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Giesel Verlag GmbH · Postfach 120158 · D-30907 Isernhagen · www.alu-<strong>web</strong>.<strong>de</strong> – PVST H 13410 – Dt. Post AG – Entgelt bezahlt<br />
Dr. Ing. h.c. F. Porsche AG<br />
Volume 85 · September 2009<br />
International Journal for Industry, Research and Application<br />
OFFICIAL INTERNATIONAL<br />
MEDIA PARTNER<br />
OFFICIAL INTERNATIONAL<br />
MEDIA PARTNER<br />
Special 2009:<br />
Automotive<br />
<strong>Alu</strong>minium in innovative<br />
light-weight car <strong>de</strong>sign<br />
Upgrading of<br />
gas-fired billet heaters<br />
Hilfsmaßnahmen<br />
für energieintensive<br />
Betriebe in Vorbereitung<br />
9
Linear testing. Testing head for linear testing. Helical testing.<br />
Ultrasonic testing<br />
equipment<br />
There are many benefits in one-stop shopping –<br />
even for industrial goods. Reliable, cooperative<br />
planning, specifications, which meet exactly your<br />
<strong>de</strong>mands and individual service-packages to operate<br />
on first-class level throughout the whole lifetime of<br />
the plant – this can be realized by one of the most<br />
experienced suppliers: Hertwich Engineering.<br />
Major benefits<br />
Hertwich Engineering is <strong>de</strong>dicated to leading technology<br />
in the aluminum casthouse. We add value<br />
by <strong>de</strong>signing integrated turnkey solutions. From<br />
melting and remelting to testing and packing. The<br />
results are convincing: highest quality of products<br />
at lowest cost-of-ownership. This has been proven<br />
by numerous plants all over the world.<br />
HERTWICH ENGINEERING GMBH<br />
Weinbergerstrasse 6<br />
5280 Braunau, Austria<br />
Leading technology in the aluminum casthouse.<br />
Phone: +43 (0) 7722 806-0<br />
Fax: +43 (0) 7722 806-122<br />
Ultrasonic testing equipment<br />
Linear testing for inspection of center cracks<br />
Helical testing for 100 % <strong>de</strong>tection of metal<br />
volume<br />
- Designed to fulfil ASTM B594<br />
- Inspection of billets to Class A, as required<br />
for automotive and aerospace industries<br />
- Angle Beam technique for 100 % fault finding<br />
Faulty logs can be back tracked to mold number<br />
of casting station<br />
Statistical data analysis helps to pinpoint reasons<br />
for <strong>de</strong>fects and contributes to minimize scrap at<br />
the source<br />
E-mail: info@hertwich.com<br />
Internet: www.hertwich.com<br />
MEETING your EXPECTATIONS
Volker Karow<br />
Chefredakteur<br />
Editor in Chief<br />
<strong>Alu</strong>minium<br />
für umweltbewusste<br />
Mobilität<br />
<strong>Alu</strong>minium for<br />
environmentally<br />
aware mobility<br />
ALUMINIUM · 9/2009<br />
Die Automobilindustrie steckt weltweit<br />
in <strong>de</strong>r Krise. Sie ist von Überkapazitäten<br />
geprägt und viele traditionsreiche<br />
Autobauer haben in <strong>de</strong>n<br />
vergangenen Jahren zu wenig in innovative,<br />
von Leichtbau und Energieeffizienz<br />
gekennzeichnete Fahrzeug-<br />
und Motorenkonzepte investiert bzw.<br />
geforscht. Die Insolvenz von General<br />
Motors ist nur das sichtbarste Zeichen<br />
einer verfehlten Mo<strong>de</strong>llpolitik.<br />
Die Spuren <strong>de</strong>r Krise wer<strong>de</strong>n auch<br />
auf <strong>de</strong>r diesjährigen Internationalen<br />
Automobil-Ausstellung sichtbar sein,<br />
wenngleich sich die Branche selbstbewusst<br />
und mit zahlreichen Mo<strong>de</strong>llneuheiten<br />
präsentiert. Mit rund 700<br />
Ausstellern bleibt die IAA <strong>de</strong>utlich<br />
hinter <strong>de</strong>r Präsenz vor zwei Jahren<br />
zurück. Es sind vor allem die Zulieferer,<br />
die, unter <strong>de</strong>r Absatzkrise lei<strong>de</strong>nd,<br />
reihenweise auf eine Messeteilnahme<br />
in diesem Jahr verzichten.<br />
Der Verband <strong>de</strong>r Automobilindustrie<br />
(VDA) als Ausrichter zeigt sich<br />
trotz <strong>de</strong>s schwierigen wirtschaftlichen<br />
Umfel<strong>de</strong>s davon überzeugt, dass<br />
diese IAA ein Erfolg wird. VDA-Präsi<strong>de</strong>nt<br />
Matthias Wissmann verspricht<br />
ein „beeindrucken<strong>de</strong>s Innovationsfeuerwerk“<br />
und „Antworten auf die<br />
Anfor<strong>de</strong>rungen von heute und die<br />
Herausfor<strong>de</strong>rungen von morgen“. Die<br />
weitere Optimierung <strong>de</strong>r klassischen<br />
Antriebsarten – Clean Diesel und<br />
hoch aufla<strong>de</strong>n<strong>de</strong> Ottomotoren mit<br />
Direkteinspritzung – wer<strong>de</strong> auf <strong>de</strong>r<br />
IAA ebenso zu sehen sein wie die<br />
Fortschritte bei <strong>de</strong>r Elektrifizierung<br />
<strong>de</strong>s Automobils, vom Mild Hybrid bis<br />
zum Pkw mit reinem Elektroantrieb.<br />
Neben <strong>de</strong>r weiteren Reduzierung <strong>de</strong>s<br />
Verbrauchs und damit auch <strong>de</strong>r CO 2 -<br />
Emissionen stehen neuartige Assistenzsysteme<br />
im Vor<strong>de</strong>rgrund, die das<br />
Autofahren noch sicherer und komfortabler<br />
machen.<br />
Bei all<strong>de</strong>m darf <strong>de</strong>r Werkstoff <strong>Alu</strong>minium<br />
nicht vergessen wer<strong>de</strong>n. Das<br />
Leichtmetall hat sich längst seinen<br />
unverzichtbaren Platz im Automobil<br />
gesichert. Es trägt wesentlich dazu<br />
bei, die umweltpolitischen Ziele einer<br />
energieeffizienten und CO 2 -min<strong>de</strong>rn<strong>de</strong>n<br />
Mobilität zu realisieren. Das<br />
Special dieser Ausgabe zeugt davon,<br />
dass <strong>Alu</strong>minium als Guss-, Walz-,<br />
Strangpress- o<strong>de</strong>r Schmie<strong>de</strong>teil im<br />
Pkw eine feste Größe ist.<br />
e d i t o r i A l<br />
The automobile industry is still in<br />
crisis worldwi<strong>de</strong>. It is marked by excess<br />
capacities, and many automobile<br />
manufacturers, though rich in tradition,<br />
have invested or researched too<br />
little in innovative vehicles and engine<br />
concepts that embody lightweight<br />
construction and energy efficiency.<br />
The insolvency of General Motors is<br />
only the most easily visible sign of a<br />
policy mo<strong>de</strong>l that has failed.<br />
Traces of the crisis are also evi<strong>de</strong>nt<br />
at this year’s International Motor<br />
Show (IAA) in Frankfurt, Germany,<br />
even though the sector is presenting<br />
itself self-confi<strong>de</strong>ntly and with numerous<br />
mo<strong>de</strong>l innovations. With around<br />
700 exhibitors, this IAA is lagging<br />
substantially behind the exhibitor<br />
count of two years ago. And of course,<br />
it is mainly the supplier industries,<br />
which have been drastically affected<br />
by the sales crisis, that have given<br />
up participation in this year’s fair in<br />
droves.<br />
The German Association of the Automotive<br />
Industry (VDA), as organiser<br />
of the event, seems convinced that<br />
<strong>de</strong>spite the difficult economic environment<br />
this IAA will be a success.<br />
VDA Presi<strong>de</strong>nt Matthias Wissmann<br />
promises “an impressive array of innovations”<br />
and “solutions for today’s<br />
needs and tomorrow’s challenges”.<br />
The further optimisation of conventional<br />
drive systems such as clean diesel<br />
and supercharged gasoline engines<br />
with direct injection will be on show<br />
at the IAA, as also will advances in automotive<br />
electrification, ranging from<br />
mild hybrids to all-electric cars. The<br />
focus will be on a consistent further<br />
reduction of fuel consumption and<br />
CO 2 emissions, as well as on all-new<br />
assistance systems that make driving<br />
even safer and easier.<br />
In all this, the material aluminium<br />
should not be forgotten. The light<br />
metal has long secured for itself a key<br />
role in automotive engineering. It contributes<br />
substantially towards realising<br />
the environmental policy aims of<br />
energy-efficient and low-CO 2 mobility.<br />
The Special section in this issue<br />
shows that aluminium, whether in the<br />
form of castings, rolled products, extrusions<br />
or forged components, has an<br />
established and important role to play<br />
in automobiles.
i N H A l t<br />
14<br />
20<br />
22<br />
28<br />
Der ALUMINIUM-Branchentreff<br />
<strong>de</strong>s Giesel Verlags: www.alu-<strong>web</strong>.<strong>de</strong><br />
e d i t o r i A l<br />
<strong>Alu</strong>minium für umweltbewusste Mobilität ..................................<br />
A Kt U e l l e S<br />
Personen, Unternehmen, Märkte, Produkte ................................ 6<br />
W i r t S C H A F t<br />
Englischsprachige Artikel: s. nebenstehen<strong>de</strong>s Verzeichnis<br />
<strong>Alu</strong>miniumpreise .............................................................. 10<br />
Hilfsmaßnahmen für energieintensive Unternehmen in Vorbereitung ... 18<br />
S P e C i A l : A l U M i N i U M i M A U t o M o B i l<br />
Englischsprachige Artikel: s. nebenstehen<strong>de</strong>s Verzeichnis<br />
Porsche Panamera – eine Synthese aus<br />
Sportlichkeit, Komfort und Effizienz ....................................... 20<br />
BMW X1 – Premiumfahrzeug im Kompaktsegment .................... 21<br />
KS Kolbenschmidt: Technologiepaket bei Ottokolben ausgebaut ... 22<br />
Zylin<strong>de</strong>rköpfe von Honsel für die neuen VW-Dieselmotoren ......... 26<br />
Hochfeste <strong>Alu</strong>minium-Fahrwerksteile mit optimaler Topologie........ 4<br />
t e C H N o lo G i e<br />
Englischsprachige Artikel: s. nebenstehen<strong>de</strong>s Verzeichnis<br />
Kun<strong>de</strong>nspezifische, energieoptimierte<br />
Wärmebehandlungsanlagen für <strong>Alu</strong>minium .............................. 7<br />
Wärmebehandlungsanlagen für die <strong>Alu</strong>miniumindustrie ............... 40<br />
Mo<strong>de</strong>rnisierung von bestehen<strong>de</strong>n<br />
gasbeheizten Bolzenerwärmungsanlagen ................................ 41<br />
i N t e r N At i o N A l e B r A N C H e N N e W S ................... 47<br />
r e S e A r C H<br />
Englischsprachige Artikel: s. nebenstehen<strong>de</strong>s Verzeichnis<br />
V e r A N S tA lt U N G e N / d o K U M e N tAt i o N<br />
Englischsprachige Artikel: s. nebenstehen<strong>de</strong>s Verzeichnis<br />
Veranstaltung: Schweißen & Schnei<strong>de</strong>n, 14.-19. Sept. 2009 .......... 57<br />
Patente ......................................................................... 58<br />
Literaturservice ................................................................ 61<br />
Impressum ..................................................................... 81<br />
Vorschau........................................................................ 82<br />
B e Z U G S Q U e l l e N V e r Z e i C H N i S ............................ 64<br />
S t e l l e N A N G e B o t .................................................... 6<br />
4 ALUMINIUM · 9/2009
E D I T O R I A L<br />
<strong>Alu</strong>minium for environmentally aware mobility ........................... 3<br />
N E W S I N B R I E F<br />
People, companies, markets, products ..................................... 7<br />
E C O N O M I C S<br />
The curse of globalisation – must we expect crises<br />
in the aluminium industry that are more abrupt in future? .............. 14<br />
S P E C I A L : A U T O M O T I V E<br />
Porsche Panamera – a unique combination<br />
of comfort, performance and efficiency .................................. 20<br />
KS Kolbenschmidt: Gasoline engine piston<br />
technology packages expan<strong>de</strong>d ............................................ 22<br />
Cylin<strong>de</strong>r heads from Honsel for new VW diesel engines ............... 26<br />
<strong>Alu</strong>minium in innovative light-weight car <strong>de</strong>sign ........................ 28<br />
T E C H N O LO G Y<br />
Heat-treatment equipment for the aluminium industry ................ 40<br />
Upgrading of existing gas-fired billet heaters ............................ 41<br />
ABB maintenance turns around plant critical equipment .............. 43<br />
C O M PA N Y N E W S W O R L D W I D E<br />
<strong>Alu</strong>minium smelting industry ............................................... 45<br />
Bauxite and alumina activities .............................................. 47<br />
Recycling and secondary smelting ......................................... 48<br />
<strong>Alu</strong>minium semis .............................................................. 49<br />
On the move................................................................... 50<br />
Suppliers........................................................................ 51<br />
Alro – new annealing furnace put into operation ...................... 51<br />
R E S E A R C H<br />
On the dissolution of alumina in a<br />
low-melting electrolyte for aluminium production .......................... 52<br />
E V E N T S / D O C U M E N TAT I O N<br />
ALUMINIUM CHINA 2009 exceedingly successful ....................... 57<br />
Literature service .............................................................. 61<br />
Imprint .......................................................................... 81<br />
Preview ......................................................................... 82<br />
S O U R C E O F S U P P LY L I S T I N G ............................... 64<br />
ALUMINIUM · 9/2009<br />
Inserenten<br />
dieser Ausgabe<br />
List of advertisers<br />
C O N T E N T S<br />
This issue contains<br />
an enclosure from<br />
GDA Gesamtverband <strong>de</strong>r<br />
<strong>Alu</strong>miniumindustrie e. V.<br />
to which we draw<br />
your kind attention.<br />
41<br />
43<br />
Stellenangebot / Job advertisement 6<br />
Insolvenzversteigerung Scheffler GmbH 8<br />
ABB Switzerland Ltd., Schweiz 84<br />
Buss ChemTech AG, Schweiz 9<br />
Astech Angewandte Sensortechnik GmbH 23<br />
Coiltec Maschinenvertriebs GmbH 18<br />
Drache Umwelttechnik GmbH 35<br />
Edimet SpA, Italy 15<br />
Elpo GmbH 39<br />
GoIndustry Dove Bid, USA 7<br />
Hermann Gutmann Werke AG 27<br />
Haarmann Holding GmbH 31<br />
Hertwich Engineering GmbH, Österreich 2<br />
Inotherm Industrieofen-<br />
und Wärmetechnik GmbH 18, 27<br />
Messe Essen GmbH 17<br />
Reed Exhibitions Deutschland GmbH 11<br />
Sapa GmbH 19<br />
Zhengzhou Zhongshi Cell<br />
Technology Co., Ltd, China 13<br />
5
A k t u e l l e s<br />
trimet und Atag<br />
grün<strong>de</strong>n Joint Venture<br />
Die Trimet <strong>Alu</strong>minium AG, Essen, und die KS <strong>Alu</strong>minium-Technologie,<br />
Neckarsulm, wer<strong>de</strong>n künftig im<br />
<strong>Alu</strong>miniumdruckguss zusammenarbeiten. Dazu wur<strong>de</strong><br />
ein Joint Venture (KS Atag Trimet Guss GmbH) zur Herstellung<br />
von Zylin<strong>de</strong>rkurbelgehäusen aus <strong>Alu</strong>miniumlegierungen<br />
gegrün<strong>de</strong>t, das von bei<strong>de</strong>n Gesellschaften zu<br />
je 50 Prozent gehalten wird. Die Genehmigung <strong>de</strong>s Gemeinschaftsunternehmens<br />
mit Sitz in Harzgero<strong>de</strong> (Sachsen-Anhalt)<br />
durch das Bun<strong>de</strong>skartellamt ist erfolgt.<br />
Die KS Atag Trimet Guss wird mit <strong>de</strong>m Schwerpunkt<br />
Automotive die Kompetenzen <strong>de</strong>r Partner auf <strong>de</strong>n Gebieten<br />
<strong>de</strong>r Metallvere<strong>de</strong>lung, <strong>de</strong>r Gusstechnologie sowie<br />
<strong>de</strong>s Rohmaterial- und Energiemanagements zusammenführen<br />
und so Synergiepotenziale aus allen Bereichen<br />
nutzen. Bei<strong>de</strong> Partner führen ihre bestehen<strong>de</strong>n Produktionsstandorte<br />
weiter und bleiben auch künftig unter ihren<br />
eingeführten Produktnamen am Markt präsent. Das<br />
Joint Venture beschäftigt rund 50 Mitarbeiter.<br />
Wir suchen <strong>de</strong>n /die<br />
Stellenanzeige<br />
Verkaufs-Ingenieur /-in<br />
für <strong>de</strong>n Bereich <strong>Alu</strong>minium<br />
Aufgabengebiet:<br />
– Technische Beratung und<br />
Betreuung <strong>de</strong>r Kun<strong>de</strong>n<br />
– Erarbeitung individueller<br />
Feuerfest-Lösungen<br />
– Erschließung neuer und erweiterter<br />
Produkt- und Marktpotentiale<br />
Sie verfügen über ein abgeschlossenes Studium<br />
im Bereich Gießereitechnik, Schwerpunkt<br />
<strong>Alu</strong>minium, und haben i<strong>de</strong>alerweise bereits Er-<br />
fahrungen in <strong>de</strong>r <strong>Alu</strong>miniumindustrie gesammelt.<br />
Da Sie in einem internationalen Umfeld arbeiten,<br />
sind gute Englischkenntnisse von Vorteil.<br />
Wir erwarten Eigeninitiative, Durchsetzungs-<br />
kraft und Kreativität. Reisebereitschaft und die<br />
Freu<strong>de</strong> am Verkaufen machen Sie zu einem/-r<br />
i<strong>de</strong>alen Bewerber/-in für uns.<br />
Wir bieten ambitionierten Kandidaten eine<br />
nicht alltägliche Karrierechance in einem internationalen<br />
wachsen<strong>de</strong>n Unternehmen mit sehr<br />
guten Entwicklungschancen.<br />
Bitte richten Sie Ihre Bewerbung unter<br />
Berücksichtigung <strong>de</strong>r Chiffre-Nr AL-1759 an<br />
die Giesel Verlag GmbH, Postfach 12 01 58,<br />
30907 Isernhagen.<br />
ksM Castings erweitert<br />
<strong>Alu</strong>minium-Fahrwerksgießerei<br />
KSM Castings mit Sitz in Hil<strong>de</strong>sheim errichtete in <strong>de</strong>n<br />
Jahren 2001/02 am Standort Wernigero<strong>de</strong> eine <strong>de</strong>r mo<strong>de</strong>rnsten<br />
<strong>Alu</strong>minium-Fahrwerksgießereien in Europa<br />
und baute diese in <strong>de</strong>r Folge weiter aus. Anfang Mai 2009<br />
wur<strong>de</strong> eine zusätzliche Produktionshalle für jährlich drei<br />
Millionen Pumpengehäuse in Betrieb genommen.<br />
Im Juli dieses Jahres wur<strong>de</strong> <strong>de</strong>r zweite Ausbau <strong>de</strong>s<br />
Werkes abgeschlossen. Mit einer eigens für die Herstellung<br />
sicherheitsrelevanter Fahrwerksteile im Gegendruck-Kokillengussverfahren<br />
errichteten Fertigung für<br />
Porsche und VW baut KSM Castings damit auch in wirtschaftlich<br />
schwierigen Zeiten seinen Standort in Wernigero<strong>de</strong><br />
weiter aus.<br />
KSM Castings beschäftigt aktuell mehr als 200 Mitarbeiter<br />
am Standort Wernigero<strong>de</strong> und befin<strong>de</strong>t sich trotz<br />
<strong>de</strong>r Krise in <strong>de</strong>r Automobilindustrie dank mehrerer Neuaufträge<br />
weiterhin in einer Wachstumsphase. In <strong>de</strong>n Ausbau<br />
<strong>de</strong>s Werkes wur<strong>de</strong>n circa 25 Mio. Euro investiert.<br />
tube <strong>de</strong>s Jahres 2009 gekürt<br />
Auf <strong>de</strong>m diesjährigen Kongress in Istanbul feierte <strong>de</strong>r<br />
europäische Verband <strong>de</strong>r Tubenhersteller etma sein 50jähriges<br />
Bestehen. Auf mittlerweile 28 Jahre bringt es <strong>de</strong>r<br />
Branchenwettbewerb „Tube <strong>de</strong>s Jahres“, <strong>de</strong>r erstmals<br />
1981 durchgeführt wur<strong>de</strong>. Bei diesem Preis wählen sieben<br />
Experten aus <strong>de</strong>m etma-Mitglie<strong>de</strong>rkreis die jeweils<br />
beste und innovativste Tube in <strong>de</strong>n Kategorien <strong>Alu</strong>minium-,<br />
Laminat- und Kunststoff sowie Prototypen.<br />
Im Jubiläumsjahr 2009 erhielt bei <strong>de</strong>n <strong>Alu</strong>miniumtuben<br />
das Produkt „Essensity Soft Permanent Colour Cream“<br />
<strong>de</strong>r Firma Schwarzkopf Professional die meisten Stimmen.<br />
Hergestellt wur<strong>de</strong> die Tube von Tubex Wasungen<br />
aus Deutschland. Sie wur<strong>de</strong> mit einem weißen Mattlack<br />
mit speziellem Haptikeffekt versehen und mit <strong>de</strong>m Computer-to-Plate-Verfahren<br />
in einem bewusst puristischen<br />
Design bedruckt. Die Kombination aus hochwertigem<br />
weißen Mattlack, <strong>de</strong>n ins Auge fallen<strong>de</strong>n grünen Grafikelementen<br />
und <strong>de</strong>r auf das Druckbild abgestimmten Verschlussfarbe<br />
geben <strong>de</strong>r Tube ihre extravagante Note.<br />
etma<br />
ALUMINIUM · 9/2009
EAFA<br />
economic conditions hit alufoil production<br />
Given current economic conditions<br />
figures for the first half of 2009 show a<br />
13 percent fall in the European alufoil<br />
<strong>Alu</strong>foil tray<br />
production to 371,400 tonnes, compared<br />
to the corresponding period a<br />
year earlier.<br />
Thicker alufoil gauges, used mainly<br />
for the manufacture of semi-rigid<br />
foil trays and technical applications<br />
rusal agrees terms<br />
of <strong>de</strong>bt restructuring<br />
ALUMINIUM · 9/2009<br />
for the automotive and building sectors<br />
were the worst affected falling<br />
by 26 percent, while thinner gauges<br />
used mainly in flexible packaging<br />
and household foil were better off<br />
<strong>de</strong>clining by 7 percent.<br />
Despite this slump in production,<br />
representatives of the alufoil<br />
industry are looking ahead more<br />
optimistically than some months<br />
ago. “It is not all bad news for the<br />
alufoil sector as the one-off effect<br />
of stock reduction along the supply<br />
chain seems to be over”, says Stefan<br />
Glimm, Executive Director of<br />
the European <strong>Alu</strong>minium Foil Association<br />
(EAFA). “Data for the last<br />
two months show a bottoming out<br />
in particular for thicker gauges and<br />
exports.”<br />
<strong>Alu</strong>minium foil is an essential<br />
part of many flexible packaging and<br />
container applications. Other uses inclu<strong>de</strong><br />
automotive and heat exchange<br />
components, insulation material and<br />
many other industrial applications.<br />
UC Rusal has agreed the principal terms of a long-term <strong>de</strong>bt<br />
restructuring with the Coordinating Committee which represents<br />
more than 70 international len<strong>de</strong>rs. According to the<br />
agreement, Rusal will settle its <strong>de</strong>bt to international banks<br />
within seven years. The restructuring will be split into two<br />
phases. During the first period of four years, Rusal will focus<br />
on maximising efficiencies across the business and taking<br />
full advantage of the recovery in <strong>de</strong>mand. Rusal has periodical<br />
<strong>de</strong>bt reduction targets in place and will seek to repay a<br />
total of five billion US-dollars of <strong>de</strong>bt owed to all len<strong>de</strong>rs by<br />
the fourth quarter 2013.<br />
During this period principal repayments will be ma<strong>de</strong> on<br />
a ‘pay-if-you-can’ basis based on the performance of the business,<br />
thereby ensuring the full sustainability and integrity of<br />
its operations. Interest will be paid partly in cash, at a rate<br />
ranging from Libor +1.75% to 3.5%, with the remaining portion<br />
to be capitalised. Furthermore, in or<strong>de</strong>r to preserve cash<br />
for len<strong>de</strong>rs and the business, no divi<strong>de</strong>nds will be paid until<br />
the net <strong>de</strong>bt to Ebitda ratio reaches 3x.<br />
The second phase of the restructuring will involve the<br />
refinancing of the remaining <strong>de</strong>bt by existing len<strong>de</strong>rs for an<br />
additional three years. Such refinancing will be at Rusal’s<br />
option, as it may opt for an alternative refinancing of the<br />
<strong>de</strong>bt on market terms should this prove more favourable to<br />
the company.<br />
By Or<strong>de</strong>r of a Secured Creditor<br />
For more information and<br />
terms of sale, please visit<br />
www.Go-Dove.com<br />
N e w s i N b r i e F<br />
Zenergy to supply<br />
innovative induction<br />
heater to sapa Profili<br />
Zenergy Power has received a further<br />
commercial or<strong>de</strong>r for a low-energy,<br />
high-productivity induction heater.<br />
The facility, which is based on Zenergy’s<br />
superconductor technology, has<br />
been purchased by the Italian subsidiary<br />
of Sapa, Sapa Profili Srl.<br />
The induction heater or<strong>de</strong>red by<br />
Sapa will be used as a replacement<br />
for a conventional gas-fired heating<br />
furnace currently installed at its<br />
aluminium plant located in Bolzano,<br />
Northern Italy. It is anticipated that<br />
the replacement of the plant’s conventional<br />
equipment with Zenergy’s superconductor-based<br />
heater will lead<br />
to improved operational efficiency<br />
and thus enhance the plant’s overall<br />
commercial potential. In particular,<br />
Sapa will exploit the superconducting<br />
heater’s processing versatility to<br />
enable the heating of several different<br />
types of aluminium alloy at the same<br />
plant.<br />
(2) Complete <strong>Alu</strong>minum Extrusion<br />
Facilities of Signature <strong>Alu</strong>minum, Inc.<br />
Live & Webcast Auction<br />
Sale Date: Thursday, 24 th September 2009 at 10:00 AM CDT<br />
Auction Locations:<br />
Temroc Metals, 4375 Willow Drive, Hamel (Minneapolis),<br />
MN 55340 (Live & Webcast)<br />
Atlantic <strong>Alu</strong>minum, 18631 MC Highway 71, Lumber Bridge<br />
(Fayetteville), NC 28357 (Webcast only, to be sold from MN location)<br />
Inspection: Hamel - Wednesday, 23rd September 2009<br />
from 10:00 AM to 4:00 PM CDT or by appointment;<br />
Lumber Bridge – By Appointment Only<br />
Assets inclu<strong>de</strong>:<br />
• 5-Axis 6-Si<strong>de</strong>d CNC Profile Machining Center: Handtmann<br />
PBZ-NT-800 A.S. (2002)<br />
• 4-Axis CNC Vertical Machining Centers: (7) Haas; Fadal; Chiron<br />
• <strong>Alu</strong>minum Extrusion Presses, Billet Ovens, & Aging Ovens:<br />
(2) Sutton 1650-Ton; Wean 2250-Ton; Lombard 1250-Ton<br />
• Hydraulic Press Brakes: (6) Accurpress 150, 130, 100 & 60-Ton;<br />
Cincinnati 135-Ton<br />
• CMMs: (3) Brown & Sharpe (Late as 2002); Numerex<br />
• Toolroom Equipment: Mills; Lathes; Presses; Welding Systems;<br />
Cutoff Saws; Shot Blast & Inspection Equipment<br />
• Paint Line: Electrostatic<br />
• Material Handling & Plant Support Equipment: Bridge Cranes;<br />
Forklifts; Air Compressors; Parts; Spares; Office Equipment &<br />
Much More<br />
Also available as an entirety: Complete billet casting and<br />
extrusion facility with 4 press lines located in Greenville, PA.<br />
For further information, please contact: BRYAN GOODMAN<br />
Tel: +1 410 654 7500 ext. 235 Email: bryan.goodman@go-dove.com<br />
*Virtual Brochure is Available on the Website
A k t u e l l e s<br />
Europäischer <strong>Alu</strong>minium Kongress, 23./24. Nov. ‘09<br />
<strong>Alu</strong>minium im Automobil<br />
<strong>Alu</strong>minium ist ein unverzichtbarer Werkstoff im Automobil<br />
gewor<strong>de</strong>n: Gussteile für Kurbelgehäuse und als<br />
Strukturbauteile in <strong>de</strong>r Karosserie sind heute Stand <strong>de</strong>r<br />
Technik. Aber auch Halbzeuge und Schmie<strong>de</strong>teile fin<strong>de</strong>n<br />
in Fahrzeugen zunehmend Anwendung.<br />
Vor diesem Hintergrund veranstaltet <strong>de</strong>r Gesamtverband<br />
<strong>de</strong>r <strong>Alu</strong>miniumindustrie (GDA), Düsseldorf, am<br />
23./24. November 2009 einen europäischen Kongress<br />
zum Thema „<strong>Alu</strong>minium im Automobil – Werkstoff für<br />
Leichtbau und Design“. Auf <strong>de</strong>m Kongress wer<strong>de</strong>n sowohl<br />
die unterschiedlichen Einsatzmöglichkeiten von<br />
<strong>Alu</strong>minium, die <strong>de</strong>rzeit im Pkw verwen<strong>de</strong>t wer<strong>de</strong>n, vorgestellt<br />
und über mögliche Weiterentwicklungen diskutiert,<br />
die die Fahrzeuge <strong>de</strong>r Zukunft noch leichter und<br />
energieeffizienter wer<strong>de</strong>n lassen. Hochkarätige Vertreter<br />
aus <strong>de</strong>r Automobil- und <strong>Alu</strong>miniumindustrie sowie von<br />
Hochschulen wer<strong>de</strong>n innovative aktuelle und visionäre<br />
Lösungen präsentieren. Programminfos und Anmel<strong>de</strong>formulare<br />
unter www.aluminium-congress.com.<br />
Kontakt: Anncathrin Wener (GDA), Tel: 0211 4796 282,<br />
anncathrin.wener@aluinfo.<strong>de</strong><br />
INSOLVENZVERSTEIGERUNG<br />
Scheffler GmbH<br />
Dieselstraße 109 – 111, 33442 Herzebrock-Clarholz<br />
Di., 13. Oktober 2009, 10.00 Uhr<br />
12 <strong>Alu</strong>minium-Druckgussmaschinen, z.B. Frech DAK 720-71<br />
Zuhaltekraft 8.000 kN Bj. 04, 2x DAK 580-62 Zuhaltekraft 6.400<br />
kN Bj. 99/01, 3x DAK 450-40RC/54 Zuhaltekraft 5.000 kN Bj.<br />
01, DSD H 700 R Zuhaltekraft 7.000 kN Bj. 03, 6 4-Säulen-<br />
Hydraulik-Entgratpressen Reis z.B. SEP 9-30 Dialog, CLP-<br />
30D, SEP 9-100W, Presskraft 300-1.000 kN bis Bj. 99,<br />
<strong>Alu</strong>minium Schachtschmelzofen Striko MH 800/500 oel Etamax<br />
II Schmelzleistung 500 kg/h max. Betriebstemperatur 750<br />
°C Bj. 91, Durchlauf-Gleitschliffanlage Trowal/Schney<strong>de</strong>r m.<br />
Trockenkanal, 3 Rund-Gleitschliffanlagen Rössler R 300 A /<br />
RM 600, Wasseraufbereitungsanlage Rössler ZH 800 HA<br />
Turbo-Floc Bj. 00, kompl. Werkzeugbau mit CNC-Bearbeitungszentren,<br />
CNC-Drehmaschine Gil<strong>de</strong>meister, Werkzeugfräsmaschinen,<br />
Bohrmaschinen u.v.a.m.<br />
Besichtigung: Mo., 12. Oktober 2009 von 12.00 – 17.00 Uhr<br />
sowie am Versteigerungstag von 08.00 – 09.45 Uhr<br />
Zahlung: sofort bar, LZB-Scheck o. bankbestätigtem V-Scheck.<br />
Ausgabe <strong>de</strong>r Bieterkarte nur gegen eine Kaution von € 100,–.<br />
Ausführlicher Katalog unter www.industrie-rat.<strong>de</strong><br />
sowie Faxabruf 01805 / 77 69 66 07<br />
Gerhardi nimmt neue<br />
strangpresse in betrieb<br />
Im Beisein zahlreicher Gäste aus <strong>de</strong>m Kun<strong>de</strong>n- und Lieferantenkreis,<br />
von politischen Vertretern <strong>de</strong>r Lan<strong>de</strong>sregierung<br />
NRW, <strong>de</strong>s Märkischen Kreises und <strong>de</strong>r Stadt Lü<strong>de</strong>nscheid,<br />
<strong>de</strong>s Ausrüsters GIA und <strong>de</strong>r Industrie- und Han<strong>de</strong>lskammer<br />
zu Hagen und, natürlich, <strong>de</strong>s Gesellschafterkreises hat Gerhardi<br />
<strong>Alu</strong>technik GmbH & Co. KG am 20. August 2009 seine<br />
neue 33-MN-Strangpresse in Betrieb genommen. Mit <strong>de</strong>r<br />
von <strong>de</strong>m spanischen Ausrüster GIA gelieferten Presse will<br />
Gerhardi seine Profilproduktion bis 2013 auf rund 13.000<br />
Tonnen verdoppeln.<br />
Der NRW-Lan<strong>de</strong>sminister für Arbeit, Gesundheit und<br />
Soziales, Karl-Josef Laumann, begrüßte das „klare Ja“ zum<br />
Standort Lü<strong>de</strong>nscheid und die mutige Investition in die Zukunft.<br />
Geschäftsführer Christoph Deiters machte <strong>de</strong>utlich:<br />
„Die neue Strangpresse braucht Futter und ich möchte Sie,<br />
die Kun<strong>de</strong>n, bitten, sie mit Aufträgen zu füttern.“ Betriebsrat<br />
Martin Eickbaum ergänzte in seinem Grußwort: „Und wenn<br />
Sie, die Gäste, die Anlage gleich sehen – ich kann Ihnen<br />
sagen: Das ist schon ein Hammer.“<br />
Offizielle Inbetriebnahme <strong>de</strong>r neuen Gerhardi-Strangpresse durch<br />
<strong>de</strong>n NRW-Arbeitsminister Karl-Josef Laumann (2.v.l.). Im Vor<strong>de</strong>rgrund<br />
Geschäftsführer Christoph Deiters sowie Stephanie Hueck aus<br />
<strong>de</strong>m Gesellschafterkreis von Gerhardi <strong>Alu</strong>technik.<br />
Gesamtansicht <strong>de</strong>r 33-MN-Strangpresse<br />
Fotos: ALUMINIUM<br />
ALUMINIUM · 9/2009
European <strong>Alu</strong>minium Congress, 23 / 24 Nov 2009, Düsseldorf, Germany<br />
<strong>Alu</strong>minium Automotive Applications<br />
<strong>Alu</strong>minium has become an indispensable<br />
material in automobiles: today,<br />
castings for engine blocks, cylin<strong>de</strong>r<br />
heads and gearbox casings as well as<br />
structural components in the body<br />
area are state of the art. But semi-finished<br />
products in the form of sheet,<br />
extru<strong>de</strong>d profiles and forgings are also<br />
increasingly finding use in vehicles:<br />
for example, as body sheet and crashrelevant<br />
components such as bumper<br />
crossbeams or longitudinal chassis<br />
beams. Against this background the<br />
German tra<strong>de</strong> association GDA, Düsseldorf,<br />
is organising the European<br />
<strong>Alu</strong>minium Congress titled ‘<strong>Alu</strong>minium<br />
Automotive Applications – Material<br />
for Lightweight Construction and<br />
<strong>Alu</strong>minium jumps<br />
over UsD2,000 hurdle<br />
A lack of aluminium combined with<br />
stronger <strong>de</strong>mand from carmakers has<br />
pushed up prices of the metal, even<br />
though stocks in LME warehouses are<br />
at record highs. <strong>Alu</strong>minium breached<br />
the USD1,800/t threshold in July, a<br />
level last seen in November 2008,<br />
and even jumped over the USD2,000/<br />
t hurdle in early August. The i<strong>de</strong>a of<br />
shortages may seem odd at first glance,<br />
but a close inspection reveals that a<br />
lot of the 4.5m tonnes of aluminium<br />
stored in LME warehouses is tied up<br />
in <strong>de</strong>als to release cash for producers.<br />
That <strong>de</strong>mand could come from the car<br />
industry, which has help from government<br />
stimuli to junk old cars for new<br />
cars, and is gradually reviving after<br />
months of collapsing sales.<br />
Lack of material is already being<br />
reflected in premiums paid for physical<br />
material over futures contracts.<br />
In June, Japanese primary aluminium<br />
consumers agreed to a 30 percent<br />
hike in premiums for the current<br />
quarter. In Europe, the premium has<br />
risen to USD65 a tonne compared<br />
with USD10 in March. About 70 percent<br />
of the stocks in LME warehouses<br />
(3.15m tonnes) is thought to be tied up<br />
in financing <strong>de</strong>als until May 2010.<br />
paw<br />
ALUMINIUM · 9/2009<br />
Design’ from 23 to 24 November 2009.<br />
At the congress, the various applications<br />
of aluminium currently being<br />
used in motor cars will be presented.<br />
Moreover, top-class representatives<br />
from the car and aluminium industry<br />
and from universities will present and<br />
discuss currently used and far-sighted<br />
innovative solutions.<br />
Further information as well as various<br />
registration forms can be found<br />
on the <strong>special</strong> congress <strong>web</strong>site at<br />
www.aluminium-congress.com.<br />
Contact:<br />
Anncathrin Wener, GDA<br />
Tel: +49 211 4796 282<br />
anncathrin.wener@aluinfo.<strong>de</strong><br />
YO U R PA R T N E R F O R T E C H N O L O G I E S<br />
BUSS ChemTech AG<br />
Hohenrainstrasse 10, CH-4133 Pratteln 1/Schweiz<br />
Tel. +41 (0) 618 256 462, Fax +41 (0) 618 256 737<br />
info@buss-ct.com<br />
www.buss-ct.com<br />
N e w s i N b r i e f<br />
KAP gets cheaper<br />
power un<strong>de</strong>r MoU<br />
Struggling Kombinat <strong>Alu</strong>minijuma<br />
Podgorica (KAP), owned by heavily in<strong>de</strong>bted<br />
Oleg Deripaska’s EN+ Group,<br />
acquired cheaper energy un<strong>de</strong>r an<br />
MoU with the Montenegrin government.<br />
The future is looking more positive<br />
for the aluminium smelter un<strong>de</strong>r<br />
the recently signed <strong>de</strong>al, which enables<br />
KAP to buy power at a cheaper rate of<br />
20.44 euros (USD28.66) MWh while<br />
the LME price is un<strong>de</strong>r USD1,700 per<br />
tonne. The Montenegrin government<br />
sold KAP to EN+ Group in June 2005.<br />
In return the government would provi<strong>de</strong><br />
KAP with 135m euros in loan<br />
guarantees which would be used to<br />
pay its <strong>de</strong>bts and go towards working<br />
capital at the plant. paw<br />
SUCCESS IS BASED ON COLLABORATION<br />
USE BCT TECHNOLOGY<br />
TO INCREASE<br />
Profi t<br />
Productivity<br />
Reliability<br />
Flexibility<br />
BCT Preheater<br />
BCT Paste Knea<strong>de</strong>r<br />
BCT Cooler<br />
Ano<strong>de</strong> Press<br />
Green Ano<strong>de</strong> Plant<br />
Pitch Melting Plant<br />
Coke Processing Plant<br />
HTM Plant<br />
We maintain proactive cooperation to fulfil your requirements in or<strong>de</strong>r to build your project successfully.<br />
We are your responsible partner with the realisation of entire ano<strong>de</strong> plants from raw material to formed ano<strong>de</strong>s,<br />
as well as the supply of key equipment.<br />
We are committed to excellence to ensure you a reliable and efficient plant performance. Whenever, wherever<br />
supported by our service team.
