

t e c h n o l o g y
Automated billet casting lines
in the aluminium industry
R. Edtmeier, HPI; A. Warkenstein, FFT
With many years of experience and a wide-ranging portfolio, FFT
Produktionssysteme and HPI High Performance Industrietechnik
offer customer-specific solutions for the aluminium industry. In
collaboration with their customers, both companies together realize
complete turn-key production lines with the lowest possible
interface. The turn-key concept is central to this approach. Taking
into account all constraints such as quality and deadline requirements,
and assuming overall responsibility, FFT and HPI manage
the project up to the handover. Their aim as a general contractor
is to work closely with the customer at all stages of the process, so
as to provide an optimal solution. By integrating their know-how
in engineering and realization, they ensure a smooth start of production
at the plants.
RODDING
IN-LINE ROD
REPAIR
Robotic welding of anode studs
For more than 30 years HPI has been working as a manufacturer for
the light metal industry, and responds to individual customer requests
with passion for special solutions. The inner commitment to this excellence
is also the foundation for the next steps, not only to work as a pure
mechanical engineering company, but also to secure the future of HPI
through technological leadership. Within the Ebner Group there was a
joint agreement, together with the sister company Gautschi, to build a
technology centre in Ranshofen, the Austrian heart of the aluminium
industry. This centre is available to customers since 2020.
FFT Produktionssysteme GmbH & Co. KG is a global supplier of
automated and flexible production lines. Since its founding in 1974, the
company has displayed dynamism, solidity and the constant pursuit of
technological leadership. As a turn-key partner for automobile manufacturers
and the aviation industry, as well as for the aluminium industry,
FFT is responsible for the implementation of complete production plants.
Furthermore, as a global supplier of innovative, flexible and highly
complex manufacturing systems, FFT is also a specialist in research,
development, testing and design. With an implementation rate of about
1,000 robots a year, and expertise in Industry 4.0 and Machine Learning,
FFT has extensive experience in various fields.
Together, FFT and HPI develop customized production lines, starting
with the furnaces, and continuing through to finished product pick
up at the end of line, without operator intervention. This provides fully
autonomous casting lines incorporating the highest level of technology.
Consequently, it is not surprising that an innovative casthouse is being
built with joined forces at EGA Al Taweelah, employing a completely
new mould technology.
Water is a precious resource in the United Arab Emirates, which is
why it was so important to optimize the water supply to the moulds.
Using computational fluid dynamics (CFD) simulations, HPI ensures that
each strand receives the same amount of water; this positively impacts
both water economy and production uniformity.
In combination with the lowest oil requirement, perfectly smooth
cast ingots are produced, without any annoying elephant-skin-like surface,
and minimizing the number of undesirable oxides. This new quality
ingot is the preferred material for extruders, especially for the high
demands of the automotive industry.
FFT’s Industry 4.0 technology, like connected industrial robots and
FEATURES
•
• Reliable
• Scalable
• Industry 4.0
• Low space requirements
BENEFITS
• Fewer rods and trolleys needed
•
• Redundancy
www.storvik.no
ALUMINIUM · 3/2021

t e c h n o l o g y
autonomous driving systems, ensures largescale
production designed for casthouse conditions.
They bring benefits to the projects,
such as simulation software expertise, and the
use of virtual commissioning of automated
systems. This means that individual processing
will be accomplished, quality improved
and on-time delivery secured.
Special benefits arise for our customers
where both expertises are brought together
to create Industry 4.0 readiness for the aluminium
casting industry. HPI’s engineering
spirit eliminates the single copper block
moulds, that have been used for decades,
from today’s casthouses and replaces them
with sophisticated mould technology. Other
benefits include lower maintenance and reduced
total cost of ownership.
In addition, FFT is simulating all equipment
in a virtual world. This reduces the commissioning
and going live time needed at customer
facilities. Using virtual machine models,
FFT is creating a digital twin, allowing precommissioning
before all equipment has been
built. Summarizing machine data, together
with line information, can be used for predictive
maintenance and so increase overall
performance as the machine tells the operator
when maintenance should be performed.
The line is equipped with machine vision,
taking care of overall quality control, and inspecting
all ingots on the fly during process.
All produced ingots are individually inspected
and the machine learns to link production
parameters with the defects and damages.
The inspection line automatically discards
non-conforming parts. Products with zero defect
get further processed and shipped to the
customer. All these developments are bringing
casting lines to a next level, where production
output and casting speed are greatly
increased. FFT’s capabilities bring previous
manual or semi-automatic operations to full
automation: complete bundling, packaging,
laser marking and strapping is done by industrial
robots.
Authors
Rainer Edtmeier is president of HPI High Performance
Industrietechnik, based in Braunau, Austria.
Andreas Warkenstein is project manager of FFT
Produktionssysteme GmbH & Co. KG, based in
Fulda, Germany.
Pioneering research into aluminium
grain refiner efficiency back in business
© MQP
Pioneering research into the efficiency of
grain refiner to bring down aluminium
waste, carbon emissions and manufacturing
costs is back underway at Brunel
University London.
The major research, a collaboration between
the University’s Brunel Centre for Advanced
Solidification Technology (BCast) and grain
refiner specialist MQP, began in February last
year, but had to be put on hold due to the
MQP is collaborating with BCast to improve grain refiner efficiency
Covid-19 lockdown in March. Dr Jayesh Patel,
who is working on the three-year project
in a team led by BCast founder and director
Professor Zhongyun Fan, commented: “We’d
literally got the research underway when the
university had to close, which was really disappointing
for us. However, the lab is now
back up and running and early findings are
looking positive.”
The collaboration between BCast and
MQP was formed after a decade’s research
by BCast into the industry-wide problem of
inconsistency of aluminium quality on a global
scale, resulting in huge waste and substandard
products across manufacturing, from the foil
and extrusions sectors to aerospace and automotive.
Key to this is the well documented
inconsistency of grain refiner, which is added
in the production process by casthouses to
eliminate cracking, waste and poor quality
material in billets and slabs for
everything from airframes to
food cans.
MQP had been following
the published academic studies
aimed at understanding the
mechanism of how grain refiners
work, primarily research by
Lyndsey Greer et al at Cambridge
University on the discovery
of the presence of Al3Ti
on the surfaces of TiB2 particles
and how this might play a
critical role in nucleation. Discovering
that BCast had gone
even further in studying the Al3Ti layer at
the atomic level using state-of-the-art High
Resolution Transmission Electron Microscopy
(HRTEM), of which there are only four units
in existence worldwide, the scene was set
for a collaborative research project to implement
the science in an industrial setting.
MQP’s technical manager, Dr Shervin
Tabrizi, who is also part of the research team,
said: “Aluminium is being increasingly used
in manufacturing. It’s far lighter than steel, so
results in less carbon emissions, helping protect
the environment and the climate. However,
the inconsistency in quality because of
the fluctuating impact of the grain refiner is
a problem worldwide. With this research, we
are using highly sophisticated technology to
put BCast’s findings into practice, unlocking
the technology to ensure grain refiner can
deliver higher efficiencies and improve aluminium
quality and the manufacturing process
on a global scale.”
MQP’s Optifine grain refiner was chosen
to go under the microscope due to its high
efficiency. High efficiency results in lower
addition rates which lead to significant improvements
in melt quality, with up to a 70%
reduction in particle count as measured by
Limca, reducing the potential for defects in
finished product. Through the BCast research,
results could go even higher.
As casthouses only need to use a third of
the amount of standard TiBAI grain refiners
typically used, it can also bring costs down
by half and means less coil changes and transportation
around the casthouse and lower
warehouse inventory. Produced in a stateof-the-art
facility, Optifine is now achieving
exceptional results in the production of over
three million tonnes of aluminium alloys annually
in 34 major casthouses worldwide, and
is increasing its market share in North and
South America, China and Asia. ■
50 ALUMINIUM · 3/2021

t e c h n o l o g y
Storvik’s furnace tending tools – the optimal solution for casthouses
Storvik’s furnace tending tools have been
on the marked for about eight years and
have proven extended lifetime, better
efficiency and more consistency than
conventional mild steel tools in routine
furnace tending operations. These tools
are currently in regular use in more than
30 casthouses around the world, assisting
aluminium producers in achieving consistent
furnace operations, having their furnaces
ready on time and to specification.
Storvik’s customers are typically top tier upstream
and downstream aluminium producers
with the highest standards and demanding criteria,
which include supplying specific alloys
with narrow material specifications. Storvik
tools ensure that no metal contamination is
measurable through their use.
The furnace tending tools are made from
Storvik’s proprietary alloys, which have been
specially developed to maximize durability
and erosion resistance to aluminium and alloying
material, which is usually highly corrosive
to most types of steel.
Storvik’s furnace tending tool lasts up to
eight times longer than a regular mild steel
tool and also provides a consistent process
effect throughout its lifetime. This is because
the Storvik tools maintain their shape and
size throughout their lifetime, whereas most
conventional mild steel tools deteriorate,
bend and warp quite quickly.
Improvement is key at our company and
we are constantly striving to improve all our
processes and products. A good example of
this is the range of furnace tending tools,
which add value by improving the processes
at the customer and at the same time providing
notable savings on furnace tending tools
and tool maintenance.
Storvik’s current furnace tool line-up consists
of 14 different tools, so it is very likely
that customers will be able to find tools from
this selection, that are applicable for their furnace
size, type of furnace and vehicle. The
furnace tools are designed for long-lasting
and efficient use in a demanding production
environment. To achieve this, Storvik uses advanced
computer simulations for thermal and
stress analysis of the tools, as well as flow simulations
to optimize efficiency in operation.
The tools for oven maintenance are made
of non-weldable materials, so Storvik has developed
a robust and simple cast iron screw
system for fastening, which secures the tool
to a mild steel boom or tool holder.
Storvik offers
technical support in
adapting the tools to
customers’ vehicles
and best practice
training for operators.
Best practice
training on the use
of Storvik’s furnace
treatment tools is
highly recommended
to achieve optimal
life of each tool while improving the furnace
tending process.
Storvik stands for the highest standards
of its products and deliverables, and our furnace
tending tools are no exception. We put
Storvik furnace tending tools
The skimming process with furnace tending vehicle
Illustration of thermal and stress analysis
Example showing flow simulations
our honour in always delivering the desired
capacity, redundancy and quality on time
and within the agreed budget.
Author: Helgi Magnusson,
managing director of Storvik Iceland
© Storvik
ALUMINIUM · 3/2021 51

t e c h n o l o g y
In production operations whose
plants have to cope with frequent
product changes, flexible
adapting of the equipment is of
prime importance. In a press
shop that mainly produces automobile
components, the rapid
supply of complex tools weighing
up to seven tonnes to the
presses is paramount. The use
of stackable racks enables an
improvement of 50 percent in
the utilization of the height of
the workshops compared with
a stacker-operated high-bay
warehouse. The use of barcodes
on the racks, together with
connection to the AV or ERP
software makes it possible to
supply the tools fully automatically
and just-in-time to where
they are to be used.
Fully automatic supply with tools and material
Flexible crane logistics for a press shop
“We are sheet component manufacturers,
supplying the automotive
industry and other sectors with
high-grade stamped and bent components
and with finished assemblies
made of steel, aluminium,
brass or copper,” says Hans-Martin
Tekeser, managing director of Alzner Automotive
in Grafenau, Germany. In this activity
the company, founded in 2004, sets great store
by the most modern production technologies,
top quality and its competence in the collaborative
development of new systems, for example
in the field of electro-mobility.
Stamping technology goes together with
many other processes, such as bending, laser
cutting, welding, clinching and ToxClinching,
as well as finishing with additional components
made of metal, rubber, foils or adhesive
pads. In this the company accepts full responsibility
for the production of complete, readyto-fit
assemblies which the customer can incorporate
directly in his own manufacturing
process. Very important for Alzner are additional
competences is the sectors of design,
die construction, quality control and logistics.
Accordingly, a particular part is played by
the most complete possible interlinking of all
processes, from development to production,
with the help of modern IT-supported methods.
The Schuler presses mostly used therefore
have the IloT-Connector, with which the
operational status of the machines can be
The automatic crane transports racks that can be loaded with tools,
sheet or coils. The racks are stacked along the wall of the shed;
in front on the right, a rack loaded with a follow-up tool on the shuttle
called up at any time. This includes all the information
about the current tool, the number
of strokes, the press force and the lubrication
and cooling circuits.
High flexibility of production-run sizes …
“Since in the press sector we produce numerous
and widely differing products in greatly
varying production-run sizes for each order,
from a few tens of thousands
down to individual prototypes,
we have to adapt our equipment
frequently,” explains Tekeser. For
this, flexibility in complying with
the wishes of customers is of the
highest priority.
Most dies are so-termed followup
tools. These in turn are themselves
in principle complex units
in which the parts desired are produced
in several consecutive steps
from a through-going strip, which
is first stamped and then deformed
in stages. They consist of an upper
and a lower portion with numerous
moving parts, they are up to
six metres in length and weigh up
to seven tonnes. After use they
are inspected and maintained, and
then returned to the warehouse.
The rapidity and efficiency when
such tools are exchanged and deposited
or recovered from store,
greatly influences the productivity
of the plant and hence the economy
of the production process.
… demand efficient
tool supply
“At the end of 2018 Alzner asked us to propose
a suitable solution,” recalls Jan Guthmann,
the managing director of H + H Herrmann
+ Hieber in Denkendorf, Germany. It
concerned the transport and fully automatic
storage of around 100 tools in two sheds with
a covered cold section between them for truck
transport. Besides a high change-over rate, it
The left side of the warehouse, with up to six die racks stacked above one another
© Klaus Vollrath
52 ALUMINIUM · 3/2021

t e c h n o l o g y
was necessary to take up as little floor space
in the sheds as possible and to use the existing
height of the sheds in the best possible way.
In addition, the equipment should be suitable
not only for storing tools, but also coils
and sheets stored on Europallets. For the further
transport of the tools or materials from
and to the presses or to external transfer positions,
it should be possible to use both the
existing shed cranes and also heavy-load
forklifts. The customer set great store by the
maximum possible reliability of the system,
since the supply of the presses with their press
forces of up to 630 tonnes depends on that.
Faster automatic crane
and self-supporting racks
“The solution we proposed consists of a fully
automatic crane in combination with racks,
two ground-level transfer shuttles and a
bridge shuttle to a transfer tower in the adjacent
shed,” explains Guthmann. The crane
track was self-supporting and built on its own
pillars. The crane, designed for speed and a
load-bearing capacity of 8.5 tonnes, works at
a lifting speed of 0.3 m/s and a linear travel
speed of 1.5 m/s.
The outstanding special feature of the system
is the use of self-supporting, stackable
racks. Compared with a classical stacker-operated
high-bay warehouse, this made it possible,
within the existing shed height, to store
six tools one above the other instead of only
four. The use of this automatic block store
also eliminated the need for any additional
stacker manoeuvring area to be left free. The
individual racks are stacked above one another
or deposited on the transfer shuttle by
the crane with the help of a gripper crossbeam
held by four cables,
and cleared out of the
store area.
Connection to the
presses in the adjacent
shed takes place
via a high bridge with
the help of a separate
shuttle. Thus, the truck
and stacker traffic can
move freely in the intermediate
area. In the
adjacent shed the racks
are taken up by a vertical
conveyor and either
stored intermediately
in four storage areas
or ejected directly.
Chaotic storage and
optimized supply
“The use of a block
store with storage
racks enables optimum
capacity utilization of
The gripper crossbeam, held by four cables,
the warehouse volume
can raise and lower the racks automatically
available. In this case
the store management is chaotic,” confesses
Guthmann. To access a rack in one of the
lower layers, the racks above it have to be
lifted and placed on another stack. So the
respective storage positions are constantly
changing and are known only by the control
system. These sorting cycles are carried out
by the crane in the intervals between the
individual supply journeys. In that way the
stacking sequence in the warehouse can be
continually matched to the ERP planning in
an optimum manner. The system works with
extensive storage strategies, for example so
that racks which are rarely needed are stored
in the lower and outer storage levels.
The start of a long-term partnership
“Since considerable proportions of our production
depend on this central die logistics
system, the decision in favour of Herrmann +
Hieber was preceded by thorough scrutiny,”
states Tekeser. The company, which has been
active for decades, had a good reputation also
as regards the quality and durability of the
projects it has carried out.
Talks began in 2018 and soon showed that
the consultations and planning were taking
place with a high level of professional and
technical competence. Although the individual
components were tried and tested products
the plant in this form was unique, among
other things as regards the high crane loading
of 8.5 tonnes in total.
Overall commissioning was concluded successfully
in October 2019. “As regards quality,
H + H Herrmann + Hieber fulfilled our expectations
and we look forward to a partnership
collaboration that will last for many years,”
summarizes the managing director of Alzner,
Mr Tekeser.
The complex follow-up dies for the presses weigh up to seven tonnes
Author: Klaus Vollrath, b2dcomm.ch
ALUMINIUM · 3/2021 53