w i r t s C h A F t<br />
10 ALUMINIUM · 9/2009
ALUMINIUM 2010<br />
8 th World Tra<strong>de</strong> Fair & Conference<br />
Weltweit wichtigster Treffpunkt für <strong>Alu</strong>minium<br />
Innovationen | Produkte | Technologien<br />
I<strong>de</strong>en | Anwendungen | Networking<br />
14. - 16. September, Messe Essen<br />
www.aluminium-messe.com<br />
Organiser: Institutional Patron: Partner:
w i r t s C h A F t<br />
Produktionsdaten <strong>de</strong>r <strong>de</strong>utschen <strong>Alu</strong>miniumindustrie<br />
Primäraluminium Sekundäraluminium Walzprodukte > 0,2 mm Press- & Ziehprodukte**<br />
Produktion<br />
(in 1.000 t)<br />
+/in<br />
% *<br />
Produktion<br />
(in 1.000 t)<br />
+/-<br />
in % *<br />
Produktion<br />
(in 1.000 t)<br />
+/in<br />
% *<br />
Produktion<br />
(in 1.000 t)<br />
Jun 50,8 9,2 68,4 -8,2 164,2 -0,3 53,6 3,7<br />
Jul 52,1 7,0 62,5 -14,4 166,7 -0,2 53,5 0,4<br />
+/in<br />
% *<br />
Aug 51,8 5,8 49,4 -24,6 147,2 -10,6 49,5 -3,9<br />
Sep 49,9 6,2 61,9 -13,7 157,7 0,6 51,6 2,8<br />
Okt 51,2 2,0 57,9 -23,9 152,7 -10,6 50,4 -9,0<br />
Nov 47,2 -5,0 48,1 -35,8 123,4 -20,8 40,4 -24,8<br />
Dez 44,8 -14,1 28,8 -49,7 90,7 -23,8 23,2 -25,0<br />
Jan 40,6 -23,1 40,3 -43,3 108,6 -29,6 34,4 -33,2<br />
Feb 33,9 -31,3 36,7 -47,0 117,1 -26,5 31,8 -40,1<br />
Mrz 27,5 -47,7 45,6 -29,0 133,2 -19,9 33,0 -31,9<br />
Apr 17,5 -65,5 40,3 -45,6 121,3 -30,8 33,1 -40,1<br />
Mai 17,5 -66,8 45,9 -29,7 120,0 -24,6 33,6 -29,1<br />
Jun 18,2 -64,2 48,8 -28,7 135,8 -17,3 37,5 -30,1<br />
* gegenüber <strong>de</strong>m Vorjahresmonat, ** Stangen, Profi le, Rohre; Mitteilung <strong>de</strong>s Gesamtverban<strong>de</strong>s <strong>de</strong>r <strong>Alu</strong>miniumindustrie (GDA), Düsseldorf<br />
Primäraluminium<br />
walzprodukte > 0,2 mm<br />
sekundäraluminium<br />
Press- und Ziehprodukte<br />
12 ALUMINIUM · 9/2009
CELL TECHNOLOGY
Rio Tinto e c o n o m i c s<br />
The curse of globalisation – must we expect crises in<br />
the aluminium industry that are more abrupt in future?<br />
B.G. Rüttimann, Singen; U.P. Fischer, Zollikerberg<br />
The increasing disintegration of value chains and co-operation that has its branches worldwi<strong>de</strong> obstruct<br />
the view of real aggregate <strong>de</strong>mand …<br />
Economic cycles are experiencing<br />
more frequent and more pronounced<br />
fluctuations in all sectors.<br />
The economic system is swinging<br />
from massive over-<strong>de</strong>mand directly<br />
into a severe sales crisis. Moreover,<br />
even experts appear to be<br />
surprised by such extreme swings.<br />
Are managers blind? No, they are<br />
merely looking at the wrong types<br />
of <strong>de</strong>mand, namely the local <strong>de</strong>mand<br />
that has been ma<strong>de</strong> visible<br />
for them, which today differs from<br />
the real aggregate <strong>de</strong>mand significantly<br />
more than it did in the<br />
past. The reason for this lies in the<br />
increasing disintegration of value<br />
chains and globally networked cooperation.<br />
These trends obstruct<br />
the view of the real aggregate<br />
<strong>de</strong>mand. Essentially each stage of<br />
industry concentrates on its direct<br />
competitors, customers or suppliers<br />
and not on the value chain as<br />
a whole. This is a strategic error.<br />
Why does the mining giant Rio Tinto<br />
only discover in November 2008<br />
that its sales of raw materials for the<br />
whole of 2008 will be ten percent<br />
less than expectations? Why didn’t<br />
Arcelor Mittal or<strong>de</strong>r a single tonne of<br />
iron ore from Vale between October<br />
2008 and March 2009? Why is Dow<br />
Chemicals temporarily closing a third<br />
of all of its production facilities? Why<br />
are Rieter and GF cutting shipments<br />
of their products to the car industry<br />
by 50 percent practically overnight?<br />
Why are Chinese ports sud<strong>de</strong>nly full<br />
of iron ore carriers and American<br />
ports full to overflowing with vehicles<br />
from BMW and Merce<strong>de</strong>s? In or<strong>de</strong>r<br />
to answer these questions one has to<br />
analyse more closely the global value<br />
chains in these sectors and above all<br />
the changes they have un<strong>de</strong>rgone as a<br />
result of globalisation since the beginning<br />
of the 1990s.<br />
The strategy of unlimited growth<br />
Starting in the 1960s, our industrial<br />
system has experienced continual<br />
growth. Demand for all types of consumer<br />
goods far excee<strong>de</strong>d supply;<br />
during this period, production and<br />
supply was easy. Markets were, to a<br />
large extent, local and<br />
in part closed. Unemployment<br />
was practically<br />
unheard of. By<br />
the 1980s at the latest,<br />
this imbalance between<br />
supply and <strong>de</strong>mand had<br />
shifted in the <strong>de</strong>veloped<br />
countries and no longer<br />
favoured producers;<br />
market segmentation<br />
and response to specific<br />
customer <strong>de</strong>mands<br />
were called for in or<strong>de</strong>r<br />
to counter increased<br />
competition.<br />
The end of the Cold<br />
War and the opening<br />
up of eastern Europe<br />
brought new opportunities<br />
and risks after 1990:<br />
not only was the market<br />
expan<strong>de</strong>d by over 100<br />
million potential new customers, there<br />
was additional competitive pressure<br />
with very favourable production costs<br />
in the eastern European countries.<br />
The globalisation in the West that took<br />
place at the same time and allowed<br />
companies to pursue new markets in<br />
the rapidly growing economies ma<strong>de</strong><br />
it possible for companies to continue<br />
with their growth-oriented business<br />
strategies. The paradigm of unlimited<br />
growth was still embed<strong>de</strong>d in the<br />
minds of managers – also urged on by<br />
short term oriented investors luring<br />
the managers with excessive bonuses<br />
(and salaries). These compensation<br />
packages are very strongly <strong>de</strong>pen<strong>de</strong>nt<br />
on the size of the companies. In<br />
the meantime, there have been fundamental<br />
changes in the structure of the<br />
value chain, abetted not least by low<br />
transport costs and advanced means<br />
of telecommunication: a network<br />
of suppliers and sub-suppliers with<br />
branches worldwi<strong>de</strong> is now striving<br />
– to a large extent in an uncoordinated<br />
manner – to achieve a supposed cost<br />
optimum within the value chain.<br />
There began a parallel race to cap-<br />
14 ALUMINIUM · 9/2009
ture the new markets (market and cost<br />
lea<strong>de</strong>rship) while at the same time securing<br />
existing markets – directly by<br />
enormous investments in increasing<br />
capacity and indirectly by optimising<br />
capacity by means of mergers and<br />
takeovers, and spurred on by the megalomania<br />
of the managers. This strategy<br />
aimed at unlimited growth was<br />
financed by readily available liquidity<br />
and low interest rates. The target markets<br />
both for expansion of production<br />
capacity and increased turnover were<br />
mostly the upcoming BRIC countries,<br />
but in addition to Russia there were<br />
also other eastern European countries<br />
with favourable labour costs.<br />
Unfortunately, all competitors had<br />
the same i<strong>de</strong>a, that is to say the same<br />
business mo<strong>de</strong>l. The managers appear<br />
not to want to think about where this<br />
might lead. A simple calculation of<br />
the additional overall capacities and<br />
the real growth would reveal the resultant<br />
imbalance in the market. Furthermore,<br />
the company takeovers and<br />
mergers have not only overstrained<br />
the organisations but also completely<br />
ALUMINIUM · 9/2009<br />
ruined healthy balance sheets – we<br />
are now seeing the results. A lack of<br />
farsightedness and ina<strong>de</strong>quate systemic<br />
thinking? Not only that but also<br />
a sizeable portion of naivety and the<br />
lack of courage to prepare a Plan B in<br />
case there is a period of bad weather<br />
and to present it to the sharehol<strong>de</strong>rs.<br />
But this is precisely what responsible<br />
management is all about.<br />
The great disenchantment<br />
What happens now when there is a<br />
small fall in <strong>de</strong>mand? Distracted by<br />
increasing turnover and blin<strong>de</strong>d by<br />
extrapolated business plans based<br />
on wrong assumptions, the managers<br />
sud<strong>de</strong>nly and astonishingly discover<br />
that, oops, they are producing too<br />
much – supply is significantly greater<br />
than the real <strong>de</strong>mand. It is interesting<br />
that this realisation was first triggered<br />
by the American subprime crisis and<br />
the overheated economy subsequently<br />
collapsed like a house of cards.<br />
And it gets even worse because<br />
prices also go into free fall as a result<br />
e c o n o m i c s<br />
…making it particularly difficult for industries<br />
<strong>de</strong>tached from the end markets …<br />
of overcapacities, higher fixed costs<br />
and lower marginal costs. The effect<br />
of the fall in prices is thus significantly<br />
more serious than the reduced quantity<br />
because it brings the potential<br />
competitiveness of the company into<br />
question – there are indications<br />
EXTRUSION - DIECASTING - FOUNDRY - ROLLING - FINISHING - MACHINING - WELDING - RECYCLING<br />
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14-17 April 2010<br />
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adnord.it ➝<br />
15<br />
Vimetco
e c o n o m i c s<br />
of trouble ahead. The current crisis is<br />
far more pronounced than the consequences<br />
of the dotcom bubble bursting<br />
in 2000.<br />
What has happened in the past few<br />
months is a consequence of the wi<strong>de</strong>ly<br />
branched global value chain. The supposedly<br />
strong increase in turnover is<br />
mainly due to an ever-longer ‘pipeline’<br />
(see also: Dynamics of the ‘pipeline<br />
filling’ effect in the aluminium semis<br />
industry, ALUMINIUM, 5/2001, p.<br />
336ff). This building up of an intermediate<br />
stock, which was even strongly<br />
supported by increasing prices for<br />
raw materials, came to an abrupt<br />
end and was sud<strong>de</strong>nly replaced by<br />
<strong>de</strong>stocking. Thus as the aggregate <strong>de</strong>mand<br />
fell, the producing companies<br />
were immediately affected – and the<br />
more so the further they were from<br />
the end market because the downstream<br />
<strong>de</strong>mand was immediately met<br />
by the well-filled ‘pipeline’.<br />
In such a situation, an attempt<br />
is also ma<strong>de</strong> to compensate for<br />
liquidity losses resulting from<br />
reduced operative income by<br />
further cutbacks in stocks. In the<br />
present crisis, this phenomenon<br />
has increased drastically as a<br />
result of the financing of the net<br />
working capital becoming ever<br />
more difficult or even impossible<br />
because of the restrictions on<br />
giving credit. If the fall in production<br />
is unduly large compared<br />
with a company’s fixed costs,<br />
restructuring and redundancies<br />
are inevitable. If the abrupt<br />
cut-back in production resulting<br />
from the emptying of the ‘supply<br />
chain’ is also superimposed on<br />
possible interest and capital repayments<br />
for short-sighted purchases<br />
of companies, it is no longer possible<br />
to rule out bankruptcies. And all of<br />
this because one has lost sight along<br />
the value chain of the end market.<br />
The question as to whether state aid<br />
and <strong>de</strong>mand-stimulating spending<br />
programmes should be carried out<br />
at the taxpayer’s expense is another<br />
problem in the making.<br />
And nothing learned…?<br />
If we fail to learn from this, we can<br />
paraphrase German dramatist Bertolt<br />
Brecht and say, “And when the whole<br />
shebang is over, it will start from the<br />
beginning again.” As soon as the pipeline<br />
of intermediate stock is empty,<br />
the aggregate <strong>de</strong>mand will again work<br />
its way along the value chain via the<br />
components to the semis and finally<br />
through to the raw materials suppliers.<br />
The pipeline is very long so consi<strong>de</strong>rable<br />
lead times are necessary before<br />
material reaches the final seller. That<br />
is why we are already hearing cries of<br />
“Can’t you supply it tomorrow? Where<br />
are the goods, I need them immediately?”<br />
reverberating today ... and have<br />
not learned anything. There are unpleasant<br />
forms of feedback from dynamic<br />
systems that we gladly ignore.<br />
Actually, this phenomenon is known<br />
as the Forrester–Burbidge effect and<br />
was already being mo<strong>de</strong>lled 40 years<br />
ago on a small scale (using simple value<br />
chains). The time it takes to pass<br />
through the production stage means<br />
the effects on the stock quantities are<br />
limited to something of the or<strong>de</strong>r of<br />
several weeks or months by. Supposedly<br />
skilful negotiating on the part<br />
of the purchaser as a result of large<br />
quantity discounts exaggerates this<br />
effect still further. Everyone suboptimises<br />
his area and thus even damages<br />
the others by thinking lean. On<br />
top of the globalisation effects of a<br />
broadly branched value chain (which<br />
benefits from cheap production locations<br />
in far away places) there are the<br />
long transport times, in other words a<br />
warehouse that is on the move.<br />
If we also take into account the<br />
increased investment activities on a<br />
global scale for installing additional<br />
production capacities, one recognises<br />
the dangerous multiplier again,<br />
but on a large scale. The throughput<br />
times for investments to expand capacity<br />
and open up markets – from<br />
the instant a <strong>de</strong>cision is ma<strong>de</strong>, via the<br />
planning through to commissioning<br />
– is measured on a timescale of years.<br />
Whether the new capacities come on<br />
stream when the economic cycle is<br />
on a downward slope instead of on<br />
an upward one is to a large extent<br />
random. It is paradoxical that the <strong>de</strong>cision<br />
to create new capacities is usually<br />
based on the maximum amplitu<strong>de</strong><br />
of the swing, which far exceeds the aggregate<br />
<strong>de</strong>mand. The consequence is<br />
expensive overcapacity, which in the<br />
worst case is subsidised with taxpay-<br />
…to react in good time to imbalances in the real economy<br />
ers’ money, and later on has to be reorganised<br />
again using taxpayers’ money.<br />
The <strong>de</strong>struction of vertically integrated<br />
industrial concerns that can<br />
actually see the end market and their<br />
replacement by companies <strong>special</strong>ising<br />
in a single stage of the value chain,<br />
mostly accompanied by horizontal<br />
mergers, is particularly apparent in<br />
mature industries (see also: Which<br />
globalisation for the aluminium industry?,<br />
ALUMINIUM, Part I in 1-<br />
2/2008, p. 16ff, Part II in 3/2008, p.<br />
16ff). The prospects have probably<br />
not improved.<br />
16 ALUMINIUM · 9/2009<br />
Norsk Hydro
What can be done?<br />
The main problem is the distorted perception of<br />
the actual aggregate <strong>de</strong>mand of the individual<br />
stages of the value chain. The momentum of the<br />
value chain, which is influenced by systemic<br />
feedback not directly linked to the actual aggregate<br />
<strong>de</strong>mand, dominates more and more the further<br />
one gets from the end market. Three major,<br />
interrelated approaches to supply-chain management<br />
are necessary:<br />
• Firstly, a shortening of the value chain by means<br />
of integration using an exchange of information<br />
and a reduction in the throughput time using lean<br />
techniques. In general, the lean approach, which<br />
means eliminating every possible source of wastage,<br />
will become even more important in future.<br />
The result will be a smaller amplitu<strong>de</strong> with faster<br />
reaction time.<br />
• Secondly, the reduced amplitu<strong>de</strong> will allow<br />
better planning of the necessary production capacity,<br />
which is based on the real aggregate <strong>de</strong>mand.<br />
This will not eliminate the expansion of<br />
overcapacities but it will at least reduce it.<br />
• Thirdly, taking all value chains into account<br />
with which one is in competition, instead of only<br />
one’s own stage. This applies to existing capacities<br />
as well as to planned extensions.<br />
In addition, real-economy planning is necessary<br />
in or<strong>de</strong>r to avoid the serious socio-economic<br />
consequences that we are currently experiencing.<br />
Now this is consistent with the i<strong>de</strong>al world<br />
we know from theoretical books. In practice, this<br />
means that the mo<strong>de</strong>lling of scenarios should not<br />
remain an aca<strong>de</strong>mic exercise and supervisory<br />
boards should insist on planning based facts;<br />
some sharehol<strong>de</strong>rs (true company owners with<br />
social responsibility) and the employees will be<br />
grateful. The other sharehol<strong>de</strong>rs (pure speculators)<br />
on the other hand will probably view the current<br />
crisis more as an opportunity to again get<br />
involved in the stock exchange in a big way. New<br />
opportunity for the one and possible unemployment<br />
for the other, who can actually do nothing<br />
for the mistakes of managers.<br />
Authors<br />
Bruno G. Rüttimann, Dr. Ing. MBA, studied at the Polytechnic<br />
Institute in Milan and the Bocconi School of<br />
Economics. As a Master Black Belt in Lean Six Sigma<br />
he is introducing Continuous Improvement techniques<br />
at Alcan Engineered Products. He is the author of Mo<strong>de</strong>ling<br />
Economic Globalization, Monsenstein & Vannerdat,<br />
2006.<br />
Urs P. Fischer, lic. rer. pol, studied Economics at the<br />
University of Bern. He worked for many years in various<br />
financial positions and as business unit presi<strong>de</strong>nt at<br />
Alcan/<strong>Alu</strong>suisse and is now an advisor to the managements<br />
of international groups. He is the owner of the<br />
management consultancy firm Lean Solution.<br />
ALUMINIUM · 9/2009<br />
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W i R T s c H A F T<br />
Hilfsmaßnahmen für energieintensive Betriebe in Vorbereitung<br />
Seit Jahren beklagt die <strong>de</strong>utsche<br />
NE-Metallindustrie die<br />
hohen heimischen Strompreise<br />
und verweist darauf, dass die<br />
europäischen Wettbewerber mit<br />
günstigen Industriestrompreisen<br />
versorgt wer<strong>de</strong>n. Mehr als einmal<br />
ist von führen<strong>de</strong>n Branchen- und<br />
Unternehmensvertretern darauf<br />
hingewiesen wor<strong>de</strong>n, dass die<br />
energieintensiven Betriebe diese<br />
Kostennachteile auf Dauer nicht<br />
tragen können. Inzwischen scheint<br />
auch in Berlin und Brüssel die<br />
Einsicht zu wachsen, dass dieser<br />
Entwicklung entgegengesteuert<br />
wer<strong>de</strong>n muss. Mit kurz-, mittel-<br />
und langfristigen Maßnahmen soll<br />
die Position <strong>de</strong>r energieintensiven<br />
Betriebe in Deutschland nun gestärkt<br />
wer<strong>de</strong>n.<br />
Heinz-Peter Schlüter, Inhaber und<br />
Aufsichtsratsvorsitzen<strong>de</strong>r <strong>de</strong>r Trimet<br />
<strong>Alu</strong>minium AG zeigte sich in einem<br />
Gespräch mit Journalisten am Hüttenstandort<br />
Essen erfreut darüber,<br />
dass die Bun<strong>de</strong>sregierung konkrete<br />
Schritte eingeleitet hat, um <strong>de</strong>n Erhalt<br />
<strong>de</strong>r klimaschonend produzieren<strong>de</strong>n<br />
<strong>Alu</strong>miniumhütten in Deutschland<br />
zu sichern. Der dazu aufgelegte dreigliedrige<br />
Maßnahmenplan wur<strong>de</strong><br />
vom energiepolitischen Sprecher <strong>de</strong>r<br />
SPD-Bun<strong>de</strong>stagsfraktion Rolf Hempelmann<br />
erläutert, <strong>de</strong>r das laufen<strong>de</strong><br />
Verfahren wesentlich vorangetrieben<br />
und mit gestaltet hat. Der Plan umfasst<br />
eine<br />
• Soforthilfe für 2009 über einen<br />
Son<strong>de</strong>rfonds im Konjunkturpaket 2<br />
• Überbrückungslösung für die Jahre<br />
2010 bis 2012<br />
Planung, Konstruktion und Ausführung<br />
von Industrieofenanlagen<br />
Konstantinstraße 1a<br />
41238 Mönchengladbach<br />
Telefon +49(0)2166/987990<br />
Telefax +49(0)2166/987996<br />
E-mail info@inotherm-gmbh.<strong>de</strong><br />
Internet www.inotherm-gmbh.<strong>de</strong><br />
Nehmen zu <strong>de</strong>n geplanten Hilfsmaßnahmen für energieintensive Unternehmen Stellung,<br />
v.l.n.r.: Heinz-Peter Schlüter, Rolf Hempelmann (MdB), Heribert Hauck<br />
• Befreiung <strong>de</strong>r stromintensiven Unternehmen<br />
von <strong>de</strong>n CO 2 -Kosten im<br />
Strom im Rahmen <strong>de</strong>r Emissionshan<strong>de</strong>lsrichtlinie<br />
für die 3. Han<strong>de</strong>lsperio<strong>de</strong><br />
ab 2013.<br />
Zur Stützung <strong>de</strong>r stromintensiven<br />
Unternehmen <strong>de</strong>r NE-Metallproduktion<br />
hat die Bun<strong>de</strong>sregierung für das<br />
zweite Halbjahr 2009 einen För<strong>de</strong>rbetrag<br />
in Höhe von 40 Mio. Euro bereitgestellt.<br />
Das Bun<strong>de</strong>swirtschaftsministerium<br />
hat eine Richtlinie zu<br />
dieser För<strong>de</strong>rmaßnahme erarbeitet,<br />
die En<strong>de</strong> Juli zur Notifizierung nach<br />
Brüssel ging. Hempelmann zeigte sich<br />
überzeugt, dass Brüssel dieser Regelung<br />
zustimmen wird.<br />
Bemessungsgrundlage für die<br />
Hilfsgel<strong>de</strong>r ist <strong>de</strong>r für die Elektrolyse<br />
benötigte Strom <strong>de</strong>s <strong>de</strong>m Antragsmonat<br />
jeweils vorvergangenen Monats.<br />
Dies kompensiert circa die Hälfte <strong>de</strong>r<br />
CO 2 -Kosten im Strom. Bei <strong>de</strong>r Trimet<br />
schlugen diese Kosten im letzten<br />
Geschäftsjahr mit insgesamt 33 Mio.<br />
Euro zu Buche, das Unternehmen erhofft<br />
sich daher rund 16,5 Mio. Euro<br />
aus <strong>de</strong>m Fonds.<br />
Als Überbrückungslösung bis 2012<br />
wird eine Vergütung abschaltbarer<br />
n Rolling mills cold/hot<br />
n Roll grinding machines<br />
n Continuous casters<br />
n Levellers/straighteners<br />
n Drawing machines<br />
We purchase and supply:<br />
n Slitting lines<br />
n Cut-to-length lines<br />
n Coilers<br />
n Coil carriages<br />
n Rollformers<br />
Leistung zur Sicherung <strong>de</strong>r Netzstabilität<br />
angestrebt. Hierzu wur<strong>de</strong><br />
eine Studie in Auftrag gegeben, die<br />
die technisch-wirtschaftlichen sowie<br />
rechtlichen Rahmenbedingungen zur<br />
Umsetzung dieser Lösung untersucht<br />
und substanziiert. Alternativ bzw. ergänzend<br />
hierzu hat die Bun<strong>de</strong>sregierung<br />
die Fortsetzung <strong>de</strong>r För<strong>de</strong>rung<br />
über Haushaltsmittel für <strong>de</strong>n Zeitraum<br />
2010 bis 2012 zugesagt.<br />
Heribert Hauck, Leiter <strong>de</strong>s Trimet-Ressorts<br />
Energiewirtschaft, verwies<br />
darauf, dass <strong>Alu</strong>miniumhütten<br />
durch die gleichmäßige Abnahme von<br />
Grundlaststrom wesentlich zur Netzstabilität<br />
beitragen und <strong>de</strong>n Netzbetreibern<br />
auf diese Weise die Vorhaltung<br />
teurer Regelenergie ersparen.<br />
Eine Ausgleichszahlung dafür erfolge<br />
jedoch nicht, sodass heute allein die<br />
Stromkonzerne von <strong>de</strong>n so vermie<strong>de</strong>nen<br />
Kosten profitierten.<br />
Darüber hinaus wur<strong>de</strong> im Dezember<br />
2008 in Brüssel die Emissionshan<strong>de</strong>lsrichtlinie<br />
3 beschlossen, die<br />
für stromintensive Unternehmen, die<br />
<strong>de</strong>m sogenannten Carbon-Leakage-<br />
Risiko unterliegen, eine Befreiung von<br />
<strong>de</strong>n direkten, aber auch indirekten,<br />
Please ask for our sales list!<br />
n Tube welding machines<br />
n Extrusion presses<br />
n Joining presses<br />
n Packing lines for strips<br />
COILTEC Maschinenvertriebs GmbH · Silberkaute 4 · 57258 Freu<strong>de</strong>nberg<br />
Phone +49 (0) 2734/271190 · Fax +49 (0) 2734/271195<br />
www.coiltec.<strong>de</strong> · email: info@coiltec.<strong>de</strong><br />
18 ALUMINIUM · 9/2009<br />
Jürgen Clemens
im Strom eingepreisten CO2-Kosten erlaubt. Die Modalitäten zur Befreiung<br />
insbeson<strong>de</strong>re von <strong>de</strong>n indirekten<br />
CO2-Kosten im Strom müssen jedoch<br />
noch präzisiert und in nationales<br />
Recht umgesetzt wer<strong>de</strong>n, damit diese<br />
Möglichkeit zu einer belastbaren Planungsgrundlage<br />
wird.<br />
Schlüter und Hauck betonten,<br />
dass eine vollständige Befreiung von<br />
<strong>de</strong>n im Strompreis nachgewiesenen<br />
CO2-Kosten notwendig sei. Bei<strong>de</strong><br />
verwiesen darauf, dass die Preisbildung<br />
bei Strom nach <strong>de</strong>r sogenann-<br />
ten Merit Or<strong>de</strong>r erfolgt,<br />
das heißt nach<br />
<strong>de</strong>m letzten, teuren<br />
Kraftwerk, das für<br />
ein schnelles, flexibles<br />
Angebot in <strong>de</strong>r<br />
Spitzenlast sorgt.<br />
Unternehmen wie<br />
Trimet brauchten<br />
als Grundlastabnehmer<br />
jedoch keine<br />
<strong>de</strong>rartige Flexibilität<br />
und seien somit<br />
auch nicht an <strong>de</strong>n<br />
damit verbun<strong>de</strong>nen<br />
höheren Kosten zu<br />
beteiligen. Industriestrompreise<br />
wie in<br />
europäischen Nachbarlän<strong>de</strong>rn<br />
nähmen<br />
dagegen Rücksicht<br />
auf eine Grundlastabnahme.<br />
Eine „flache“Stromabnahme,<br />
verbun<strong>de</strong>n mit<br />
<strong>de</strong>m möglichen Verzicht<br />
auf „primäre<br />
Regelreserve“ und<br />
die Unterstützung<br />
<strong>de</strong>r Netzstabilität<br />
„rechtfertigen substanziellIndustriestrompreise<br />
bzw.<br />
Preise mit Son<strong>de</strong>rkonditionen“<br />
auch<br />
für die heimischen<br />
e n e r g i e i n t e n s i -<br />
ven Betriebe, so<br />
Schlüter.<br />
Er betonte, dass<br />
Trimet wie alle<br />
Industriebetriebe<br />
dringend Planungssicherheit<br />
über einen<br />
längerfristigen<br />
ALUMINIUM · 9/2009<br />
Zeithorizont benötige. Dies gelte<br />
beson<strong>de</strong>rs mit Blick auf die Kun<strong>de</strong>n<br />
aus <strong>de</strong>r Automobilindustrie, die langfristige<br />
Liefer- und Preisgarantien bei<br />
<strong>de</strong>r Abnahme von <strong>Alu</strong>miniumprodukten<br />
verlangten. Die könne Trimet<br />
aber nur abgeben, „wenn wir selbst<br />
längerfristige Planungssicherheit haben.<br />
Nota bene: Planungssicherheit<br />
in <strong>de</strong>r Herstellung von <strong>Alu</strong>minium<br />
ist untrennbar verbun<strong>de</strong>n mit Planungssicherheit<br />
in <strong>de</strong>r bezahlbaren<br />
Beschaffung <strong>de</strong>s Rohstoffes Strom“,<br />
sagte Schlüter.<br />
WE MAKE SURE THAT FUTURE PROSPECTS LOOK BRIGHT.<br />
WITH SOLUTIONS FOR EVERY STANDARD.<br />
As the market lea<strong>de</strong>r for alumi -<br />
nium profi les Sapa means more<br />
than cus tomized solutions: we also<br />
supply standard products with<br />
which you can work suc cess fully<br />
long term. As a group that operates<br />
world wi<strong>de</strong> we react quickly<br />
and fl exibly, regard less of what it<br />
Sapa GmbH<br />
European Trading Business<br />
W i R T s c H A F T<br />
Trimet fährt Öfen wie<strong>de</strong>r hoch<br />
Angesichts einer inzwischen leicht<br />
erhöhten Nachfrage gegenüber <strong>de</strong>m<br />
drastischen Nachfrageeinbruch im<br />
Januar / Februar dieses Jahres und gestiegener<br />
<strong>Alu</strong>miniumpreise seit <strong>de</strong>m<br />
Tiefststand im März fährt Trimet seine<br />
Produktion von Hüttenaluminium<br />
am Standort Essen wie<strong>de</strong>r hoch. „Wir<br />
strengen uns an, dass wir im ersten<br />
Quartal 2010 wie<strong>de</strong>r voll produzieren“,<br />
sagte Schlüter.<br />
■<br />
is you need and where you need it.<br />
Together with market knowledge<br />
based on many years’ experience<br />
this makes us a strong partner<br />
with whom you can look calmly<br />
into the future. For further information<br />
go to www.sapagroup.com/<br />
europeantrading<br />
19
Abbildungen: Dr. Ing. h.c. F. Porsche AG<br />
A L U M I N I U M I M A U t o M o b I L<br />
Porsche Panamera – eine Synthese<br />
aus Sportlichkeit, Komfort und Effizienz<br />
Bereits im April 2009 ist im<br />
Porsche-Werk Leipzig die Serienproduktion<br />
<strong>de</strong>r vierten Baureihe<br />
Panamera angelaufen. In <strong>de</strong>r <strong>de</strong>rzeit<br />
mo<strong>de</strong>rnsten Automobilfabrik<br />
<strong>de</strong>r Welt montiert <strong>de</strong>r Sportwagenhersteller<br />
mit neuesten Fertigungsmetho<strong>de</strong>n<br />
<strong>de</strong>n viertürigen<br />
Gran Turismo gemeinsam mit <strong>de</strong>m<br />
Gelän<strong>de</strong>wagen Cayenne auf einer<br />
Linie. Mit <strong>de</strong>m Panamera will Porsche<br />
neue Käuferschichten aus <strong>de</strong>r<br />
Oberklasse gewinnen.<br />
Der Panamera zeichnet sich durch hohen<br />
Komfort, ein außergewöhnliches<br />
Raumangebot und extrem sportliche<br />
Fahreigenschaften bei gleichzeitig geringem<br />
Verbrauch aus. Zur Markteinführung<br />
am 12. September in Deutsch-<br />
Produktionsanlauf <strong>de</strong>s neuen Panamera<br />
Production start-up for the new Panamera<br />
land ging <strong>de</strong>r Sportwagen zunächst in<br />
drei Varianten an <strong>de</strong>n Start, die mit<br />
einem 400 PS starken V8-Saugmotor<br />
bzw. mit einem V8-Biturbo-Aggregat<br />
mit 500 PS ausgestattet sind. Die Motoren<br />
wer<strong>de</strong>n mit kraftstoffsparen<strong>de</strong>r<br />
Benzin-Direkteinspritzung angeboten.<br />
Porsche plant, über <strong>de</strong>n gesamten<br />
Lebenszyklus hinweg jährlich rund<br />
20.000 Fahrzeuge abzusetzen.<br />
Fünf technische Innovationen,<br />
die erstmals in einem Serienmo<strong>de</strong>ll<br />
<strong>de</strong>r Oberklasse eingeführt wer<strong>de</strong>n,<br />
zeichnen <strong>de</strong>n Panamera aus: darunter<br />
das erste Start-Stopp-System in<br />
Verbindung mit einem automatisch<br />
schalten<strong>de</strong>n Getriebe und die aktive<br />
Aerodynamik mit einem beim Panamera<br />
Turbo mehrdimensional verstellbaren,<br />
ausfahrbaren Heckspoiler.<br />
Das Fahrwerk verbin<strong>de</strong>t Sportlichkeit<br />
mit Komfort. In <strong>de</strong>r Grundabstimmung<br />
bietet es sehr hohen Reisekomfort,<br />
verwan<strong>de</strong>lt sich aber auf Knopfdruck<br />
dank<br />
<strong>de</strong>s aktiven<br />
D ä m p f e r s y s -<br />
tems PASM in<br />
ein fahraktives<br />
Sportfahrwerk.<br />
Darüber hinaus<br />
e r m ö g l i c h t<br />
die beim Panamera<br />
Turbo<br />
serienmäßige,<br />
ansonsten optionale<br />
adaptive<br />
Luftfe<strong>de</strong>rung<br />
mit schaltbarem<br />
Zusatzvolumen<br />
in je<strong>de</strong>r Fe<strong>de</strong>r<br />
– ein absolutes<br />
Novum im<br />
Automobilbau<br />
– eine noch<br />
größere Spreizung<br />
zwischen<br />
sportlichen und<br />
komfortablen<br />
Fahrwerksprogrammen.<br />
Die Karosserie<br />
ist eine<br />
Synthese aus<br />
s p o r t w a g e n -<br />
typischem Leichtbau, großzügigem<br />
Platzangebot und effizienter Aerodynamik.<br />
Porsche setzt in <strong>de</strong>r Karosserie<br />
<strong>de</strong>s Panamera einen Materialmix<br />
Porsche Panamera – a<br />
unique combination<br />
of comfort, performance<br />
and efficiency<br />
Already in April 2009 series production<br />
of Porsche’s fourth mo<strong>de</strong>l<br />
line, the Panamera, started in the<br />
carmaker’s Leipzig plant. In the<br />
world’s most mo<strong>de</strong>rn automotive<br />
factory to date the manufacturer of<br />
premium sports vehicles is assembling<br />
the four-door Gran Turismo<br />
together with the Cayenne sports<br />
utility vehicle on one line using<br />
the latest production methods.<br />
With the Panamera Porsche has its<br />
eyes firmly set on new groups of<br />
buyers from the luxury class.<br />
The vehicle is characterised by a high<br />
<strong>de</strong>gree of comfort, exceptional space<br />
and extremely sporty driving features<br />
with low consumption. For its market<br />
introduction on 12 September in Germany,<br />
the Gran Turismo was launched<br />
in three variations, equipped with a<br />
400-hp V8 induction engine or with<br />
a V8 biturbo engine with 500 hp. The<br />
engines feature the most advanced direct<br />
fuel injection. Porsche is planning<br />
to sell yearly some 20,000 vehicles<br />
over the entire lifecycle.<br />
The Panamera is marked by five<br />
technological innovations which are<br />
for the first time seen in a production<br />
car in the luxury performance range:<br />
these inclu<strong>de</strong> the first automatic start/<br />
stop in conjunction with automatic<br />
transmission and active aerodynamics<br />
with a multi-stage, adjustable rear<br />
spoiler moving up when required on<br />
the Panamera Turbo.<br />
The chassis and suspension of the<br />
Panamera combines sporting performance<br />
and superior comfort. In<br />
its basic setting it offers a very high<br />
standard of driving comfort. But then,<br />
at the touch of a button on the active<br />
PASM damper system, it turns into a<br />
thoroughbred sports suspension. As<br />
another highlight the adaptive air suspension<br />
with its extra volume ad<strong>de</strong>d<br />
on whenever required – an absolute<br />
innovation in automotive technology<br />
– featured as standard on the Turbo<br />
and otherwise coming as an option<br />
on the other mo<strong>de</strong>ls, offers an even<br />
20 ALUMINIUM · 9/2009
S P E C I A L<br />
A L U M I N I U M I M A U t o M o b I L<br />
greater variation of sporting and comfort<br />
features.<br />
The body is the synthesis of lightweight<br />
technology typical of a sports<br />
car, generous spaciousness and<br />
efficient aerodynamics.<br />
A broad range of<br />
lightweight<br />
materials<br />
is used on<br />
the body,<br />
including<br />
all kinds<br />
of steel<br />
g r a d e s ,<br />
light alloys<br />
such as aluminium<br />
and magnesium, as well as plastics.<br />
The lightweight doors feature a<br />
load-bearing structure ma<strong>de</strong> of lasertreated<br />
pressure-cast aluminium, an<br />
aluminium outer skin and door window<br />
frames ma<strong>de</strong> of thin-walled pressure-cast<br />
magnesium. Thanks to this<br />
lightweight structure, the Panamera S,<br />
for example, weighs just 1,770 kg.<br />
The Panamera is the first car in its<br />
segment with a complete cover on the<br />
un<strong>de</strong>r-floor also extending all round<br />
the drivetrain tunnel and rear-end silencers.<br />
This clearly helps to reduce<br />
Mit <strong>de</strong>m X1 ergänzt BMW seine X-<br />
Mo<strong>de</strong>lle um ein Premiumfahrzeug im<br />
Kompaktsegment. Die erhöhte Sitzposition,<br />
ein großzügiges Raumgefühl<br />
und <strong>de</strong>r variabel nutzbare Innenraum<br />
bieten „i<strong>de</strong>ale Voraussetzungen für<br />
einen von Agilität, Spontaneität und<br />
Vielseitigkeit geprägten Einsatz im urbanen<br />
Umfeld und darüber hinaus“,<br />
heißt es bei BMW. Der 4,45 Meter lange<br />
Fünftürer ist trotz seiner geringen<br />
Abmessungen gegenüber <strong>de</strong>n X3-,<br />
X5- und X6-Mo<strong>de</strong>llen klar als BMW<br />
X-Mo<strong>de</strong>ll erkennbar.<br />
Je nach Mo<strong>de</strong>llvariante stehen<br />
kraftvolle, wirtschaftliche und emissionsarme<br />
Benzin- und Dieselmotoren,<br />
das Allradsystem xDrive sowie<br />
umfangreiche Funktionen wie Bremsenergie-Rückgewinnung,<br />
Auto-Start/<br />
Stop und Schaltpunktanzeige für<br />
eine kraftstoffsparen<strong>de</strong> Fahrweise<br />
zur Verfügung. Herausragen<strong>de</strong> Effi-<br />
both air resistance<br />
and lift forces<br />
on<br />
Leichtbaukarosserie aus einem intelligenten<br />
Materialmix inklusive <strong>Alu</strong>minium<br />
Lightweight body with intelligent<br />
mix of materials, including aluminium<br />
the axles, which in practice means<br />
lower fuel consumption and higher<br />
driving dynamics. The visible highlight<br />
of the overall aerodynamic package<br />
is the active four-way rear spoiler<br />
on the Panamera Turbo. Through its<br />
efficient management of control angles<br />
and surface geometry geared to<br />
driving conditions, the rear spoiler<br />
optimises the car’s aerodynamics and<br />
performance all in one. ■<br />
bMW X1 – Premiumfahrzeug im Kompaktsegment<br />
zienz erreicht <strong>de</strong>r X1 sDrive18d mit<br />
Hinterradantrieb und einem Durchschnittsverbrauch<br />
nach EU von 5,2<br />
Litern je 100 Kilometer sowie einem<br />
CO 2 -Wert von 136 g/km.<br />
Die Motorenpalette bei <strong>de</strong>n Dieselaggregaten<br />
setzt auf ein Vollaluminium-Kurbelgehäuse,<br />
<strong>de</strong>r xDrive28i<br />
wird von einem Reihensechszylin<strong>de</strong>r-Benzinmotor<br />
mit Magnesium-<strong>Alu</strong>minium-Verbundkurbelgehäuse<br />
a n g e t r i e b e n .<br />
Das Fahrwerk<br />
umfasst eine<br />
Doppelgelenk-<br />
Druckstreben-<br />
bzw. <strong>Alu</strong>minium-Doppelgelenk-Zugstrebenachse<br />
vorn<br />
A U t o M o t I v E<br />
aus Stählen unterschiedlicher Güte,<br />
Leichtmetallen wie <strong>Alu</strong>minium und<br />
Magnesium sowie Kunststoffen ein.<br />
Die Leichtbautüren besitzen eine tragen<strong>de</strong><br />
Struktur aus laserbearbeitetem<br />
<strong>Alu</strong>miniumdruckguss, eine <strong>Alu</strong>miniumaußenhaut<br />
und einen Türfensterrahmen<br />
aus dünnwandigem Magnesiumdruckguss.<br />
Durch <strong>de</strong>n Einsatz<br />
dieser Leichtbaukomponenten wiegt<br />
<strong>de</strong>r Panamera S lediglich 1.770 kg<br />
– das ist für einen Sportwagen dieser<br />
Dimensionen bemerkenswert wenig.<br />
Erstmals in diesem Fahrzeugsegment<br />
wird beim Panamera die Verkleidung<br />
<strong>de</strong>s Unterbo<strong>de</strong>ns auch im<br />
Bereich <strong>de</strong>s Tunnels und <strong>de</strong>r Nachschalldämpfer<br />
umgesetzt. Sie hilft,<br />
<strong>de</strong>n Luftwi<strong>de</strong>rstand und <strong>de</strong>n Auftrieb<br />
an <strong>de</strong>n Achsen zu reduzieren. In <strong>de</strong>r<br />
Praxis heißt das: weniger Kraftstoffverbrauch<br />
und höhere Fahrdynamik.<br />
Sichtbares Highlight <strong>de</strong>s aerodynamischen<br />
Gesamtpaketes ist <strong>de</strong>r aktive<br />
Vier-Wege-Heckspoiler beim<br />
Panamera Turbo. Durch sein fahrsituationsabhängiges<br />
Management von<br />
Anstellwinkel und Flächengeometrie<br />
optimiert er Aerodynamik und Performance.<br />
■<br />
und eine Fünflenker-Hinterachse in<br />
Stahlleichtbauweise.<br />
Die Produktion <strong>de</strong>s X1 erfolgt im<br />
BMW-Werk Leipzig. Dort wird das<br />
neue Mo<strong>de</strong>ll parallel zur dreitürigen<br />
Variante, <strong>de</strong>m Coupé und <strong>de</strong>m Cabrio<br />
<strong>de</strong>r 1er-Reihe gefertigt. Markteinführung<br />
<strong>de</strong>s X1 für Europa ist am 24. Oktober<br />
2009.<br />
■<br />
21 ALUMINIUM · 9/2009<br />
ALUMINIUM · 9/2009 21<br />
BMW AG
A L U M I N I U M I M A U t o M o b I L<br />
KS Kolbenschmidt GmbH<br />
technologiepaket bei ottokolben ausgebaut<br />
Downsizing, Aufladung, Direkteinspritzung<br />
und höhere Leistungsdichten<br />
sind die wesentlichen<br />
Trends, wenn es um<br />
mo<strong>de</strong>rne Ottomotoren geht. Für<br />
die Motorkomponente Kolben<br />
heißt das: hohe Festigkeit und<br />
Zuverlässigkeit bei möglichst<br />
wenig Gewicht und möglichst<br />
geringer Reibung. Die Antwort<br />
<strong>de</strong>r KS Kolbenschmidt GmbH auf<br />
diese Anfor<strong>de</strong>rungen ist ein auf<br />
Leichtbau und reduzierte Reibung<br />
abgestimmtes Technologiepaket,<br />
das in verbrauchs- und CO 2 -optimierten<br />
Motorengenerationen<br />
zum Einsatz kommt. Bausteine <strong>de</strong>s<br />
Pakets sind die neu entwickelte<br />
Hochleistungslegierung KS 309,<br />
das weiter ausgebaute Leichtbaukonzept<br />
LiteKS-2 und die Kolbenbeschichtung<br />
NanofriKS, die mittlerweile<br />
in Serie läuft.<br />
Werkstoffseitig wird das Technologiepaket<br />
von Kolbenschmidt durch die<br />
Legierung KS 309 komplettiert. Sie<br />
erzielt eine um 20 bis 25 Prozent höhere<br />
Kolbenfestigkeit im relevanten<br />
Temperaturbereich von 200 bis 350<br />
Grad Celsius. Damit unterstützt sie<br />
optimal die Anfor<strong>de</strong>rungen reibungs-<br />
und gewichtsoptimierter Kolben, wie<br />
sie in heutigen und zukünftigen Motoren<br />
zum Einsatz kommen wer<strong>de</strong>n.<br />
Zusätzlich wur<strong>de</strong> KS 309 mit einem<br />
beson<strong>de</strong>ren Fokus auf die Gießbarkeit<br />
entwickelt, um auch innerhalb<br />
<strong>de</strong>r Prozesstechnologie weitere Potenziale<br />
hinsichtlich Leichtbau und<br />
Gewichtsreduktion durch dünnwandigeren<br />
<strong>Alu</strong>miniumguss realisieren<br />
zu können.<br />
Die bereits auf <strong>de</strong>r IAA 2007 vorgestellte,<br />
damals neu entwickelte<br />
Schaftbeschichtung NanofriKS spielt<br />
bei <strong>de</strong>r Entwicklung mo<strong>de</strong>rner Ottokolben<br />
ebenfalls eine zentrale Rolle.<br />
Sie wur<strong>de</strong> 2008 erstmalig bei einem<br />
großen europäischen Kun<strong>de</strong>n in Serie<br />
eingeführt. Es folgten zahlreiche weitere<br />
Serienprojekte in Europa, Nordamerika<br />
und Japan. Wie motorische<br />
Reibleistungsuntersuchungen inzwischen<br />
bestätigten, weist die Schaft-<br />
KS Kolbenschmidt GmbH<br />
Gasoline engine piston<br />
technology packages expan<strong>de</strong>d<br />
Produktion bei Kolbenschmidt Production at Kolbenschmidt<br />
Downsizing, turbocharging, direct<br />
injection and higher power <strong>de</strong>nsities<br />
are the buzzwords associated<br />
with mo<strong>de</strong>rn gasoline engines.<br />
For their pistons, these trends<br />
spell a need for higher strength<br />
and reliability combined with<br />
low weight and as little friction<br />
as possible. The response by KS<br />
Kolbenschmidt, Neckarsulm/Germany,<br />
to these challenges is to<br />
assemble lightweight and reduced<br />
friction technology packages used<br />
in engine generations <strong>de</strong>signed for<br />
reduced consumption and CO 2<br />
emissions. The elements of the<br />
package are the newly <strong>de</strong>veloped<br />
high-performance KS 309 alloy,<br />
the further advanced LiteKS-2<br />
lightweight concept and the NanofriKS<br />
piston coating which has<br />
meanwhile gone into series production.<br />
The KS 309 alloy is another addition<br />
to the materials ingredients and<br />
achieves up to 20 to 25 percent higher<br />
piston strength at the critical temperature<br />
range from 200 to 350°C. This is<br />
an alloy that acts as a perfect foil to the<br />
low-friction, low-weight pistons to be<br />
used in present and future engine<br />
generations. Also, KS 309 has been<br />
engineered for good casting properties<br />
to enable, within the process<br />
technology options, further potential<br />
for lightweight manufacturability and<br />
weight reductions through thinnerwalled<br />
aluminium castings.<br />
Introduced at the 2007 International<br />
Motor Show (IAA), the newly<br />
<strong>de</strong>veloped NanofriKS shaft coating<br />
likewise plays a lead role in the <strong>de</strong>sign<br />
of today’s gasoline engine pistons. It<br />
was first launched into series production<br />
for a major European OEM<br />
in 2008, followed by many other such<br />
projects in Europe, North America<br />
and Japan. As meanwhile endorsed<br />
by engine friction analyses, piston<br />
shafts coated with nanoparticles show<br />
up to ten percent less friction compared<br />
with conventional piston coatings,<br />
and up to 50 percent less wear.<br />
The outcome: enhanced reliability<br />
and optimum piston performance.<br />
Nanocoating is also used on the<br />
LiteKS-2 lightweight pistons likewise<br />
premiering at the IAA 2007.<br />
Since then, this type of piston has<br />
met with positive customer response<br />
throughout and has been playing a<br />
22 ALUMINIUM · 9/2009<br />
Images: Kolbenschmidt
S P E C I A L<br />
A L U M I N I U M I M A U t o M o b I L<br />
key role in current global gasoline engine<br />
projects. Since its introduction,<br />
LiteKS-2 has been further <strong>de</strong>veloped<br />
and now has even higher weight savings<br />
of altogether 25 percent and up<br />
to 50 percent less shaft friction over<br />
standard gasoline pistons. Together<br />
with the new KS 309 performance<br />
alloy and the NanofriKS shaft coating,<br />
KS Kolbenschmidt is offering a<br />
high-technology package tailored to<br />
customer needs, one that in terms of<br />
friction and weight reductions makes<br />
a major contribution to the <strong>de</strong>velopment<br />
of low-CO 2 gasoline engines.<br />
Atag: sophisticated casting technology<br />
for downsized engines<br />
As mentioned above, downsizing<br />
accompanied by performance compensation<br />
through specific output<br />
NanofriskS-Beschichtung NanofriskS piston coating<br />
enhancement is a trend that entails a<br />
sharp rise in engine component stress.<br />
So, there is a concurrent <strong>de</strong>mand for<br />
small, lightweight yet high-strength<br />
engine blocks that are, moreover,<br />
very economical to manufacture.<br />
Against this background, KS <strong>Alu</strong>minium-Technologie<br />
(Atag) – which<br />
belongs to Kolbenschmidt Pierburg<br />
as well as sister company KS Kolbenschmidt<br />
– is focusing more closely on<br />
the volume production of aluminium<br />
engine blocks, specifically for small<br />
yet high-duty engines.<br />
Advances in both diesel engine<br />
combustion and direct-injection<br />
gasoline engines with either turbocharger<br />
or compressor entail higher<br />
ignition pressures and, specifically,<br />
bearing block bur<strong>de</strong>ns. On the other<br />
hand, the repeated shrinkage in ➝<br />
beschichtung mit Nanopartikeln im<br />
Vergleich zu bestehen<strong>de</strong>n Kolbenbeschichtungen<br />
bis zu zehn Prozent<br />
weniger Reibung und bis zu fünfzig<br />
Prozent weniger Verschleiß auf. Dies<br />
gewährleistet eine hohe Zuverlässigkeit<br />
und optimale Performance im<br />
Motorbetrieb.<br />
Zum Einsatz kommt die Nanobeschichtung<br />
unter an<strong>de</strong>rem im Leichtbaukolben<br />
LiteKS-2, <strong>de</strong>r ebenfalls<br />
2007 vorgestellt wur<strong>de</strong>. Er stieß seither<br />
auf eine durchweg hohe Kun<strong>de</strong>nresonanz<br />
und spielt die Hauptrolle in<br />
allen aktuellen globalen Otto-Serienprojekten<br />
<strong>de</strong>s Herstellers. In <strong>de</strong>n letzten<br />
zwei Jahren wur<strong>de</strong> LiteKS-2 weiterentwickelt.<br />
Der Kolben weist jetzt<br />
noch größere Gewichtseinsparungen<br />
von insgesamt etwa 25 Prozent bei<br />
konstant hoher Schaftreibungsreduktion<br />
von bis zu 50 Prozent gegenüber<br />
Standard-Ottokolben<br />
auf. Zusammen<br />
mit <strong>de</strong>r neuen<br />
Legierung KS 309<br />
sowie <strong>de</strong>r SchaftbeschichtungNanofriKS<br />
bietet KS<br />
K o l b e n s c h m i d t<br />
damit ein auf die<br />
Bedürfnisse seiner<br />
Kun<strong>de</strong>n maßg<br />
e s c h n e i d e r t e s<br />
Hochleistungstechnologiepaket<br />
an,<br />
das hinsichtlich<br />
Reibung und Gewichtsreduktion<br />
einen wesentlichen<br />
Beitrag zur Entwicklung CO2-opti mierter Ottomotoren leisten wird.<br />
Atag: Weiterentwickelte Gießtechnik<br />
für downgesizte Motoren<br />
Ähnlich wie KS Kolbenschmidt reagiert<br />
die Schwestergesellschaft KS<br />
<strong>Alu</strong>minium-Technologie GmbH – bei<strong>de</strong><br />
gehören zur Obergesellschaft Kolbenschmidt<br />
Pierburg – auf <strong>de</strong>n Trend<br />
zum Downsizing. Die damit einhergehen<strong>de</strong><br />
Leistungskompensation durch<br />
eine Steigerung <strong>de</strong>r spezifischen<br />
Leistung führt zu einer drastischen<br />
Erhöhung <strong>de</strong>r Bauteilbeanspruchung<br />
im Motor. Dies verlangt nach sehr<br />
wirtschaftlich herstellbaren, kleinen,<br />
leichten und <strong>de</strong>nnoch hochfesten<br />
Zylin<strong>de</strong>rkurbelgehäusen. Vor ➝<br />
Velocity + Length<br />
Angewandte Sensortechnik<br />
Schonenfahrerstr. 5<br />
D-18057 Rostock<br />
Germany<br />
Tel. #49 381 44073-0<br />
FAX #49 381 44073-20<br />
www.astech.<strong>de</strong><br />
info@astech.<strong>de</strong><br />
A U t o M o t I v E<br />
23 ALUMINIUM · 9/2009<br />
ALUMINIUM · 9/2009 23<br />
Non Contact Measurement with Light<br />
VLM 250
A L U M I N I U M I M A U t o M o b I L<br />
Produktion bei Atag Production at Atag<br />
diesem Hintergrund richtet sich die<br />
KS <strong>Alu</strong>minium-Technologie (Atag)<br />
stärker auf die Volumenfertigung von<br />
<strong>Alu</strong>minium-Zylin<strong>de</strong>rkurbelgehäusen<br />
speziell für kleine Hochleistungsmotoren<br />
aus.<br />
Die weitere Optimierung <strong>de</strong>r dieselmotorischen<br />
Verbrennung, aber<br />
auch die Benzindirekteinspritzung<br />
mit Abgasturboaufladung o<strong>de</strong>r Kompressor<br />
beim Ottomotor lassen die<br />
Zünddrücke und damit speziell die<br />
Lagerstuhlbeanspruchung weiter<br />
steigen. An<strong>de</strong>rerseits verstärken die<br />
stetige Reduzierung von Hubraum<br />
und Zylin<strong>de</strong>rzahl <strong>de</strong>n Kostendruck,<br />
dies verlangt möglichst kostengünstige<br />
Bauteilkonzepte. Verfahrensbedingt<br />
eignet sich gera<strong>de</strong> <strong>de</strong>r Druckguss<br />
für eine kosteneffiziente Massenfertigung,<br />
doch liefert herkömmlicher<br />
Druckguss nicht die erfor<strong>de</strong>rliche<br />
Bauteilqualität.<br />
Atag stellte bereits zur IAA 2007<br />
mit ihrem „Modularen Druckgusskonzept“<br />
Lösungen zur Festigungssteigerung<br />
downgesizter Zylin<strong>de</strong>rkurbelgehäuse<br />
vor. Basierend darauf<br />
entwickelte das Unternehmen Kurbelgehäuse<br />
für einen kleinen R4-<br />
Zylin<strong>de</strong>r-DI-Dieselmotor mit einem<br />
Zünddruck von mehr als 200 bar.<br />
Die erfor<strong>de</strong>rliche statische und dynamische<br />
Festigkeitssteigerung basiert<br />
dabei auf uneingeschränkt wärmebehan<strong>de</strong>lbarem<br />
Druckguss. Dieser<br />
beinhaltet neben zahlreichen Einzelmaßnahmen<br />
eine optimal behan<strong>de</strong>lte<br />
Schmelze, eine stark evakuierte<br />
Druckgießform und ein innovatives<br />
Formkühlungskonzept. Die geringen<br />
Gaseinschlüsse entsprechen einem<br />
niedrigen Porositätsgrad auf Kokillengussniveau.<br />
Dies ist eine Grundvoraussetzung<br />
für höhere Festigkeit<br />
und <strong>de</strong>ren weiterer Steigerung mittels<br />
einer Wärmebehandlung. Die geringe<br />
Porosität im Zylin<strong>de</strong>rbohrungsbereich<br />
eröffnet zu<strong>de</strong>m die Option einer<br />
Laufflächenbeschichtung.<br />
Darüber hinaus hat Atag ein innovativesSchwerkraft-Kippgießverfahren<br />
entwickelt, das <strong>de</strong>n beson<strong>de</strong>ren<br />
Anfor<strong>de</strong>rungen hoch beanspruchter<br />
Motoren gerecht wird. Hintergrund<br />
ist hier, dass sich Gusslegierungen<br />
in Form hochwertiger AlSiMg-<br />
Primärlegierungen im Motorbetrieb<br />
großer Anfor<strong>de</strong>rungen hinsichtlich<br />
<strong>de</strong>r thermomechanischen Festigkeit<br />
gegenübersehen. Die heutigen<br />
Anfor<strong>de</strong>rungen an die Lebensdauer<br />
von Motoren können nur mit einem<br />
äußerst feinen Gussgefüge lokal im<br />
engine displacement and number of<br />
cylin<strong>de</strong>rs has stepped up cost pressure<br />
and called for components engineered<br />
for maximum cost efficiency.<br />
In terms of manufacturing process,<br />
pressure die-casting is i<strong>de</strong>al for highvolume,<br />
low-cost production, albeit<br />
in its conventional form failing to<br />
<strong>de</strong>liver the necessary component<br />
quality.<br />
Already at the IAA 2007, Atag<br />
presented in the form of its modular<br />
die-casting strategy a number of options<br />
including some for enhancing<br />
the strength of downsized engine<br />
blocks. On the basis of this particular<br />
modular option, the company has<br />
<strong>de</strong>veloped engine blocks for a small<br />
inline 4-cylin<strong>de</strong>r diesel engine with<br />
an ignition pressure that breaks the<br />
200-bar barrier.<br />
The necessary gain in strength<br />
(both static and dynamic) is based on<br />
the use of diecast parts with unlimited<br />
heat-treatability. This is the outcome<br />
of, besi<strong>de</strong>s numerous individual<br />
measures, optimum melt treatment, a<br />
largely evacuated die, and an innovative<br />
die-cooling system. The much<br />
reduced gas occlusions signify a low<br />
level of porosity on a par with permanent-mould<br />
casting. In fact, this is<br />
24 ALUMINIUM · 9/2009
S P E C I A L<br />
A L U M I N I U M I M A U t o M o b I L<br />
a prime requisite for ad<strong>de</strong>d strength<br />
which is further enhanced through<br />
heat treatment. Moreover, the slight<br />
porosity in the cylin<strong>de</strong>r bore zone<br />
opens up the option of coating the<br />
working surface.<br />
Furthermore, Atag has <strong>de</strong>veloped<br />
an innovative inhouse gravity tilt<br />
casting technique inten<strong>de</strong>d for the<br />
<strong>special</strong> operating environment of<br />
high-duty engines, as aluminium in<br />
the form of aluminium castings from<br />
high-gra<strong>de</strong> AlSiMg primary alloys<br />
poses vast challenges regarding thermal<br />
strength. Durability benchmarks<br />
are only addressable with the aid of<br />
an extremely fine microstructure<br />
in the combustion zone of the fire<br />
<strong>de</strong>ck.<br />
One solution to this problem is the<br />
new gravity tilt casting process as it<br />
guarantees a largely low-turbulence<br />
mould-filling at the camshaft end and<br />
a rising layer-by-layer filling of the<br />
mould promoted by the tilting action.<br />
A <strong>de</strong>cisive factor is the highly intense<br />
chilling of the combustion zone at the<br />
fire <strong>de</strong>ck si<strong>de</strong>. The achievable low<br />
<strong>de</strong>ndrite arm spacing reaches benchmark<br />
level.<br />
Another plank in the Atag business<br />
strategy of reducing <strong>de</strong>pen<strong>de</strong>ncy on<br />
engine products is the casting of large<br />
and technologically challenging chassis/suspension<br />
parts in aluminium, a<br />
move that will bolster the company’s<br />
automotive business.<br />
Sectional view of cylin<strong>de</strong>r head cast by gravity tilt casting technique<br />
Brennraumbereich <strong>de</strong>s Feuer<strong>de</strong>cks<br />
erfüllt wer<strong>de</strong>n.<br />
Das neue Schwerkraft-Kippgießverfahren<br />
trägt zur Problemlösung<br />
bei, in<strong>de</strong>m es für eine weitgehend<br />
turbulenzarme Formfüllung auf <strong>de</strong>r<br />
Nockenwellenseite und eine vom<br />
Kippvorgang begünstigte, schichtend<br />
steigen<strong>de</strong> Füllung <strong>de</strong>r Kokille sorgt.<br />