t e c h n o l o g i e
Huissel betreibt Schuler-Presse neuester Bauart
Die Huissel GmbH mit Sitz im pfälzischen
Enkenbach-Alsenborn ist auf Werkzeugbau,
Lohnfertigung, Stanz- und Umformtechnik
spezialisiert. Das Unternehmen
ist der erste Kunde von Schuler mit einer
800 Tonnen starken Presse der neu entwickelten
MSP-Baureihe. Den Geschäftsführer
Gerald Schug hat vor allem das innovative
Konzept der Anlage überzeugt:
Bei ihr kommen zwei ausschließlich elektronisch
synchronisierte Antriebsstränge
in gegenüberliegender Anordnung zum
Einsatz, die aus jeweils einem hoch dynamischen
Servomotor, einem Bremsmodul
und einer Exzenterwelle bestehen.
Huissel operates Schuler
press of latest design
„Durch den Verzicht auf Zahnräder ist die
Maschine viel dynamischer als bisherige Servopressen“,
erklärt Schug. In herkömmlichen
mechanischen Pressen sorgt ein Getriebe im
Kopfstück für den Gleichlauf der Motoren.
Bei der MSP-Baureihe liegen außerdem die
Druckpunkte weiter außen, als man es vom
traditionellen Pressenbau kennt, wodurch sich
die mögliche außermittige Belastung erhöht.
Teil des Gesamtkonzepts ist auch eine sehr
feine elektronische Parallelitätsüberwachung
für den Stößel.
„Der Kniehebelantrieb in Querwellenbauweise
spielt vor allem im unteren Arbeitsbereich
seine Stärken aus“, ergänzt Schug.
Die konstante Umformgeschwindigkeit kurz
vor dem unteren Umkehrpunkt bietet vor
allem beim Prägen, Biegen und Ziehen mechanische
Vorteile. Davon profitiert Huissel
unter anderem bei der Umformung von Deckeln
und Schalen für Lüftungsanlagen oder
von einem etwa 20 Millimeter flachen Blechteil
aus Aluminium für einen großen Automobilhersteller.
Auch mit der Automation der Presse,
die Schuler ebenfalls geliefert hat, ist Schug
rundum zufrieden. Zum Lieferumfang gehören
eine Bandanlage in Langbauform vom
Typ Power Line, der Walzenvorschub Power
Feed und der modulare elektronische Dreiachstransfer
ProTrans mit aktiver Schwingungskompensation.
Eine Dreifach-Beölung
des Bandmaterials sorgt für optimale Umformbedingungen.
Werkzeug-Simulation
verhindert mögliche Kollisionen
Darüber hinaus investierte Huissel unter anderem
für den eigenen Werkzeugbau in die
Simulationslösung DigiSim. Damit lässt sich
Die Huissel-Geschäftsführer Gerald Schug (rechts) und Peter Busalt (links) mit Schuler-Divisionsleiter Frank
Klingemann vor der neuen 800-Tonnen-Presse / Huissel managing directors Gerald Schug (right) and Peter
Busalt (left) with Schuler’s head of division, Frank Klingemann in front of the new 800-tonne press
Huissel GmbH, based in Enkenbach-
Alsenborn, Germany, specializes in die
making, contract manufacturing, and
stamping and forming technology. The
company is Schuler’s first customer with
an 800-tonne press of the newly developed
MSP series. Managing director
Gerald Schug was particularly impressed
by the innovative concept of the lines:
they use two exclusively electronically
synchronized drive trains in an opposite
arrangement, each consisting of a highly
dynamic servo motor, a brake module,
and an eccentric shaft.
“The absence of gears makes the machine
much more dynamic than previous servo presses,”
explains Schug. In conventional mechanical
presses, a gearbox in the crown ensures
the synchronization of the motors. In addition,
the pressure points on the MSP series
are further out than those on traditional
presses, which increases the possible eccentric
load. Part of the overall concept is also a very
fine electronic parallelism monitoring system
for the slide.
“The knuckle-joint drive in transverse
shaft design plays to its strengths particularly
in the lower working range,” adds Schug. The
constant forming speed shortly before the
bottom dead centre offers mechanical advantages,
especially in embossing, bending and
drawing. Huissel benefits from this, for example,
when forming lids and shells for ventilation
systems or an approx. 20 mm flat sheet
metal part made of aluminium for a major
automotive manufacturer.
Schug is also completely satisfied with
the automation of the press, which Schuler
likewise supplied. Furthermore, the scope of
supply includes a Power Line type coil line
in long design, the Power Feed roll feed, and
the ProTrans modular electronic three-axis
transfer with active vibration compensation.
Triple oiling of the strip material ensures optimum
forming conditions.
Die simulation prevents
possible collisions
Huissel also invested in the DigiSim simulation
solution for its own die making operations,
among other things. Thus, the possible
collision with the transfer can be detected
while the die is still in the design phase. During
a training course held last October with
Schuler’s experts, the users learned about the
extensive possibilities of the software and
how to operate it.
On the other hand, no great prior knowledge
is required to control the press, as
operators can select from six already programmed
slide movement curves which are
matched to the desired product. The Smart
Assist also guides the operator step-by-step
through the setup process for new dies, which
helps shorten Huissel’s production start-up.
If, despite everything, a maloperation
© Schuler
54 ALUMINIUM · 3/2021

t e c h n o l o g y
should occur, the electronic overload protection
prevents worse: it immediately registers
an excessive press force and changes the
torque of the main drive in the opposite direction
within a few milliseconds to minimize
die damage.
Thanks to an energy storage unit, the
connected load of the overall system is significantly
reduced. Last but not least, for
Gerald Schug, the external appearance of
the largest investment in Huissel’s company
history to date is right: “The design of the
machine is impressive,” is how the managing
director puts it – especially since the MSP 800
can also convince with its internal values.
Forging lines installed
for Chinese customer
In the middle of the Corona pandemic, Schuler
has also installed two forging lines in
China, one of which has already been handed
over and the other is about to be. This was
made possible not least by remote maintenance
and virtual commissioning, which allowed
all functions to be simulated in advance
on the computer and adapted to the customer’s
needs. The screw press and the crank
press forge aluminium chassis parts fully
automatically. Schuler supplied the lines including
the dies and furnaces.
The production data of the lines can optionally
be accessed via the ‘mySchuler’ portal
from anywhere and at any time. The ‘Production
Monitor’ displays the operating status
and the current stroke rate. The ‘Press Force
Monitor’ provides information about the load
on the machine and die, ‘Drive Analytics’ enables
operators to monitor the main drives
and ‘Cooling Analytics’ allows them to monitor
the cooling circuits. ‘Lubrication Analytics’
makes it possible to control the lubrication
circuit including lubrication cycles, system
pressure or oil temperature depending
on the stroke rate. In this way, possible deviations
can be detected at an early stage
and quickly remedied.
Screw presses from Schuler feature a press
force of between 250 and 28,000 tonnes. The
water-cooled servo direct drive transmits the
torque of the motor without losses and offers
a high level of robustness, precision, operational
reliability and economy. The 750 to
16,000-tonne crank presses are particularly
suitable for mass production. Depending on
the specific requirements, the press frame as
well as the drive system is designed for high
manufacturing precision and high production
rates.
■
eine mögliche Kollision eines Werkzeugs mit
dem Transfer bereits erkennen, während sich
dieses noch in der Konstruktionsphase befindet.
Im Rahmen einer Schulung im Oktober
2020 mit den Experten von Schuler lernten
die Anwender die umfassenden Möglichkeiten
der Software kennen und bedienen.
Zur Steuerung der Presse braucht es dagegen
keine großen Vorkenntnisse, da die Bediener
bei Bedarf unter sechs bereits einprogrammierten
Bewegungskurven des Stößels
auswählen können, die auf das gewünschte
Produkt abgestimmt sind. Der Smart Assist
führt außerdem Schritt für Schritt durch den
Einrichtevorgang für neue Werkzeuge, wodurch
sich der Produktionsanlauf bei Huissel
verkürzen lässt.
Sollte es dennoch zu einer Fehlbedienung
kommen, verhindert die elektronische Überlastsicherung
Schlimmeres: Sie registriert sofort
ein Überschreiten der Presskraft und ändert
innerhalb von wenigen Millisekunden das
Drehmoment des Hauptantriebs in die entgegengesetzte
Richtung, um einen Werkzeugschaden
zu minimieren.
Dank eines Energiespeichers reduziert
sich die Anschlussleistung des Gesamtsystems
deutlich. Nicht zuletzt stimmt für Gerald
Schug das äußere Erscheinungsbild der bisher
größten Investition in der Unternehmensgeschichte:
„Der Aufbau der Maschine macht
was her“, formuliert es der Geschäftsführer –
zumal die MSP 800 auch mit ihren inneren
Werten überzeugen kann.
Schmiedelinien für chinesischen
Kunden installiert
Mitten in der Corona-Pandemie hat Schuler
zwei Schmiedelinien in China installiert, von
der eine bereits übergeben ist und die andere
kurz davor steht. Möglich wurde dies nicht
zuletzt durch Fernwartung und eine virtuelle
Inbetriebnahme der Anlagen, mit der sich
sämtliche Funktionen bereits vorab am Computer
simulieren und an die Bedürfnisse des
Kunden anpassen ließen. Es handelt sich um
eine Spindel- und eine Kurbelpresse, die voll
automatisiert Fahrwerksteile aus Aluminium
schmieden. Schuler lieferte die Linien einschließlich
der Gesenke und Öfen.
Die Produktionsdaten beider Linien sind
optional über das Portal mySchuler von überall
und jederzeit abrufbar. So zeigt der Production
Monitor den Betriebsstatus und die
aktuelle Hubzahl an. Der Press Force Monitor
gibt Aufschluss über die Belastung von Presse
und Gesenk, mit Drive Analytics können
Bediener die Hauptantriebe überwachen und
mit Cooling Analytics die Kühlkreisläufe.
Lubrication Analytics ermöglicht die Kontrolle
des Schmierkreislaufs einschließlich der
Schmierzyklen, des Systemdrucks oder der
Öltemperatur in Abhängigkeit der Hubzahl.
Auf diese Weise können mögliche Abweichungen
früh erkannt und schnell behoben
werden.
Spindelpressen von Schuler verfügen über
eine Presskraft zwischen 250 und 28.000
Tonnen. Der wassergekühlte Servo-Direktantrieb
überträgt das Drehmoment des Motors
ohne Verluste und bietet eine hohe Robustheit,
Präzision, Betriebssicherheit und Wirtschaftlichkeit.
Die 750 bis 16.000 Tonnen
starken Kurbelpressen eignen sich besonders
für die Massenfertigung. Der Pressenrahmen
sowie das Antriebssystem sind abhängig von
den jeweiligen Anforderungen für hohe Fertigungspräzision
und hohe Produktionszahlen
ausgelegt.
■
Auf den Schmiedelinien werden Fahrwerksteile aus Aluminium hergestellt
The forging lines produce aluminium chassis parts
ALUMINIUM · 3/2021 55

© Starrag / Ralf Baumgarten
Kurze Wege, schlanke Strukturen und strikte Prozessorientierung kennzeichnen die Produktion von Industria Metalli
Short distances, lean structures and strict process orientation characterise the production process of the cast parts producer
Industria Metalli – mit Hochdruck
in die Gussteilbearbeitung
Während im Lockdown in Italien viele
Unternehmen verzweifelten, nutzte eine
Traditionsgießerei in der Lombardei die
Zwangspause zum Aufbau einer mechanischen
Fertigung. Die rohen Gussteile
verlassen künftig zur Endbearbeitung
nicht mehr das Werk, sondern bekommen
den letzten Schliff direkt von zwei
Heckert-Bearbeitungszentren verpasst.
Der Einstieg zum Systemlieferanten gelang
dank Starrag-Support trotz Pandemie
ohne nennenswerte Verzögerung.
Die Kunden von Industria Metalli stammen
aus der Fahrzeugindustrie, eine der anspruchsvollsten
Branchen überhaupt. Spezialisiert ist
das Unternehmen auf Fahrzeugkomponenten
– von Stützen und Halterungen bis hin zu
Gehäusen aller Art. In hoher Fertigungstiefe
entstehen in der Fabrik pro Jahr aus 8.000
Tonnen Sekundäraluminium über fünf Millionen
Aluminium-Gussteile für 160 Kunden
auf der ganzen Welt. Der Mittelständler aus
der Lombardei macht seinen Umsatz zu 40
Prozent mit der Automobilindustrie sowie zu
jeweils rund 30 Prozent mit Nutzfahrzeugherstellern
und Agrartechnik-Unternehmen.
Geschäftsführer und Mitinhaber Fausto
Becchetti erläutert, dass er viel von seiner
früheren Arbeit als ABB-Manager von der
Fahrzeugbranche und deren prozessorientierter
Denkweise gelernt hat: Die in drei Fertigungsinseln
gegliederte Fabrik folgt ähnlichen
Prinzipien. Verbunden sind alle Fertigungsbereiche
digital über ein Manufacturing Exe-
Industria Metalli – pressing ahead
with the machining of castings
While the lockdown in Italy saw many
companies struggle, a traditional foundry
in Lombardy used the involuntary break
in production to establish a mechanical
manufacturing facility. In future, the
rough cast parts will no longer need to
leave the factory to be finished – instead,
they will be finished on-site using two
Heckert machining centres. Thanks to
intensive support from Starrag, the
company was able to take the next step
towards becoming a system supplier
without any significant delays, despite
the pandemic.
Industria Metalli’s customers come from
the automotive sector – one of the most demanding
industries. The company specializes
in vehicle components, from supports and
brackets through to all manner of housings.
With a high level of vertical integration, each
year the factory produces more than five
million cast aluminium parts for 160 customers
around the world using 8,000 tonnes of
secondary aluminium. The medium-sized
company from Lombardy generates 40% of
its turnover from the automotive industry,
around 30% from commercial vehicle manufacturers
and around another 30% from
agricultural technology companies.
During the tour of the large factory
premises, Fausto Becchetti, managing director
and co-owner, explains that he learned
a lot from his previous work on the automotive
sector management team at ABB and the
process-oriented thinking that this required:
the factory is divided into three production
cells and follows similar principles. All of the
production areas are connected digitally via
a manufacturing execution system which controls
the entire manufacturing process in real
time. Every production step is carried out in
accordance with Toyota’s Poka-Yoke principle,
which detects and prevents faults. It is
supported by a production-oriented and seamless
quality assurance system, which is based
on the strict requirements of IATF 16949
(International Automotive Task Force).
In the factory, Becchetti points to one of
the four gas-fired furnaces in the first production
cell. “The aluminium immediately
reaches the ideal processing temperature of
700 °C, at which point it becomes fluid,” he
says. “The next steps are degassing and transport.”
In the meantime, the manufacturing
execution system fully automatically organizes
just-in-time transport and assigns a driver
via the digital network. The forklift truck is
located nearby and features a tablet that informs
the driver which furnace to collect the
56 ALUMINIUM · 3/2021