Von entschei<strong>de</strong>n<strong>de</strong>r Be<strong>de</strong>utung ist<br />
dabei eine höchst intensive Abschreckung<br />
<strong>de</strong>s Brennraumbereichs auf <strong>de</strong>r<br />
Feuer<strong>de</strong>ckseite. Hierbei erreicht <strong>de</strong>r<br />
A U t o M o t I v E<br />
Mit ihrem modularen Druckgusskonzept steigert Atag die Festigkeit downgesizter<br />
Zylin<strong>de</strong>rkurbelgehäuse<br />
Atag has <strong>de</strong>veloped the modular die-casting concept for enhancing the strength of downsized<br />
engine blocks<br />
erzielbare, geringe Dendritenarmabstand<br />
Atag zufolge „Benchmarkniveau“.<br />
Zukünftig soll ein gänzlich neues<br />
Produktfeld das Atag-Geschäft unabhängiger<br />
vom Antriebskonzept machen.<br />
Dazu gehört beispielsweise das<br />
Gießen großer und komplexer, mithin<br />
gießtechnisch herausfor<strong>de</strong>rn<strong>de</strong>r<br />
Fahrwerksteile aus <strong>Alu</strong>minium. Mit<br />
dieser Neuausrichtung wird das Unternehmen<br />
sein Automotive-Geschäft<br />
weiter stärken.<br />
■ ■<br />
25 ALUMINIUM · 9/2009<br />
ALUMINIUM · 9/2009 25
Honsel<br />
A L U M I N I U M I M A U t o M o b I L<br />
Zylin<strong>de</strong>rköpfe von Honsel für<br />
die neuen vW-Dieselmotoren<br />
Zu <strong>de</strong>n Highlights, die Honsel<br />
auf <strong>de</strong>r diesjährigen Ausstellung<br />
„Zulieferer Innovativ“ in Ingolstadt<br />
präsentierte, gehörten die<br />
Zylin<strong>de</strong>rköpfe für die neuen, auf<br />
Common Rail-Technologie basieren<strong>de</strong>n<br />
Zweiliter-Dieselmotoren<br />
von Volkswagen und Audi, die im<br />
VW Golf VI, Tiguan und Passat sowie<br />
im Audi A3, A4 und Q5 zum<br />
Einsatz kommen. Die Motoren<br />
sind beson<strong>de</strong>rs sparsam und leistungsstark.<br />
Mit steigen<strong>de</strong>r Effizienz nimmt die<br />
Belastung <strong>de</strong>r einzelnen Komponenten<br />
zu, insbeson<strong>de</strong>re <strong>de</strong>r aus <strong>Alu</strong>minium<br />
gegossenen Zylin<strong>de</strong>rköpfe. Das<br />
von Honsel eingesetzte Kipp-Kokil-<br />
Im Kipp-Kokillenguss produzierter Zylin<strong>de</strong>rkopf von Honsel<br />
Cylin<strong>de</strong>r head from Honsel, produced in permanent mould<br />
tilt casting process<br />
lengießverfahren ermöglicht es, die<br />
hohen Anfor<strong>de</strong>rungen zu erfüllen und<br />
die notwendige Gefügequalität zu gewährleisten.<br />
Die Zylin<strong>de</strong>rköpfe müssen vor<br />
allem hohe Festigkeitsanfor<strong>de</strong>rungen<br />
erfüllen, um die hohen Zünddrücke<br />
zu ertragen, sind aber auch sehr<br />
dünnwandig konstruiert, um während<br />
<strong>de</strong>s Motorbetriebs eine optimale<br />
Brennraumkühlung zu gewährleisten<br />
und insgesamt Gewicht einzusparen.<br />
Da zu<strong>de</strong>m eine beson<strong>de</strong>rs hohe Gussqualität<br />
im Bereich <strong>de</strong>s Brennraums<br />
gefor<strong>de</strong>rt ist, wer<strong>de</strong>n sie im Kipp-<br />
Kokillengießverfahren hergestellt.<br />
Bei diesem Gießverfahren wird das<br />
flüssige <strong>Alu</strong>minium über eine spezielle<br />
Angussleiste turbulenzarm in<br />
<strong>de</strong>n Formhohlraum gefüllt. Während<br />
<strong>de</strong>s Gießvorgangs wird die Kokille gekippt,<br />
was die Gefahr <strong>de</strong>r Oxidbildung<br />
<strong>de</strong>s <strong>Alu</strong>miniums reduziert. Das Ergebnis<br />
ist ein poren- und oxidarmes Gefüge,<br />
auch in <strong>de</strong>n nur 2,5 mm dünnen<br />
Bauteilwän<strong>de</strong>n. Dies ist beson<strong>de</strong>rs<br />
wichtig, um das Potenzial <strong>de</strong>s <strong>Alu</strong>miniumwerkstoffs<br />
über <strong>de</strong>n vollen<br />
Querschnitt ausnutzen zu können.<br />
Schließlich sind die Zylin<strong>de</strong>rköpfe<br />
gera<strong>de</strong> an diesen filigranen Stellen<br />
beson<strong>de</strong>rs stark belastet.<br />
Volkswagen hat Honsel schon in<br />
einer sehr frühen Entwicklungshase<br />
<strong>de</strong>r neuen Dieselmotorenbaureihe<br />
einbezogen,<br />
sodass die gießereispezifische<br />
Auslegung <strong>de</strong>s<br />
Bauteils und die<br />
entsprechen<strong>de</strong><br />
Fertigungsvorbereitung<br />
in<br />
sehr kurzer Zeit<br />
umgesetzt wer<strong>de</strong>n<br />
konnte. Innerhalb<br />
von nur<br />
zwölf Wochen<br />
stellte Honsel<br />
erste Prototypen<br />
für Motorentests<br />
zur Verfügung.<br />
Im Zeitraum<br />
von zwei Jahren<br />
erfolgten die weitere Serienentwicklung<br />
und <strong>de</strong>r Aufbau <strong>de</strong>r Serienfertigung.<br />
Dabei halfen Formfüll- und<br />
Erstarrungssimulationen, die Werkzeugauslegung<br />
und Gießtechnik zu<br />
optimieren. Parallel wur<strong>de</strong>n Funktion<br />
und Festigkeit <strong>de</strong>s Bauteils zusammen<br />
mit Volkswagen ständig weiterentwickelt.<br />
Nach<strong>de</strong>m im November 2006 die<br />
erste Seriengießmaschine in Betrieb<br />
genommen wur<strong>de</strong>, lieferte Honsel allein<br />
2008 rund 300.000 Zylin<strong>de</strong>rköpfe<br />
für <strong>de</strong>n neuen Zweiliter-Dieselmotor<br />
an Volkswagen.<br />
Cylin<strong>de</strong>r heads from<br />
Honsel for new vW<br />
diesel engines<br />
Among the highlights which<br />
Honsel presented at a suppliers<br />
exhibition in Ingolstadt, Germany,<br />
were the cylin<strong>de</strong>r heads for the<br />
Volkswagen Group’s new 2.0 litre<br />
diesel engines with common-rail<br />
high-pressure injection to be used<br />
in the VW Golf VI, Tiguan and Passat,<br />
as well as the Audi A3, A4 and<br />
Q5. These engines are e<strong>special</strong>ly<br />
economical and powerful.<br />
With increasing efficiency, however,<br />
stress on the individual components<br />
grows, e<strong>special</strong>ly on the cylin<strong>de</strong>r<br />
heads cast in aluminium. The permanent<br />
mould tilt casting method<br />
applied by Honsel meets these high<br />
<strong>de</strong>mands and contributes to the required<br />
structural quality.<br />
To cope with the high ignition pressures,<br />
the cylin<strong>de</strong>r heads have to meet<br />
high <strong>de</strong>mands regarding strength. At<br />
the same time, they are <strong>de</strong>signed with<br />
very thin walls to ensure optimum<br />
combustion chamber cooling and to<br />
reduce the overall weight.<br />
As a particularly high casting quality<br />
is also nee<strong>de</strong>d in the area of the<br />
combustion chamber, they are produced<br />
in the permanent mould tilt<br />
casting method. In this casting process,<br />
the liquid aluminium is poured<br />
into the mould cavity with low turbulence<br />
via a <strong>special</strong> gating strip. The<br />
mould is tilted during the casting<br />
process to reduce the risk of the aluminium<br />
forming oxi<strong>de</strong>s. The result is a<br />
low-pore and low-oxi<strong>de</strong> joint, even in<br />
the only 2.5 mm thin walls of the component.<br />
This is e<strong>special</strong>ly important to<br />
exploit the potential of the aluminium<br />
over the entire cross-section. After all,<br />
the cylin<strong>de</strong>r heads face particularly<br />
strong loads at these <strong>de</strong>licate points.<br />
Volkswagen involved Honsel already<br />
at a very early stage into the <strong>de</strong>velopment<br />
of the new series of diesel<br />
engines, so that the foundry-specific<br />
<strong>de</strong>sign of the component and the corresponding<br />
production preparation<br />
could be realised in the shortest possible<br />
time: Honsel provi<strong>de</strong>d the first<br />
prototypes for engine testing within<br />
only twelve weeks. Further series <strong>de</strong>-<br />
26 ALUMINIUM · 9/2009
A S LPU M E ICN I UA M L I M A U t o M o b I L A U t o M o t I v E<br />
velopment and the set-up for series<br />
production took place over a period<br />
of two years. Mould pouring and solidification<br />
simulations helped to optimise<br />
the tooling <strong>de</strong>sign and casting<br />
technique. In parallel, the function<br />
and strength of the component un<strong>de</strong>rwent<br />
continuous further <strong>de</strong>velopment<br />
together with Volkswagen.<br />
After putting the first series casting<br />
machine into operation in November<br />
2006, Honsel <strong>de</strong>livered 300,000 cylin<strong>de</strong>r<br />
heads for the new engine to<br />
Volkswagen in 2008 alone.<br />
Financial restructuring of<br />
Honsel completed successfully<br />
The financial restructuring of Honsel<br />
has been successfully completed, and<br />
the company’s new capital and sharehol<strong>de</strong>r<br />
structure has now been put in<br />
place. Honsel’s term <strong>de</strong>bt to the len<strong>de</strong>rs<br />
un<strong>de</strong>r its syndicated credit agreements<br />
has been reduced from over<br />
510 to 140 million euros. The main<br />
sharehol<strong>de</strong>r, RHJ International, is injecting<br />
50 million euros of new capital<br />
in return for a 51% shareholding<br />
in the restructured Honsel group. In<br />
return for waiving a large portion of<br />
the <strong>de</strong>bt held by them, a consortium of<br />
senior len<strong>de</strong>rs, led by BlueBay Asset<br />
Management and Oaktree, will take a<br />
49% stake in Honsel.<br />
The company’s employees are also<br />
making a significant contribution to<br />
restructuring the company and securing<br />
its future. A combination of<br />
reduced hours and shorter working<br />
weeks is <strong>de</strong>signed to avoid redundancies<br />
and retain know-how within the<br />
company. Moreover, non-tariff and<br />
managerial staff are waiving substantial<br />
portions of their salaries.<br />
Honsel sees attractive market opportunities<br />
in the medium and long<br />
term due to the stricter requirements<br />
for reduction of fuel consumption and<br />
CO2 emissions. This will lead to the<br />
increased use of light metal components,<br />
particularly for powerful yet<br />
economical small engines. With high<br />
strength components and a breakthrough<br />
method for coating cylin<strong>de</strong>r<br />
linings, Honsel is generating new opportunities<br />
for car manufacturers to<br />
use weight-reducing light metals.<br />
■<br />
ALUMINIUM · 9/2009<br />
Finanzielle Restrukturierung<br />
erfolgreich abgeschlossen<br />
Die finanzielle Restrukturierung <strong>de</strong>r<br />
Honsel AG ist inzwischen erfolgreich<br />
abgeschlossen wor<strong>de</strong>n. Damit ist die<br />
neue Kapital- und Eigentümerstruktur<br />
<strong>de</strong>s Unternehmens wirksam. Die Verbindlichkeiten<br />
gegenüber <strong>de</strong>n Banken<br />
sinken von 510 auf 140 Mio. Euro. Der<br />
Hauptanteilseigner RHJ International<br />
S.A. führt 50 Mio. Euro neues Kapital<br />
zu und wird weiterhin 51 Prozent<br />
<strong>de</strong>r Anteile halten. Im Gegenzug für<br />
einen weitgehen<strong>de</strong>n Schul<strong>de</strong>nverzicht<br />
übernimmt ein Konsortium von<br />
Kreditgebern, geführt durch BlueBay<br />
Asset Management und Oaktree, 49<br />
Prozent <strong>de</strong>r Anteile an <strong>de</strong>m Leichtmetallzulieferer.<br />
Einen wesentlichen Beitrag zur<br />
Restrukturierung und Zukunftssicherung<br />
erbringen auch die Mitarbeiter<br />
von Honsel. Mit einer auf die<br />
betrieblichen Erfor<strong>de</strong>rnisse abgestellten<br />
Kombination aus Kurzarbeit<br />
und verringerter Wochenarbeitszeit<br />
sollen betriebsbedingte Kündigungen<br />
vermie<strong>de</strong>n und das Know-how im<br />
www.gutmann-group.com<br />
Unternehmen gehalten wer<strong>de</strong>n. Die<br />
außertariflichen und leiten<strong>de</strong>n Angestellten<br />
leisten einen erheblichen<br />
Gehaltsverzicht.<br />
Anzeige<br />
Mittel- und langfristig attraktive<br />
Marktchancen sieht das Unternehmen<br />
aufgrund <strong>de</strong>r verschärften For<strong>de</strong>rungen<br />
zur Reduktion von Kraftstoffverbrauch<br />
und CO2-Emissionen. Dies wird zu einem erhöhten Einsatz<br />
von Leichtmetallkomponenten führen,<br />
nicht zuletzt für leistungsstarke<br />
und zugleich verbrauchsarme kleine<br />
Motoren. Mit beson<strong>de</strong>rs belastbaren<br />
Komponenten und einem innovativen<br />
Verfahren zur Beschichtung von Zylin<strong>de</strong>rlaufflächen<br />
eröffnet Honsel <strong>de</strong>n<br />
Automobilherstellern gera<strong>de</strong> beim<br />
Downsizing neue Perspektiven für<br />
<strong>de</strong>n Einsatz von Gewicht sparen<strong>de</strong>m<br />
Leichtmetall.<br />
■<br />
MEHR ERFAHRUNG. MEHR KOMPETENZ. MEHR NUTZEN.<br />
G U T M A N N - E I N E G R U P P E M I T P R O F I L<br />
HERMANN GUTMANN WERKE AG | GARTNER EXTRUSION GMBH | NORDALU GMBH
A U t o M o t I v E<br />
<strong>Alu</strong>minium in innovative light-weight car <strong>de</strong>sign<br />
J. Hirsch, Bonn 1<br />
This paper presents principal<br />
aspects and recent trends in average<br />
and specific use of aluminium<br />
in passenger cars. Aspects of<br />
material selection and innovative<br />
concepts of car construction using<br />
light-weight materials that help to<br />
meet economical and environmental<br />
requirements are discussed<br />
as well as <strong>special</strong> aluminium<br />
alloys <strong>de</strong>veloped for the increasing<br />
<strong>de</strong>mands in higher strength<br />
and better formability for light<br />
weighting and crash worthiness<br />
aspects and the specific advances<br />
of aluminium semi products as<br />
castings, extrusions and sheet.<br />
Examples are presented for successful<br />
aluminium solutions in the<br />
most advanced SLC ’SuperLIGHT-<br />
Car’ concept, which reaches 34%<br />
weight reduction within a cost<br />
increment of 7.8 €/kg saved.<br />
The European automotive industry is<br />
known world wi<strong>de</strong> as the technically<br />
most advanced and innovative. Based<br />
on economical and political pressure<br />
to reduce fuel consumption and CO 2<br />
emission the efforts for light weighting<br />
in automobile <strong>de</strong>sign and constructions<br />
have increased significantly and<br />
specific solutions based on the inten-<br />
1 This paper was presented at the Volkswagen<br />
Conference ’Innovative Developments for Lightweight<br />
Vehile Structures’ on 26/27 May 2009.<br />
Fig. 1: State-of-the-art ’body in white’ multimaterial concept<br />
sive use of aluminium as modified or<br />
new alloys have been <strong>de</strong>veloped in<br />
the last <strong>de</strong>ca<strong>de</strong>s [1-5]. The European<br />
automotive industry has more than<br />
doubled the average amount of aluminium<br />
used in passenger cars during<br />
the last <strong>de</strong>ca<strong>de</strong> and will do even more<br />
so in the coming years.<br />
The European automotive industry’,<br />
in close co-operation with the<br />
European aluminium industry, has<br />
<strong>de</strong>veloped and introduced numerous<br />
innovative light-weighting solutions<br />
based on established and improved<br />
aluminium alloys [2-9] and optimized<br />
aluminium oriented car <strong>de</strong>sign. Synergic<br />
effect together with a multimaterial<br />
exploitation can guarantee<br />
an optimum <strong>de</strong>sign solution. One of<br />
the main advances of aluminium is its<br />
availability in a large variety of semifinished<br />
forms, such as shape castings,<br />
extrusions and sheet, all suitable for<br />
mass production and innovative solutions.<br />
Compact and highly integrated<br />
parts meet the high <strong>de</strong>mands for high<br />
performance, quality and cost efficient<br />
manufacturability. Challenges<br />
involved here are mainly joining and<br />
surface treatment issues for which<br />
many suitable solutions have been<br />
<strong>de</strong>veloped. <strong>Alu</strong>minium semis are applied<br />
as castings, extrusions and sheet<br />
increases, e. g. in engine blocks and<br />
power train parts, space frames (e. g.<br />
Audi A8, BMW Z8, Lotus Elise), sheet<br />
structures (Honda NSX, Jaguar) or as<br />
closures and hang-on parts (e.g. Daimler<br />
E-class, Renault, Peugeot) and other<br />
structural components [1-3].<br />
The average total aluminium content<br />
per European car was 132 kg in<br />
2005 [9]. It has been analysed systematically<br />
as:<br />
• Power-train (engine, fuel system,<br />
liquid lines): 69 kg (25 compo-<br />
nents analysed) in engine block<br />
and cylin<strong>de</strong>r head, transmission<br />
housings and radiators<br />
• Chassis and suspension (cradle,<br />
axle): 37 kg (17 components<br />
analysed) in wheels, suspension<br />
arms and steering systems<br />
• Car body (body-in-white (BIW),<br />
hoods, doors, wings, bumpers and<br />
interiors): 26 kg (20 components<br />
analysed) in bonnets and doors,<br />
front structure and bumper beams.<br />
This shows that for the body the most<br />
potential exists. Seen as one component<br />
the BIW is the heaviest part of<br />
a conventional car with a share between<br />
25 and 30% of the complete<br />
car’s weight, <strong>de</strong>pending mainly on<br />
options installed, engine size, and integrated<br />
safety features.<br />
State-of-the-art<br />
for the body in white (bIW)<br />
As state-of-the-art for a BIW ’extrusion<br />
intensive <strong>de</strong>sign’ the Aston Martin<br />
Vanquish, mo<strong>de</strong>l year 2001, is<br />
mentioned with a volume of 350 cars<br />
28 ALUMINIUM · 9/2009<br />
Images: Hydro
S P E C I A L<br />
A L U M I N I U M I M A U t o M o b I L<br />
per year. It has a BIW mass of 145 kg<br />
(excluding closures and outer skin),<br />
consisting of 40 extrusion (100 kg)<br />
and 40 sheet parts (45 kg) with joining<br />
methods used of rivets and adhesive<br />
bonding. With a volume of 2,500 cars<br />
per year the BMW Z8 Roadster has a<br />
BIW mass of 300 kg with 86 straight<br />
and 24 bend extrusion parts, 24 bent<br />
parts, no castings and 290 sheet parts.<br />
As joining methods MIG welding and<br />
rivets (1,000 pcs) are applied.<br />
The state-of-the-art space frame<br />
concept is the Audi A8 (D3), mo<strong>de</strong>l<br />
year 2002, with a scheduled volume<br />
of 25,000 cars per year and a BIW<br />
mass of 277 kg, consisting of 59 extrusions<br />
with 61 kg, 31 castings with<br />
39 kg and 170 sheet parts with 177 kg.<br />
Rivets (2,400 pcs), MIG, laser, laserhybrid<br />
welds, roll-folding, adhesive<br />
bonding are the main joining methods<br />
applied.<br />
In the category of ’stamped sheet<br />
monocoque’ the Jaguar XJ, mo<strong>de</strong>l<br />
year 2002, must be mentioned with<br />
30,000 cars per year (scheduled) and<br />
a BIW mass of 295 kg, consisting of<br />
22 extrusions with 21 kg, 15 castings<br />
with 15 kg and 273 sheets with 259<br />
kg. Joining methods used are mainly<br />
adhesive, rivets (3,000 pcs), clinches<br />
and MIG welding.<br />
For the new concept of ’multi-material<br />
<strong>de</strong>signs’ (for high volume cars)<br />
is an alternative to the all-aluminium<br />
<strong>de</strong>signs of BIW’s mentioned above. It<br />
consists of applications of aluminium<br />
together with high and ultra-high<br />
strength steels, magnesium and plastics<br />
or composites, where applicable.<br />
The principle i<strong>de</strong>a is to use the ‘best’<br />
material for the appropriate functions.<br />
The additional goal is to achieve an<br />
overall cost efficient light-weight <strong>de</strong>sign.<br />
Here, state-of-the-art in this area<br />
is BMW 5 (E60) (Fig. 1) which uses<br />
20% as <strong>de</strong>ep drawing steels, 42% as<br />
higher strength steels, 20% as highest<br />
strength steels and 18% aluminium<br />
alloys. The front-end substructure<br />
consists of 16.4 kg steel and 29.4 kg<br />
in 86 aluminium parts (as stamped<br />
sheet, extrusions, high-pressure die<br />
castings, and hydroformed tubes).<br />
Wrought aluminium alloys<br />
for automotive applications<br />
In the multi-material SLC <strong>de</strong>sign the<br />
contribution of the aluminium concern<br />
new alloys as well as alternative production<br />
methods for aluminium parts.<br />
<strong>Alu</strong>minium sheet is predominantly<br />
used for BIW panels and closures.<br />
Despite the existing ‘all aluminium<br />
vehicles’ like Audi A8 and Jaguar XJ,<br />
aluminium in mass produced vehicles<br />
needs to reduce <strong>de</strong>velopment time and<br />
other additional costs in new production<br />
methods and/or new alloys.<br />
The main aluminium alloy classes<br />
for automotive sheet application are<br />
the non-heat treatable Al-Mg (EN<br />
5xxx series) and the heat treatable Al-<br />
Mg-Si (EN 6xxx series) alloy system,<br />
some e<strong>special</strong>ly tailored by variations<br />
in chemical composition and processing,<br />
e. g. Al-Mg alloys optimized for<br />
strength and corrosion resistance for<br />
use in chassis or Al-Mg-Si alloys applied<br />
for autobody sheets have been<br />
improved for formability, surface appearance<br />
and age har<strong>de</strong>ning response.<br />
The specific properties and principal<br />
differences are illustrated in Fig. 2.<br />
The effects of varying alloy additions<br />
and process parameters as <strong>de</strong>scribed<br />
A U t o M o t I v E<br />
in [4] are well <strong>de</strong>veloped and controlled<br />
for enhanced performance and efficient<br />
manufacturing.<br />
Age har<strong>de</strong>ning Al-Mg-Si alloys:<br />
6xxx series alloys contain magnesium<br />
and silicon. Current 6xxx alloys<br />
used for autobody sheets are AA6016<br />
(Europe) and AA6111 (America)<br />
and, more recently, AA6181A was<br />
ad<strong>de</strong>d for recycling aspects. In the<br />
US, AA6111 is often used for outer<br />
panels in gauges of 0.9 to 1.0 mm<br />
which combines high strength with<br />
good formability. In Europe, EN-6016<br />
is preferred and applied in gauges of<br />
around 1 to 1.2 mm. It shows a superior<br />
formability and filiform corrosion<br />
resistance and allows flat hems even<br />
on parts with local pre-<strong>de</strong>formation.<br />
However, the bake-har<strong>de</strong>ned strength<br />
of AA6016 is significantly lower than<br />
that of AA6111 [6].<br />
In recent years alloy and processing<br />
modifications have been introduced to<br />
meet the increased requirements [5].<br />
Higher strength alloys may allow outer<br />
panel thickness reductions with no<br />
loss of <strong>de</strong>nt resistance, provi<strong>de</strong>d stiffness<br />
requirements are met. As paintbake<br />
temperatures <strong>de</strong>crease, there is<br />
increasing <strong>de</strong>mand for a significantly<br />
higher age har<strong>de</strong>ning response. However,<br />
for some parts formability remains<br />
the major difficulty. Therefore<br />
<strong>special</strong> alloy modifications with either<br />
improved formability or strength have<br />
recently been <strong>de</strong>veloped by European<br />
aluminium sheet manufacturers and<br />
agreed upon as standards by the automotive<br />
industry.<br />
Non heat-treatable Al-Mg-Mn alloys:<br />
Al-Mg-Mn alloys show an optimum<br />
combination of formability and<br />
strength achieved by the mechanism<br />
of solid solution and <strong>de</strong>formation har<strong>de</strong>ning<br />
due to their specific high strain<br />
har<strong>de</strong>ning. Further improvement in<br />
properties required for specific applications<br />
(e. g. surface appearance,<br />
corrosion resistance, thermal stability)<br />
have been achieved by small additions<br />
of other alloy elements and/or<br />
modified processing routes [4, 7, 8, 9],<br />
e. g. stretcher strain free (SSF) sheet,<br />
avoiding Lü<strong>de</strong>rs-lines [10].<br />
Non heat-treatable Al-Mg-Mn alloys<br />
are applied in Europe for auto-<br />
mobile parts in larger quantities as hot<br />
Fig. 2: EN-AW 5xxx and 6xxx alloys competing for car body sheets and cold rolled sheet and hydro- ➝<br />
29 ALUMINIUM · 9/2009<br />
ALUMINIUM · 9/2009 29
A U t o M o t I v E<br />
formed tubes, due to their good formability<br />
which can always be regained<br />
during complex forming operations<br />
by inter-annealing where quenching<br />
is nee<strong>de</strong>d for age har<strong>de</strong>ning. In chassis<br />
parts or wheel applications the benefit<br />
is twofold since the weight reduction<br />
in the unsprung mass of moving<br />
parts additionally enhances driving<br />
comfort and reduces noise levels.<br />
A well established high Mg containing<br />
alloy, AlMg5Mn (AA5182), is<br />
used for high strength and complex<br />
stampings. For 5xxx alloys containing<br />
> 3% Mg the precipitation of ß-<br />
Mg5Al8 particles at grain boundaries<br />
can result in susceptibility to intergranular<br />
corrosion cracking (ICC)<br />
by long term exposure at > 80°C. For<br />
these conditions <strong>special</strong> high Mg alloys<br />
have been <strong>de</strong>veloped with a good<br />
compromise for sufficient strength<br />
and ICC resistance.<br />
For all other cases <strong>special</strong> high<br />
Mg alloys (> 6% Mg) have been introduced<br />
which show high strength and<br />
strain har<strong>de</strong>ning, thus also enhancing<br />
formability. Al-Mg-Mn alloy sheet<br />
has also been successfully applied or<br />
is currently being tested in many parts<br />
for structural support, pedal boxes,<br />
heat reflectors, lever arms, etc.<br />
Al-Mn EN-AW 3xxx alloys are applied<br />
for heat-exchangers which is<br />
another success story of aluminium<br />
sheet and extrusion applications that<br />
started in Europe many years ago. It<br />
is an increasing market with intensive<br />
R&D, established for advanced lightweight<br />
technology for radiators and<br />
air conditioning systems in cars (and<br />
elsewhere) world wi<strong>de</strong>.<br />
New aluminium alloys for automotive<br />
applications: Several new<br />
product <strong>de</strong>velopments were introduced<br />
in the SLC project to meet<br />
specific <strong>de</strong>mands of the BIW that cannot<br />
be met by the present aluminium<br />
alloys. For example, a high Mg 5xxx<br />
alloy <strong>special</strong>ly <strong>de</strong>dicated to warm<br />
forming [12]. New 6xxx alloys and<br />
7xxx alloys for structural applications<br />
were introduced [11], such as ‘crash<br />
alloy’ is used for the crash members in<br />
the front structure of the SLC mo<strong>de</strong>l<br />
or a ‘roof alloy’ with <strong>special</strong> attention<br />
when placed on steel structure.<br />
Here a 6xxx alloy (6013 type) has<br />
been introduced [11] with fast paint<br />
bake response to withstand the thermally<br />
induced plastic <strong>de</strong>formation.<br />
The final SLC structure has a magnesium<br />
roof where the finished roof<br />
is mounted after the BIW has passed<br />
through the paint line. High strength<br />
7xxx alloys applied in aerospace<br />
have been tested in the SLC study to<br />
<strong>de</strong>termine their potential for weight<br />
saving replacing steel in the Golf V Bpillar<br />
for a si<strong>de</strong> impact simulation. The<br />
alloy selected was a 7081 type alloy<br />
with yield strength around 600 MPa in<br />
an artificially aged temper. The result<br />
of the impact simulation shows that a<br />
3.5mm thick 7081 matches the performance<br />
of 2 mm thick boron steel.<br />
More importantly the aluminium part<br />
is 2.4 kg lighter, so achieving a weight<br />
saving of around 40% [11].<br />
Other aspects investigated in <strong>de</strong>tail<br />
in the SLC project were:<br />
• Heat forming is a new technique for<br />
making complex aluminium tubular<br />
shapes using internal gas pressure to<br />
form hollow bodies or tubes within a<br />
warm environment [12]. It provi<strong>de</strong>s a<br />
competitive alternative to hydro- or<br />
superplastic- (SPF) forming.<br />
• Tailor wel<strong>de</strong>d blanks (TWBs) is a<br />
mature product for steel automotive<br />
applications easy to apply to aluminium.<br />
There is only one example of alu-<br />
minium TWBs in series production;<br />
the backplate of the front wheel house<br />
of the Lamborghini Gallardo [11]. The<br />
SLC project proved that aluminium<br />
TWBs can be applied for <strong>de</strong>manding<br />
<strong>de</strong>ep drawn parts at higher volumes.<br />
Fig. 3 shows the geometry of the TWB<br />
and a final result of a pressed part of<br />
door inner. The aluminium TWBs<br />
have been successfully stamped to<br />
produce inner door panels, using a<br />
two-step operation to obtain 140 mm<br />
<strong>de</strong>ep drawing <strong>de</strong>pth without breaks<br />
in laser weld seam. Geometrical accuracy<br />
of stamped panel was checked<br />
and found to be acceptable for production<br />
use, showing that the process<br />
is technical feasible.<br />
Laser brazing steel-aluminium:<br />
The next logical step after steel TWBs<br />
and aluminium TWBs is a combination<br />
steel-aluminium TWB. This, however,<br />
is more complicated because<br />
of the joining of steel to aluminium.<br />
Conventional fusion welding is gives<br />
poor quality joints due to the formation<br />
of brittle Fe-Al intermetallics.<br />
Besi<strong>de</strong>s the well-known technologies<br />
such as mechanical fastening and adhesive<br />
bonding, a recently <strong>de</strong>veloped<br />
technology called laser brazing shows<br />
good potential for joining steel to<br />
aluminium [11].<br />
<strong>Alu</strong>minium in the<br />
final SLC body concept<br />
The final SLC-body concept (Fig. 4)<br />
chosen shows an optimum between<br />
weight reduction of 95 kg (34%), i. e.<br />
a weight saving of 41% vs. reference<br />
(from 65 to 110 kg) and a additional<br />
part costs of 7.8 €/kg. It has an Mg roof<br />
and a steel floor frame (i. e. lighter on<br />
top than un<strong>de</strong>rneath) and torsion ring<br />
of the si<strong>de</strong> structure in form-har<strong>de</strong>ned<br />
high strength steel combined with an<br />
aluminium sheets frame. For the inner<br />
B-pillar TWB steel sheets are used<br />
with an external aluminium skin. <strong>Alu</strong>minium<br />
is used as sheet panels and as<br />
extrusion in front rail and for bumper<br />
and crash elements and in the rear<br />
un<strong>de</strong>rbody rail and wheelhouse structure<br />
as HPDC (high pressure die cast).<br />
Compared to the good formable (conventional)<br />
steel gra<strong>de</strong>s aluminium is<br />
less formable, so the manufacturabil-<br />
Fig. 3: Door inner produced from TWB ity of such parts is not obvious. ➝<br />
30 ALUMINIUM · 9/2009
© Kastenhuber Wergeagentur/Foto<strong>de</strong>sign · Tel. (0 9142) 204 558<br />
S P E C I A L<br />
A L U M I N I U M I M A U t o M o b I L<br />
Fig. 4: Final SLC-body multi material concept<br />
The procedure is to start with a simulation<br />
and by mutual agreement with<br />
<strong>de</strong>sign and engineering <strong>de</strong>partments,<br />
to adapt the <strong>de</strong>sign of a part so it<br />
can be produced (simulated) while it<br />
fulfils all requirements. This interactive<br />
<strong>de</strong>velopment procedure can take<br />
some time, but in case of the SLC <strong>de</strong>monstrator<br />
it is sufficient to show the<br />
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D-91781 Weißenburg<br />
Tel. +49-(0)91 41-8 55 65-0<br />
www.profhal.<strong>de</strong><br />
feasibility, not necessarily to <strong>de</strong>velop<br />
a failure free simulation.<br />
<strong>Alu</strong>minium sheet<br />
forming simulation<br />
As an example the si<strong>de</strong> panel is shown<br />
based on present steel <strong>de</strong>sign. It is a<br />
very difficult part for aluminium be-<br />
A U t o M o t I v E<br />
cause of steep <strong>de</strong>ep drawing around<br />
sharp corners. Easiest – but unrealistic<br />
– solutions for SLC are to split the<br />
panel into more sections or to drastically<br />
change the <strong>de</strong>sign by creating<br />
corners with larger radii. Here the<br />
simulation strategy is to investigate<br />
different options to control material<br />
flow to lower the strain in critical<br />
areas, using AutoForm incremental<br />
software 4.1. Input material data are<br />
taken from the SLC SP2 database<br />
generated, tool geometry is generated<br />
by the program based in the CAD<br />
files of the parts. Fig. 5 shows the<br />
initial simulation. It is obvious that a<br />
straightforward pressing of the part<br />
will not lead to an OK part. Indicated<br />
at the problem areas are the options<br />
to improve the material flow.<br />
To improve the formability of the<br />
si<strong>de</strong> panel draw beads are inclu<strong>de</strong>d<br />
in the centre sections and the radius<br />
is adjusted to 10 mm in the doors.<br />
Increasing the radius and the draw<br />
beads are clearly an improve- ➝<br />
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31 ALUMINIUM · 9/2009<br />
ALUMINIUM · 9/2009 31<br />
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A L U M I N I U M I M A U t o M o b I L<br />
Fig. 5: Initial simulation of SLC si<strong>de</strong> panel in aluminium<br />
ment. It is obvious that the new simulation<br />
is safer (more green area). Some<br />
critical areas disappeared and some<br />
have become less critical. This can<br />
also be observed when comparing<br />
the FLD plots. The red area is clearly<br />
shifted from critical <strong>de</strong>ep drawing on<br />
the left si<strong>de</strong> to the middle section. One<br />
option to go forward is to further optimise<br />
the <strong>de</strong>ep drawing process with<br />
simulation in or<strong>de</strong>r to reduce the red<br />
zones. However, this middle zone of<br />
an FLC is typically an area that is also<br />
strongly influenced by friction and<br />
typically friction is one of the parameters<br />
that can easily be controlled in<br />
prototyping.<br />
Therefore, this is the point where<br />
simulation shows that the si<strong>de</strong> panel<br />
is feasible in aluminium. The proposed<br />
layout of the <strong>de</strong>ep drawing process<br />
behind the simulation from Fig.<br />
6 is taken as the starting point for the<br />
prototype toolmakers. The part being<br />
produced now is perfect. Thus simulations<br />
are used as a last but necessary<br />
step to <strong>de</strong>scribe conditions of the <strong>de</strong>ep<br />
drawing process for the manufacturability<br />
of aluminium parts. <strong>Alu</strong>minium<br />
makes an important contribution to<br />
this multi-material concept due to the<br />
favourable combination of low <strong>de</strong>nsity<br />
and low production costs, with<br />
aluminium solutions easily applicable<br />
for high volume production.<br />
Extrusions<br />
Another wi<strong>de</strong> field of aluminium solutions<br />
and applications is opened by<br />
making use of the well established<br />
technology of aluminium extrusions.<br />
Here quite complex shapes of profiles<br />
can be achieved allowing innovative<br />
light weight <strong>de</strong>sign with integrated<br />
functions. In Europe complete new<br />
and flexible car concepts (e. g. the<br />
aluminium space frame) and complex<br />
sub-structures (e. g. in chassis<br />
parts, bumpers, crash elements, air<br />
bags, etc.) have been <strong>de</strong>veloped using<br />
aluminium extrusions. Their high potential<br />
for complex <strong>de</strong>sign and functional<br />
integration is most suitable<br />
for cost-effective mass production.<br />
Medium strength AA6xxx and high<br />
strength AA7xxx age har<strong>de</strong>ning alloys<br />
are used, since the required quenching<br />
occurs during the extrusion process.<br />
Formability and final strength<br />
is controlled by subsequent heating<br />
for age har<strong>de</strong>ning. Extrusions are applied<br />
for bumper beams and crash elements/boxes,<br />
also in the SLC car.<br />
Castings<br />
The highest volume of aluminium<br />
components in cars are castings,<br />
such as engine blocks, cylin<strong>de</strong>r heads<br />
and <strong>special</strong> chassis parts. The substitution<br />
of cast iron engine blocks continues.<br />
Even diesel engines, which<br />
continue to gain a substantial increase<br />
in market share in Europe now, are<br />
being cast in aluminium where, due<br />
to the high requirements on strength<br />
and durability, cast iron has generally<br />
been used. However, progress<br />
in aluminium alloy <strong>de</strong>velopment (Al-<br />
Si-Cu-Mg-Fe-type) and new casting<br />
techniques came up with improved<br />
material properties and functional<br />
integration that enables aluminium<br />
to meet the requirements. <strong>Alu</strong>minium<br />
castings are also gaining acceptance<br />
in the construction of space frame,<br />
axle parts and structural components.<br />
Complex parts are produced by <strong>special</strong><br />
casting methods that ensure optimal<br />
mechanical properties and allow<br />
enhanced functional integration<br />
[5]. For high pressure die cast HPDC<br />
new AlSiMgMn alloys have been <strong>de</strong>veloped<br />
with enhanced strength and<br />
ductility combination. In the SLC<br />
project structural parts in the wheel<br />
house architecture have been <strong>de</strong>signed<br />
using advanced aluminium die<br />
cast with an integrated striker plate.<br />
Summary and Conclusions<br />
Due to its low weight, good formability<br />
and corrosion resistance, aluminium<br />
is the material of choice for many automotive<br />
applications such as chassis,<br />
autobody and many structural components<br />
[13]. <strong>Alu</strong>minium alloys tailored<br />
by suitable variations in chemical<br />
composition and processing best fit<br />
many requirements, like the non-heat<br />
treatable Al-Mg alloys used in chassis<br />
optimized for superb resistance<br />
against intercrystalline corrosion and<br />
concurrent high strength or the heat<br />
treatable AlMgSi alloys for extrusions<br />
and autobody sheet modified for improved<br />
age har<strong>de</strong>ning response during<br />
the automotive paint bake cycle.<br />
32 ALUMINIUM · 9/2009
S P E C I A L<br />
A L U M I N I U M I M A U t o M o b I L<br />
With a sound knowledge about the<br />
specific material properties and effects<br />
excellent light weight solutions<br />
for automotive applications have<br />
been successfully applied by the<br />
European automobile industries.<br />
Intensive R&D and continuous collaboration<br />
of material suppliers and<br />
application engineers provi<strong>de</strong>d optimum<br />
solutions for sometimes contradicting<br />
aspects of the specific requirements,<br />
e. g. for the specific material<br />
selection and optimum combinations<br />
of strength and formability.<br />
Material specific processing<br />
routes and individual solutions have<br />
been <strong>de</strong>veloped in close cooperation<br />
with OEM partners and suppliers.<br />
Applying the full knowledge about<br />
the physical processes involved and<br />
the microstructure/properties correlation<br />
a tuning of properties is possible<br />
in or<strong>de</strong>r to produce optimum<br />
and stable products required for the<br />
high <strong>de</strong>mands in automobile applications.<br />
The examples given for the successful<br />
prove the major breakthrough<br />
in automotive applications for aluminium<br />
that has been achieved during<br />
recent years by <strong>de</strong>veloping innovative<br />
light weight and cost efficient<br />
solutions. With the reference of the<br />
SLC project results it is expected that<br />
in the near future the use of aluminium<br />
with specifically improved properties<br />
will grow in many automobile<br />
applications meeting the increased<br />
economical and ecological <strong>de</strong>mands.<br />
Due to the positive experience gained<br />
in the project and from former successful<br />
applications its volume fraction<br />
used in cars of all classes and<br />
all sizes will grow significantly.<br />
Fig. 6: Final simulation of SLC si<strong>de</strong> panel in aluminium<br />
The SLC concept shows clearly that<br />
aluminium can be used for the car<br />
body structure and that there can be<br />
a weight advantage of at least 30%<br />
without losing performance. For<br />
most parts the present gra<strong>de</strong>s used<br />
for exterior panels can be applied.<br />
In some cases where very high<br />
strengths are <strong>de</strong>man<strong>de</strong>d, 7xxx series<br />
alloys can be used to maintain this<br />
significant weight advantage. For<br />
large volume aluminium solutions<br />
are most cost effective. Castings will<br />
be applied for areas where strong<br />
part integration is feasible. Extrusions<br />
can be easily applied as straight profiles,<br />
but also forming of an extru<strong>de</strong>d<br />
profile is a competitive process for<br />
high volumes, e. g. as bumper beams<br />
as used in the SLC prototype car.<br />
<strong>Alu</strong>minium is the i<strong>de</strong>al lightweighting<br />
material as it allows a<br />
weight saving of up to 50% over<br />
competing materials in most applications<br />
without compromising safety.<br />
Acknowledgement<br />
The research activity presented in<br />
this paper has been performed within<br />
the European fun<strong>de</strong>d project SLC<br />
(Sustainable Production Technologies<br />
of Emission Reduced Light weight<br />
Car concepts) Proposal/Contract no.:<br />
516465 [8] in the EU 6 th Framework<br />
Programme which is gratefully acknowledged.<br />
The authors also thank the SLC<br />
consortium and the European <strong>Alu</strong>minium<br />
Association EAA for their<br />
support.<br />
The support of Dr. Wieser, Mr.<br />
Brünger, Dr. Jupp, Dr. Brinkman is<br />
gratefully acknowledged.<br />
References<br />
A U t o M o t I v E<br />
[1] Automobil-Produktion, Juni 2001,<br />
S.136<br />
[2] <strong>Alu</strong>minium materials technology for<br />
automobile construction, ed. by W.J. Bartz,<br />
Mech. Eng. Publ. London (1993) p.1<br />
[3] <strong>Alu</strong>miniumwerkstofftechnik für <strong>de</strong>n<br />
Automobilbau, Kontakt & Studium Werkstoffe,<br />
Band 375, TAE, Expert Verlag, Ehningen<br />
(1992)<br />
[4] J. Hirsch, ICAA5 (4) Materials Science<br />
Forum Volume, 242 Transtec Publications,<br />
Switzerland, (1997) p.33-50<br />
[5] J. Hirsch, Automotive Trends in <strong>Alu</strong>minium<br />
– The European Perspective,<br />
ICAA9, edt. J.F. Nie, A.J. Morton, B.C.<br />
Muddle, Mater. Forum 28, Inst. of Mat.<br />
Eng. Australasia Ltd., ISBN 1876855 223,<br />
Vol.1, p. 15-23<br />
[6] A.K. Gupta, G.B. Burger, P.W. Jeffrey,<br />
D.J. Lloyd; ICAA4, Proc. 4th Int. Conf. on Al<br />
alloys, Atlanta/GA USA (1994) ed. by T.H.<br />
San<strong>de</strong>rs, E.A. Starke, Vol.3, p.177<br />
[7] E. Brünger, O. Engler, J. Hirsch, Al-Mg-<br />
Si Sheet for Autobody Application, in ‘Virtual<br />
Fabrication of <strong>Alu</strong>minium Products’<br />
chapter I-6, Wiley-VCH Verlag, Weinheim<br />
2006, (ISBN: 3-527-31363-X), pp. 51-61<br />
[8] H.P. Falkenstein, W. Gruhl, G. Scharf,<br />
Metallwissenschaft und Technik 37/12<br />
(1983), p.1197, H.P. Falkenstein, VDI-<br />
Berichte 65 (1984), VDI-Verlag Düsseldorf<br />
[9] KGP study, <strong>Alu</strong>minium average content<br />
for new European Cars in 2005<br />
[10] E. Gold, W. Horn, J. Maier, Metall 42/3<br />
(1988) p 248<br />
[11] C. Lahaye, J. Hirsch, D. Bassan, B.<br />
Criqui, P. Urban, M. Goe<strong>de</strong>, in: <strong>Alu</strong>minium<br />
Alloys, Their Physical and Mechanical<br />
Properties, edited by J. Hirsch et. al. proceedings<br />
ICAA-11 (2008) Aachen, ISBN-<br />
10: 3-527-32367-8, p. 236-237<br />
[12] J. Hirsch, E. Brünger, St. Keller, K.<br />
Kipry, in: <strong>Alu</strong>minium Alloys, Their Physical<br />
and Mechanical Properties, edited by J.<br />
Hirsch et. al. proceedings ICAA-11 (2008)<br />
Aachen, ISBN-10: 3-527-32367-8, p. 2388-<br />
2393<br />
[13] <strong>Alu</strong>minium Automotive Manual, Internet<br />
address: www.eaa.net/aam<br />
Author<br />
Prof. Dr.-Ing. Jürgen Hirsch is Senior<br />
Scientist at the R&D Centre of Hydro <strong>Alu</strong>minium<br />
Deutschland, located in Bonn.<br />
Mr Hirsch is an internationally renowned<br />
scientist in research and <strong>de</strong>velopment of<br />
aluminium alloys and their application.<br />
He is author of numerous publications of<br />
metallurgic-related topics, e<strong>special</strong>ly aluminium,<br />
and received several awards for<br />
his scientific work.<br />
33 ALUMINIUM · 9/2009<br />
ALUMINIUM · 9/2009 33
Abbildungen: Otto Fuchs A L U M I N I U M I M A U t o M o b I L<br />
Hochfeste <strong>Alu</strong>minium-Fahrwerksteile<br />
mit optimaler topologie<br />
G. Proske, J. Krämer, Meinerzhagen<br />
Die hohen Energiekosten und die<br />
For<strong>de</strong>rung nach CO2-Reduktion lassen <strong>de</strong>n Leichtbau und die<br />
Leichtmetalle noch stärker in <strong>de</strong>n<br />
Fokus <strong>de</strong>r Konstrukteure rücken.<br />
Um die Bauteilabmessungen bzw.<br />
-querschnitte zu reduzieren und<br />
somit Gewicht zu sparen, ist <strong>de</strong>r<br />
Einsatz von immer höherfesten<br />
Legierungen erfor<strong>de</strong>rlich. Darüber<br />
hinaus bedarf es entsprechen<strong>de</strong>r<br />
Konstruktionstools, um die Bauteile<br />
optimal bezüglich Spannung<br />
und Topologie auszulegen.<br />
Geschmie<strong>de</strong>te <strong>Alu</strong>miniumbauteile<br />
haben sich in zahlreichen Anwendungen<br />
in <strong>de</strong>r Automobilindustrie<br />
fest etabliert. Durch <strong>de</strong>n Einsatz von<br />
stranggepresstem Vormaterial und<br />
<strong>de</strong>n nachfolgen<strong>de</strong>n Schmie<strong>de</strong>prozess<br />
wird ein poren- und lunkerfreies Gefüge<br />
eingestellt. Dieses Gefüge in Verbindung<br />
mit <strong>de</strong>r abschließen<strong>de</strong>n Wärmebehandlung<br />
führt zu Bauteilen mit<br />
ausgezeichneten statischen und dynamischen<br />
Festigkeitseigenschaften in<br />
Kombination mit guter Duktilität und<br />
Zähigkeit.<br />
Die Otto Fuchs KG mit Sitz in Meinerzhagen<br />
fertigt seit etwa 40 Jahren<br />
geschmie<strong>de</strong>te Komponenten aus<br />
<strong>Alu</strong>miniumlegierungen <strong>de</strong>r 6000er<br />
Serie für die Automobilindustrie<br />
und ist Marktführer im Bereich geschmie<strong>de</strong>ter<br />
stabförmiger Fahrwerksteile<br />
wie Querlenker, Zug- und Druckstreben<br />
(Abb. 1).<br />
In Europa wird hauptsächlich die<br />
Legierung EN AW-6082 = EN AW-<br />
AlSi1MgMn = Otto Fuchs(OF-)Legierung<br />
AS10 gemäß DIN EN 573-3 [1]<br />
Abb. 1: Geschmie<strong>de</strong>te <strong>Alu</strong>minium-Fahrwerksteile<br />
<strong>de</strong>r Otto Fuchs KG<br />
Tab. 1: Festigkeitsklassen <strong>de</strong>r <strong>Alu</strong>miniumlegierungen EN AW-6082 T6 und EN AW-6110A T6<br />
und DIN EN 586-2 [2] verwen<strong>de</strong>t. Bedingt<br />
durch steigen<strong>de</strong> Anfor<strong>de</strong>rungen<br />
an die geschmie<strong>de</strong>ten Fahrwerkskomponenten<br />
konnten die garantierten<br />
Min<strong>de</strong>stwerte dieser Legierung im<br />
voll wärmebehan<strong>de</strong>lten Zustand (T6 =<br />
lösungsgeglüht, abgeschreckt und maximal<br />
ausgehärtet) im Laufe <strong>de</strong>r Jahre<br />
durch Optimierung <strong>de</strong>r gesamten<br />
Prozesskette (Gießen, Strangpressen,<br />
Schmie<strong>de</strong>n und Wärmebehandlung)<br />
ausgehend von <strong>de</strong>r Festigkeitsklasse<br />
F31 über F34 auf mittlerweile F38<br />
(Tab. 1) gesteigert wer<strong>de</strong>n.<br />
Anfang <strong>de</strong>r neunziger Jahre wur<strong>de</strong><br />
von Otto Fuchs <strong>de</strong>r Werkstoff EN AW-<br />
6110A = EN AW-AlMgSiCu = AS28<br />
entwickelt [3]. Auch für diesen Werkstoff<br />
konnten im Laufe <strong>de</strong>r Jahre die<br />
garantierten Min<strong>de</strong>stwerte aufgrund<br />
von Prozessoptimierungen ausgehend<br />
von F38 auf F42 erhöht wer<strong>de</strong>n.<br />
Neben diesen bei<strong>de</strong>n seit Jahren<br />
von Otto Fuchs erfolgreich eingesetzten<br />
Legierungen wird seit kurzem <strong>de</strong>r<br />
Werkstoff AS29 angeboten. Hierbei<br />
han<strong>de</strong>lt es sich um eine Eigenentwick-<br />
Abb. 2: Roh- und Fertigteil einer Zugstrebe<br />
aus <strong>de</strong>r OF-Legierung AS29<br />
lung auf Basis <strong>de</strong>r Legierung AS28 =<br />
EN AW-6110A. Nachfolgend wer<strong>de</strong>n<br />
die Eigenschaften dieser Legierung im<br />
Vergleich zu <strong>de</strong>n Werkstoffen AS10<br />
und AS28 vorgestellt. Ziel war eine<br />
weitere Steigerung <strong>de</strong>r statischen Festigkeit<br />
auf F45 und <strong>de</strong>r dynamischen<br />
Festigkeit bei ausreichen<strong>de</strong>r Duktilität<br />
und Korrosionsbeständigkeit. Alle<br />
Eigenschaften wur<strong>de</strong>n an Proben<br />
aus Zugstreben (Abb. 2) o<strong>de</strong>r an <strong>de</strong>n<br />
Zugstreben selber ermittelt, die unter<br />
Serienbedingungen geschmie<strong>de</strong>t und<br />
wärmebehan<strong>de</strong>lt wur<strong>de</strong>n. Die Untersuchungen<br />
erfolgten im Zustand T6.<br />
Die an <strong>de</strong>n Zugstreben aus dieser<br />
Legierung ermittelten Streckgren-<br />
Abb. 3: Typische Festigkeitswerte <strong>de</strong>r Zugstreben aus <strong>de</strong>n OF-Legierungen AS10,<br />
AS28 und AS29 im voll ausgehärteten Zustand<br />
34 ALUMINIUM · 9/2009
S P E C I A L<br />
A L U M I N I U M I M A U t o M o b I L<br />
zen- und Zugfestigkeitswerte liegen<br />
typischerweise bei 440 bzw. 470<br />
MPa (Abb. 3) und damit etwa 25 bzw.<br />
30 MPa bei nahezu unverän<strong>de</strong>rter<br />
Bruch<strong>de</strong>hnung oberhalb <strong>de</strong>r Werte<br />
für die Legierung AS28.<br />
Im Fahrwerksbereich wer<strong>de</strong>n die<br />
Mehrzahl <strong>de</strong>r Bauteile, wie Zug- und<br />
Druckstreben, auf Missbrauch ausgelegt,<br />
das heißt, dass diese nicht vor<br />
Erreichen einer Min<strong>de</strong>stkraft, aber<br />
spätestens bei Erreichen einer Maximalkraft<br />
versagen dürfen bzw. müssen.<br />
Auslegungskriterium ist in diesem<br />
Fall die Steifigkeit <strong>de</strong>r Bauteile,<br />
die sehr stark geometrieabhängig ist,<br />
während die Festigkeitseigenschaften<br />
nur einen geringen Einfluss haben.<br />
Die für die Untersuchung ausgewählte<br />
Zugstrebe hat bei Verwendung <strong>de</strong>r<br />
Legierung AS28 im Vergleich zu <strong>de</strong>r<br />
Legierungen AS10 eine um etwa 15<br />
Prozent höhere Knickkraft. Durch<br />
Einsatz von AS29 kann die Knickkraft<br />
bei dieser Strebe gegenüber AS28 um<br />
weitere circa fünf Prozent gesteigert<br />
wer<strong>de</strong>n.<br />
Interessant sind die Werkstoffe<br />
AS29 und AS28 beson<strong>de</strong>rs für Bau-<br />
Spouts and<br />
Stoppers<br />
Abb. 4: Ermüdungsversuche an Zugstreben aus <strong>de</strong>n OF-Legierungen AS10, AS28 und AS29<br />
teile, die nicht auf Steifigkeit, son<strong>de</strong>rn<br />
auf eine dynamische Belastung hin<br />
ausgelegt wer<strong>de</strong>n müssen. Im Falle<br />
<strong>de</strong>r untersuchten Zugstrebe (Abb. 2)<br />
lagen die auf einem Bauteilprüfstand<br />
bei dynamischer Belastung ermittelten<br />
Lebensdauern für die Bauteile<br />
aus <strong>de</strong>r Legierung AS28 etwa um <strong>de</strong>n<br />
Faktor 2 bis 3 (Abb. 4) höher als die<br />
aus <strong>de</strong>r Legierung AS10. Durch die<br />
Verwendung <strong>de</strong>r noch höherfesten<br />
Legierung AS29 konnte die Lebensdauer<br />
gegenüber AS28 noch einmal<br />
A L U M I N I U M I M A U t o M o b I L<br />
for <strong>Alu</strong>minium DC<br />
casting<br />
Drache<br />
u m w e l t t e c h n i k<br />
etwa um <strong>de</strong>n Faktor 2 bis 3 gesteigert<br />
wer<strong>de</strong>n. Die Lebensdauersteigerung<br />
gegenüber AS10 und AS28 ist von<br />
<strong>de</strong>r Bauteilgeometrie (z. B. Kerbwirkung)<br />
abhängig und kann je nach <strong>de</strong>r<br />
Ausführung von Kerben und Radien<br />
unterschiedlich ausgeprägt sein<br />
Neben <strong>de</strong>r Beständigkeit gegenüber<br />
allgemeiner Korrosion (Salzsprühnebelprüfung<br />
nach DIN EN ISO<br />
9227) wur<strong>de</strong> auch die interkristalline<br />
Korrosionsbeständigkeit (gemäß IGC<br />
04.24.123) im Vergleich zu <strong>de</strong>n ➝<br />
Ceramic Foam<br />
Filters<br />
for <strong>Alu</strong>minium DC<br />
casting<br />
Drache Umwelttechnik GmbH · mail@drache-gmbh.<strong>de</strong> · www.drache-gmbh.<strong>de</strong><br />
35 ALUMINIUM · 9/2009<br />
ALUMINIUM · 9/2009 35
A L U M I N I U M I M A U t o M o b I L<br />
Legierungen AS10 und AS28 überprüft.<br />
Die Angriffstiefen bei <strong>de</strong>r allgemeinen<br />
Korrosion (Abb. 5) als auch<br />
bei <strong>de</strong>r interkristallinen Korrosion<br />
sind im Vergleich zu <strong>de</strong>r Legierung<br />
AS10 etwas höher, aber nahezu i<strong>de</strong>ntisch<br />
mit <strong>de</strong>n Ergebnissen <strong>de</strong>r Legierung<br />
AS28, die bereits seit Jahren<br />
ungeschützt, wie die Legierung AS10,<br />
im Fahrwerksbereich erfolgreich eingesetzt<br />
wird.<br />
Mit <strong>de</strong>r OF-Legierung AS29 gibt<br />
es eine Legierung <strong>de</strong>r 6000er Serie<br />
mit höchsten statischen und dynamischen<br />
Festigkeitseigenschaften, vergleichbar<br />
mit <strong>de</strong>nen <strong>de</strong>r hochfesten<br />
7000er Legierung 7075 bei einer<br />
<strong>de</strong>utlich höheren Bruch<strong>de</strong>hnung und<br />
<strong>de</strong>utlich besserem Korrosionsverhalten.<br />
Aufgrund <strong>de</strong>r hohen Festigkeitswerte<br />
und <strong>de</strong>r guten Schweißbarkeit<br />
wird diese Legierung bereits für lasergeschweißte<br />
Luftfahrtprofile verwen<strong>de</strong>t,<br />
die unter an<strong>de</strong>rem im Airbus<br />
A318 und A380 eingesetzt wer<strong>de</strong>n.<br />
Neben <strong>de</strong>r richtigen Legierungsauswahl<br />
ist die Topologieoptimierung<br />
bei Otto Fuchs ein wichtiges Hilfsmittel,<br />
um gewichtsoptimierte Bauteile<br />
auszulegen. Dabei wer<strong>de</strong>n auf Basis<br />
von linear-elastischen FEM-Berechnungen<br />
wenig belastete Teile einer<br />
Ausgangsgeometrie (Abb. 6a) entfernt.<br />
Zurück bleibt eine Struktur, die<br />
nur noch aus „tragen<strong>de</strong>n“ Elementen<br />
besteht. In <strong>de</strong>r Vergangenheit waren<br />
diese Strukturen größtenteils für eine<br />
Fertigung nicht geeignet, da oft Hohlräume<br />
o<strong>de</strong>r sehr filigrane Verstrebungen<br />
im Bauteil entstan<strong>de</strong>n (Abb.<br />
6b). Inzwischen können aber Fertigungsrestriktionen<br />
für Schmie<strong>de</strong>teile<br />
berücksichtigt wer<strong>de</strong>n, zum Beispiel<br />
die Vermeidung von Hinterschnitten.<br />
Die Ergebnisse sind aber immer noch<br />
keine fertigen Schmie<strong>de</strong>teile. Oft sind<br />
in <strong>de</strong>m topologieoptimierten Bauteil<br />
Bereiche vorhan<strong>de</strong>n, die durch die<br />
i<strong>de</strong>alisierte Lagerung im Mo<strong>de</strong>ll zu<br />
Abb. 6: Entwicklung <strong>de</strong>r Geometrie durch Topologieoptimierung<br />
Abb. 5: Korrosionsversuche an Zugstreben aus <strong>de</strong>n OF-Legierungen AS10, AS28 und<br />
AS29: Salzsprühnebelprüfung nach DIN EN ISO 9227 [4], Dauer 240 Std.; Interkristalline<br />
Korrosion nach IGC 04.24.103 [5]<br />
wenig belastet wer<strong>de</strong>n und dadurch<br />
sehr dünn ausfallen. Hier muss <strong>de</strong>r<br />
Konstrukteur manuell eingreifen, um<br />