t e c h n o l o g y
crucible from and which of the 16 robot-assisted
high-pressure die-casting presses in
the second production cell is waiting for the
liquid aluminium.
Outsourcing slows down
the flow of materials
Like most firms in the industry, the company
has so far relied on outsourcing. After the
die casting process, the components have a
near-net shape and therefore have to be taken
to a nearby workshop to be finished. Outsourcing
leads to an increase in logistical considerations
and cost, while quality decreases.
For example, small air pockets known as
blowholes can occur in cast parts, but these
are often not detected during X-rays and are
only picked up during final machining. The
late detection of these blowholes by external
companies results in significant delays to the
production process and increases the cost
enormously: there is no immediate quality
check after high-pressure die-casting on the
machine tool. The result: the process chain
becomes slower and the part has to be melted
down and poured again. These bottlenecks
were a thorn in the former manager’s side.
The turning point came with the arrival of
a new project manager, who had worked as
a machining specialist in the automotive industry
and who recommended purchasing a
five-axis Heckert X40 and a four-axis Heckert
H40 to assist the establishment of a mechanical
manufacturing facility. “We ordered the
two machining centres in autumn 2019,”
explains Becchetti. “Despite the lockdown,
we decided to go through with setting up a
mechanical manufacturing facility as it is an
cution System, das den gesamten Herstellungsprozess
in Echtzeit regelt. Alle Produktionsschritte
geschehen nach dem Poka-Yoke-
Prinzip von Toyota, das Fehler aufdeckt und
verhindert. Unterstützt wird es von einem
fertigungsnahen und lückenlosen Qualitätssicherungssystem,
das sich an den strengen
Vorgaben der IATF 16949 (International Automotive
Task Force) orientiert.
In der Fabrik weist der ehemalige ABB-
Manager in der ersten Fertigungsinsel auf einen
der vier gasbetriebenen Schmelzöfen hin.
„Gleich erreicht das Aluminium die ideale
Weiterverarbeitungstemperatur von 700 °C,
bei der es flüssig wird“, erklärt Becchetti.
Eine der insgesamt 16 Hochdruckguss-Pressen, die mit Robotern eng zusammenarbeiten
One of the 16 high-pressure die-casting presses that work in close collaboration with robots
In hoher Fertigungstiefe entstehen pro Jahr aus 8.000 Tonnen Sekundäraluminium
über fünf Millionen Aluminium-Gussteile für 160 Kunden auf der ganzen Welt
With a high level of vertical integration, more than five million cast aluminium parts are
produced for 160 customers around the world using 8,000 tonnes of secondary aluminium
„Danach folgen Entgasen und Transport.“ Das
Manufacturing Execution System hat inzwischen
vollautomatisch den Just-in-time-
Transport organisiert und über das digitale
Netzwerk einen Fahrer bestellt. Direkt in der
Nähe steht sein Stapler, auf dem ein Tablet
den Fahrer informiert, von welchem Ofen er
den Schmelztiegel abholen soll und welche
der insgesamt 16 roboterunterstützten Hochdruckguss-Pressen
in der zweiten Fertigungsinsel
bereits auf das flüssige Aluminium wartet.
Outsourcing bremst den Materialfluss
Wie die meisten Firmen der Branche setzte
Industria Metalli bisher auf Outsourcing: Die
Bauteile besitzen nach dem Druckgießen
Near-net-shape-Qualität und müssen daher
in einem benachbarten Job-Shop den letzten
Schliff erhalten. Die Folgen des Outsourcings:
Der Logistikaufwand und die Kosten
steigen, während die Qualität sinkt. So fallen
kleinere Lufteinschlüsse in Gussteilen,
sogenannte Lunker, oft nicht beim Röntgen,
sondern erst beim abschließenden Zerspanen
auf. Das späte Entdecken der Lunker in einem
externen Betrieb verzögert und verteuert
den Produktionsprozess enorm: Es fehlt der
unmittelbare Qualitätscheck nach dem Hochdruckguss
auf der Werkzeugmaschine. Die
Folge: Die Prozesskette wird langsamer, das
Teil muss erneut eingeschmolzen und neu
gegossen werden. Diese Engpässe waren Becchetti
ein Dorn im Auge.
Die Wende kam mit dem neuen Projekt-
ALUMINIUM · 3/2021 57

t e c h n o l o g i e
manager, einem Spezialisten für Zerspanung
aus der Fahrzeugindustrie, der für den Einstieg
in die mechanische Fertigung den Kauf
einer fünfachsigen
Heckert X40 und
einer vierachsigen
Heckert H40 empfahl.
„Bestellt hatten
wir die beiden Bearbeitungszentren
im
Herbst 2019“, blickt
Becchetti zurück.
„Doch trotz des
Lockdowns beschlossen
wir, den Einstieg
in die mechanische
Fertigung durchzuführen,
denn es ist
eine Investition in
die Zukunft – obwohl
es im Frühjahr
keinen Markt für unsere
Produkte gab.“
Hier kam von
Anfang an Thomas
Kässner ins Spiel:
Der Sales-Manager
bei Heckert spricht
fließend Italienisch und half auch bei der
Inbetriebnahme in der Lockdown-Zeit, die
dank des direkten Kontakts zum Starrag-
Werk in Chemnitz nahezu ohne Verzögerung
ablief. Für die beiden Bearbeitungszentren
entschied sich das Unternehmen wegen der
stabilen Bauweise, des damit verbundenen
höheren Spanabtrags, der Dauergenauigkeit
und des technologischen Leistungspuffers.
Bewusst steif ausgelegt sind alle Gestellbaugruppen
vom Maschinenbett, Ständer, Tisch
bis hin zur Dreh-/Schwenkeinheit. „Ich freue
mich besonders über die hohe durchgängige
Maschinensteifigkeit, denn wir schlichten die
Druckgussteile mit Diamantwerkzeugen“, lobt
Becchetti die Bearbeitungszentren. „Selbst
bei 20.000 Umdrehungen pro Minute bricht
der Diamant nicht, wenn er auf einen Lunker
trifft.“
Cleveres Zusammenspiel von Diamantwerkzeug
und Nassbearbeitung
Minimalmengenschmierung oder Trockenbearbeitung
kommt bei der Bearbeitung von
Aluminiumbauteilen in der Regel nicht infrage.
Die Italiener verwenden eine elektronisch
gesteuerte Kühlschmierstoffzufuhr, die
unter anderem für die Temperierung von
Werkstück und Werkzeug sorgt. „Ohne effektive
Nassbearbeitung käme es nicht zu
einem optimalen Späneabtransport“, ergänzt
Becchetti. Mit dem Entfernen der Späne steht
und fällt aber die saubere und schnelle Bearbeitung,
denn Aluspäne bleiben sonst leicht
Industria Metalli startete auf den beiden Heckert-Bearbeitungszentren
mit der Bearbeitung von einfachen Gehäusen für Ölfilter
Industri Metalli using the two Heckert machining
centres to machine simple housings for oil filters.
am Diamant kleben und verkratzen oder
verletzen das Gussbauteil.
Besonders erfreut ist der Zerspanungs-Experte
von der Qualität und der sehr schnellen
Bearbeitungszeit. „Obwohl viele Bauteile
schwer zugängliche Stellen wie Bohrungen
oder Taschen besitzen, sank die Bearbeitungszeit
gegenüber der unseres Dienstleisters um
mehrere Sekunden pro Spannlage, da wir
deutlich höhere Schnittgeschwindigkeiten
fahren können“, berichtet er. „Gleichzeitig
erreichen wir Spitzenqualität.“ Mit dem Heckert-Duo
wird eine Oberflächenrauheit Ra
von 20 µm erreicht, sodass eine Nachbearbeitung
entfällt.
Der Aufwand hat sich gelohnt: Industria
Metalli startete mit der Bearbeitung von einfachen
Gehäusen für Ölfilter. Das Unternehmen
zerspant in seiner neuen Fertigungsinsel
bereits jedes Zehnte seiner Bauteile. „Ich bin
optimistisch, dass wir bald weitere Produkte
mit den Heckert-Bearbeitungszentren endbearbeiten
und dank der mechanischen Fertigung
im Haus auch Aufträge für völlig neue
Komponenten erhalten“, zeigt sich Becchetti
zuversichtlich. „Im nächsten Schritt steht nun
die Automatisierung an.“ Doch schon ohne
diese Integration konnte Industria Metalli den
Wertschöpfungsanteil an Bauteilen deutlich
steigern – sogar mit besserer Marge.
Doch was visiert der Geschäftsführer langfristig
an? „Mit dem Aufbau und der Integrainvestment
in the future – even though there
was no market for our products in the
spring“.
Thomas Kässner was involved
in the process right
from the start: the Heckert
sales manager speaks fluent
Italian and also helped with
commissioning during the
lockdown period, which took
place almost without any delays
thanks to direct contact
with the Starrag plant in Chemnitz.
The company decided in
favour of the two machining
centres because of their robust
design, greater swarf removal,
continuous precision and the
technological performance
buffer. All the frame assemblies
are deliberately rigid,
from the machine bed, column
and table to the rotary swivelling
unit. “I am particularly
pleased about the high and
consistent machine rigidity as
we use diamond tools to finish
the die-cast parts,” says
the project manager, clearly satisfied with the
machining centres. “Even at 20,000 revolutions
per minute, the diamond doesn’t break
when it hits a blowhole.”
An intelligent partnership:
diamond tools and wet machining
Minimal-volume lubrication or dry machining
is generally not an option when machining
aluminium components. The company uses
an electronically controlled coolant supply,
which ensures the temperature stabilization
of the workpiece and the tool, amongst much
more. “Without effective wet machining, it
would be impossible to achieve optimum
swarf removal,” adds the project manager.
The removal of the swarf is the linchpin of a
clean and rapid process, as aluminium swarf
will otherwise easily stick to the diamond
and scratch or impair the cast component.
The machining expert is especially pleased
with the quality and the very fast processing
time. “Although many components have
hard-to-reach areas such as holes or pockets,
the processing time has been reduced by several
seconds per clamping surface compared
to that offered by our service provider, as we
can run at significantly higher cutting speeds,”
says Becchetti. “At the same time, we can
also achieve top quality.” The two Heckert
machines are able to achieve a surface rough-
58 ALUMINIUM · 3/2021

t e c h n o l o g y
ness (Ra) of 20 µm, meaning that no further
processing is required.
The effort was worthwhile: Industria Metalli
has begun processing simple housings for
oil filters. The company is already machining
one in ten of its components in its new production
cell. “I am optimistic that we will
soon be able to finish more products using the
Heckert machining centres and that, thanks
to the in-house mechanical manufacturing
facility, we will also receive orders for completely
new components,” states Becchetti.
“Automation is now the next step.” However,
the benefits are obvious, even without this
integration: The company has considerably
increased the proportion of value added for
its components – and with better margins too.
The boss is already looking ahead, but what
are his long-term strategic plans? “By establishing
a mechanical manufacturing facility
and incorporating it into our production
system, our opportunities to progress to tier
one, to become a system supplier, have increased
significantly,” explains the managing
director. “Our products are now significantly
more competitive in comparison to those
from many of our competitors, who do not
have in-house machining. The two Heckert
machining centres represent the first milestone
in our journey.”
Company profile
Industria Metalli srl, based in Bedizzole, has
around 100 employees and manufactures
components weighing between 0.5 and 30.0
kg using the aluminium high-pressure diecasting
process. The product range includes
housings for steering systems, gears and oil
filters, supports, brackets, lighting fixtures and
much more.
The second-generation family-owned company
oversees the entire production process,
from the melting of the secondary aluminium,
degassing, high-pressure die-casting, heat
treatment, shot-blasting, deburring, mechanical
processing and assembly, all with a high
level of vertical integration. The quality control
process spans the entire company, from
the incoming goods department with a quality
control laboratory that analyses aluminium
alloys using a spectrometer, to the X-ray
machine for detecting blowholes and the expensive
3D coordinate measuring machine.
This ‘cultura di qualità’ is the result of
quality management certificates received for
compliance with IATF 16949 and ISO 9001.
Due to its sustainable, low-emission production,
the company has also received ISO
14001 certification.
■
Mit dem Einstieg in die mechanische Fertigung mit einer 5-achsigen Heckert X40 (vorne)
und einer 4-achsigen Heckert H40 schließt Industria Metalli eine wichtige Fertigungslücke
Industria Metalli has closed a significant gap in its production process by establishing a
mechanical manufacturing facility with a five-axle Heckert X40 (front) and a four-axle Heckert H40
tion der mechanischen Fertigung in unser
Produktionssystem hat sich die Chance zum
Aufstieg zum Tier One, zum Systemlieferanten,
deutlich erhöht“, meint Becchetti.
„Wir können nun unsere Produkte im Vergleich
zu den vielen Wettbewerbern ohne
Inhouse-Machining deutlich wettbewerbsfähiger
anbieten. Die beiden Heckert-Bearbeitungszentren
sind dabei der erste Meilenstein
auf unserem Weg.“
Firmenprofil
Industria Metalli srl, Bedizzole, stellt mit bis
zu 100 Mitarbeitern auf einer Produktionsfläche
von rund acht Fußballfeldern im Aluminium-Hochdruckgussverfahren
Bauteile mit
einem Gewicht von 0,5 bis 30,0 Kilogramm
her. Die Produktpalette umfasst unter anderem
Gehäuse für Lenkungen, Getriebe und
Ölfilter, Stützen, Halterungen sowie Beleuchtungskörper.
In hoher Fertigungstiefe übernimmt das
in zweiter Generation geführte Familienunternehmen
die komplette Produktion vom
Schmelzen des Sekundäraluminiums (im Jahr
rund 8.000 Tonnen), Entgasen, Hochdruckguss,
Wärmebehandlung, Kugelstrahlen, Entgraten,
mechanische Bearbeitung bis zur Montage.
Lückenlos reicht die Qualitätskontrolle
vom Wareneingang mit Qualitätskontroll-
Labor, das unter anderem mit dem Spektrometer
Aluminiumlegierungen analysiert, bis
hin zum Röntgengerät zum Aufspüren von
Lunkern und der teuren 3D-Koordinaten-
Messmaschine.
Dieser „cultura di qualità“ verdankt das
Qualitätsmanagement Zertifikate nach IATF
16949 (International Automotive Task Force)
und ISO 9001. Wegen ihrer nachhaltigen,
emissionsarmen Produktion erhielt das Unternehmen
außerdem das Öko-Zertifikat ISO
14001.
■
Elektronisch gesteuerte Kühlschmierstoffzufuhr sorgt für die Temperierung von Werkstück sowie
Werkzeug und den Späneabtransport / An electronically controlled coolant supply ensures the
temperature stabilisation of the workpiece and the tool and takes care of swarf removal
ALUMINIUM · 3/2021 59

t e c h n o l o g i e
Doppelte Standzeit durch geringen Verschleiß
Ein entscheidender Faktor für die Prozesseffizienz
bei der Metallverarbeitung ist
die Standzeit der Werkzeuge. Müssen
Werkzeuge wegen hohem Verschleiß
häufig ausgetauscht werden, steigen die
Produktionskosten durch Stillstände
der Maschinen. Um den Verschleiß zu
reduzieren und dadurch die Standzeiten
von Werkzeugen zu erhöhen, haben die
Experten der K.-H. Müller Präzisionswerkzeuge
GmbH die neue Werkzeugbeschichtung
MC 3100 entwickelt. Tests
haben dabei gezeigt, dass die Werkzeuge
mit der neuen Beschichtung doppelt so
viele Bohrungen durchführen können wie
vergleichbare Werkzeuge.
In allen Branchen, in denen Metall verarbeitet
wird, ist die Standzeit der Werkzeuge ein
wichtiges Thema. Dabei streben Unternehmen,
wie in allen anderen Bereichen auch, nach
größtmöglicher Effizienz. Müssen Werkzeuge
wie zum Beispiel Bohrer häufig wegen Verschleiß
ausgetauscht werden, senkt dies die
Effizienz der Bearbeitungsprozesse. Für den
Austausch der Werkzeuge müssen die Maschinen
gestoppt werden und können in dieser
Zeit nicht produzieren. Darüber hinaus
sind neue Werkzeuge ein Kostenfaktor und
der Austausch bindet Mitarbeiter. Um die
Standzeiten von Werkzeugen zu erhöhen,
haben die Experten für Sonderwerkzeuge der
K.-H. Müller Präzisionswerkzeuge GmbH aus
dem rheinland-pfälzischen Sien eine neue
Beschichtung entwickelt, die dank ihrer speziellen
Eigenschaften dafür sorgt, dass die Werkzeuge
doppelt so hohe Standzeiten erreichen
wie vergleichbare Werkzeuge mit konventionellen
Beschichtungen.
Neue, verschleißarme
Werkzeugbeschichtung
„Wir wollten zusammen mit einem unserer
Partner, einem Beschichtungsanlagenhersteller,
die ohnehin hohe Standzeit unserer
Werkzeuge weiter erhöhen“, erklärt Matthias
Klinke, Außendienstmitarbeiter für Bayern
bei Müller, den Hintergrund der Entwicklung.
„Die ersten Tests der neuen Werkzeugbeschichtung
bei einem Kunden aus der Automobilindustrie
haben die Erwartungen dann
sogar übertroffen.“ Bei den Tests vor Ort
wurden die Werkzeuge mit neuer Beschichtung
direkt mit den bisher verwendeten Werkzeugen
verglichen. Dabei zeigte sich, dass die
bisherigen Werkzeuge circa 7.000 Bohrungen
Tool life doubled thanks to low wear
A decisive factor for process efficiency in
metalworking is the tool life. If tools have
to be replaced frequently due to high
wear, production costs increase as a result
of machine downtime. In order to reduce
wear and thereby increase the tool life,
the experts at K.-H. Müller Präzisionswerkzeuge
GmbH have developed the
new MC 3100 tool coating. Tests have
shown that tools with the new coating can
drill twice as many holes as comparable
tools.
In all metalworking industries, tool life is an
important issue. Here, as in all other sectors,
companies strive for the greatest possible efficiency.
If tools, such as drills, have to be replaced
frequently due to wear, the efficiency
of the machining processes is reduced. To
replace tools, machines have to be stopped
and cannot produce during this time. Furthermore,
new tools are a cost factor and the
replacement ties up employees. In order to
increase the tool life, the experts for special
tools at K.-H. Müller Präzisionswerkzeuge
from Sien, Germany, have developed a new
high-tech coating. Thanks to its special characteristics,
it ensures that the tools achieve
twice the lifespan of comparable tools with
conventional coatings.
New, low-wear tool coating
“Together with one of our partners, a coating
machine manufacturer, we wanted to further
increase the already high lifespan of our
tools,” explains Matthias Klinke, sales representative
for Bavaria at Müller, the background
of the development, adding: “The first
test results of the new tool coating at a customer
from the automotive industry actually
exceeded expectations,” he continues. During
on-site tests, tools with the new coating have
been directly compared with the tools used
previously. The previous tools reached up to
about 7,000 drill holes before they had to be
replaced due to wear. Tools with the new coating,
on the other hand, reached up to 14,000
drill holes and more. “These results of doubling
the tool life were verified in other tests
with other customers,” reports Klinke.
Verschleißbedingter Austausch der Werkzeuge kostet Zeit und Geld und bindet Mitarbeiter
Replacing tools due to wear costs time and money and ties up employees
He continues: “The resistance to wear is
decisive for the tool life. Sticking and built-up
edges cause faster wear and reduces tool life.”
In order to reduce built-up edges and sticking
as much as possible, Müller incorporated
a combination of measures in the development
of the new MC 3100 coating. “MC 3100
has an extremely tough main layer. In combination
with an ultra-hard top layer and the
use of the element boron, we have been able
© Müller Präzisionswerkzeuge
60 ALUMINIUM · 3/2021

t e c h n o l o g y
to achieve a very high wear resistance,” he
describes. This combination results in almost
no built-up edges and sticking. The wear of
the tool can be significantly delayed. As a result,
twice as many holes can be drilled without
any loss of quality and
furthermore the tool life
can be doubled.
A new microfinishing
process developed by Müller
in collaboration with
the Robot Academy at
Birkenfeld University also
plays an important role.
This special finishing of
the tools helps to reduce
sticking and built-up edges
even further. “The optimized
combination of new
coating and microfinishing
increases tool life even further,”
explains Klinke.
Possible applications
for the tools with the new
coating are almost unlimited.
“We carried out the
first tests in normal ST
52 steel. In principle, our tools can be used
wherever coated tools are used,” says Klinke.
The tools can be manufactured in all common
diameters. Due to a variety of geometries,
all common materials can be machined with
the MC 3100 coated tools, for example
St 52-2, 16MnCr5 and GG30.
Cost savings due to
reduced demand for tools
Doubling the tool life has numerous advantages
for users. On the one hand, downtimes
for tool replacement can be reduced, which
increases the efficiency of the production
process. On the other hand, actual costs can
also be reduced. “If you normally need 500
tools per year, you can now reduce the need
to about 250 tools. This lowers not only acquisition
costs, but also reduces on-site need
for storage space,” he says.
Customers on-site staff is also relieved.
“Tools are always exchanged manually. By
doubling the tool life, the responsible employees
have more time for other tasks. Of
course, this also contributes to efficiency in
production,” Klinke sums up. “The tests at
our customers were so successful that most
of them switched to our tools with the new
coating immediately afterwards. Especially
the short period of time that passed from the
start of the test to first noticeable results was
convincing.”
■
schafften, bevor sie wegen Verschleiß ausgetauscht
werden mussten. Die Werkzeuge mit
der neuen Beschichtung schafften dagegen
14.000 Bohrungen und mehr. „Diese Ergebnisse
der Verdopplung der Standzeit bestätigten
sich auch bei anderen Tests bei anderen
Kunden“, berichtet Klinke.
Er fährt fort: „Entscheidend für die Standzeit
eines Werkzeugs ist die Widerstandsfähigkeit
gegenüber Verschleiß. Aufklebungen und
Aufbauschneiden sorgen für eine schnellere
Abnutzung und senken damit die Standzeit.“
Um Aufbauschneiden und Aufklebungen so
weit wie möglich zu reduzieren, hat man bei
Müller eine Kombination aus Maßnahmen bei
der Entwicklung der neuen Beschichtung MC
3100 einfließen lassen. „MC 3100 hat einen
extrem zähen Hauptlayer. In Kombination mit
einem ultraharten Toplayer und der Verwendung
des Elements Bor haben wir dadurch
eine sehr große Verschleißfestigkeit erreichen
können“, sagt Klinke. Durch die Kombination
zäher Hauptlayer, ultrahartem Toplayer
und Bor entstehen nahezu keine Aufbauschneiden
und Aufklebungen. Dadurch lässt
sich der Verschleiß des Werkzeugs deutlich
hinauszögern. Dies führt dazu, dass doppelt
so viele Bohrungen ohne Qualitätsverlust als
bisher möglich sind und sich die Standzeit
des Werkzeugs damit verdoppeln lässt.
Ebenfalls eine Rolle spielt ein neues Verfahren
zum Microfinishing, das Müller in Zusammenarbeit
mit der Roboter-Akademie der
Hochschule Birkenfeld entwickelt hat. Diese
spezielle Endbearbeitung des Werkzeugs trägt
dazu bei, Aufklebungen und Aufbauschneiden
noch weiter zu reduzieren. „Die optimale
Kombination aus neuer Beschichtung und
Microfinish macht eine weitere Erhöhung der
Standzeit möglich“, erläutert Klinke.
Die Einsatzmöglichkeiten der Werkzeuge
mit der neuen Beschichtung sind dabei nahezu
unbegrenzt. „Die ersten Tests haben
wir in normalen
Stahl des Typs ST
52 durchgeführt.
Prinzipiell können
die Werkzeuge
überall dort eingesetzt
werden,
wo beschichtete
Werkzeuge eingesetzt
werden“,
erklärt Klinke.
Die Werkzeuge
sind in allen üblichen
Durchmessern
herstellbar.
Durch eine Vielzahl
an Geometrien
können mit
den mit MC 3100
b e s c h i c h t e t e n
Werkzeugen alle
gängigen Materialien
bearbeitet werden, zum Beispiel St 52-2,
16MnCr5 und GG30.
Durch eine Kombination aus zähem Hauptlayer, ultrahartem Toplayer und Bor lässt sich der Verschleiß
von Werkzeugen deutlich hinauszögern und Standzeiten so verlängern / A combination of tough
main layer, ultra-hard top layer and boron significantly delays tool wear and thus extends tool life
Kostenersparnis durch
verringerten Werkzeugbedarf
Die Verdopplung der Standzeit von Werkzeugen
hat für Anwender zahlreiche Vorteile.
Einerseits lassen sich die Stillstandszeiten zum
Werkzeugtausch reduzieren und dadurch die
Effizienz des Produktionsprozesses steigern.
Andererseits lassen sich auch konkret Kosten
sparen. „Wenn man pro Jahr normalerweise
500 Werkzeuge benötigt, kann man den Bedarf
nun auf ungefähr 250 Werkzeuge senken.
Das macht sich dann nicht nur in den
Anschaffungskosten bemerkbar, man spart
darüber hinaus auch Lagerflächen ein“, erläutert
Klinke.
Auch das Personal vor Ort wird entlastet.
„Der Austausch der Werkzeuge wird immer
manuell durchgeführt. Durch eine Verdopplung
der Standzeit haben die zuständigen
Mitarbeiter mehr Zeit für andere Aufgaben.
Das trägt natürlich auch zur Effizienz im Betrieb
bei“, resümiert Klinke. „Die Tests bei
unseren Kunden waren so erfolgreich, dass
die meisten direkt danach auf unsere Werkzeuge
mit der neuen Beschichtung umgestellt
haben. Besonders die geringe Zeitspanne, die
von Testbeginn bis zu den ersten spürbaren
Resultaten verging, hat überzeugt.“ ■
ALUMINIUM · 3/2021 61

t e c h n o l o g y
GM launches USD100m expansion for transmissions production
© General Motors
GM‘s Romulus, Michigan plant – investment to expand
machining capability for diecast aluminium transmissions
General Motors has announced a new
capital-investment programme worth
USD100 million to expand production
of 10-speed automatic transmissions for
its Chevrolet Silverado and GMC Sierra
light-duty, full-size pickups. The bulk of
the investment will be made at the Romulus,
Michigan plant, where GM is committing
USD93 million to add machining
capability.
The Romulus Powertrain facility produces
V6 engines and 10-speed transmissions for
various Chevrolet, Buick, GMC and Cadillac
vehicles, and GM notes that since 2009 it
has invested more than USD880 million at
this location to expand capacity and update
manufacturing capabilities. Last October, the
carmaker pledged USD17 million to improve
automation and expand capacity for the
10-speed transmission products there. The
remaining USD7 million will be invested at
the Bedford, Indiana foundry operation to
expand aluminium diecasting capacity. The
facility produces cast aluminium transmission
casings, converter housings, and cylinder
heads.
Both expansion projects will begin immediately,
according to GM. “Demand for our
Chevrolet Silverado and GMC Sierra fullsize
pickups continues to be very strong and
we are taking action to increase the availability
of our trucks for our dealers and customers,”
stated Phil Kienle, GM vice president,
North America Manufacturing and Labor Relations.
(KS)
New Nissan SUV based on closed-loop recycled aluminium
The all-new Nissan 2021 Rogue, the first
global SUV model from the Japanese
multinational automobile manufacturer,
is built using closed-loop recycling systems
for producing aluminium parts at
the company’s plants in Kyushu, Japan,
and Smyrna, Tennessee.
The system helps reduction of CO 2 emissions
when compared with using parts made with
primary alloys from raw materials. It also
promotes the use of materials that do not rely
on newly mined resources, as well as reducing
process waste from production plants. To
support the process, Nissan has collaborated
with Kobe Steel and UACJ in Japan, and
with Arconic and Novelis in the USA.
The closed-loop recycling system centres
on a large pneumatic conveyor device. As
hoods and doors are stamped into shape,
scrap material is shredded and extracted,
keeping aluminium grades separate. Nissan
says that the separation ensures that highquality
scrap can be returned to suppliers who
convert the separated and reprocessed aluminium
scrap into alloy sheet and re-deliver
it to Nissan for use in production.
The bonnet and doors of the 2021 Rogue
are stamped from aluminium alloy, a material
that reduces vehicle weight and helps to
enhance fuel efficiency and power performance.
Nissan aims to replace 30% of the raw
materials used in cars in 2022 with materials
that do not rely on newly mined resources,
according to the company’s 2022 ‘Green Programme’.
To achieve this, the company will
use recycled materials, develop biomaterials,
carry out recycling activities both with suppliers
and in-house, and seek to reduce the
weight of car bodies.
According to the Aluminum Association
in the USA, recycling scrap aluminium saves
more than 90% of the energy needed to create
a comparable amount of metal from raw
materials. (KS)
■
Nissan Rogue 2021 – closed loop system used for recycled aluminium alloy
© Nissan
62 ALUMINIUM · 3/2021

F o r s c h u n g
Besser kleben im Leichtbau:
Projekt GoHybrid optimiert Hybridverbindungen
© Fraunhofer LBF
Leichtbau ist aus der Mobilitätsbranche
nicht mehr wegzudenken. Im Zuge der
Mischbauweise mit Leichtmetallen und
Faser-Kunststoff-Verbunden rücken nun
hybride Klebverbindungen in den Fokus.
Aufgrund der unterschiedlichen Wärmeausdehnungen
der Materialien kann es
Am Projekt GoHybrid
beteiligte Partner
dort bei großen Temperaturdifferenzen
zu hohen Eigenspannungen und somit
zum Versagen im Klebstoff kommen.
Vor allem bei Verbindungen unter hohen
strukturellen Lasten lassen sich diese
Eigenspannungen nur bedingt durch die
Wahl des Klebstoffs ausgleichen. Daher
ist es notwendig, die Gestaltungsparameter
der Verbindung und der Fügepartner
gesamtheitlich zu betrachten. Das Fraunhofer-Institut
für Betriebsfestigkeit und
Systemzuverlässigkeit LBF untersucht
dies gemeinsam mit Partnern in dem im
Frühjahr 2020 gestarteten Forschungsprojekt
GoHybrid.
Ziel des Projekts ist es, durch Gestaltung,
Materialauswahl und Materialaufbau die Beanspruchungen
in der stoffschlüssigen Hybrid-
Verbindung aus Aluminium und faserverstärkten
Kunststoffen (FKV) so zu reduzieren,
dass hierdurch ein relevantes Leichtbaupotential
erschlossen werden kann. „Als
Ergebnis dieses Projektes erwarten wir eine
signifikante Steigerung der Marktdurchdringung
und der industriellen Anwendung von
Hybridverbindungen bei sicherheitsrelevanten
Komponenten, da sich die gewonnenen
Erkenntnisse nicht nur auf andere automobile
Komponenten wie etwa Querlenker und
Achsen übertragen lassen, sondern insbesondere
auch im Aerospace-Bereich und in
weiteren Branchen angewendet werden können“,
betont Jens-David Wacker, der das Projekt
GoHybrid am Fraunhofer LBF betreut.
In dem Projekt passt das Forscherteam
prinzipiell bestehende, jedoch noch nicht
großserientaugliche, stoffschlüssige Verbin-
dungstechnologien vor allem durch gestalterische
Maßnahmen an hybride Werkstoffsysteme
an, um unterschiedlichste Einsatzbereiche
zu erschließen. Die Umsetzbarkeit und
Zuverlässigkeit von Klebverbindungen unter
hohen Betriebslasten und Temperaturen soll
an einem Pkw-Hybridrad mit einem Radstern
aus Aluminium und einer Felge aus FKV demonstriert
werden. Insbesondere bei Rädern
gibt es solche Klebverbindungen noch nicht.
Üblicherweise werden Räder in hybrider Bauweise
mit CFK-Felge und Aluminium-Stern
mit mechanischen Elementen wie Schrauben
gefügt.
Im Rahmen des Forschungsprojektes Go-
Hybrid stehen beim LBF die Entwicklung
von Gestaltungslösungen der Hybridverbindung
und die experimentelle Untersuchung
im Fokus. Dazu sollen unterschiedliche Verbindungsproben
unter thermischen und zyklischen
Beanspruchungen geprüft werden.
Die Expertise des Darmstädter Instituts basiert
auf langjähriger Erfahrung der Lösungsfindung
und Prüfung von strukturellen Komponenten
wie dem Rad, das hohen Betriebslasten
und thermischen Einflüssen durch die
Temperatur der Bremsen ausgesetzt ist. Als
Ergebnis von GoHybrid erhoffen sich die
Wissenschaftler verkürzte Entwicklungszeiten,
effizientere Fertigungsprozesse, günstigere
Produkte und eine verbesserte Ressourceneffizienz
bei gleichbleibender Sicherheit.
„Schlussendlich geht es um die Entwicklung
von großserientauglichen, stoffschlüssigen
Verbindungstechnologien für hybride Werkstoffsysteme,
die in unterschiedlichen Einsatzbereichen
Anwendung finden können,
und das mit hohem Individualisierungsgrad
und hoher Variantenvielfalt“, so Wacker. ■
Hybride Klebverbindung – beispielhaft
Hybride Klebverbindung unter Temperaturänderung – beispielhaft
ALUMINIUM · 3/2021 63