aus <strong>de</strong>m errechten „Designvorschlag“<br />
ein schmie<strong>de</strong>fähiges Bauteil (Abb.<br />
6c) zu gestalten. Danach kann ein<br />
„Feintuning“ <strong>de</strong>s Bauteils durch eine<br />
Shape-Optimierung erfolgen. Dazu<br />
wird das auf Basis <strong>de</strong>r Topologieoptimierung<br />
neu konstruierte Teil erneut<br />
vernetzt und wie<strong>de</strong>r mit <strong>de</strong>n überlagerten<br />
Betriebslasten beaufschlagt.<br />
Stark belastete Elemente <strong>de</strong>s Netzes<br />
wachsen (unter Einhaltung <strong>de</strong>s Bauraumes)<br />
nach außen, während wenig<br />
belastete Elemente schrumpfen. Es<br />
ergibt sich eine gleichmäßigere Spannungsverteilung.<br />
Natürlich wird <strong>de</strong>r Schmie<strong>de</strong>prozess<br />
eines auf diese Art optimierten<br />
Teils nicht einfacher; aufgrund von<br />
Durchbrüchen und Rippen ist eine<br />
sehr genaue Vorformauslegung nötig,<br />
um Schmie<strong>de</strong>fehler zu vermei<strong>de</strong>n.<br />
Oft sind Verfahren zur Materialvordosierung,<br />
wie Reck- o<strong>de</strong>r Querwalzen<br />
notwendig, um fehlerfrei und<br />
wirtschaftlich zu fertigen. Auch diese<br />
Verfahren können und wer<strong>de</strong>n inzwischen<br />
im Unternehmen durch eine<br />
Umformsimulation abgebil<strong>de</strong>t.<br />
Mit <strong>de</strong>n Werkstoffen AS10, AS28<br />
und AS29 hat die Otto Fuchs KG<br />
drei Legierungen, die ein breites Eigenschaftsspektrum<br />
bzw. Anfor<strong>de</strong>rungsprofil<br />
ab<strong>de</strong>cken. Zusammen mit<br />
Simulationsverfahren zur Topologieoptimierung<br />
wie auch zum Umformprozess<br />
können so gewichts- und<br />
eigenschaftsoptimierte Bauteile entwickelt<br />
und sicher in Großserie hergestellt<br />
wer<strong>de</strong>n.<br />
Literatur<br />
[1] DIN EN 573-3, <strong>Alu</strong>minium und <strong>Alu</strong>miniumlegierungen<br />
– Chemische Zusammensetzung<br />
und Form von Halbzeug<br />
– Teil 3: Chemische Zusammensetzung<br />
und Erzeugnisformen<br />
[2] DIN EN 586-2; <strong>Alu</strong>minium und <strong>Alu</strong>miniumlegierungen<br />
– Schmie<strong>de</strong>stücke – Teil<br />
2: Mechanische Eigenschaften und zusätzliche<br />
Eigenschaftsanfor<strong>de</strong>rungen<br />
[3] AS28: Ein neuer hochfester Konstruktionswerkstoff<br />
auf <strong>de</strong>r Legierungsbasis<br />
Al-Mg-Si, Son<strong>de</strong>rdruck aus: Leichtmetalle<br />
im Automobilbau 95/96, Son<strong>de</strong>rdruck von<br />
ATZ und MTZ, Franckh-Kosmos-Verlags-<br />
GmbH & Co., Stuttgart<br />
[4] DIN EN ISO 9227; Korrosionsprüfungen<br />
in künstlichen Atmosphären – Salzsprühnebelprüfungen<br />
(ISO 9227: 2006)<br />
[5] Alliages d’<strong>Alu</strong>minium, Essai <strong>de</strong> Susceptibilité<br />
à la Corrosion intergranulaire<br />
Autoren<br />
Dr. Gerhard Proske, Otto Fuchs KG,<br />
Meinerzhagen, Werkstofftechnologie und<br />
Pressteile Automotive.<br />
Jürgen Krämer, Otto Fuchs KG, Meinerzhagen,<br />
Produkt- und Verfahrensentwicklung<br />
FEM-Simulation<br />
36 ALUMINIUM · 9/2009
Abbildungen: Elpo<br />
Kun<strong>de</strong>nspezifische, energieoptimierte<br />
Wärmebehandlungsanlagen für <strong>Alu</strong>minium<br />
V. Burkhardt, Backnang<br />
Wärmebehandlung, allgemeine Definition:<br />
Wärmebehandlung versteht<br />
sich als eine Folge von Wärmebehandlungsschritten,<br />
in <strong>de</strong>ren Verlauf<br />
ein Werkstück ganz o<strong>de</strong>r teilweise<br />
einer Zeit-Temperatur-Folge unterworfen<br />
wird, um eine Än<strong>de</strong>rung<br />
seines Gefüges und/o<strong>de</strong>r seiner<br />
Eigenschaften herbeizuführen. Eine<br />
Warmformgebung o<strong>de</strong>r mit Erwärmung<br />
verbun<strong>de</strong>ne Verfahren <strong>de</strong>s<br />
Oberflächenschutzes fallen nicht<br />
unter „Wärmebehandlung“. Unter<br />
Ausscheidungshärten, die unter an<strong>de</strong>rem<br />
bei <strong>Alu</strong>miniumlegierungen<br />
angewen<strong>de</strong>t wer<strong>de</strong>n, versteht man in<br />
<strong>de</strong>r Wärmebehandlung alle Maßnahmen,<br />
die das temperaturabhängige<br />
Lösungsvermögen <strong>de</strong>r Mischkristalle<br />
nutzen, um eine Festigkeitssteigerung<br />
herbeizuführen.<br />
Gefügekun<strong>de</strong>: Die Eigenschaften<br />
eines Werkstoffs wer<strong>de</strong>n durch sein<br />
Gefüge bestimmt, auch wenn in <strong>de</strong>r<br />
Wärmebehandlung eher Härtewerte<br />
o<strong>de</strong>r Härteverlaufskurven und seltener<br />
bestimmte Gefüge vorgeschrieben<br />
wer<strong>de</strong>n. Die Gefügestruktur wird<br />
durch Wärmeeinwirkung und Verformungen<br />
beeinflusst und je nach<br />
Werkstoff und Temperatur verän<strong>de</strong>rt.<br />
Dadurch kann es zu Spannungen innerhalb<br />
<strong>de</strong>s Werkstücks kommen,<br />
die teilweise erwünscht, manchmal<br />
jedoch für die weitere Verwendung<br />
ungeeignet sind.<br />
Abb. 1: Zeit-Temperatur-Verlauf einer Wärmebehandlung in<br />
allgemeiner Darstellung<br />
ALUMINIUM · 9/2009<br />
Die Wärmebehandlung muss <strong>de</strong>mentsprechend<br />
gezielt eingesetzt wer<strong>de</strong>n,<br />
um die je nach gestellter Anfor<strong>de</strong>rung<br />
geeigneten Gefüge einzustellen. Die<br />
Gefügekun<strong>de</strong> ist daher eine Grundlage<br />
zum Verständnis <strong>de</strong>r inneren<br />
Vorgänge bei <strong>de</strong>r Wärmebehandlung<br />
und ihrer Ergebnisse. Eine <strong>de</strong>taillierte<br />
Beschreibung dieser Vorgänge wür<strong>de</strong><br />
jedoch <strong>de</strong>n Rahmen dieses Beitrages<br />
sprengen, es sei daher auf die entsprechen<strong>de</strong><br />
Fachliteratur verwiesen.<br />
<strong>Alu</strong>miniumwerkstoffe in <strong>de</strong>r Automobilindustrie:<br />
Die Automobilindustrie<br />
setzt seit <strong>de</strong>n achtziger Jahren auf<br />
<strong>de</strong>n leichten Werkstoff <strong>Alu</strong>minium.<br />
Der wesentliche Vorteil von <strong>Alu</strong>minium<br />
gegenüber Stahl ist das günstige<br />
Verhältnisse von Festigkeit zu Dichte.<br />
Die Festigkeit entspricht <strong>de</strong>r <strong>de</strong>s<br />
allgemeinen Baustahls, bei dreimal<br />
niedrigerer Dichte gegenüber Stahl<br />
und Kupfer. In diesem Zusammenhang<br />
wird auch <strong>de</strong>r Begriff <strong>de</strong>r Spezifischen<br />
Festigkeit eingeführt: Spezifische<br />
Dichte = Festigkeit/Dichte.<br />
Weiterhin zeichnet sich <strong>Alu</strong>minium<br />
durch hohe thermische und elektrische<br />
Leitfähigkeit aus, die nur von<br />
Silber, Kupfer und Gold übertroffen<br />
wird, sowie durch gute Witterungs-<br />
und sehr gute Korrosionsbeständigkeit<br />
aufgrund einer stabilen Oxidbildung.<br />
Gute technologische Eigenschaften<br />
wie Verformbarkeit, Schweißbarkeit<br />
und Legierbarkeit sind weitere Vorteile<br />
von <strong>Alu</strong>minium<br />
und <strong>Alu</strong>miniumlegierungen.<br />
Neben <strong>de</strong>r metallurgischenWeiterentwicklung<br />
hat<br />
im Laufe <strong>de</strong>r Zeit<br />
auch eine intensive<br />
Entwicklung hinsichtlich<br />
<strong>de</strong>r Verarbeitbarkeitstattgefun<strong>de</strong>n.<br />
Die heutigenEntwicklungsschwerpunkte<br />
bei<br />
<strong>de</strong>r Verarbeitung<br />
von <strong>Alu</strong>minium lie-<br />
t e c h n o l o g i e<br />
gen im Bereich <strong>de</strong>r Gießtechnologie<br />
und <strong>de</strong>r Wärmebehandlung. Wärmebehan<strong>de</strong>lt<br />
wer<strong>de</strong>n heute hauptsächlich<br />
Zylin<strong>de</strong>rköpfe und Kurbelgehäuse,<br />
aber auch Formteile für Achsträger,<br />
Rahmen, Konsolen und Seitenteile.<br />
Die Abläufe bei <strong>de</strong>r Wärmebehandlung<br />
von <strong>Alu</strong>miniumlegierungen<br />
erfolgt in drei Schritten:<br />
• Lösungsglühen mit <strong>de</strong>m Ziel, ein<br />
homogenes Mischkristall zu erhalten.<br />
Als Maßnahme dient das vollständige<br />
Lösen <strong>de</strong>s Legierungsbestandteils in<br />
<strong>de</strong>r <strong>Alu</strong>miniummatrix durch Wärmebehandlung.<br />
• Abschrecken mit <strong>de</strong>m Ziel, ein<br />
übersättigtes Mischkristall zu erhalten.<br />
Als Maßnahme dient das Einfrieren<br />
<strong>de</strong>s durch die Glühung erzielten<br />
Zustands. Dies wird durch Abschrecken<br />
<strong>de</strong>r Glühtemperatur auf Raumtemperatur<br />
erreicht.<br />
• Aushärten mit <strong>de</strong>m Ziel, die härten<strong>de</strong><br />
Phase aus <strong>de</strong>m übersättigten<br />
Mischkristall auszuschei<strong>de</strong>n. Als<br />
Maßnahme dient die Kaltaushärtung<br />
(bei Raumtemperatur) und die<br />
Warmaushärtung (bei circa 120 bis<br />
200 °C). Es erfolgt, je nach Dauer,<br />
eine Konzentrationsverschiebung in<br />
Richtung Gleichgewicht.<br />
Nachfolgend wer<strong>de</strong>n die Anfor<strong>de</strong>rungen<br />
und realisierten Anlagenausführungen<br />
zum Warmaushärten/Auslagern<br />
von <strong>Alu</strong>miniumlegierungen an<br />
Hand eines typischen Anfor<strong>de</strong>rungsprofils<br />
dargestellt.<br />
Anfor<strong>de</strong>rungsprofil zur Warmauslagerung<br />
von Bauteilen aus <strong>Alu</strong>miniumlegierungen<br />
(z. B. Kurbelgehäuse,<br />
Zylin<strong>de</strong>rköpfe):<br />
Aufheizen: von ca. 20 °C auf max.<br />
250 °C +/- 5 °C in 60 min<br />
Halten: bei 250 °C +/- 5 °C, Dauer:<br />
150 min +/- 10 min<br />
Abkühlen: auf 25 °C +/- 5 °C in<br />
120 min.<br />
Wichtige Anfor<strong>de</strong>rung: Die Haltetemperatur<br />
von 250 °C +/- 5 °C darf<br />
das Zeitfenster von 150 min +/- 10<br />
min in keinem Falle unter- o<strong>de</strong>r überschreiten.<br />
37
t e c h n o l o g i e<br />
Abb. 2 und 3: Wärmebehandlung im<br />
Kammerofen<br />
Nach <strong>de</strong>m Lösungsglühen und Abschrecken<br />
soll wie vorstehend beschrieben<br />
bei <strong>de</strong>r Warmauslagerung<br />
das Ausschei<strong>de</strong>n <strong>de</strong>r härten<strong>de</strong>n Phase<br />
aus <strong>de</strong>m übersättigten Mischkristall<br />
in einer vorgegebenen Zeit-Temperatur-Kurve<br />
erfolgen. Um über das<br />
Werkstück verteilt nur sehr geringe<br />
Unterschie<strong>de</strong> hinsichtlich <strong>de</strong>r Festigkeitswerte<br />
zu erzielen, ist daher eine<br />
sehr geringe Temperaturtoleranz äußerst<br />
wichtig.<br />
Der in Abb. 1 dargestellte allgemeine<br />
Verlauf einer Wärmebehandlung<br />
gibt <strong>de</strong>n Zusammenhang zwischen<br />
Zeit und Temperatur für ein Werkstück<br />
an.<br />
Die Haltedauer muss <strong>de</strong>mnach so<br />
groß gewählt wer<strong>de</strong>n, dass auch im<br />
Abb. 4: Zweispurige Wärmebehandlungsanlage bestehend aus Anwärmofen, Halteofen<br />
und Kühler<br />
Werkstückkern die gefor<strong>de</strong>rte Temperatur<br />
erreicht ist und somit <strong>de</strong>r Ausscheidungsprozess<br />
ablaufen kann.<br />
Ein Überhitzen und Unterschreiten<br />
<strong>de</strong>r vorgegebenen Zeit-Temperatur-Kurve<br />
muss vermie<strong>de</strong>n wer<strong>de</strong>n,<br />
um die gefor<strong>de</strong>rten Werkstückeigenschaften<br />
zu garantieren. Für die Wirtschaftlichkeit<br />
eines Bauteils ist die<br />
exakte Wärmebehandlung von ausschlaggeben<strong>de</strong>r<br />
Be<strong>de</strong>utung.<br />
Die Ofenanlage: Die beson<strong>de</strong>re<br />
Herausfor<strong>de</strong>rung gemäß <strong>de</strong>m Anfor<strong>de</strong>rungsprofil<br />
liegt im gleichmäßigen<br />
Aufheizen innerhalb <strong>de</strong>r Zeit-Temperatur-Vorgabe,<br />
ohne die maximal vorgegebene<br />
Temperatur zu überschreiten,<br />
sowie im gleichmäßigen Halten<br />
bzw. Kühlen innerhalb dieser Vorgaben.<br />
Prinzipiell unterschei<strong>de</strong>t man zwischen<br />
diskontinuierlichem Betrieb<br />
(z. B. im Kammerofen, Abb. 2, 3) und<br />
kontinuierlichem Betrieb im Durchlaufofen.<br />
Bei <strong>de</strong>n Durchlaufanlagen<br />
(Abb. 4, 6) wird zwischen ein- und<br />
mehrspurigen Anlagen unterschie<strong>de</strong>n.<br />
Die Wärmeübertragung an das<br />
Wärmebehandlungsgut erfolgt für bei<strong>de</strong><br />
Ofentypen über Konvektion. Das<br />
Aufheizen erfolgt im ersten Teil <strong>de</strong>r<br />
Anlage (bei Durchlauföfen). Durch<br />
intensive Luftumwälzung und Luft-<br />
Abb. 5: Typisches Zeit-Temperatur-Diagramm, Fa. Elpo GmbH<br />
führung wird gewährleistet, dass zum<br />
einen die erfor<strong>de</strong>rliche Zeit-Temperatur-Kennlinie<br />
eingehalten wird und<br />
zum an<strong>de</strong>ren keine lokale „Überhitzung“<br />
an <strong>de</strong>n Teilen auftritt.<br />
Im Haltebereich <strong>de</strong>s Ofens wer<strong>de</strong>n<br />
die Teile auf Temperatur gehalten, um<br />
<strong>de</strong>n eigentlichen Warmauslagerungsprozess<br />
durchzuführen. Auch hier ist<br />
eine gezielte Luftführung erfor<strong>de</strong>rlich,<br />
unter Umstän<strong>de</strong>n abweichend<br />
zu <strong>de</strong>r in <strong>de</strong>r Anwärmzone, um die<br />
gefor<strong>de</strong>rten Temperaturtoleranzen<br />
an allen Werkstückbereichen einzuhalten.<br />
Die Abkühlung im nachfolgen<strong>de</strong>n<br />
Kühler kann meist so schnell wie<br />
möglich erfolgen, es sind aber auch<br />
Wärmebehandlungen gefor<strong>de</strong>rt, bei<br />
<strong>de</strong>nen ein vorgegebener Temperaturgradient<br />
nicht über- o<strong>de</strong>r unterschritten<br />
wer<strong>de</strong>n darf.<br />
Ofen und Kühler sind durch elektromotorisch<br />
betrieben Hubtore voneinan<strong>de</strong>r<br />
getrennt.<br />
Das Zeit-Temperatur-Diagramm<br />
einer Durchlaufanlage während einer<br />
Ofenfahrt wird in Abb. 5 dargestellt.<br />
Die Messkurve 1 zeigt die Lufttemperatur,<br />
die Messkurven 2, 3 und 4 zeigen<br />
die Temperatur an <strong>de</strong>n verschie<strong>de</strong>nen<br />
Stellen in <strong>de</strong>n Gussteilen <strong>de</strong>s<br />
Glühgestells.<br />
38 ALUMINIUM · 9/2009
t e c h n o l o g i e<br />
konstruktion ist darauf zu achten, dass<br />
die Chargierung so gewählt wird, dass<br />
bei einer optimalen Auslastung noch<br />
eine ausreichen<strong>de</strong> Anströmung <strong>de</strong>r<br />
Teile gewährleistet wird. Üblicherweise<br />
ist die Ausführung <strong>de</strong>r Gestelle<br />
<strong>de</strong>rart, dass die Werkstücke in mehreren<br />
senkrechten und waagrechten<br />
Reihen gestapelt wer<strong>de</strong>n.<br />
Der Transport <strong>de</strong>r Glühgestelle<br />
durch <strong>de</strong>n Ofen kann unterschiedlich<br />
durchgeführt wer<strong>de</strong>n: entwe<strong>de</strong>r auf<br />
Schienen, wobei die Gestelle durch<br />
<strong>de</strong>n Ofen geschoben wer<strong>de</strong>n, o<strong>de</strong>r auf<br />
Doppelspur-Kettenför<strong>de</strong>rer, wobei<br />
die Gestelle auf <strong>de</strong>m Kettenför<strong>de</strong>rer<br />
abgestellt wer<strong>de</strong>n.<br />
Die För<strong>de</strong>rtechnik: Eine erhöhte<br />
Aufmerksamkeit kommt bei diesen<br />
Anlagen einer zuverlässigen und auf<br />
die Anwendung angepassten För<strong>de</strong>r-<br />
Wärmebehandlungsanlagen<br />
für die <strong>Alu</strong>miniumindustrie<br />
Die Firma Schwartz in Simmerath ist<br />
spezialisiert auf <strong>de</strong>n Bau von Wärmebehandlungsanlagen<br />
für das Anwärmen,<br />
Lösungsglühen mit Abschrecken,<br />
Warmauslagern und Kühlen<br />
von <strong>Alu</strong>miniumbolzen und Formteilen<br />
in <strong>de</strong>r <strong>Alu</strong>miniumindustrie. Zu<br />
Schwartz Die Glühgestelle: Bei <strong>de</strong>r Glühgestell-<br />
Montage <strong>de</strong>s Durchlaufofens<br />
Conveyor furnace during assembly<br />
<strong>de</strong>n Ofenanlagen gehören die für <strong>de</strong>n<br />
automatisierten Betrieb notwendigen<br />
Übergabeeinrichtungen zur Schmie<strong>de</strong>presse,<br />
zwischen <strong>de</strong>n Behandlungsanlagen<br />
bis zur Verpackung. Die<br />
technik zu. Diese beginnt an <strong>de</strong>r Aufnahme<br />
<strong>de</strong>r Bauteile, beinhaltet die<br />
För<strong>de</strong>rung durch die Wärmebehandlungsanlage<br />
bis zur Abnahme und<br />
schließt auch die umliegen<strong>de</strong> Logistik<br />
ein. Dabei ist es von großem Vorteil<br />
für <strong>de</strong>n Kun<strong>de</strong>n, wenn För<strong>de</strong>rtechnik<br />
und Ofenanlage für die Thermoprozesstechnik<br />
von ein und <strong>de</strong>mselben<br />
Lieferanten stammen, da diese Kom-<br />
Abb. 6: Durchlaufanlage mit Hubtor<br />
angewandten teilweise patentierten<br />
Ofensysteme gewährleisten eine kurze<br />
und gleichmäßige Erwärmung bei<br />
geringem Energiebedarf.<br />
Die Abbildung zeigt eine Ofenanlage<br />
für das Erwärmen von <strong>Alu</strong>miniumbolzen<br />
und -scheiben mit einer<br />
max. Leistung von 4<br />
t/h bei <strong>de</strong>r Montage.<br />
Der Ofen wur<strong>de</strong> 2008<br />
im eigenen Werk Simmerath<br />
aufgebaut. Das<br />
eingesetzte Transportsystem<br />
lässt die Behandlung<br />
einer Vielzahl<br />
von Bolzendurchmessern<br />
und Scheiben<br />
zu. Die Beschickung<br />
<strong>de</strong>s Ofens sowie die<br />
Übergabe vom Ofen<br />
zur Schmie<strong>de</strong>presse<br />
erfolgen mittels<br />
Roboter. Damit eine<br />
gleichmäßige, schnelle<br />
Erwärmung bei unterschiedlichen<br />
Guthöhen erreicht wer<strong>de</strong>n kann, wird<br />
die Innenhöhe <strong>de</strong>s Ofens über ein<br />
vorgewähltes Programm elektromotorisch<br />
<strong>de</strong>m Glühgut angepasst. ■<br />
bination beson<strong>de</strong>rs flexible und kun<strong>de</strong>nspezifische<br />
Lösungen ermöglicht.<br />
Die Elpo GmbH aus <strong>de</strong>m süd<strong>de</strong>utschen<br />
Backnang ist unter an<strong>de</strong>rem<br />
spezialisiert auf Wärmebehandlungsöfen<br />
für <strong>Alu</strong>minium, einschließlich<br />
<strong>de</strong>r zugehörigen För<strong>de</strong>rtechnik. Weiterhin<br />
wer<strong>de</strong>n von Elpo Schlichtetrockner,<br />
Mikrowellentrockner, Konvektionstrockner<br />
für unterschiedlichste<br />
Anwendungsfälle, Kühler und<br />
Warmhalteöfen sowie För<strong>de</strong>r- und<br />
Handlingtechnik entwickelt, konstruiert<br />
und in eigenen Produktionsstätten<br />
gefertigt.<br />
Autor<br />
Dipl.-Ing.(FH) Volker Burkhardt, Verkauf<br />
/ Kun<strong>de</strong>nbetreuung bei <strong>de</strong>r Elpo GmbH<br />
Luft- und Trocknungstechnik mit Sitz in<br />
Backnang.<br />
heat-treatment<br />
equipment for the<br />
aluminium industry<br />
Schwartz GmbH of Simmerath, Germany,<br />
<strong>special</strong>ises in the manufacture<br />
of heat treatment equipment for preheating,<br />
solution-heat treating and<br />
quenching, artificial aging and cooling<br />
of aluminium billets and shaped parts.<br />
The heat treatment lines also inclu<strong>de</strong><br />
the requisite automated handling systems<br />
for transfers between furnaces,<br />
forging press and packing station. The<br />
systems implemented in the partly<br />
patented furnaces are <strong>de</strong>signed to ensure<br />
short and uniform heating and<br />
low energy consumption.<br />
The figure shows a furnace during<br />
assembly in the company’s works<br />
in 2008. This furnace for heating of<br />
aluminium billets and disks is rated<br />
for a maximum capacity of 4 tonnes<br />
per hour. The conveyor system can<br />
accommodate a multitu<strong>de</strong> of billet<br />
diameters and disk sizes. Loading of<br />
the furnace and transfer from furnace<br />
to forging press are handled by robots.<br />
To achieve uniform and quick heating<br />
of different height feedstocks the<br />
insi<strong>de</strong> height of the furnace automatically<br />
adapts to the feedstock in accordance<br />
with a preselected program. ■<br />
40 ALUMINIUM · 9/2009
ALUMINIUM · 9/2009<br />
t e c h n o l o g y<br />
Bereit für die Zukunft: Mo<strong>de</strong>rnisierung von bestehen<strong>de</strong>n<br />
gasbeheizten Bolzenerwärmungsanlagen<br />
o. Flamm und D. Menzler, Simmerath; y. Karamahmut, grand Rapids<br />
Fit for the future: upgrading of<br />
existing gas-fired billet heaters<br />
O. Flamm and D. Menzler, Simmerath; Y. Karamahmut, Grand Rapids<br />
As <strong>de</strong>mands on thermal equipment<br />
are becoming more exacting in many<br />
fields, existing gas-fired billet heaters<br />
are not exempt from the mo<strong>de</strong>rnisation<br />
drive. In this context, Otto Junker<br />
places the focus not merely on asset<br />
maintenance which restores the plant<br />
approximately to its as-<strong>de</strong>livered condition.<br />
The company rather relies on<br />
concepts aimed at boosting the system’s<br />
efficiency and utility value for<br />
the benefit of the user. These essentially<br />
comprise the following:<br />
• increase in throughput rate<br />
• more homogenous heating quality<br />
• more uniform heating power<br />
input into the billets<br />
• reduction in energy consumption<br />
• lower maintenance costs<br />
• improved exhaust gas quality.<br />
The aforementioned targets can be<br />
easily achieved by implementing the<br />
action package outlined in the following.<br />
The scope of this upgra<strong>de</strong> package<br />
can be adapted and implemented<br />
in line with the technical state of the<br />
equipment to be revamped.<br />
For maximum success, new-generation<br />
burner nozzles are installed<br />
in the heating system and a<br />
newly <strong>de</strong>veloped fuel gas/air<br />
mixer as well as a pilot nozzle<br />
with integrated lambda probe<br />
are retrofitted in each zone.<br />
The fuel gas control train of<br />
each zone is fitted with a linear<br />
actuator for fine-adjustment<br />
of the fuel gas input.<br />
The nozzles, mixers and<br />
lambda control system are <strong>de</strong>veloped<br />
by a partner company<br />
and adapted for industrial application<br />
in cooperation with<br />
Otto Junker. The patented<br />
technologies have been ma<strong>de</strong><br />
available to Otto Junker on an exclusive<br />
basis.<br />
The new burner nozzles are characterised<br />
by a very broad control ratio<br />
and stable flame formation over the<br />
entire control range. Their ignition behaviour<br />
is very good, even at very low<br />
output levels. The choice of appropriate<br />
metallic and ceramic materials<br />
ensures a clearly increased nozzle life.<br />
The new mixer provi<strong>de</strong>s optimum<br />
mixing of fuel gas and air and has a<br />
markedly reduced interior pressure<br />
loss over the entire control range.<br />
Thanks to the lambda control system,<br />
the impact of air pressure, air humidity<br />
and air temperature variations on<br />
the combustion process and exhaust<br />
gas quality are reliably compensated<br />
for. Fluctuations in fuel gas quality<br />
can be balanced out in the same<br />
manner. In this way the equipment<br />
performance will remain constant at<br />
all times, summer and winter, day and<br />
night. At the same time, exhaust air<br />
quality has been improved and stabilised<br />
– an important achievement in<br />
view of today’s pollution-based taxes<br />
and charges. In addition, the ability to<br />
Regelstrecken von Brenngas und Verbrennungsluft<br />
einer Heizzone nach Einbau <strong>de</strong>r Lambda-Regelung<br />
Fuel gas and combustion air control trains of a<br />
heating zone upon installation of lambda control<br />
Abbildungen: Otto Junker<br />
Aufgrund <strong>de</strong>r in vielen Bereichen steigen<strong>de</strong>n<br />
Anfor<strong>de</strong>rungen an thermische<br />
Anlagen stehen auch für <strong>de</strong>rzeit im<br />
Einsatz befindliche gasbeheizte BolzenerwärmungsanlagenMo<strong>de</strong>rnisierungen<br />
an. Das Hauptaugenmerk legt<br />
Otto Junker hierbei nicht auf reine<br />
Substanz erhalten<strong>de</strong> Maßnahmen,<br />
die die Anlagen wie<strong>de</strong>r annähernd in<br />
<strong>de</strong>n Lieferzustand zurückversetzen;<br />
vielmehr sind die Konzepte auf Steigerungen<br />
von Gebrauchs- und Nutzwert<br />
zugunsten <strong>de</strong>r Betreiber ausgerichtet.<br />
Dies sind im Wesentlichen:<br />
• Steigerung <strong>de</strong>r Durchsatzleistung<br />
• Vergleichmäßigung <strong>de</strong>r<br />
Erwärmungsqualität<br />
• Vergleichmäßigung <strong>de</strong>s Leistungs-<br />
eintrags in die Bolzen<br />
• Senkung <strong>de</strong>s Energieverbrauchs<br />
• Senkung <strong>de</strong>r Wartungskosten<br />
• Verbesserung <strong>de</strong>r Abgasqualität.<br />
Diese Ziele können leicht erreicht<br />
wer<strong>de</strong>n, wenn das nachfolgend beschriebene<br />
Maßnahmenpaket umgesetzt<br />
wird. Dies lässt sich je nach<br />
technischem Stand <strong>de</strong>r umzubauen<strong>de</strong>n<br />
Anlage anpassen und umsetzen.<br />
Um <strong>de</strong>n größtmöglichen Erfolg zu<br />
erzielen, wird eine neue Generation<br />
von Brennerdüsen in <strong>de</strong>r Beheizung<br />
eingesetzt sowie je Heizzone ein neu<br />
entwickelter Brenngas/Luft-Mischer<br />
und eine Pilotdüse mit integrierter<br />
Lambdason<strong>de</strong> nachgerüstet. In <strong>de</strong>r<br />
Brenngasregelstrecke je<strong>de</strong>r Zone wird<br />
ein Linearstellglied zur Feinregelung<br />
<strong>de</strong>r Brenngasmenge nachgerüstet.<br />
Die Düsen und Mischer sowie die<br />
Lambdaregelung wur<strong>de</strong>n von einem<br />
Partnerunternehmen entwickelt und<br />
in Zusammenarbeit mit Otto Junker<br />
für <strong>de</strong>n Industrieeinsatz adaptiert.<br />
Die patentierten Technologien stehen<br />
Otto Junker exklusiv zur Verfügung.<br />
Die neuen Brennerdüsen zeichnen<br />
sich durch ein sehr großes Regelverhältnis<br />
und eine über <strong>de</strong>n gesamten<br />
Regelbereich sehr stabile Flammenbildung<br />
aus. Das Zündverhalten, auch<br />
bei kleinen bis sehr kleinen Leistungen,<br />
41
t e c h n o l o g i e<br />
Bolzentemperatur und Bolzentemperaturgradient vor und nach <strong>de</strong>r Umrüstung<br />
Billet temperature and billet temperature gradient before and after the upgra<strong>de</strong><br />
ist sehr gut. Die entsprechen<strong>de</strong> Wahl<br />
metallischer und keramischer Werkstoffe<br />
sorgt für eine <strong>de</strong>utlich erhöhte<br />
Standzeit <strong>de</strong>r Düsen.<br />
Der neue Mischer gewährleistet<br />
eine optimale Vermischung von<br />
Brenngas und Luft bei <strong>de</strong>utlich reduziertem<br />
inneren Druckverlust über<br />
<strong>de</strong>n gesamten Regelbereich. Durch<br />
die Lambdaregelung wer<strong>de</strong>n die Einflüsse<br />
auf Verbrennung und Abgasqualität,<br />
wie sie durch Schwankungen<br />
<strong>de</strong>s Luftdrucks, <strong>de</strong>r Luftfeuchte und<br />
<strong>de</strong>r Lufttemperatur auftreten, ausgeglichen.<br />
Ebenso lassen sich Schwankungen<br />
in <strong>de</strong>r Brenngasqualität ausregeln.<br />
Dadurch wird die Anlage, egal<br />
ob Sommer o<strong>de</strong>r Winter, ob Tag o<strong>de</strong>r<br />
Nacht, mit <strong>de</strong>rselben Ofenleistung<br />
betrieben. Zusätzlich wird die Qualität<br />
<strong>de</strong>s Abgases verbessert und stabilisiert,<br />
was im Hinblick auf abgasbezogene<br />
Steuern und Abgaben von<br />
hoher Be<strong>de</strong>utung ist.<br />
Darüber hinaus bietet die je<strong>de</strong>rzeit<br />
mögliche Vorwahl eines bestimmten<br />
Lambdawertes <strong>de</strong>m Betreiber eine erhöhte<br />
Flexibilität <strong>de</strong>r Anlage; es kann<br />
je nach Erfor<strong>de</strong>rnis abgas-, energieverbrauchs-<br />
o<strong>de</strong>r leistungsoptimiert<br />
produziert wer<strong>de</strong>n. Durch einfache<br />
Absenkung <strong>de</strong>s Soll-Lambdawertes<br />
kann für die wenigen Produkte, die<br />
<strong>de</strong>r Bolzenerwärmungsanlage die<br />
maximale Durchsatzleistung abverlangen,<br />
die Heizleistung gesteigert<br />
wer<strong>de</strong>n – ausreichen<strong>de</strong>r Brenngasanschluss<br />
vorausgesetzt. In solchen<br />
Son<strong>de</strong>rfällen kann <strong>de</strong>r dann höhere<br />
spezifische Brenngasverbrauch meist<br />
akzeptiert wer<strong>de</strong>n.<br />
Eine komplette Umrüstung, bestehend<br />
aus Brennerdüsen, Brenngas/<br />
Luft-Mischer und Lambdaregelung<br />
(siehe Foto) wur<strong>de</strong> sehr erfolgreich<br />
im Presswerk <strong>de</strong>r Hydro <strong>Alu</strong>minium<br />
in Uphusen durchgeführt. Hier wur<strong>de</strong><br />
eine von Elhaus gelieferte Bolzenerwärmungsanlage<br />
modifiziert. Bei<br />
Vergleichsmessungen vor und nach<br />
<strong>de</strong>r Umrüstung wur<strong>de</strong> die Leistungsfähigkeit<br />
<strong>de</strong>s Konzepts unter Beweis<br />
gestellt (siehe Grafik). Die erreichten<br />
Werte sprechen für sich, die Anlagenleistung<br />
konnte um mehr als zehn<br />
Prozent gesteigert und <strong>de</strong>r spezifische<br />
Brenngasverbrauch in gleicher<br />
Größenordnung gesenkt wer<strong>de</strong>n. Die<br />
CO 2 -Emission hängt ab vom Lambdawert.<br />
Demzufolge schwankt die<br />
CO 2 -Emission nach <strong>de</strong>m Umbau nicht<br />
mehr in Abhängigkeit <strong>de</strong>r sich ständig<br />
än<strong>de</strong>rn<strong>de</strong>n Randbedingungen, son<strong>de</strong>rn<br />
wird über <strong>de</strong>n Lambdawert auf<br />
einen konstanten Wert geregelt.<br />
Je nach Aufwand, <strong>de</strong>r sich durch<br />
<strong>de</strong>n Zustand <strong>de</strong>r Anlagen und ihre ursprüngliche<br />
technische Ausstattung<br />
ergibt, beträgt die Amortisationszeit<br />
für solche Umrüstungen zwei bis drei<br />
Jahre mit künftig fallen<strong>de</strong>r Ten<strong>de</strong>nz.<br />
Prä<strong>de</strong>stiniert für die Umrüstungen<br />
sind naturgemäß die Anlagen, die<br />
von <strong>de</strong>r Otto Junker GmbH und <strong>de</strong>r<br />
Elhaus Industrieanlagen GmbH geliefert<br />
wur<strong>de</strong>n. Technisch lassen sich<br />
natürlich nach eingehen<strong>de</strong>r vorheriger<br />
Prüfung auch die Anlagen an<strong>de</strong>rer<br />
Hersteller umrüsten.<br />
Autoren<br />
Oliver Flamm und Dr. Dirk Menzler, Otto<br />
Junker GmbH, Simmerath.<br />
Yildirim Karamahmut, High-Tec Engineering,<br />
Grand Rapids, Michigan, USA.<br />
pre-select a specific lambda value at<br />
any time gives the operator increased<br />
flexibility since the plant can be run<br />
in an exhaust gas optimised, energy<br />
consumption optimised or output optimised<br />
mo<strong>de</strong>, <strong>de</strong>pending on current<br />
production needs. For the few products<br />
requiring maximum throughput<br />
from the billet heater, heating power<br />
can be raised at any time by simply<br />
reducing the lambda value setpoint<br />
(assuming a sufficient fuel gas supply).<br />
In such <strong>special</strong> cases, the associated<br />
higher specific fuel gas consumption<br />
will usually be found acceptable.<br />
A complete revamp comprising<br />
burner nozzles, fuel gas/air mixer and<br />
lambda control system (see photo) has<br />
been very successfully implemented<br />
at Hydro <strong>Alu</strong>minium’s extrusion plant<br />
in Uphusen, Germany. In this case,<br />
the upgra<strong>de</strong> involved a billet heater<br />
originally supplied by Elhaus. The<br />
performance of the new system was<br />
<strong>de</strong>monstrated by comparative measurements<br />
before and after the upgra<strong>de</strong><br />
(see chart). The values achieved speak<br />
for themselves – equipment output<br />
was raised by more than ten percent<br />
while the specific fuel gas consumption<br />
was reduced by about the same<br />
margin. Since CO 2 emissions <strong>de</strong>pend<br />
on the lambda value, the CO 2 output<br />
of the upgra<strong>de</strong>d system will no longer<br />
vary with ever changing boundary<br />
conditions but is kept constant by the<br />
lambda control system.<br />
Depending on project cost, which<br />
is a function of the equipment condition<br />
and original technical equipment<br />
level, the payback period for such an<br />
upgra<strong>de</strong> is in the region of two to<br />
three years and will <strong>de</strong>cline in the future.<br />
Naturally, equipment supplied<br />
by Otto Junker GmbH and Elhaus<br />
Industrieanlagen GmbH are specifically<br />
pre<strong>de</strong>stined for this kind of upgra<strong>de</strong>.<br />
However, from an engineering<br />
viewpoint, it goes without saying that<br />
systems ma<strong>de</strong> by other manufacturers<br />
can likewise be revamped following a<br />
<strong>de</strong>tailed prior analysis.<br />
Authors<br />
Oliver Flamm and Dr. Dirk Menzler, Otto<br />
Junker, Simmerath, Germany.<br />
Yildirim Karamahmut, High-Tec Engineering,<br />
Grand Rapids, Michigan, USA.<br />
42 ALUMINIUM · 9/2009
When ABB formed the maintenance<br />
alliance at the Hydro Kurri<br />
Kurri aluminium smelting plant<br />
in Newcastle, Australia, the ABB<br />
Full Service team was taking<br />
over the maintenance for four<br />
business units. One of them, the<br />
carbon plant, is responsible for<br />
manufacturing the ano<strong>de</strong>s that<br />
are consumed in the production<br />
of aluminium. At that time, the<br />
power and free conveyors in the<br />
carbon plant were suffering from<br />
years of poor maintenance due<br />
to <strong>de</strong>sign variations, inconsistent<br />
parts supply and poor turnaround<br />
time. The previous offsite contractor,<br />
who had been responsible for<br />
carriage repairs, was unable to<br />
ramp up the refurbishments, nor<br />
achieve the higher quality standards<br />
imposed by the ABB Maintenance<br />
Alliance Reliability Team.<br />
Power and free conveyor improvement<br />
project – The power and free (P&F)<br />
conveyor is responsible for carrying<br />
the ano<strong>de</strong>s through the production<br />
processes to the bake furnace where<br />
the green ano<strong>de</strong>s are converted. When<br />
the ABB maintenance alliance started<br />
in 2006, the system was in <strong>de</strong>sperate<br />
need of repair. The losses in produc-<br />
ALUMINIUM · 9/2009<br />
tion due to damaged carriages were<br />
nearing the point where production<br />
would need to stop, since the lost time<br />
per shift was approaching the length<br />
of time that the shift operated. Performance<br />
of the conveyors was as low<br />
as 70 percent of the target minimum,<br />
which was the minimum number of<br />
carriages on the conveyor to prevent<br />
lost time. ABB immediately focused<br />
on bringing the carriages back into<br />
the system as quickly as possible and<br />
increasing the reliability of the entire<br />
system.<br />
Within four months, the ABB onsite<br />
maintenance team led the plant<br />
to:<br />
• Increase productivity by 30 percent<br />
• Achieve performance target of<br />
greenmix and baked chain<br />
• Annual ROI of 84,000 percent<br />
• Recover four hours of lost time<br />
per shift.<br />
t e c h n o l o g y<br />
ABB maintenance turns around plant critical equipment<br />
“The carriage repair project has had<br />
great success in targeting the <strong>de</strong>fects on<br />
this equipment. We have gone from a<br />
position of vulnerability to a position of<br />
structure behind our carriage repairs”,<br />
says Kevin Heame, Production Team Coordinator<br />
for the Kurri Kurri smelter.<br />
Fig. 1: Damage distribution – P&F stockpile<br />
Fig. 2: Number of carriages on carbon plant power and free conveyors<br />
Diagrams: ABB<br />
ABB also <strong>de</strong>veloped an in-house refurbishment<br />
programme, which ensures<br />
that stringent quality assurance<br />
procedures will be adhered to for<br />
years to come.<br />
I<strong>de</strong>ntifying a root cause for system<br />
failure – A significant problem ABB<br />
i<strong>de</strong>ntified was that operators were removing<br />
the carriages from the system<br />
whenever they jammed. Once a carriage<br />
was removed, it joined the pile<br />
of some 200 carriages that were waiting<br />
to be refurbished. This inefficient<br />
method was addressed by making<br />
the carriage removal a maintenance<br />
task. ABB <strong>de</strong>veloped a troubleshooting<br />
gui<strong>de</strong> for the maintenance crew,<br />
who would then perform a series of<br />
inspections leading to several in-service<br />
repairs before the carriage was removed.<br />
This procedure not only ma<strong>de</strong><br />
addressing the issues more efficient,<br />
but it also reduced the annual ➝<br />
43
t e c h n o l o g y<br />
Aerial view of the Kurri Kurri plant in Australia<br />
maintenance costs by USD14,000<br />
eliminating unnecessary freight and<br />
material handling charges.<br />
Improving the refurbishment<br />
programme – Once the system inefficiencies<br />
were eliminated, ABB took<br />
a closer look at the repair process<br />
for the carriages. Here issues were<br />
i<strong>de</strong>ntified with throughput, quality of<br />
repairs and lead times for parts. The<br />
assessment resulted in the set-up of<br />
an internal refurbishment programme<br />
using the on-site work shop, since<br />
they had the necessary tools and jigs<br />
to perform the repairs efficiently.<br />
Streamlining the repair process –<br />
ABB then examined the specific problems<br />
occurring with the equipment, so<br />
data was captured, compared and the<br />
results are shown in Figure 1. An overwhelming<br />
50 percent of the carriages<br />
in the stockpile were due to damage<br />
with the front trolley. This information<br />
then allowed ABB to focus on specific<br />
equipment improvements.<br />
Using this information, a cannibalisation<br />
programme was <strong>de</strong>veloped, and<br />
over 80 carriages were i<strong>de</strong>ntified for<br />
rapid return to the system by substituting<br />
some small and easy to change<br />
parts from other damaged carriages<br />
thus avoiding the longer standard repair<br />
process. Combined with quality<br />
assurance checks, the central work<br />
shop was able to quickly turn around<br />
large numbers of carriages and provi<strong>de</strong><br />
enough work for operations to<br />
continue until the shipment of new<br />
parts arrive, allowing the complete<br />
carriage refurbishments to proceed.<br />
Once the number of working carriages<br />
had begun to stabilise, focus<br />
shifted to prepare a <strong>de</strong>tailed refurbishment<br />
procedure which enabled quality<br />
repairs and the implementation of<br />
a quality assurance programme. The<br />
comprehensive document <strong>de</strong>tailed<br />
the complete overhaul of the carriages<br />
providing tra<strong>de</strong>smen with a valuable<br />
tool to ensure compliance on a daily<br />
basis regardless of who was doing the<br />
repair.<br />
Figure 2 shows the improvement<br />
that was achieved on the two conveyor<br />
lines. Starting with both lines well<br />
below the minimum target, performance<br />
was improved to over the mini-<br />
The Kurri Kurri aluminium smelter has<br />
been operational since 1969 and is<br />
currently owned and operated by Hydro.<br />
The plant is located close to Newcastle in<br />
New South Wales, Australia. Production<br />
capacity of the smelter is currently at<br />
153,000 tonnes annually.<br />
mum target on both lines for the first<br />
time since ABB took over the maintenance.<br />
The greenmix part of the plant<br />
is where all the raw material batching,<br />
mixing and forming occurs, whilst<br />
the baked section is where the formed<br />
raw ingredients, that is the output of<br />
the greenmix plant are consolidated<br />
by baking. ABB’s project lea<strong>de</strong>r Adam<br />
Cooper says: “This has been an excellent<br />
example how ABB’s tools and system<br />
analysis methodologies can help<br />
customers like Hydro Kurri Kurri.<br />
We were able to <strong>de</strong>velop an innovative<br />
solution that resulted in a reliable<br />
system and increased productivity for<br />
the plant.”<br />
Since the power and free conveyor<br />
is a bottle neck piece of equipment<br />
that actually runs through the entire<br />
carbon plant, the refurbishment of the<br />
system has enabled the plant to operate<br />
at much higher efficiency than<br />
before. This not only promotes safety,<br />
but also increases operator morale<br />
since they no longer have such a high<br />
interaction with <strong>de</strong>fective equipment.<br />
This improvement has also enabled<br />
the ABB maintenance alliance personnel<br />
to spend their time on other<br />
equipment, further increasing the reliability<br />
and stability of operation of<br />
the plant.<br />
■<br />
44 ALUMINIUM · 9/2009<br />
Norsk Hydro
Norsk Hydro<br />
aluminium smelting industry<br />
Chinalco likely to<br />
back rio rights-issue<br />
China’s state-owned Chinalco is likely<br />
to participate in global miner Rio Tinto’s<br />
USD15.2bn rights offer, in a sign<br />
China is keen to retain its interest in<br />
the world’s top iron ore miner. Strong<br />
<strong>de</strong>mand for the Rio offer, the fifthbiggest<br />
on record, is expected to ease<br />
pressure on Rio to sell assets at throwaway<br />
prices and to give it the stability<br />
to pursue growth amid signs that the<br />
global economy is on the mend.<br />
Rio is raising money to cut a<br />
USD38bn <strong>de</strong>bt mountain it accumulated<br />
when it bought Canadian aluminium<br />
group Alcan at the top of the<br />
commodities market in 2007. The key<br />
issue for Rio is to <strong>de</strong>ci<strong>de</strong> whether to<br />
sell some downstream Alcan assets<br />
now, or whether to hold them for 3 to<br />
5 years to realise better value.<br />
Chinalco’s aluminium relations<br />
with Rio soured early in June after<br />
the in<strong>de</strong>bted miner called off a bigger<br />
equity partnership that would have<br />
seen the Chinese group invest another<br />
USD19.5bn into dual-listed Rio Tinto.<br />
Instead, Rio ditched the <strong>de</strong>al in favour<br />
of the rights issue and an iron ore joint<br />
venture with rival BHP Billiton, raising<br />
howls of protest from China. Rio’s<br />
21-for-40 rights issue was priced at a<br />
steep discount of AD28.29 per Australian-listed<br />
share and 1,400 pence<br />
per London-listed share.<br />
Chinalco, Rio’s top sharehol<strong>de</strong>r,<br />
owns about 9% of the combined group<br />
ALUMINIUM · 9/2009<br />
and a full take-up of the rights would<br />
cost it around USD1.5bn. If Chinalco<br />
takes up its entitlement in full,<br />
it would bring down its average holding<br />
cost in Rio. Chinalco bought its<br />
initial stake at 60 pounds (USD99.69)<br />
a share in February 2008 in a raid on<br />
the London-listed stock.<br />
Hindalco may go slow<br />
on aditya aluminium project<br />
India’s Hindalco Industries Ltd may<br />
go slow on its Aditya <strong>Alu</strong>minium<br />
project in Orissa state, which envisions<br />
a 1.5m tpy alumina refinery and<br />
a 360,000 tpy aluminium smelter.<br />
It is facing problems getting the required<br />
land and water supplies as<br />
well as environmental clearance. It<br />
is unclear what the <strong>de</strong>lay will be, but<br />
mechanical completion of the plant<br />
had been expected in 2011, and full<br />
production by 2013. Hindalco also<br />
plans to build two aluminium smelters<br />
of 360,000 tpy each in Jharkhand<br />
and Madhya Pra<strong>de</strong>sh states in the<br />
next four years. The Mahan Smelter<br />
in Madhya Pra<strong>de</strong>sh is due for completion<br />
in late 2010, with first metal<br />
expected in 2011. Equipment for the<br />
captive 900 MW power plant has been<br />
or<strong>de</strong>red, together with around 40% of<br />
the smelter equipment.<br />
To feed its three new smelters Hindalco<br />
is also building Utkal <strong>Alu</strong>mina,<br />
a 1.5m tpy alumina refinery, by early<br />
2011, with first alumina in July 2011.<br />
C o m p a n y n e w s w o r l d w i d e<br />
It also plans to build a 90 MW power<br />
plant and a 2m tpy bauxite mine, and<br />
to expand its 138,000 tpy alumina refinery<br />
in Belgaum to 313,000 tpy in<br />
2011. Hindalco is raising USD500m to<br />
finance the expansions.<br />
rio rejects Usd80m<br />
lifeline for anglesey<br />
as it prepares for closure<br />
Rio Tinto Alcan will continue with<br />
plans to close its Anglesey aluminium<br />
smelter in Wales after it rejected a<br />
£48m (USD79m) government bailout<br />
on 1 July. There is no possibility of a<br />
realistic subsidy being available, and<br />
without a permanent power solution,<br />
any subsidy would only provi<strong>de</strong> interim<br />
relief and would not represent<br />
a sustainable solution. Rio has looked<br />
at other options, but has not i<strong>de</strong>ntified<br />
any alternative and affordable source<br />
of power. The 145,000 tpy aluminium<br />
smelter is owned by Rio with a 51%<br />
stake, and by Kaiser <strong>Alu</strong>minum which<br />
has the remaining 49%. The Anglesey<br />
plant employs around 500 people.<br />
German neuss aluminium<br />
plant stays open near term<br />
Hydro <strong>Alu</strong>minium, the German unit<br />
of Norwegian group Norsk Hydro, is<br />
to keep its large German aluminium<br />
plant at Neuss open for the immediate<br />
future while a new German state aid<br />
plan for metal companies is assessed.<br />
Hydro said in April it would stop production<br />
at the loss-making aluminium<br />
plant at Neuss in June because of high<br />
German electricity costs and weak<br />
<strong>de</strong>mand. But the Neuss plant will<br />
remain in operation at its current reduced<br />
level while the <strong>de</strong>tails of a new<br />
German government plan to help the<br />
non-ferrous metals industry are assessed.<br />
Germany’s ruling government<br />
coalition has <strong>de</strong>ci<strong>de</strong>d to give extra aid<br />
of €40m (USD55.91m) in 2009 to help<br />
the NF metals industry overcome the<br />
impact of the economic slowdown<br />
and high German power costs. The<br />
Neuss plant has capacity to produce<br />
230,000 tpy of primary aluminium,<br />
but is currently producing only about<br />
4,000 tpm or about 50,000 tpy. ➝<br />
45
C o m p a n y n e w s w o r l d w i d e<br />
The €40m aid package for 2009 could<br />
be paid out to firms in around two<br />
months. Details of how the aid will be<br />
paid out were being worked out by<br />
Germany’s Economy Ministry, and<br />
the plan would have to be approved<br />
by the EU Commission.<br />
German metals producers faced<br />
electricity costs as much as 30% higher<br />
than neighbouring countries.<br />
Greenland <strong>de</strong>lays<br />
<strong>de</strong>cision on alcoa plant<br />
Greenland has <strong>de</strong>layed a <strong>de</strong>cision on<br />
joining Alcoa Inc. in a planned aluminium<br />
venture, and has scaled back its<br />
possible stake to 10 to 30%. More time<br />
was nee<strong>de</strong>d to estimate construction<br />
costs at the smelter and hydropower<br />
venture in Maniitsoq. Greenland’s<br />
parliament will <strong>de</strong>ci<strong>de</strong> on the venture<br />
in spring 2010 instead of this autumn<br />
as earlier planned. Alcoa and Greenland<br />
announced in 2007 they would<br />
explore building a plant and said construction<br />
could begin in 2010, with<br />
production starting in 2014. The proposal<br />
consists of a smelter with a capacity<br />
of at least 350,000 tpy and two<br />
hydropower plants. Annual revenue<br />
is estimated at 3 to 4 billion Danish<br />
crowns (USD566-754.7m). Since Alcoa<br />
is only looking for a 50% share, the<br />
door could be open to other partners.<br />
Vedanta to double output<br />
at orissa aluminium smelter<br />
Vedanta <strong>Alu</strong>minium will double production<br />
at its new smelter at Jharsuguda,<br />
Orissa, to 500,000 tpy in the near<br />
future. The smelter will get alumina<br />
from Vedanta’s Lanjigarh refinery,<br />
which is also ramping up production,<br />
to 1.4m tpy in the next month<br />
from 1m tpy. Vedanta’s aluminium<br />
smelting capacity in India has, however,<br />
fallen as it has <strong>de</strong>commissioned<br />
two 50,000 tpy potlines at its plant in<br />
Korba, Chhattisgarh state. Vedanta is<br />
also likely to <strong>de</strong>commission another<br />
50,000 tpy of old smelting capacity at<br />
Korba within a year, leaving a 245,000<br />
tpy smelter commissioned only a few<br />
years ago. Vedanta plans to replace<br />
the old smelters un<strong>de</strong>r a 600,000 tpy<br />
brownfield expansion plan. It aims to<br />
produce over 1m tpy of aluminium by<br />
2010/11.The 600,000 tpy fresh smelting<br />
capacity at Korba is expected to be<br />
commissioned by 2010/11.<br />
Venezuela will announce<br />
aluminium recovery plan<br />
in the near future<br />
The priority of Venezuela’s government<br />
will be to invest some 410m<br />
Bolivares (USD190m) in local bauxite<br />
and alumina producer CVG Bauxilum.<br />
Bauxilum has been producing only<br />
3,200 to 3,500 tpd of alumina, while<br />
its capacity is 5,800 tpd (2.11m tpy).<br />
Alcasa’s situation is also very difficult,<br />
since almost 400 of its 680 electrolytic<br />
cells are idle at the moment on the lack<br />
of technological update. Alcasa has<br />
been producing only some 350 tpd<br />
(126,000 tpy) of aluminium, well below<br />
its installed capability of around 550<br />
tpd (200,000 tpy). Venalum has been<br />
operating near its installed capacity<br />
of 1,180 tpd (430,000 tpy), although<br />
there were some output losses due to<br />
protests. The whole aluminium sector<br />
would need some USD5.5bn to fully<br />
recover, according to a study recently<br />
completed by the Chinese government<br />
at the request of Venezuela’s authorities.<br />
Production costs in Venezuela<br />
are around USD3,700 per tonne of<br />
aluminium, while prices were still in<br />
the USD1,800/t level. The government<br />
will pay <strong>de</strong>layed benefits and wages to<br />
the sector’s workers, totalling roughly<br />
213m Bolivares in three instalments<br />
– one on 31 July, the second on 15 September<br />
and the last on 31 October.<br />
Century to restart<br />
construction at iceland smelter<br />
Despite lingering concerns about<br />
oversupply in the aluminium market,<br />
Century <strong>Alu</strong>minum Co. is preparing<br />
to restart major construction at and<br />
expand the capacity of its proposed<br />
primary smelter in Iceland. Plans for<br />
the smelter in Helguvik, Iceland, were<br />
effectively put on hold late in 2008<br />
due to tightening credit markets, the<br />
collapse of the Icelandic economy,<br />
and the downturn within the alumin-<br />
ium industry. Century is now ramping<br />
up construction and is planning<br />
to expand the eventual capacity of<br />
the smelter to 360,000 tpy from its<br />
previous target of 250,000 tpy. Century<br />
has reconfigured the phasing of<br />
the project. Originally, the company<br />
hoped to build a 250,000 tpy smelter<br />
in two stages, with the first 150,000<br />
tpy first stage going online in late<br />
2010.<br />
Now Century plans building the<br />
smelter in four phases of 90,000 tpy<br />
each. The company did not disclose<br />
when the first phase might be completed.<br />
Century is still formulating<br />
how much it plans on spending on<br />
construction costs in 2009. When<br />
built, Helguvik will be Century’s<br />
second plant in Iceland. Its low-cost<br />
Grundartangi smelter shipped at a<br />
rate of approx. 276,000 tpy during the<br />
second quarter.<br />
Century recalls 28 workers<br />
to Hawesville smelter<br />
Century <strong>Alu</strong>minum Co. has brought<br />
back 28 workers to its Hawesville/<br />
Kentucky smelter as the company<br />
plans to restart 21 pots that have been<br />
left idled or damaged. Seven workers<br />
will replace retiring employees, while<br />
the remaining 21 will be tasked with<br />
rebooting the pots that were allowed<br />
to go out. While the repairs will not<br />
directly lead to increased production,<br />
they will allow the facility to operate<br />
more efficiently. The Hawesville<br />
smelter has a nameplate capacity of<br />
244,000 tpy over five potlines, each<br />
with 112 pots. But the company is<br />
only running four potlines currently,<br />
equating to an annualized production<br />
rate of 180,000 tpy. The rationale for<br />
bring back the employees is twofold.<br />
First, LME prices are in the midst of a<br />
rally. Three-month aluminium closed<br />
second-ring tra<strong>de</strong> at USD1,837 per<br />
tonne on 28 July, a 17.3% gain from<br />
the USD1,565 level seen on 13 July,<br />
based largely on improved <strong>de</strong>mand<br />
and a tightening marketplace. Additionally,<br />
the company just completed<br />
a new long-term power contract with<br />
Big Rivers Electric Corp., which will<br />
supply the smelter with electricity<br />
through 2023. ■<br />
46 ALUMINIUM · 9/2009
UC Rusal<br />
Bauxite and alumina activities<br />
Vedanta’s india bauxite<br />
mining to begin by october<br />
Vedanta Resources Plc. will begin<br />
bauxite mining for its alumina plant<br />
in eastern India by October and will<br />
invest USD1.23bn to expand its capacity<br />
sixfold by 2011. The start of the<br />
mining to feed the alumina refinery<br />
in India’s eastern state of Orissa has<br />
been <strong>de</strong>layed for at least four years by<br />
protests from indigenous people, who<br />
consi<strong>de</strong>r the area that will be mined<br />
as sacred ground. In August 2008,<br />
India’s Supreme Court allowed the<br />
London-listed company to proceed to<br />
mine bauxite from open-cast mines.<br />
Vedanta has so far invested USD823m<br />
in the plant, and will spend another<br />
USD1.23bn to expand the capacity to<br />
6m tpy from 1m tpy by 2011. The company<br />
has <strong>de</strong>posited USD28m with the<br />
government as payments to ensure it<br />
preserves wildlife, does reforestation<br />
projects and launches <strong>de</strong>velopment<br />
work for resi<strong>de</strong>nts. The Orissa Mining<br />
Corp., Vedanta’s joint-venture partner,<br />
will supply 150m tpy of bauxite<br />
to Vedanta’s plant from various locations,<br />
including Niyamgiri, which has<br />
a 79m-tonne <strong>de</strong>posit.<br />
Venezuela’s CVG Bauxilum announces<br />
Usd110m recovery plan<br />
Venezuelan bauxite and alumina producer<br />
CVG Bauxilum has announced<br />
an immediate recovery plan worth<br />
236.5 million bolivares (USD110m)<br />
ALUMINIUM · 9/2009<br />
to enable it to produce 3,200 tpd of<br />
alumina throughout the second half.<br />
CVG Bauxilum expects a total output<br />
of 1.4m tonnes for 2009 once the recovery<br />
plan has been completed. The<br />
boost in output for the second half<br />
would allow the company to feed<br />
the domestic market and attend sale<br />
commitments in the international<br />
market. Around 183.85m bolivares<br />
(USD85.5m) will be used to revamp<br />
works and to purchase raw materials<br />
in Venezuela and other countries. The<br />
remaining money will be used to pay<br />
the company’s workforce labour benefits.<br />
CVG Bauxilum did not say when<br />
it intends to finalise the 236.5m bolivares<br />
(USD110m) investment, but it is<br />
likely that the capital will be spent by<br />
December. The company is aiming to<br />
produce 1.65m tonnes of alumina in<br />
2010 and, afterwards, intends to reach<br />
its installed capability of 2m tpy, with<br />
further investment of 610.6m bolivares<br />
(USD284m).<br />
Chinese firm buys 2.5m t<br />
of alumina from Trafigura<br />
China’s CPI Mengdong Energy Group,<br />
the parent of smelter HMHJ <strong>Alu</strong>minium,<br />