F o r s c h u n g
Schwingfestigkeit hybrid gefügter Materialverbindungen:
Fraunhofer LBF ermittelt hohes Potenzial für Leichtbau
Zunehmend schärfere gesetzliche Emissionsgrenzwerte
drängen die Automobilindustrie
zu innovativen Leichtbaulösungen.
In diesem Kontext gewinnt die Schwingfestigkeit
von gefügten Feinblechverbindungen,
insbesondere an Multimaterialverbindungen,
an Bedeutung. Im Rahmen
des von der EU geförderten Forschungsprojektes
„Alliance“ hat der Autohersteller
Opel zusammen mit dem Fraunhofer-
Institut für Betriebsfestigkeit und Systemzuverlässigkeit
LBF und dem Fachgebiet
SAM der TU Darmstadt innovative numerische
Methoden auf Basis von Schwingfestigkeitsversuchen
von Scherzug- und
Schälzugproben zur Lebensdauerabschätzung
für Multi-Material-Fügetechniken
entwickelt. Die Validierung der Methode
erfolgte durch das Fraunhofer LBF mit
Schwingfestigkeitsversuche an bauteilähnlichen
Tellerproben mit der Materialpaarung
Stahl-Aluminium.
Der Einsatz bauteilähnlicher Tellerproben
liefert praxisnahe Erkenntnisse über die
Schwingfestigkeitseigenschaften von Strukturbauteilen,
die sich in dieser Art nicht an den
üblichen einfach überlappenden Standardproben
ermitteln lassen. Die Versuche zur
Schwingfestigkeit dienen als Grundlage zur
Validierung von numerischen Methoden zur
Abschätzung der Lebensdauer und ermöglichen
Einblicke in real auftretende Schädigungsmechanismen.
Erste Einblicke in die
komplexe Welt der Schwingfestigkeit von
Sponsors and partners
Six leading European carmakers (Daimler,
Volkswagen, Fiat-Chrysler Research Centre,
Volvo, Opel, and Toyota) have joined forces
to form the Alliance consortium (Affordable
Lightweight Automobiles Alliance) together
with the four suppliers Thyssenkrupp, Novelis,
Batz, Benteler and eight knowledge
partners (Swerea, Inspire, Fraunhofer LBF,
RWTH-Ika, Kit-Ipek, University of Florence,
Bax & Company, and Ricardo). The Alliance
initiative is endorsed by EUCAR (European
Council for Automotive R&D) and EARPA
(European Automotive Research Partners Association).
It is supported by European Union
Horizon 2020.
Fatigue strength of hybrid joined steelaluminium
structures: Fraunhofer LBF identifies
high potential for lightweight design
Increasingly stringent statutory emission
limits are pushing the automotive industry
toward innovative lightweight design
solutions. In this context, the fatigue
strength of thin sheet metal structures,
especially made from multi-material, is
becoming increasingly important. As part
of the EU-funded research project ‘Alliance’
on the topic of lightweight design
and CO 2 reduction, the car manufacturer
Opel, together with the Fraunhofer Institute
for Structural Durability and System
Reliability LBF and the SAM department
of the Technical University of Darmstadt,
has developed innovative numerical
fatigue strength assessment approaches
for multi-material joints based on fatigue
tests of hybrid joined shear and peel
specimens. The method was validated by
Fraunhofer LBF scientists with fatigue
tests on component-like bowl specimens
with the material pairing steel-aluminium.
Increasingly stringent statutory emission limits
are pushing the automotive industry toward
innovative lightweight design solutions. In
this context, the fatigue strength of thin sheet
metal structures, especially made from multimaterial,
is becoming increasingly important.
As part of the EU-funded research project
‘Alliance’ on the topic of lightweight design
Bauteilähnliche Napfprobe CAD- und CAE-Modell
Component-like bowl specimen CAD and CAE model
and CO 2 reduction, the car manufacturer
Opel Automobile GmbH, together with the
Fraunhofer Institute for Structural Durability
and System Reliability LBF and the System
Reliability, Adaptive Structures, and Machine
Acoustics department of the Technical University
of Darmstadt, has developed innovative
numerical fatigue strength assessment
approaches for multi-material joints based
on fatigue tests of hybrid joined shear and
peel specimens. The method was validated by
Fraunhofer LBF scientists with fatigue tests
on component-like bowl specimens with the
material pairing Steel-Aluminium.
The use of component-like bowl specimens
provides practical insights into fatigue
properties of structural components, which
cannot be determined in this way on the usual
standard specimens with a simple overlap.
The fatigue tests serve as a basis for the validation
of numerical methods for fatigue life
estimation and provide insights into damage
mechanisms that occur in real life. The test
results from Fraunhofer LBF now offer first
insights into the complex world of the fatigue
strength of hybrid joined structural components.
“The potential of this joining process,
especially for future lightweight construction
concepts in the automotive industry, is very
promising. However, in order to fully exploit
it and use its full potential for industrial ap-
© Fraunhofer LBF
64 ALUMINIUM · 3/2021

R e s e a r c h
plication, it is imperative to further optimize
manufacturing processes,” emphasizes Dr
Jörg Baumgartner, who is in charge of the research
project at Fraunhofer LBF.
Fatigue properties – investigated
close to practical conditions
For the bowl specimen, a deep-drawn bowl is
connected to a firmly clamped flat base plate
in the area of the formed flange of the bowl.
The great advantage is that both forces and
moments can be introduced into the bowl in
any direction in the test setup and thus a defined
stress state (combination of shear and
peel stress) can be applied. Thus, this specimen
form enables the fatigue properties of structural
components to be investigated as closely
as possible to practical conditions but still
on a laboratory scale.
In order to determine the lightweight
potential of structural components in multimaterial
design, the researchers carried out
fatigue tests on bonded, riveted and hybrid
joined bowl specimens. The bonded bowl
specimens showed significantly higher fatigue
load capacities compared to the riveted ones.
Similar results were seen for the shear specimens.
However, unlike the shear specimens,
the hybrid joined bowl specimens exhibited
lower fatigue load capacities compared to the
bonded bowl specimens.
“We suspect that one of the possible reasons
for this behaviour is that the hybrid
manufacturing process has not yet been optimized,
resulting in improper bonding of
the components. This can also be seen in the
comparison between the different batches of
the hybrid joined bowl specimens,” explains
Baumgartner.
An additional fixing of the sheets during
rivet setting proved to be a helpful approach.
This reduced the amount of gap between the
two sheets during the bonding process and
thus increased the bonding quality and fatigue
strength.
Dr Boris Künkler, manager CAE Methods,
Expertise and Support at Opel in Rüsselsheim,
Germany, also emphasizes the promising results
of the Alliance project: “One of the objectives
of the Alliance project was the development
of an application-oriented simulation
method for the reliable fatigue assessment of
bonded and punch riveted sheet metal joints.
The results of the bowl specimen tests developed
and conducted at Fraunhofer LBF were
extremely helpful in validating the method
under combined loading conditions.” ■
hybrid gefügten Strukturteilen bieten nun die
Versuchsergebnisse aus dem Fraunhofer LBF.
„Das Potenzial dieses Fügeverfahrens, insbesondere
für zukünftige Leichtbaukonzepte
der Automobilindustrie, ist vielversprechend.
Um es voll ausschöpfen zu können und für
eine industrielle Anwendung zu nutzen, ist es
jedoch zwingend erforderlich, Fertigungsprozesse
weiter zu optimieren“, betont Dr. Jörg
Baumgartner, der das Forschungsprojekt am
Fraunhofer LBF betreut.
Schwingfestigkeitseigenschaften
praxisnah untersucht
Bei der Tellerprobe wird ein tiefgezogener
Napf im Bereich des umgeformten Flansches
mit einer fest eingespannten ebenen Grundplatte
verbunden. Der große Vorteil: Sowohl
Kräfte als auch Momente lassen sich im Versuchsaufbau
in beliebiger Richtung in den
Napf einleiten und so ein definierter Bean-
spruchungszustand als Kombination aus
Scherzug und Schälzug einstellen. Somit ermöglicht
diese Probenform, die Schwingfestigkeitseigenschaften
struktureller Bauteile
möglichst praxisnah und dennoch im Labormaßstab
untersuchen zu können.
Um das Leichtbaupotenzial von Strukturbauteilen
in Multi-Material-Bauweise zu ermitteln,
führte das LBF-Team Schwingfestigkeitsversuche
an geklebten, genieteten und
hybrid gefügten Tellerproben durch. Dabei
zeigten die geklebten Tellerproben deutlich
höhere zyklische Beanspruchbarkeiten
gegenüber den genieteten Tellerproben. Ähnliches
war bei den Versuchsergebnissen der
Scherzugproben zu sehen. Die hybriden Tellerproben
zeigen jedoch, anders als bei den
Scherzugproben, geringere zyklische Beanspruchbarkeiten
gegenüber den geklebten
Tellerproben.
„Einen der möglichen Gründe für dieses
Verhalten vermuten wir in dem noch nicht
optimierten hybriden Fertigungsprozess, wodurch
eine unsachgemäße Verklebung beider
Fügepartner resultiert. Dies lässt sich ebenfalls
im Vergleich zwischen den untersuchten unterschiedlichen
Chargen der hybriden Tellerproben
erkennen“, erklärt Baumgartner.
Als hilfreicher Ansatz zeigte sich eine zusätzliche
Fixierung der Bleche beim Setzen
der Niete. Hierdurch konnte das Aufklaffen
der beiden Bleche während des Fügeprozesses
reduziert und somit eine Erhöhung der
Fügequalität und Steigerung der Schwingfestigkeit
erzielt werden.
Die vielversprechenden Ergebnisse des
Alliance-Projekts betont auch Dr.-Ing. Boris
Künkler, Manager CAE Methods, Expertise
and Support bei Opel in Rüsselsheim: „Eines
der Ziele im Projekt Alliance war die Ent-
Beispielhafte Darstellung eines Steifigkeitsverlaufs in Korrelation mit thermoelastischer Spannungsanalyse
Exemplary representation of a stiffness curve in correlation with thermoelastic stress analysis
wicklung einer anwendungsorientierten Simulationsmethode
zur zuverlässigen Betriebsfestigkeitsbewertung
geklebter und stanzgenieteter
Blechverbindungen. Dabei waren
die Testergebnisse der am Fraunhofer LBF
entwickelten und geprüften Tellerproben zur
Validierung der Methode bei kombinierten
Belastungszuständen extrem hilfreich.“ ■
Für Neugierige
www.alu-web.de
Tagesaktuelle News
ALUMINIUM · 3/2021 65

C o m p a n y N e w s w o r l d w i d e
Aluminium smelting industry
integration of fluctuating electricity volumes
from wind and solar power plants. The carbon
dioxide emissions generated during electricity
production largely determine the carbon
footprint of primary aluminium.
Currently, about half of the electricity used
for aluminium production in Germany comes
from renewable energy sources, Trimet points
out. This share should increase even further.
With that in mind, the company views with
concern progressively emerging hurdles to
the further expansion of onshore and offshore
wind power generation.
■
Bauxite and
alumina activities
© EGA
EGA completes refurbishment
of Al Taweelah Potline 3
Emirates Global Aluminium has completed a
major periodic refurbishment of its Potline 3 at
Al Taweelah, one of the longest and most productive
potlines in the world. The reduction
cells in which aluminium is smelted require relining
after several years of production. During
the refurbishment of the 444 reduction cells in
Line 3, EGA installed steel collector bars with
copper inserts, designed within the company
to improve performance. Reduction cells elsewhere
across EGA’s sites at Al Taweelah and
Jebel Ali are also being upgraded as part of
their potlines’ ongoing re-lining processes.
Copper is highly conductive of electricity.
Its use in the collector bars reduces power
consumption and GHG emissions, and enables
increased productivity as the reduction
cells can be run at a higher amperage. As extra
voltage becomes available in the power-supply
system, this will also open opportunities
to install additional pots in the same circuit.
Rio Tinto reaches power
agreement for Isal smelter
Rio Tinto has reached agreement on an
amended power contract that will allow the
Isal aluminium smelter in Iceland to continue
operating with an improved competitive
position. The agreement with power supplier
Landsvirkjun will deliver a more competitive
power price and energy flexibility that is
mutually beneficial for both Isal and Landsvirkjun.
Rio Tinto Aluminium CEO Alf Barrios
said: “This provides a stronger footing to continue
operations at the smelter and gives increased
security for the team at Isal. We will
continue to work to strengthen Isal’s future in
order to keep supplying low-carbon aluminium
to customers in Europe and North America,
and making a significant contribution to
Iceland’s economy.”
In parallel to the new agreement, Rio Tinto
has decided to withdraw a complaint filed
with the Icelandic Competition Authority in
July 2020 regarding the energy supply for
Isal. The smelter is wholly-owned by Rio Tinto
and employs around 500 workers on site.
Trimet favours rapid expansion
of renewable energy
Trimet Aluminium SE in Essen, Germany, is
committed to the rapid and increased expansion
of power generation from renewable energy
sources. The company says Germany will
only remain competitive and viable as an industrial
location with products manufactured
in a climate-friendly manner. This is why, as
a supplier of basic materials, Trimet supports
the energy transition and provides solutions
to key energy supply challenges through innovative
processes.
The mechanical shutdown capability of
the Trimet production plants and the flexibilization
of the electrolysis process contribute
to the stability of the electricity grid and the
GMR recovers bauxite residues
at Vaudreuil Alumina site
The Global Mineral Recovery Company
(GMR) has published the commissioning of
its commercial demonstration plant for the
recovery of bauxite residues on the site of
Rio Tinto’s Vaudreuil Alumina plant. The
On the move
Under a new organizational structure, Rio
Tinto will retain four product groups – Aluminium,
Copper, Iron Ore, and Minerals. The
new leadership team, effective by 1 March,
includes Ivan Vella, who will become Rio
Tinto Aluminium’s CEO, succeeds Alf Barrios,
who will become chief commercial officer.
Hong Kong Exchanges & Clearing Ltd
(HKEX) has appointed Alejandro Nicolas
Aguzin as its new CEO, effective 24 May
2021.
Century Aluminum has named Gunnar
Gudlaugsson as executive VP, Global Operations.
John Hoerner, Century’s executive VP,
North American Operations, will retire.
On 1 October 2020, Gerold Keune joined
Hertwich Engineering, based in Braunau,
Austria, as the new managing director and
head of sales.
Helena Nonka has been appointed executive
VP for Corporate Development in Hydro.
She will start the new position in April,
replacing Arvid Moss, who has been acting
in this newly established role since mid-2019.
Mrs Genoveva Nastase was reappointed
as financial manager of Alro for a four-yearsmandate.
66 ALUMINIUM · 3/2021

c o m p a n y n e w s w o r l d w i d e
USD9m project was initiated in 2017. GMR
has designed a pyrometallurgical technology
to treat and recover the bauxite residues from
the production of alumina. This process transforms
and extracts specific compounds from
the residue, making it useful in certain building
material applications.
GMR will also transform and market the
substantial portion of the ‘red’ iron oxide
mined from the bauxite residue. Ultimately,
GMR intends to succeed in extracting several
metal oxides that can be used in many industrial
applications. The objective of the project
is to set up the first and only factory of its kind
to process this material on an industrial scale
in Saguenay-Lac-Saint-Jean and then across
Canada. On an industrial scale, this process
will help reduce the accumulation of bauxite
residues on the Usine Vaudreuil site, and it
could create around 100 jobs in the region.
The Quebec government has granted a
USD2m loan to GMR to support the development
phases of this project, which should
generate interesting economic spinoffs in
Quebec.
■
Secondary smelting
and recycling
Novelis to expand
automotive capabilities and
recycling operations in China
Novelis signed a Memorandum of Understanding
(MoU) in February with the Zhenjiang
Jingkou Industrial Zone in Jiangsu Province,
to invest around USD300m to expand
its automotive aluminium capabilities and recycling
operations at its Zhenjiang plant. The
investment will include expanding its hot mill,
adding a cold mill, and establishing the first
automotive closed-loop recycling system in
the country. The project is expected to break
ground towards the middle of 2021 and upon
completion will create a fully integrated supply
chain for its automotive customers, from
coil production to heat treatment to recycling.
This commitment extends Novelis’ strong
position in China,.
The Asian automotive market is forecast
to grow to one-third of global auto demand
by 2025. By integrating complementary regional
assets, including recycling, casting, rolling
and finishing capabilities, Novelis will be
able to more efficiently deliver lightweight
aluminium products to meet increased customer
demand in Asia.
The investment in building a closed-loop
recycling system for aluminium recycling will
greatly reduce emissions of carbon dioxide,
contributing to China’s national energy conservation
and emission reduction. ■
Downstream activities
Novelis launches new aluminium
alloy for automakers
Novelis Inc. has unveiled its strongest automotive
aluminium product to date – Advanz
7UHS-s701. The 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
cars that require high in-service strengths
such as A and B pillar reinforcements and side
impact door beams. Commercial and electric
vehicles will also benefit from using this material,
as it offers mass reduction to enable
increased payload and longer battery range,
while still meeting all crash, loading and overall
design requirements.
“The s701 technology represents the future
of high-strength material in automotive
applications and offers a clear alternative to
the most advanced high-strength steel products,”
said Philippe Meyer, chief technician at
Novelis. “Aluminium is already the material
of choice for lightweighting, and now we are
offering a solution that helps automakers design
even safer, lighter and better performing
vehicles.”
Novelis will leverage its knowledge and
expertise in the aerospace industry to manufacture
7UHS-s701. To enable rapid adoption
of this advanced alloy, Novelis Customer Solution
Centre (CSC) network has expertise to
engage with automotive engineers on how to
best incorporate this material on new development
projects. The CSC teams have invested
considerable time and resources to demonstrate
the material’s capabilities, as well as the
value it delivers while addressing any potential
implementation questions from OEMs.
Advanz 7UHS-s701 allows downgauging
in applications which already use aluminium
and offers further lightweighting possibilities.
The material’s targeted use in age-hardened
tempers means it does not age, giving it an indefinite
shelf life and providing automakers
significant supply chain flexibility.
Critically important to automotive designers
and engineers, the alloy is compatible with
hot stamping processes. In fact, Novelis is actively
working with hot stampers and technology
partners, such as Telos Global, to further
facilitate rapid aluminium adoption. Telos
specializes in conception, design, training and
manufacturing associated with high-quality
press hardened steel and aluminium stampings,
tooling, and related thermal and production
equipment.
“We have been co-developing targeted
hot formed application solutions using Advanz
7UHS-s701 for some time now, delivering
greater economic value through increased
levels of mass reduction while meeting critical
safety requirements,” said Rick Teague, CEO
of Telos Global. “Launching this product into
the market will now give automakers even
more flexibility to engineer highly efficient,
multi-material structures.”
➝
© Assan
ALUMINIUM · 3/2021 67

C o m p a n y N e w s w o r l d w i d e
The 7UHS-s701 material allows scrap collected
from the manufacturing process to be
fed into a closed loop recycling system for
reforming into the same products from which
it was derived. As a result, Novelis and its customers
maximize product value while minimizing
environmental impact through reduced
CO 2 emissions and transport costs.
Showa Denko sells aluminium
business to Apollo
Japan’s Showa Denko KK has signed a definite
agreement to sell its aluminium rolling
and can businesses to US investment fund
Apollo Global Management. Showa Denko’s
aluminium can business has provided highquality
aluminium cans for beverages through
an integrated process including the moulding
of can bodies and lids to printing. Showa Aluminium
Can, which is a consolidated subsidiary
of Showa Denko, started to manufacture
aluminium beverage cans in 1971, becoming
the first company in Japan to do so.
In 2014, the company acquired shares of
Hanacans Joint Stock Co. in Vietnam, and has
been developing its business in the rapidly
growing Vietnamese aluminium can market.
Against this background Showa completed its
third manufacturing facility in Vietnam in July
2020. In the domestic aluminium can market,
the business environment is challenging and
will be so in the future as non-alcoholic beverage
cans have increasingly been replaced
with PET bottles. In order to respond to such
changes in the domestic market, the company
has been working to strengthen its domestic
business base, including by optimizing production
capacity at its domestic production
bases in June 2020.
As regards the aluminium rolling business,
Showa Denko produces high-purity aluminium
foil for electrolytic capacitors and aluminium
plates that are used for building materials
as well as cap and printed base materials.
The company has the number one position in
the global market for aluminium electrolytic
capacitor foil.
As a result of its restructuring process,
Showa Denko has reached the conclusion that
the expansion of the aluminium can and rolling
businesses would be best achieved through
partners that have specialized knowledge
and management resources to enable future
growth in these businesses.
Apollo Global Management has a wealth
of experience supporting aluminium-related
industries for more than 20 years. The deal
marks the first private equity investment in
Japan for Apollo after the firm opened its
dedicated office there last year to facilitate
more investment in the region. Apollo comments
that the transaction with Showa Denko
“presents an opportunity to invest in highquality
assets with multi-pronged growth opportunities
in Japan as well as in the broader
Asia market.”
Subject to satisfaction of customary closing
conditions and regulatory approvals, the
transaction is expected to be completed by
August 2021.
Hell Energy starts aluminium
can production with Hydro Circal
Can production at Hell Energy’s subsidiary in
Hungary, Quality Pack, has begun with Hydro
Circal aluminium strip which contains a high
ratio of post-consumer recycled aluminium
from cans. Since the beginning of the year, 400
tonnes of Circal have already been delivered.
The first cans produced with this material and
filled with Hell Energy beverages will be available
in stores in mid-February.
The strip supplied by Hydro Rolling for the
production of can bodies is made of Circal
75R, which is certified to contain at least 75%
aluminium scrap from used beverage cans.
This significantly reduces energy consumption
in the production phase and is a big step forward
towards closing the loop in can production
and recycling while maintaining the same
product quality.
In July 2020, Hydro Rolling agreed on a
partnership with Hell Energy Group to use recycled
materials in beverage can production.
The declared aim of the energy and soft drinks
manufacturer is to offer the “greenest beverage
can in the world,” as the management said
at the signing of the contract.
Ball to build new aluminium
can plant in Pilsen
Packaging manufacturer Ball Corp. plans to
begin the construction of a new production
facility near Pilsen in the spring of this year.
The development, in the West of Czech Republic,
would expand the company’s output in
the region to meet the growing demand from
consumers who want sustainable and recyclable
beverage packaging. The facility will employ
up to 200 people and launch operations
in October 2022.
“In the Pilsen region we know we can find
a skilled workforce close to our key customers,
who will continue to benefit from our cut-
ting-edge production processes, our commitment
to the environment and a high-quality
and sustainable beverage package,” said Carey
Causey, president of Ball Beverage Packaging
for the region. He pointed out that the
€170m plant is part of a broader strategy for
increased investment in the wider EMEA
(Europe, Middle East & Africa) region.
The new factory with its two production
lines is planned to occupy a site of more
than 100,000 m 2 in the Pilsen Digital Park,
enabling further expansion when required. Its
construction is to be divided into two phases.
The first would create around 150 new jobs
and the second, raise the total to some 200
professional jobs in engineering and support
roles. “We plan to install sophisticated automated
equipment at the facility, leveraging
the latest modern technologies to minimize
environmental impacts, and strengthened by
our recent commitment to 100% renewable
energy to cover our operations in Europe,”
said Gerhard Mayer, VP, Operations, Ball
Beverage Packaging EMEA.
Only recently the company announced that
it would build a new aluminium end manufacturing
facility in Bowling Green, Kentucky,
USA. This facility is scheduled to begin production
early in 2022 and to expand over multiple
years to create about 200 manufacturing
jobs.
Crown Holdings to build new
aluminium can plant in Virginia
Crown Holdings, Inc. says that it will build a
beverage can manufacturing facility in Henry
County, Virginia, USA. This will represent
the company’s third greenfield beverage can
manufacturing investment in North America
over the last five years. This new plant will
supply beverage cans to customers that serve
a variety of categories including sparkling
water, energy drinks, carbonated soft drinks,
teas, functional beverages, beer and cocktails.
The plant’s geographic location expands
Crown’s North American supply network to
address the growing market for standard and
specialty beverage cans.
“The Henry County plant will give Crown
a stronger position in the specialty can market,
while allowing Crown to better serve the
needs of customers and consumers for more
sustainable packaging,” says Timothy J. Donahue,
president and CEO. The 355,000 square
foot facility is expected to begin operations
in the second quarter of 2022 and will create
126 new jobs. ■
68 ALUMINIUM · 3/2021

c o m p a n y n e w s w o r l d w i d e
Suppliers
The shutdown process will include consultation
with employee representatives and
unions, as well as key external stakeholders
such as environmental authorities and landowner
regarding the site remediation process.
The plant is currently expected to close toward
the end of 2021 and follows a thorough strategic
review to explore alternatives to closing
Aluchemie, says Hydro.
© Danieli
DanJoint slipper spindle
on the way to Hindalco
Hindalco Industries Ltd has selected Danieli
Service DanJoint heavy-duty spares for its
plate mill for aluminium rolled products at
Hirakud, Odisha, India. With a length of 12
metres and a weight of 30 tonnes, the giant
slipper-type spindle will bring new power to
the 144” heavy-duty hot rolling unit.
The spindle was manufactured at Danieli
HQ workshops in Italy in a record time of just
four months, matching the challenging customer
requirement. Hindalco chose Danieli
also for the recognized manufacturing quality
and ability to process heavy-duty equipment
and in-house heat treatment.
The shrink-fitting process of the spindle
heads was executed in vertical position in
manufacturing area dedicated for such largescale
products. Currently the new spindle is
on the way to India where it will be installed
by the Hindalco maintenance team with assistance
from Danieli Service India.
Stas delivers its 200 th
rotary fluxing injector
Stas Inc. has announced the production of its
200 th rotary flux injector (RFI) unit to a European
customer. The latter will use this simple,
yet innovative and reliable ‘fluxing’ technology
to remove different impurities in one of
their aluminium furnaces before the metal
is cast. This delivery further establishes Stas’
leadership and expertise in this segment of
aluminium production – metal treatment.
In order to meet different kinds of quality
requirements, dissolved alkalis like sodium
and calcium, non-metallic inclusions and
hydrogen need to be removed from liquid
aluminium. Whereas furnace fluxing is still
used either by spreading solid flux manually
on the metal surface or using fluxing lances
(chlorine), Stas’ RFI uses salt mixtures to significantly
improve the efficiency of the fluxing
process while guaranteeing the security of
operators in the casthouse.
The main element of the Stas RFI is the
spinning nozzle, through which a carrier gas
(nitrogen) delivers the fluxing agent (solid
salts) underneath the metal surface. The liquefied
fluxing agent is dispersed through the
combined actions of the disperser and the injection
of the carrier gas. Multiple configurations,
shapes and designs have been realized
over the past 25 years in order to match the
different types of furnaces in place around the
world. Not only does the RFI eliminate the
use of chlorine, it improves metal cleanliness
and reduces dross generation, all of which are
major concerns for small, medium and large
aluminium producers. The technology has
never ceased to improve in three decades.
Rio Tinto and Hydro plan to
close Aluchemie anode plant
Owners Rio Tinto and Hydro have come to
the joint decision of starting a consultation
process to permanently close Dutch anode
producer Aluchemie, as the highly competitive
market situation and significant reinvestment
needs in the facility make continued operations
unviable. Aluchemie is a stand-alone anode
producer located near Rotterdam in the
Netherlands, with 220 employees and owned
by Rio Tinto Alcan (53%) and Hydro (47%).
Aluchemie was opened in 1966 and has
a production capacity of more than 500,000
tpy, but annual production has been reduced
to 215,000 tonnes as four of its seven anode
baking furnaces have already been permanently
closed.
New slitting line for
can stock production
A leading aluminium producers and Salico
have signed an agreement for the supply of a
new slitting line to be installed in one of its
rolling plants in America. The line is primarily
intended for tab stock, but it will also be prepared
to run thinner and fully annealed strip,
down to 0.15 mm.
For proper thin gauge handling and processing,
the line will be equipped with specific
technical solutions such as vacuum roll and
tensioning bridle rolls. A particular focus on
operator friendly interface results in hands
free slitter tooling exchange, automatic separator
discs positioning and vacuum transfer of
scrap to a remote baller.
Equipment engineering and manufacture
will take most of 2021, leaving installation
and commissioning for first half of 2022.
First Stas-made ingot
casting stacking machine
Two years ago, Stas Inc. enlarged its portfolio
of products by acquiring ingot and sow casting
technologies from the Australian company
o.d.t. engineering, which had produced
and delivered many units over the last couple
decades, mostly in Asia Pacific. Since then,
Stas implemented a series of technological
upgrades, and was also successful in obtaining
European certification standards, meeting
all legal requirements for CE marking. This
project marks an important milestone for Stas
and for the end user, who can cast top quality
remelt ingots (secondary aluminium casting
alloys) to be sold to European customers,
mostly to the automotive industry. Stas is currently
discussing a number of projects with
aluminium producers all over the world.
Author
The author, Dipl.-Ing. R. P. Pawlek is founder of
TS+C, Technical Info Services and Consulting,
Sierre (Switzerland).
ALUMINIUM · 3/2021 69

LIEFERVERZEICHNIS
1 Smelting
technology
Hüttentechnik
Q Rubrikenverzeichnis siehe
letzte Seite
1.2 Storage facilities for
smelting
Lagermöglichkeiten i.d. Hütte
Reel Möller GmbH
Haderslebener Straße 7
D-25421 Pinneberg
Telefon: 04101 788-0
Telefax: 04101 788-115
E-Mail: info@reel-moeller.com
Internet: www.reel-moeller.com
Kontakt: Herr Steffen Pein, Director Sales
• Conveying systems bulk materials
Förderanlagen für Schüttgüter
(Hüttenaluminiumherstellung)
Reel Möller GmbH
Internet: www.reel-moeller.com
see Storage facilities for smelting 1.2
• Unloading/Loading equipment
Entlade-/Beladeeinrichtungen
Reel Möller GmbH
Internet: www.reel-moeller.com
see Storage facilities for smelting 1.2
1.3 Anode production
Anodenherstellung
B&P Littleford, LLC.
Phone: +1 989 757 1300
E-Mail: sales@bplittleford.com
Internet: www.bplittleford.com
Solios Carbone – France
www.fivesgroup.com
Storvik AS
Industriveien 13
6600 SUNNDALSØRA/NORWAY
Tel.: +47 71 69 95 00 | Fax: +47 71 69 95 55
www.storvik.no | storvik@storvik.no
• Anode Technology &
Mixing Equipment
Buss ChemTech AG, Switzerland
Phone: +4161 825 64 62
E-Mail: info@buss-ct.com
Internet: www.buss-ct.com
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: d.ross@giesel.de
• Auto firing systems
Automatische Feuerungssysteme
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 395, Fax: -5218 231
E-Mail: thomas.janousch@riedhammer.de
Internet: www.riedhammer.de
Sie möchten einen
Eintrag schalten?
Rufen Sie an:
Tel. 0821 319880-34
• Mixing Technology for
Anode pastes
Mischtechnologie für Anodenmassen
Buss AG
CH-4133 Pratteln
Phone: +41 61 825 66 00
E-Mail: info@busscorp.com
Internet: www.busscorp.com
1.4. Anode rodding
Anodenschlägerei
1.4.1 Anode baking
Anodenbrennen
see 1.6 Sawing
• Open top and closed
type baking furnaces
Offene und geschlossene Ringöfen
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 395, Fax: -5218 231
E-Mail: thomas.janousch@riedhammer.de
Internet: www.riedhammer.de
Ihr Eintrag unter
www.alu-web.de
1.5 Casthouse
Formategießerei
Furnaces
casting machines
transport crucibles
info@bartz-maschinenbau.de
www.bartz-maschinenbau.de
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstraße 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com
see Anode production 1.3
see Casting equipment 3.1
70 ALUMINIUM · 3/2021

SUPPLIERS DIRECTORY
• Degassing, filtration and
grain refinement
Entgasung, Filtern, Kornfeinung
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
• Ingot Casting Line
Bartz GmbH
see Casthous (foundry) 1.5
• Melting/holding/casting furnaces
Schmelz-/Halte- und Gießöfen
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• Transfer to the casting furnace
Überführung in Gießofen
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
• Transport of liquid metal
to the casthouse
Transport v. Flüssigmetall in Gießereien
Bartz GmbH
see Casthous (foundry) 1.5
1.6 Casting machines
Gießmaschinen
GAPCast
TM : the Swiss casting solution
see Casting machines and equipment 4.7
• Pig casting machines (sow casters)
Masselgießmaschine (Sowcaster)
Bartz GmbH
see Casthouse (foundry) 1.5
• Rolling and extrusion ingot
and T-bars
Formatgießerei (Walzbarren oder
Pressbolzen oder T-Barren)
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• Sawing / Sägen
BONETTI CUTTING EXPERTS
+39 037457203
sales@bonettigroup.eu
WWW.CUTTINGEXPERTS.NET
Otto Junker GmbH
Jägerhausstr. 22, 52152 Simmerath
Telefon +49 (2473) 601-0
E-Mail: sales@otto-junker.com
Internet: www.otto-junker.com
Sie möchten einen
Eintrag schalten?
Rufen Sie an:
Tel. 0821 319880-34
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
Sistem Teknik Endüstryel Firinlar LTD. STI.
TOSB – TAYSAD OSB 1.Cad. 14.Sok. No.: 3
Gebze, Kocaeli / Turkey
Tel.: +90 262 658 22 26
Fax: +90 262 658 22 38
E-Mail: info@sistemteknik.com
Internet: www.sistemteknik.com
Solios Thermal UK
www.fivesgroup.com
Otto Junker GmbH
Jägerhausstr. 22, 52152 Simmerath
Telefon +49 (2473) 601-0
E-Mail: sales@otto-junker.com
Internet: www.otto-junker.com
• Heat treatment of extrusion
ingot (homogenisation)
Formatebehandlung (homogenisieren)
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• Horizontal continuous casting
Horizontales Stranggießen
Offer specifically
and be found –
with your entry in the suppliers
directory.
Call us and order your entry:
Tel.: +49 (0) 821 319880-33
• Scales / Waagen
www.alu-web.de
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
ALUMINIUM · 3/2021 71

LIEFERVERZEICHNIS
• Vertical semi-continuous DC
casting / Vertikales Stranggießen
Wagstaff, Inc.
3910 N. Flora Rd.
Spokane, WA 99216 USA
+1 509 922 1404 phone
+1 509 924 0241 fax
E-Mail: info@wagstaff.com
Internet: www.wagstaff.com
1.12 Cathode repair shop
Kathodenreparaturwerkstatt
see Anode production 1.3
1.15 Storage and transport
Lager und Transport
2 Extrusion
Strangpressen
1.8 Electrolysis cell (pot)
Elektrolyseofen
• Calcium silicate boards
Calciumsilikatplatten
see Coil transport systems 3.4
Q Rubrikenverzeichnis siehe
letzte Seite
Etex Building Performance GmbH
Scheifenkamp 16, D-40878 Ratingen
Tel: +49 (0)2102 493-0 / Fax: -115
industry.verkauf@promat.de
www.promat-industry.de
• Exhaust gas treatment
Abgasbehandlung
Solios Environnement
www.fivesgroup.com
• Pot feeding systems
Beschickungseinrichtungen
für Elektrolysezellen
Reel Möller GmbH
Internet: www.reel-moeller.com
see Storage facilities for smelting 1.2
see Coil transport systems 3.4
SMS group GmbH
see Rolling mill technology 3.0
1.16 Refractory Products
Feuerfestprodukte
Chemikalien-Gesellschaft
Hans Lungmuß mbH & Co. KG
Franziusstr. 84
D-44147 Dortmund
Tel.: +49 (0) 231 982333-0
Fax: +49 (0) 231 982333-82
E-Mail: info@lungmuss.de
Internet: www.lungmuss.de
2.1 Billet preparation
Bolzenbereitstellung
extrutec GmbH
Feldstr. 25
D-78345 Moos
Tel. +49 7732 939 1390
Fax +49 7732 939 1399
E-Mail: info@extrutec-gmbh.de
Internet: www.extrutec-gmbh.de
• Billet heating furnaces
Öfen zur Bolzenerwärmung
1.9 Potroom
Elektrolysehalle
see Anode production 1.3
Refratechnik Steel GmbH
Schiessstrasse 58
40549 Düsseldorf / Germany
Phone +49 211 5858 0
E-Mail: aluminium@refra.com
Internet: www.refra.com
1.17 Protective Clothing
Schutzkleidung
IAS GmbH
Am Großen Teich 27
58640 Iserlohn
Tel. +49 2371 43460
Fax +49 2371 434643
E-Mail: info@ias-induction.com
Internet: www.ias-induction.com
see melting-, holding, and casting furnaces 1.5
• Crustbreakers / Krustenbrecher
• Dry absorption units for
electrolysis exhaust gases
Trockenabsorptionsanlage für
Elektrolyseofenabgase
Solios Environnement
www.fivesgroup.com
YOUR LAST LINE OF DEFENCE
www.charnaud.net
Specialised PPC & E
for all Aluminium and
Electrical sectors
SA: +27 11 794 6040
sales@charnaud.co.za
UK: +44 1133 507 561
sales@charnaud.eu
see 3.6 Heating furnaces
see Casthouse (foundry) 1.5
72 ALUMINIUM · 3/2021

SUPPLIERS DIRECTORY
• Cutting and handling of
extrusion logs
Schneiden und Handling von
Profilstangen
see 1.6 Sawing
2.2 Extrusion equipment
Strangpresseinrichtungen
• Press control systems
Pressensteuersysteme
Oilgear Towler GmbH
see Extrusion Equipment 2.2
2.3 Section handling
Profilhandling
see Coil transport systems 3.4
schwartz GmbH
Edisonstraße 5
D-52152 Simmerath
Telefon: +49 2473 94 88-10
Telefax: +49 2473 94 88-11
E-Mail: info@schwartz-wba.de
Internet: www.schwartz-wba.com
• Ageing- and Annealing
furnaces for extrusions
Auslagerungs- und Glühöfen für
Strangpressprofile
COMETAL ENGINEERING SPA
Via Mario Calderara, 10
25018 Montichiari, Brescia, Italy
E-Mail: info@cometaleng.com
Extrusion Equipment and Casthouse
see Extrusion equipment 2.2
see Extrusion billet preparation 2.1
Danieli & C Officine Meccaniche S.p.A.
Danieli Breda - Extrusion technology
since 1950
Via Galileo Galilei, 40
20092 Cinisello Balsamo (MI), Italy
Phone +39 0432.1958111
Mail: info.db@danieli.com
Oilgear Towler GmbH
Im Gotthelf 8
D 65795 Hattersheim
Tel. +49 (0) 6145 3770
Fax +49 (0) 6145 30770
E-Mail: info@oilgear.de
Internet: www.oilgear.de
SMS group GmbH
see Rolling mill technology 3.0
see Coil transport systems 3.4
• Packaging equipment
Verpackungseinrichtungen
see Coil transport systems 3.4
Riezenweg 9b
NL-7071 PV Ulft Netherlands
Tel.: +31 315 641352
E-Mail: info@unifour.nl
Internet: www.unifour.nl
Sales Contact: Mr. Jeroen Heerink
• Heat treatment furnaces
Wärmebehandlungsöfen
see 3.6 Heating furnaces
• Heating and control
equipment for intelligent
billet containers
Heizungs- und Kontrollausrüstung
für intelligente Blockaufnehmer
2.4 Heat treatment
Wärmebehandlung
• Homogenising furnaces
Homogenisieröfen
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
MARX GmbH & Co. KG
www.marx-gmbh.de
see Melting furnaces 4.13
BSN Thermprozesstechnik GmbH
Kammerbruchstraße 64
D-52152 Simmerath
Tel. 02473-9277-0 · Fax: 02473-9277-111
info@bsn-therm.de · www.bsn-therm.de
Ofenanlagen zum Wärmebehandeln von Aluminiumlegierungen,
Buntmetallen und Stählen
see 3.6 Heating furnaces
see Casthouse (foundry) 1.5
ALUMINIUM · 3/2021 73

LIEFERVERZEICHNIS
• Heat treatment furnaces
Wärmebehandlungsöfen
• Inductive heating
Induktive Erwärmung
see 3.6 Heating furnaces
2.11 Equipment and
accessories
Ausrüstungen und
Hilfsmittel
• Inductiv heating equipment
Induktiv beheizte
Erwärmungseinrichtungen
IAS GmbH
see 2.1 Billet heating furnaces
3 Rolling mill
technology
Walzwerktechnik
see Casthouse (foundry) 1.5
see Extrusion billet preparation 2.1
2.5 Profile cooling systems
Profilkühleinrichtungen
see Extrusion billet preparation 2.1
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 319880-34
Dennis Ross
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
• Die heating furnaces
Werkzeuganwärmöfen
see Extrusion billet preparation 2.1
Riezenweg 9b
NL-7071 PV Ulft Netherlands
Tel.: +31 315 641352
E-Mail: info@unifour.nl
Internet: www.unifour.nl
Sales Contact: Mr. Jeroen Heerink
• Ageing furnace for extrusions
Auslagerungsöfen für Strangpressprofile
see 3.6 Heating furnaces
2.12 Waste Water Plants &
Zero Liquid Discharge
Abwasserreinigungsanlagen
Compagnia Italiana Ecologia S.r.l.
Via 1° Maggio 20/22
20070 San Zenone al Lambro (MI) - Italia
Tel: +39.02.9810470 - Fax: +39.02.981075079
• Dienstleistungen
Services
see 3.6 Heating furnaces
2.13 Software systems
Software Systeme
A.t.i.e. Uno Informatica S.r.l.
Via Macon 30
23900 Lecco (LC) – Italy
Phone: +390341210444
Internet: www.unoi.it
Email: unoi@unoi.it
Q Rubrikenverzeichnis siehe
letzte Seite
3.0 Rolling mill technology
Walzwerktechnik
SMS group GmbH
Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
Telefon: +49 211 881-0
Telefax: +49 211 881-4902
communications@sms-group.com
www.sms-group.com
Geschäftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstraße 30
57271 Hilchenbach-Dahlbruch, Germany
Telefon: +49 2733 29-0
Telefax: +49 2733 29-2852
Bandanlagen
Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
Telefon: +49 211 881-5100
Telefax: +49 211 881-5200
Strangpressen, Ziehanlagen,
Barrenfräsen, Bandsägen,
Plattenstrecker
Ohlerkirchweg 66
41069 Mönchengladbach, Germany
Tel: +49 2161 350-1691
Fax: +49 2161 350-1778
Elektrik + Automation
Ivo-Beucker-Straße 43
40237 Düsseldorf, Germany
Telefon: +49 211 881-5895
Telefax: +49 211 881-775895
3.1 Casting equipment
Gießanlagen
• Electromagnetic Stirrer
Elektromagnetische Rührer
Solios Thermal UK
www.fivesgroup.com
74 ALUMINIUM · 3/2021

SUPPLIERS DIRECTORY
• Filling level indicators and controls
Füllstandsanzeiger und -regler
• Coil transport systems
Bundtransportsysteme
Wagstaff, Inc.
see Casting machines 1.6
An entry (b/w) in this format costs
82,50 per issue
For more information,
please contact:
Tel. +49 (0) 821 319880 – 33
• Melting and holding furnaces
Schmelz- und Warmhalteöfen
Bartz GmbH
see Casthous (foundry) 1.5
HOFMANN Wärmetechnik GmbH
Gewerbezeile 7
A-4202 Hellmonsödt
Tel. +43 7215 3601-22
Fax +43 7215 3601-60
E-Mail: ni@hofmann-waermetechnik.at
Internet: www.hofmann-waermetechnik.at
Solios Thermal UK
www.fivesgroup.com
• Bar heating furnaces
Barrenanwärmanlagen
see 3.6 Heating furnaces
EBNER Industrieofenbau GmbH
see Annealing furnaces 3.3
AMOVA GmbH
Obere Industriestraße 8
D-57250 Netphen
Tel. +49 2738 21-0, Fax -2222
info@amova.eu, www.amova.eu
Vollert Anlagenbau GmbH
Stadtseestraße 12, D-74189 Weinsberg
Tel. +49 7134 52 220 l Fax +49 7134 52 222
E-Mail intralogistik@vollert.de
Internet www.vollert.de
• Drive systems / Antriebe
SMS group GmbH
see Rolling mill technology 3.0
see melting-, holding, and casting furnaces 1.5
LOI Thermprocess GmbH
Am Lichtbogen 29, 45141 Essen, Germany
Telefon +49 (0) 201 / 18 91-1
E-Mail: loi@tenova.com
Internet: www.loi.tenova.com
Solios Thermal UK
www.fivesgroup.com
see 3.6 Heating furnaces
3.3 Heat treatment plants
Wärmebehandlungsanlagen
BSN Thermprozesstechnik GmbH
see Heat Treatment 2.4
• Homogenising furnaces
Homogenisieröfen
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
Solios Thermal UK
www.fivesgroup.com
see 3.6 Heating furnaces
3.4 Hot rolling equipment
Warmwalzanlagen
• Hot rolling units /
complete plants
Warmwalzanlagen/Komplettanlagen
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
SMS group GmbH
see Rolling mill technology 3.0
• Rolling mill modernisation
Walzwerksmodernisierung
• Annealing furnaces
Glühöfen
EBNER Industrieofenbau GmbH
Ebner-Platz 1, 4060 Leonding/Austria
Tel. +43 / 732 / 6868-0
E-Mail: sales@ebner.cc
Internet: www.ebner.cc
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
EBNER Industrieofenbau GmbH
see Annealing furnaces 3.3
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
SMS group GmbH
see Rolling mill technology 3.0
ALUMINIUM · 3/2021 75

LIEFERVERZEICHNIS
• Spools / Haspel
SMS group GmbH
see Rolling mill technology 3.0
Ein Eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
82,50 + MwSt.
Weitere Informationen unter
Tel. +49 (0) 821 319880- 0
• Cold rolling units /
complete plants
Kaltwalzanlagen/Komplettanlagen
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
SMS group GmbH
see Rolling mill technology 3.0
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
• Slitting lines-CTL
Längs- und Querteilanlagen
3.6 Cold rolling equipment
Kaltwalzanlagen
• Cutting and handling of
bundled plates
Schneiden und Handling von
Platten
Burghardt + Schmidt GmbH
Raiffeisenstr. 24, 75196 Remchingen
Tel.: +49 7232 3661-0
info@b-s-germany.de, www.b-s-germany.de
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
BSN Thermprozesstechnik GmbH
see Heat Treatment 2.4
• Coil annealing furnaces
Bundglühöfen
see 1.6 Sawing
• Drive systems / Antriebe
SMS group GmbH
see Rolling mill technology 3.0
www.danieli.com
• Strip shears/Bandscheren
see melting-, holding, and casting furnaces 1.5
• Heating furnaces
Anwärmöfen
Burghardt + Schmidt GmbH
see Strip Processing Lines
see 3.6 Heating furnaces
see Casting equipment 3.1
• Coil transport systems
Bundtransportsysteme
ul. Sobieskiego 8
66-200 Swiebodzin, POLAND
T: +48 68 38 20 500
E: INFO-POLAND@SECOWARWICK.COM
• Process simulation
Prozesssimulation
SMS group GmbH
see Rolling mill technology 3.0
• Trimming equipment
Besäumeinrichtungen
see Slitting lines-CTL 3.6
Burghardt + Schmidt GmbH
see Strip Processing Lines
see Coil transport systems 3.4
see Coil transport systems 3.4
• Roll exchange equipment
Walzenwechseleinrichtungen
SMS group GmbH
see Rolling mill technology 3.0
see Slitting lines-CTL 3.6
SMS group GmbH
see Rolling mill technology 3.0
76 ALUMINIUM · 3/2021

SUPPLIERS DIRECTORY
3.7 Thin strip /
foil rolling plant
Feinband-/Folienwalzwerke
3.9 Slitter and rewinder
for Aluminium foil
Rollenschneid- und Wickelmaschinen
für Alufolien
SMS group GmbH
see Rolling mill technology 3.0
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
• Strip thickness measurement
and control equipment
Banddickenmess- und
-regeleinrichtungen
• Coil annealing furnaces
Bundglühöfen
see melting-, holding, and casting furnaces 1.5
• Heating furnaces
Anwärmöfen
see 3.6 Heating furnaces
see Casting equipment 3.1
see 3.6 Heating furnaces
• Thin strip / foil rolling mills /
complete plant
Feinband- / Folienwalzwerke /
Komplettanlagen
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
SMS group GmbH
see Rolling mill technology 3.0
3.10 Process and
Automation technology
Prozess- und
Automatisierungstechnik
• Process control technology
Prozessleittechnik
SMS group GmbH
see Rolling mill technology 3.0
Wagstaff, Inc.
see Casting machines 1.6
• Roll Force Measurement equipment
Walzkraftmesseinrichtungen
ABB AB
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/rollforce
• Strip flatness measurement
and control equipment
Bandplanheitsmess- und
-regeleinrichtungen
ABB AB
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/stressometer
ABB AB
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/thicknessgauging
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SMS group GmbH
see Rolling mill technology 3.0
• Strip Tension
Measurement equipment
Bandzugmesseinrichtungen
ABB AB
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/striptension
• Strip Width & Position
Measurement equipment
Bandbreiten- und
Bandlaufmesseinrichtungen
www.alu-web.de
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
ABB AB
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/stripscanner
ALUMINIUM · 3/2021 77

LIEFERVERZEICHNIS
3.11 Coolant / lubricant
preparation
Kühl-/Schmiermittel-
Aufbereitung
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
• Coil & Colour Coating Lines
Bandlackierlinien
SMS group GmbH
see Rolling mill technology 3.0
see Slitting lines-CTL 3.6
• Filter for rolling oils and emulsions
Filter für Walzöle und Emulsionen
3.16 Coil storage systems
Bundlagersysteme
• Anodizing Lines
Anodisier-Linien
SMS group GmbH
see Rolling mill technology 3.0
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
see Coil transport systems 3.4
• Rolling oil recovery and
treatment units
Walzöl-Wiederaufbereitungsanlagen
SMS group GmbH
see Rolling mill technology 3.0
• Rolling oil rectification units
Walzölrektifikationsanlagen
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SMS group GmbH
see Rolling mill technology 3.0
3.12 Air extraction systems
Abluft-Systeme
• Rolling mill modernization
Walzwerkmodernisierung
Burghardt + Schmidt GmbH
see Strip Processing Lines
see Coil transport systems 3.4
3.17 Strip Processing lines
Bandprozesslinien
Burghardt + Schmidt GmbH
Raiffeisenstr. 24, 75196 Remchingen
Tel.: +49 7232 3661-0
info@b-s-germany.de, www.b-s-germany.de
see Slitting lines-CTL 3.6
Burghardt + Schmidt GmbH
see Strip Processing Lines
Member of
info@ungerer.com | www.ungerer.com
• Strip Annealing Lines
Bandglühlinien
EBNER Industrieofenbau GmbH
see Annealing furnaces 3.3
see melting-, holding, and casting furnaces 1.5
see 3.6 Heating furnaces
SMS group GmbH
see Rolling mill technology 3.0
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
Bilzerweg 8
3600 Genk
+32(0)89 61 15 46
www.decomecc.be
info@decomecc.be
3.18 Production
management systems
Produktionsmanagement-
Systeme
• Exhaust air purification
systems (active)
Abluft-Reinigungssysteme (aktiv)
SMS group GmbH
see Rolling mill technology 3.0
Strip Finishing Equipment
Member of
Ungerer Technology GmbH
Kandelstraße 20, D-75179 Pforzheim
T. +49 7231 942-0 | F. +49 7231 942-200
info@ungerer.com | www.ungerer.com
PSI Metals Non Ferrous GmbH
Software Excellence in Metals
Campus-Boulevard 57, D-52074 Aachen
Tel.: +49 241 927880-0
info@psimetals.de, www.psimetals.com
78 ALUMINIUM · 3/2021

SUPPLIERS DIRECTORY
3.19 Chemical specialties
for waste water plants
Chemische Zusätze
für Abwasserreinigungsanlagen
MST CHEMICALS
Milan - Tel: +39 02 9826 4351
info@mstchemicals.com
www.mstchemicals.com
Refratechnik Steel GmbH
Schiessstrasse 58
40549 Düsseldorf / Germany
Phone +49 211 5858 0
E-Mail: aluminium@refra.com
Internet: www.refra.com
4.3 Conveyor and storage
technology
Förder- und Lagertechnik
see Casting equipment 3.1
4.7 Casting machines
and equipment
Gießereimaschinen
und Gießeinrichtungen
4 Foundry
Gießerei
see Coil transport systems 3.4
see Coil transport systems 3.4
GAPCast
TM : the Swiss casting solution
Casting Technology / Automation
Tel.: +41 27 455 57 14
E-Mail: info@gap-engineering.ch
Internet: www.gap-engineering.ch
Wagstaff, Inc.
see Casting machines 1.6
Q Rubrikenverzeichnis siehe
letzte Seite
4.6 Foundry equipment
Gießereianlagen
see Extrusion Equipment 2.2.
see melting-, holding, and casting furnaces 1.5
• Mould parting agents
Kokillentrennmittel
Schröder
Schmierstofftechnik
GmbH & Co. KG
Postfach 1170
D-57251 Freudenberg
Tel. 02734/7071
Fax 02734/20784
www.schroeder-schmierstoffe.de
4.2 Heat-resistant
technology
Feuerfesttechnik
EREDI SCABINI S.r.l
ADVANCED REFRACTORY SOLUTIONS
Via Brallo, 2 - 27010 Siziano (PV) Italy
Phone +39 0382.66711
Fax +39 0382.6671492
Email info@erediscabini.com
www.erediscabini.com
Etex Building Performance GmbH
Scheifenkamp 16, D-40878 Ratingen
Tel: +49 (0)2102 493-0 / Fax: -115
industry.verkauf@promat.de
www.promat-industry.de
• Casting machines
Gießmaschinen
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• Heat treatment furnaces
Wärmebehandlungsöfen
see 3.6 Heating furnaces
see Casthouse (foundry) 1.5
Ein Eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
110,00 + MwSt.
Weitere Informationen unter
Tel. +49 (0) 821 319880- 0
4.10 Measurement technology
and materials testin
Messtechnik und
Materialprüfung
ratioTEC Prüfsysteme GmbH
In der Au 17
D-88515 Langenenslingen
Tel.: +49 (0)7376/9622-0
Fax: +49 (0)7376/9622-22
E-Mail: info@ratiotec.com
Internet: www.ratiotec.com
ALUMINIUM · 3/2021 79

LIEFERVERZEICHNIS
4.11 Metallic charge
materials
Metallische Einsatzstoffe
• Recycling / Recycling
Chr. Otto Pape GmbH
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
E-Mail: info@papemetals.com
4.12 Finishing of raw castings
Rohgussnachbehandlung
• Cutting and handling of
slabs and billets
Schneiden und Handling von
Aluminiumbarren und -bolzen
see 1.6 Sawing
• Heat treatment furnaces
Wärmebehandlungsanlagen
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
see Casting equipment 3.1
www.alu-web.de
• Holding furnaces
Warmhalteöfen
Bartz GmbH
see Casthous (foundry) 1.5
see 3.6 Heating furnaces
see Casting equipment 3.1
4.14 Melt preparation
Schmelzvorbereitung
• Degassing, filtration
Entgasung, Filtration
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: http://www.drache-gmbh.de
5 Materials
+ Recycling
Werkstoffe +
Recycling
4.13 Melt operations
Schmelzbetrieb
• Burner System
Brennertechnik
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-0
Fax: +49 (0) 211 / 5 00 91-14
E-Mail: info@bloomeng.de
Internet: www.bloomeng.de
Ein Eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
165,00 + MwSt.
Weitere Informationen unter
Tel. +49 (0) 821 319880 - 34
• Melting furnaces
Schmelzöfen
Bartz GmbH
see Casting equipment 3.1
see Casthous (foundry) 1.5
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
MARX GmbH & Co. KG
Lilienthalstr. 6-18
D-58638 Iserhohn
Tel.: +49 (0) 2371 / 2105-0, Fax: -11
E-Mail: info@marx-gmbh.de
Internet: www.marx-gmbh.de
see 3.6 Heating furnaces
• Granulated aluminium
Aluminiumgranulate
Chr. Otto Pape GmbH
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
E-Mail: info@papemetals.com
6 Materials
+ Application
Bearbeitung +
Anwendung
6.2 Semi products
Halbzeuge
• Wires / Drähte
DRAHTWERK ELISENTAL
W. Erdmann GmbH & Co.
Werdohler Str. 40, D-58809 Neuenrade
Postfach 12 60, D-58804 Neuenrade
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044
E-Mail: info@elisental.de
Internet: www.elisental.de
80 ALUMINIUM · 3/2021

SUPPLIERS DIRECTORY
6.3 Equipment for forging
and impact extrusion
Ausrüstung für Schmiedeund
Fließpresstechnik
• Hydraulic Presses
Hydraulische Pressen
LASCO Umformtechnik GmbH
Hahnweg 139, D-96450 Coburg
Tel. +49 (0) 9561 642-0
Fax +49 (0) 9561 642-333
E-Mail: lasco@lasco.de
Internet: www.lasco.com
Those who have their
entry here will
also be found online - look at:
www.alu-web.de/businessdirectory
8 Literature
Literatur
• Technical literature
Fachliteratur
Taschenbuch des Metallhandels
Fundamentals of Extrusion Technology
Giesel Verlag GmbH
Hans-Böckler-Allee 9, 30173 Hannover
Tel. 0511 / 73 04-125 · Fax 0511 / 73 04-233
Internet: www.alu-bookshop.de
• Technical journals
Fachzeitschriften
Giesel Verlag GmbH
Hans-Böckler-Allee 9, 30173 Hannover
Tel. 0511/8550-2638 · Fax 0511/8550-2405
GDMB-Informationsgesellschaft mbH
Paul-Ernst-Str.10, 38678 Clausthal-Zellerfeld
Telefon 05323-937 20, Fax -237, www.gdmb.de
Ihr Eintrag unter:
www.alu-web.de
Rubrikenverzeichnis
1 Smelting technology
Hüttentechnik
1.1 Raw materials
Rohstoffe
1.2 Storage facilities for smelting
Lagermöglichkeiten in der Hütte
1.3 Anode production
Anodenherstellung
1.4 Anode rodding
Anodenschlägerei
1.4.1 Anode baking
Anodenbrennen
1.4.2 Anode clearing
Anodenschlägerei
1.4.3 Fixing of new anodes to the
anodes bars
Befestigen von neuen Anoden
an der Anodenstange
1.5 Casthouse
Formategießerei
1.6 Casting machines
Gießmaschinen
1.7 Current supply
Stromversorgung
1.8 Electrolysis cell (pot)
Elektrolyseofen
1.9 Potroom
Elektrolysehalle
1.10 Laboratory
Labor
1.11 Emptying the cathode shell
Ofenwannenentleeren
1.12 Cathode repair shop
Kathodenreparaturwerkstatt
1.13 Second-hand plant
Gebrauchtanlagen
1.14 Aluminium alloys
Aluminiumlegierungen
1.15 Storage and transport
Lager und Transport
1.16 Refractory products
Feuerfesttechnik
1.17 Protective Clothing manufacturer
Schutzkleidung
2 Extrusion
Strangpressen
2.1 Extrusion billet preparation
Pressbolzenbereitstellung
2.1.1 Extrusion billet production
Pressbolzenherstellung
2.2 Extrusion equipment
Strangpresseinrichtungen
2.3 Section handling
Profilhandling
2.4 Heat treatment
Wärmebehandlung
2.5 Profile cooling systems
Profilkühleinrichtungen
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
2.7 Second-hand extrusion plant
Gebrauchte Strangpressanlagen
2.8 Consultancy, expert opinion
Beratung, Gutachten
2.9 Surface finishing of sections
Oberflächenveredlung
von Profilen
2.10 Machining of sections
Profilbearbeitung
2.11 Equipment and accessories
Ausrüstungen und Hilfsmittel
2.12 Waste water plants &
Zero liquid discharge
Abwasserreinigungsanlagen
2.13 Software systems
Software systeme
3 Rolling mill technology
Walzwerktechnik
und Zubehör
3.6 Cold rolling equipment
Kaltwalzanlagen
3.7 Thin strip / foil rolling plant
Feinband-/Folienwalzwerke
3.8 Auxiliary equipment
Nebeneinrichtungen
3.9 Slitter rewinder for Aluminium
foil
Rollenschneid- und Wickelmaschinen
für Alufolien
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
3.11 Coolant / lubricant preparation
Kühl-/Schmiermittel-Aufbereitung
3.12 Air extraction systems
Abluftsysteme
3.13 Fire extinguishing units
Feuerlöschanlagen
3.14 Storage and dispatch
Lagerung und Versand
3.15 Second-hand rolling equipment
Gebrauchtanlagen
3.16 Coil storage systems
Coil storage systems
3.17 Strip Processing Lines
Bandprozesslinien
3.18 Productions Management Sytems
Produktions Management Systeme
3.19 Chemical specialties for waste
water plants
Chemische Zusätze für Abwasserreinigungsanlagen
4 Foundry
Gießerei
4.5 Mould accessories and accessory
materials
Formzubehör, Hilfsmittel
4.6 Foundry equipment
Gießereianlagen
4.7 Casting machines and equipment
Gießmaschinen
und Gießeinrichtungen
4.8 Handling technology
Handhabungstechnik
4.9 Construction and design
Konstruktion und Design
4.10 Measurement technology
and materials testing
Messtechnik + Materialprüfung
4.11 Metallic charge materials
Metallische Einsatzstoffe
4.12 Finishing of raw castings
Rohgussnachbehandlung
4.13 Melt operations
Schmelzbetrieb
4.14 Melt preparation
Schmelzvorbereitung
4.15 Melt treatment devices
Schmelzebehandlungseinrichtungen
4.16 Control and regulation technology
Steuerungs- und
Regelungstechnik
4.17 Environment protection
and disposal
Umweltschutz und Entsorgung
4.18 Dross recovery
Schlackenrückgewinnung
4.19 Cast parts
Gussteile
3.1 Casting equipment
5 Materials + Recycling
Gießanlagen
Werkstoffe und Recycling
4.1 Work protection and ergonomics
3.2 Rolling bar machining
Arbeitsschutz und Ergonomie 6 Materials + Application
Walzbarrenbearbeitung
4.2 Heat-resistant technology Bearbeitung und Anwendung
3.3 Rolling bar furnaces
Feuerfesttechnik
Walzbarrenvorbereitung
4.3 Conveyor and storage technology 8 Literature
3.4 Hot rolling equipment
Förder- und Lagertechnik Literatur
Warmwalzanlagen
4.4 Mould and core production
3.5 Strip casting units
Form- und Kernherstellung Weitere Rubrikenwünsche:
and accessories
Rufen Sie uns an.
ALUMINIUM · 3/2021 Bandgießanlagen
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