has agreed to import 2.5m tonnes<br />
of alumina from international trading<br />
house Trafigura Group. The alumina<br />
will be shipped in equal amounts<br />
to the Chinese buyer over ten years<br />
from 2010. The alumina will be priced<br />
at less than 14% of the price of the<br />
three-month aluminium contract of<br />
C o m p a n y n e w s w o r l d w i d e<br />
the LME. The contract also set the<br />
maximum and minimum prices for<br />
alumina. That term price was about<br />
10% lower than prices for current<br />
spot alumina to China. Trafigura’s<br />
contract will cover 18% of HMHJ’s<br />
alumina needs in 2010, which are<br />
about 1.4 m tonnes. HMHJ’s facilities<br />
in Inner Mongolia can turn out<br />
700,000 tonnes of primary aluminium<br />
in 2010 and that output will consume<br />
around 1.4m tonnes of alumina. China<br />
produced more than 90% of its alumina<br />
needs in the first half of this year<br />
at 10.62m tonnes.<br />
alumar refinery completes<br />
2m tpy alumina expansion<br />
The <strong>Alu</strong>mar alumina refinery in Brazil<br />
has increased production as a result<br />
of a 2m tpy expansion project. With<br />
the project 98% complete, the refinery<br />
will ramp up to full production<br />
throughout the second half of the<br />
year. Total production capacity will<br />
increase to 3.5m tpy from 1.5m tpy.<br />
Alcoa is the majority stakehol<strong>de</strong>r with<br />
54%, while BHP holds a 36% stake<br />
and Rio Tinto Alcan holds the remaining<br />
10% share.<br />
nalco expects to get andhra<br />
pra<strong>de</strong>sh bauxite mines soon<br />
India’s Nalco expects to receive mining<br />
leases for its proposed 4.2m tpy of<br />
bauxite and 1.4m tpy alumina projects<br />
in September 2009. Now that the Andhra<br />
Pra<strong>de</strong>sh government has recommen<strong>de</strong>d<br />
that the central government<br />
should grant bauxite mining leases to<br />
Nalco in East Godavari and Visakapatnam<br />
districts of the state, Nalco has<br />
crossed the first hurdle to the Rs70bn<br />
(USD1.4bn) bauxite mining and alumina<br />
refinery project. The leases<br />
cover 85m tonnes of bauxite reserves<br />
of the same quality as Nalco’s other<br />
mines, 20 km away in Orissa state.<br />
However, due to a lack of land, ore<br />
from the Andhra Pra<strong>de</strong>sh mines will<br />
have to be transported 20 to 30 km<br />
to the refinery, unlike Nalco’s current<br />
operations, where mine and refinery<br />
are nearby. Nalco is one of the world’s<br />
lowest cost alumina producers ➝<br />
47
Trimet<br />
C o m p a n y n e w s w o r l d w i d e<br />
at around USD120 per tonne. Nalco<br />
will apply for forest and environment<br />
clearance after it receives the mining<br />
leases, and it may take five to seven<br />
years before alumina production<br />
starts at the export-oriented refinery.<br />
pisolite Hills bauxite<br />
resource upgra<strong>de</strong>d by 30%<br />
Cape <strong>Alu</strong>mina has raised the bauxite<br />
resource on its proposed 7m tpy<br />
Pisolite Hills project in Queensland,<br />
Australia, by 30% to 130m tonnes.<br />
This upgra<strong>de</strong>d estimate will form a<br />
‘pivotal component’ of the bankable<br />
feasibility study due to commence in<br />
September 2009. There is potential<br />
for an initial 12 to 15 year operation<br />
at Pisolite Hills at a target production<br />
rate of 7m tpy. The bauxite is suitable<br />
as a blending feed for the new breed of<br />
low-temperature Bayer-process refineries<br />
in China. Cape <strong>Alu</strong>mina expects<br />
to start construction on the Pisolite<br />
Hills project in early 2011.<br />
■<br />
recycling and secondary smelting<br />
aleris recalls<br />
workers on auto restarts<br />
Aleris International Inc. said more<br />
than 100 aluminium workers have<br />
been recalled during July at its specification<br />
alloy and recycling plants in<br />
Coldwater and Saginaw/Michigan,<br />
novelis may stop buying scrap from aB inBev<br />
Novelis Inc. has come close to saying it will<br />
drop its long-time arrangement for buying<br />
much of its can scrap through Anheuser-<br />
Busch Inbev (AB InBev), a major customer<br />
for the resulting aluminium canstock.<br />
Novelis North America announced it will<br />
change its used beverage can (UBC) procurement<br />
strategy at the end of its current<br />
contractual commitments. Come January,<br />
the most likely outcome will be an expan<strong>de</strong>d<br />
purchasing unit at Novelis buying<br />
directly from recyclers and municipalities,<br />
although there has been no rumour about<br />
the company recruiting scrap tra<strong>de</strong>rs.<br />
Long-shot possibilities are outsourcing<br />
to a nationwi<strong>de</strong> scrapyard chain or<br />
to Coca-Cola Recycling LLC, which so far<br />
plays only a minor role as a direct scrap<br />
supplier to Novelis, but which has greatly<br />
expan<strong>de</strong>d its staff and capabilities over<br />
the past 18 months. It is part of Coca-Cola<br />
Enterprises Inc. A stumbling block would<br />
be that Coca-Cola would probably want<br />
a fee-based tolling arrangement, with<br />
a fixed conversion charge, while Novelis<br />
likely would favour a buy-sell structure<br />
for flexibility and confi<strong>de</strong>ntiality.<br />
AB InBev has the twin roles of supplying<br />
Novelis with UBCs and of buying<br />
the canstock ma<strong>de</strong> from it. The two si<strong>de</strong>s<br />
of the arrangement involve different segments<br />
of AB InBev. The sort of relation-<br />
Steele/Alabama, and Morgantown/<br />
Kentucky. At the ingot casting section<br />
of the sheet mill in Lewisport/<br />
Kentucky recalls for 25 people have<br />
occurred, partly due to increased activity<br />
and partly to replace retirees.<br />
Aleris is reorganising un<strong>de</strong>r Chapter<br />
11 court protection.<br />
investment group buying<br />
two Commercial alloys smelters<br />
Commercial Alloys Corp.’s aluminium<br />
smelters in Minerva/Ohio, and<br />
Scottsboro/Alabama, which have<br />
been part of a Chapter 11 bankruptcy<br />
case since November 2008, were sold<br />
to an investment group hea<strong>de</strong>d by<br />
David Kozin of Chicago-based Imperial<br />
Zinc Corp.<br />
Imperial Coldwater Group LLC,<br />
which shares Imperial Zinc’s address,<br />
paid USD1.3m for the two facilities,<br />
plus a value not yet established for the<br />
inventory. The draft of the ‘final asset<br />
purchase agreement’ was filed in U.S.<br />
Bankruptcy Court for the Northern<br />
District of Ohio. Three scrap veterans<br />
at Imperial’s branch in Angola/Indiana<br />
– David Rid<strong>de</strong>ll, Aaron Stankewicz<br />
and Corbin Grimes – will handle<br />
metal purchase and some other<br />
responsibilities. At one time, all three<br />
worked for Imco Recycling, a company<br />
which had been eventually merged<br />
into Aleris International Inc.<br />
The Scottsboro plant is idle, while<br />
ship Anheuser-Busch and Novelis have<br />
had can be very stressful, as the rolling<br />
mill’s customer obtains intimate knowledge<br />
over time of margins between<br />
material cost and product price, partly<br />
from data fed into the <strong>de</strong>tailed pricing<br />
formulas written into the contracts.<br />
If Novelis does begin purchasing<br />
directly from a long roster of suppliers, it<br />
will need to make concessions to recycler<br />
paranoia about credit risk from <strong>de</strong>btla<strong>de</strong>n<br />
scrap consumers. If the industry’s<br />
relationships get shaken up, AB InBev<br />
might be tempted to strengthen ties to<br />
the smallest of the major canstock producers,<br />
Wise Metals Group.<br />
48 ALUMINIUM · 9/2009
the Minerva plant was producing<br />
1,800 to 2,270 tpm. Once the Minerva<br />
plant is up and running close to<br />
capacity, the Scottsboro smelter will<br />
be fired up. The Minerva smelter is<br />
expected to produce 3,600 to 4,100<br />
tpm by the end of 2009. Commercial<br />
Alloys, based in Twinsburg/Ohio,<br />
also operated scrapyards there and in<br />
Jacksonville/Florida, which had been<br />
purchased by Reserve Management<br />
Group, Solon/Ohio.<br />
UK diecaster Thomas Brothers<br />
plans to close in october<br />
Leeds-based aluminium diecaster<br />
Thomas Brothers plans to close in<br />
October as a result of falling <strong>de</strong>mand<br />
for its products and a loss of customers.<br />
The gravity diecasting company<br />
<strong>special</strong>ises in the manufacture of<br />
high quality aluminium castings for<br />
general and automotive industries,<br />
and has over 35 years experience in<br />
the industry. The company employs<br />
about 27 people.<br />
india’s Hindalco<br />
to close down wheel plant<br />
Hindalco Industries intends to shut<br />
down an aluminium alloy wheels plant<br />
at Silvassa in western India, and will<br />
take steps to sell the plant’s assets. The<br />
company did not give any reason for<br />
shutting the plant, which has the capacity<br />
to make 300,000 wheels a year,<br />
but said it would not have any impact<br />
on the operations and financials of the<br />
company. The plant’s wheels were approved<br />
for supply to most major automakers<br />
including Maruti Suzuki, Tata<br />
Motors, Ford and Hyundai.<br />
auto supplier<br />
J.l. French files for Chapter 11<br />
J.L. French Automotive Castings Inc.<br />
filed for Chapter 11 protection on 13<br />
July in response to U.S. automotive<br />
production <strong>de</strong>clines and industrywi<strong>de</strong><br />
credit restrictions. The Sheboygan/Wisconsin-based<br />
aluminium automotive<br />
components manufacturer<br />
also plans to reduce its secured <strong>de</strong>bt<br />
ALUMINIUM · 9/2009<br />
to USD65m from about USD280m<br />
through <strong>de</strong>bt-for-equity swaps with<br />
first- and second-lien term loan len<strong>de</strong>rs<br />
in an effort to provi<strong>de</strong> a stable financial<br />
foundation for its operations.<br />
The company and its domestic<br />
affiliates will complete a pre-negotiated<br />
restructuring un<strong>de</strong>r its Chapter<br />
11 filing in the U.S. Bankruptcy Court<br />
for the District of Delaware. None of<br />
the company’s foreign operations are<br />
inclu<strong>de</strong>d. J.L. French has a USD15m<br />
<strong>de</strong>btor-in-possession (DIP) facility to<br />
fund working capital needs that might<br />
arise during the reorganisation, and<br />
expects to emerge from Chapter 11<br />
within 90 days.<br />
J.L. French manufactures engineered<br />
aluminium die-cast automotive<br />
parts, including oil pans, engine<br />
front covers, engine blocks and transmission<br />
cases.<br />
southwire to pay Usd335,000<br />
epa fine at Hawesville plant<br />
Southwire Co. has agreed to pay<br />
USD335,000 in civil penalties to the<br />
aluminium semis<br />
norTH ameriCa<br />
work starts on rebuilding<br />
alcoa press in Cleveland<br />
Work has begun on the initial stages<br />
of rebuilding Alcoa’s giant aerospace<br />
forging press in Cleveland, but without<br />
any word on the vast majority of<br />
C o m p a n y n e w s w o r l d w i d e<br />
state of Kentucky for a 2006 violation<br />
of the fe<strong>de</strong>ral Clean Air Act. The fine<br />
related to testing, operational, monitoring<br />
and record-keeping requirements<br />
at the Carrollton/Georgia-based company’s<br />
secondary aluminium production<br />
facility in Hawesville/Kentucky.<br />
The fine represents the largest civil<br />
settlement obtained for violations of<br />
the Secondary <strong>Alu</strong>minium Maximum<br />
Achievable Control Technology<br />
(MACT) regulations at a single facility<br />
in the Southeastern United States.<br />
The Kentucky Energy and Environmental<br />
Cabinet Department of Air<br />
Quality has since confirmed that the<br />
air pollutant levels from the Hawesville<br />
facility now meet industry standards<br />
established by the MACT rule,<br />
which regulates the emission of metallic<br />
hazardous air pollutants, dioxins/furans,<br />
and hydrogen chlori<strong>de</strong> and<br />
fluori<strong>de</strong> and chlorine associated with<br />
secondary aluminium production. Because<br />
the facility has come into compliance<br />
with the MACT standards, the<br />
settlement requires no further action<br />
to address compliance with the Clean<br />
Air Act at the facility.<br />
■<br />
funds nee<strong>de</strong>d to bring back the disabled<br />
equipment. Engineering work<br />
had begun and some parts had been<br />
or<strong>de</strong>red as part of a preliminary US-<br />
D22m allocated by the parent company<br />
for repairing the 50,000 tonne<br />
press, built originally by Mesta Machine<br />
Co. Among the parts nee<strong>de</strong>d<br />
would be castings for the base, ➝<br />
49<br />
Vimetco
C o m p a n y n e w s w o r l d w i d e<br />
which also would require the dismantling<br />
of the press.<br />
The Cleveland facility, and the big<br />
press in particular, plays a critical role<br />
in supplying large aluminium forgings<br />
for the new F-35 Joint Strike Fighter<br />
for Lockheed Martin Co. Alcoa has<br />
been able to produce the forgings<br />
on other equipment at Cleveland,<br />
although it is assumed in the aerospace<br />
industry that the 50,000 t press<br />
would be required for the aircraft’s<br />
full production stage. Alcoa continues<br />
to forge parts for the F-35.<br />
The total cost to bring back the<br />
press – believed to be one of only<br />
three of its approximate size in the<br />
United States – is estimated at more<br />
than USD110m, including USD60m<br />
million to USD70m for rebuilding the<br />
press itself, with the remain<strong>de</strong>r for<br />
such associated projects as new manipulator<br />
arms.<br />
on the move<br />
Alain Belda, Alcoa’s Executive Chairman,<br />
retired as an executive officer on<br />
1 August. But Belda will continue to<br />
serve as Chairman of the Board until<br />
his term as a director expires at the<br />
next annual meeting of sharehol<strong>de</strong>rs<br />
on 23 April 2010. Belda was Alcoa’s<br />
CEO from 2001 until May 2008.<br />
Alcoa expects Klaus Kleinfeld,<br />
Alcoa Presi<strong>de</strong>nt and CEO, to succeed<br />
Belda as chairman of the board. Additionally,<br />
Alcoa appointed Tim D.<br />
Myers Presi<strong>de</strong>nt, Alcoa Wheel and<br />
Transportation Products, with responsibility<br />
for forged wheels and aluminium<br />
structures.<br />
Alcoa appointed Nicholas DeRoma<br />
as Executive Vice Presi<strong>de</strong>nt, Chief Legal<br />
& Compliance Officer. In addition to<br />
leading Alcoa’s legal and compliance<br />
operations worldwi<strong>de</strong>, Mr DeRoma<br />
will also serve on the Alcoa Executive<br />
Council. He succeeds Michael Schell,<br />
who continues as Executive Vice Presi<strong>de</strong>nt,<br />
Business Development, and a<br />
member of the Executive Council.<br />
<strong>Alu</strong>minium Bahrain (Alba)’s Board<br />
of Directors announced the appointment<br />
of Mohammed Mahmoud as<br />
Alba’s new Chief Operating Officer, a<br />
newly created position.<br />
In September 2008, Alcoa <strong>de</strong>clared<br />
force majeure on the press after cracks<br />
were discovered in its lower base.<br />
aluminium extru<strong>de</strong>r to be sold<br />
Patrick Industries Inc. has agreed to<br />
sell its aluminium extrusion operation<br />
in Mishawaka/Indiana to Patrick<br />
<strong>Alu</strong>minum Inc. for USD7.4m. Although<br />
classified as a discontinued<br />
operation in the fourth quarter of<br />
2008, the plant is capable of producing<br />
and painting semi-fabricated and<br />
fabricated aluminium extrusions for<br />
structural and non-structural uses.<br />
Patrick <strong>Alu</strong>minum is a unit of UMC<br />
Acquisition Corp., Lynwood/California.<br />
The extrusion operation will<br />
continue to operate un<strong>de</strong>r the name<br />
Patrick Metals.<br />
asia<br />
Hindalco plans to relocate<br />
novelis plants to india<br />
Hindalco Industries is making meticulous<br />
plans to relocate plants owned<br />
by its subsidiary Novelis to India from<br />
Europe. The sheet mill at Rogerstone<br />
in the UK employing 440 workers is<br />
already closed, and one more plant in<br />
the UK is also likely to be closed. Novelis<br />
plants in Europe bought their metal<br />
from Hindalco and other sources<br />
for sheet making, and these shipping<br />
costs can be avoi<strong>de</strong>d with the relocation.<br />
Hindalco is reportedly talking<br />
to five leading can makers to supply<br />
aluminium sheet, including Poland’s<br />
Rexam, which is building a plant near<br />
Mumbai in Taloja, and Britain’s Can<br />
Pac, which is setting up a plant to<br />
make one billion cans a year in India.<br />
India’s safeguard duty on rolled products<br />
and foils protects it from cheap<br />
imports for the next five years.<br />
eUrope<br />
armenal reports<br />
increase in production<br />
In June, Armenal produced nearly<br />
2,500 tonnes of foil, a 12% improve-<br />
ment on its nominal <strong>de</strong>sign capacity,<br />
taking the rolling mill’s half-year production<br />
to over 10,000 tonnes. The<br />
company reported a 77% production<br />
increase from January to June 2009<br />
compared to the first half of 2008 and<br />
expects to see its output double by the<br />
end of this year.<br />
Armenal, in parallel with the<br />
expansion of output, was making<br />
improvements in practically every<br />
technical and economic indicator,<br />
including a 60% reduction in production<br />
costs and fewer rejects due to<br />
production <strong>de</strong>fects. The company has<br />
enough or<strong>de</strong>rs on hand to keep the<br />
foil mill running until the end of this<br />
year. Its products are mainly exported<br />
to the United States with the Middle<br />
East becoming a rapidly growing market<br />
for them.<br />
sapa’s agreement<br />
with indalex complete<br />
At the end of July, Sapa completed its<br />
purchase of the US aluminium extrusion<br />
company Indalex. Sapa acquired<br />
Indalex’s eleven active plants, six in<br />
the US and five in Canada, with two<br />
casthouses and 29 presses, and a<br />
total capacity of about 315,000 tpy.<br />
Indalex’s sales in 2008 were about<br />
200,000 tonnes, representing US-<br />
D900m. The company employs 1,400<br />
The author<br />
The author, Dipl.-Ing. R. P. Pawlek,<br />
is foun<strong>de</strong>r of TS+C, Technical Info<br />
Services and Consulting, Sierre<br />
(Switzerland), a new service for the<br />
primary aluminium industry. He is also<br />
the publisher of the standard works<br />
<strong>Alu</strong>mina Refineries and Producers of<br />
the World and Primary <strong>Alu</strong>minium<br />
Smelters and Producers of the World.<br />
These reference works are continually<br />
updated and contain useful technical<br />
and economic information on all<br />
alumina refineries and primary aluminium<br />
smelters of the world. They<br />
are available as loose-leaf files and/or<br />
CD-ROMs from the <strong>Alu</strong>minium-Verlag,<br />
Marketing & Kommunikation GmbH<br />
in Düsseldorf, Germany.<br />
50 ALUMINIUM · 9/2009
people. Through this acquisition Sapa<br />
strengthens its geographical coverage<br />
and logistical efficiencies to better<br />
serve North America, including an expansion<br />
into Canada. The acquisition<br />
represents an un<strong>de</strong>rlying enterprise<br />
value of approx, USD95m.<br />
aFriCa<br />
anglo sells 28% of<br />
south african Hulamin<br />
Mining group Anglo American Plc.<br />
sold 28% of South Africa’s Hulamin<br />
Ltd for 732m rand (USD93m) to focus<br />
on its core mining operations. Anglo,<br />
which is fighting off an unwelcome<br />
merger approach from rival Xstrata,<br />
retained a 17% stake in Hulamin,<br />
which makes semi-fabricated aluminium.<br />
The disposal was in line with Anglo<br />
American’s strategic commitment<br />
to focus on its core mining operations.<br />
Anglo sold 61m shares to Coronation<br />
Asset Management at 12 rand per<br />
ALUMINIUM · 9/2009<br />
share, compared to Hulamin’s price<br />
in Johannesburg of 10.55 rand.<br />
Hulamin posted a sharp drop in<br />
interim profit and said that, although<br />
or<strong>de</strong>r intake was recovering, annual<br />
earnings would fall by at least 20%. At<br />
the end of July Anglo sold its remaining<br />
stake in Hulamin, bringing the<br />
transaction to a total of 1.16bn rand<br />
(USD149.4m). Anglo sold its residual<br />
35.8m shares in the aluminium products<br />
company to South African institutions<br />
at the same price of 12 rand<br />
per share as for the first stake.<br />
suppliers<br />
BwG GmbH acquires metal<br />
treatment technology from ViTs<br />
BWG Bergwerk- und Walzwerk-<br />
Maschinenbau GmbH has announced<br />
the acquisition from VITS of technology<br />
for the thermal treatment of metal<br />
strip. BWG has formed a Thermal<br />
Strip Treatment product division to<br />
C o m p a n y n e w s w o r l d w i d e<br />
alro – new annealing furnace put into operation<br />
Alro SA, the largest aluminium producer<br />
in Central and Eastern Europe, has commissioned<br />
its annealing furnace with controlled<br />
atmosphere, following an investment<br />
of three million US-dollars. The new<br />
technology improves the surface quality<br />
of Alro’s aluminium products and the reliability<br />
of its mechanical properties. The<br />
project, which began in 2007, will also<br />
result in lower consumption of energy.<br />
The start-up of the furnace is part of<br />
an investment programme focused on increasing<br />
production of high ad<strong>de</strong>d value<br />
products, in line with Alro’s long-term<br />
strategic goals. The investment has also<br />
improved quality and allowed the best<br />
response in meeting customer needs regarding<br />
product range and specifications.<br />
The mo<strong>de</strong>rnisation programme has<br />
enabled Alro to receive the NADCAP (National<br />
Aerospace and Defence Contractor<br />
Accreditation Programme) performance<br />
certification for conformity with aerospace<br />
industry requirements, in 2008. The<br />
certificate was awar<strong>de</strong>d by the NADCAP<br />
Vimetco<br />
Management Council, in accordance with<br />
SAE Aerospace Standard AS 70003, following<br />
the testing of aluminium alloys<br />
produced at Slatina for heat treatment,<br />
conductivity measurement, tensile testing,<br />
hardness and metallographic analysis.<br />
add to its established range of highquality<br />
cost-effective equipment and<br />
services. This technology transfer<br />
allows BGW to better meet the ever<br />
growing challenges and needs of the<br />
steel and aluminium industries.<br />
By adding these products to its existing<br />
portfolio, BWG has broa<strong>de</strong>ned<br />
its core competence in the field of<br />
metallurgical strip processing. The<br />
supply of thermal strip treatment<br />
equipment is a logical addition to the<br />
supply of coil coating lines and aluminium<br />
annealing lines, thus enabling<br />
the company to offer integrated technical<br />
solutions. The new division is<br />
fully integrated into BWG at its headquarters<br />
in Duisburg, Germany.<br />
BWG is an internationally active<br />
family-owned company. It <strong>de</strong>livers<br />
strip treatment lines and coil and<br />
slab handling equipment as well as<br />
carrying out mo<strong>de</strong>rnisation of existing<br />
process lines and supplying <strong>special</strong>ist<br />
equipment such as Levelflex tension<br />
levellers, temper mills, si<strong>de</strong> trimmers<br />
and slab <strong>de</strong>burrers.<br />
■<br />
Over the last seven years, Alro has invested<br />
in total more than 255 million US-dollars.<br />
This year, the company will complete<br />
all investments started in 2008, which are<br />
budgeted to reach approximately six million<br />
US-dollars.<br />
51
e s e a r c h<br />
On the dissolution of alumina in a<br />
low-melting electrolyte for aluminium production<br />
S. Rolseth, J. Thonstad, H. Gudbrandsen, K.S. Osen, and J. Kvello, Trondheim<br />
In studies of inert ano<strong>de</strong>s for<br />
aluminium production, so-called<br />
low-melting electrolytes have been<br />
tested, operating at temperatures<br />
as low as 750°C. Dissolution of<br />
alumina may then become critical,<br />
because of lower solubility<br />
and lower rate of dissolution. The<br />
rate of alumina dissolution was<br />
tested in a particular electrolyte<br />
operating at 750°C, using a very<br />
fine-grained alumina as well as industrial<br />
gra<strong>de</strong> alumina. The rate of<br />
dissolution was markedly slower<br />
in the low-melting electrolyte, and<br />
the fine-grained material dissolved<br />
more slowly than commercial<br />
gra<strong>de</strong> alumina, because it showed<br />
greater ten<strong>de</strong>ncy to agglomeration<br />
and because it was calcined<br />
at high temperature. However,<br />
crushed samples of commercial<br />
alumina also dissolved more slowly<br />
than the normal gra<strong>de</strong>.<br />
Introduction<br />
In the conventional Hall-Héroult process<br />
for aluminium electrolysis, the<br />
cryolite-based (Na 3 AlF 6 ) electrolyte<br />
normally contains 10-13 wt% excess<br />
AlF 3 , 3-6 wt% CaF 2 and 2-4 wt% Al 2 O 3 ,<br />
operating at about 960°C. In mo<strong>de</strong>rn<br />
cells the alumina feeding is performed<br />
by so-called point fee<strong>de</strong>rs, whereby<br />
alumina is fed frequently in small<br />
batches. This ensures rapid and usually<br />
trouble-free supply of alumina to the<br />
molten electrolyte (often called bath).<br />
When trying to replace the carbon<br />
ano<strong>de</strong> by oxygen-evolving, so-called<br />
inert ano<strong>de</strong>s, it is <strong>de</strong>sirable to lower<br />
the electrolyte temperature in or<strong>de</strong>r<br />
to reduce the corrosion rate of the<br />
ano<strong>de</strong> material. This is achieved by<br />
increasing the content of excess AlF 3 ,<br />
in some cases as far as ~37 wt% AlF 3<br />
(55 mol% NaF, 45 mol% AlF 3 , molar<br />
ratio NaF/AlF 3 , CR=1.22), allowing<br />
an operating temperature of about<br />
750°C. At the same time the solubility<br />
of alumina <strong>de</strong>creases from about<br />
10 wt% to about 3 wt% [1]. Thereby<br />
the rate of dissolution of alumina may<br />
become critical.<br />
When a batch of alumina is being<br />
fed to aluminium cells, rapid and<br />
complete dissolution is <strong>de</strong>sirable in<br />
or<strong>de</strong>r to control the concentration<br />
of alumina in the bath and to avoid<br />
so-called ano<strong>de</strong> effects and to avoid<br />
accumulation of undissolved alumina<br />
(sludge). Dissolution tests performed<br />
in cryolite melts at around 1,000°C<br />
have shown that when the alumina<br />
gets effectively dispersed in the bath,<br />
the dissolution is very rapid, i. e. it is<br />
completed in less than 10 s [2], but<br />
the dissolution process is normally<br />
slowed down because the alumina<br />
has a ten<strong>de</strong>ncy to form clumps/aggregates.<br />
When cold alumina is ad<strong>de</strong>d as<br />
a batch to the molten bath, it is difficult<br />
to achieve complete dispersion<br />
of the alumina particles. When hitting<br />
the bath, the alumina spreads out,<br />
and bath freezes on to the alumina.<br />
This results in the formation of flakeshaped<br />
agglomerates. The formation<br />
of such agglomerates strongly reduces<br />
the contact area between alumina and<br />
bath compared to what would be the<br />
case if all the alumina grains were effectively<br />
dispersed in the bath.<br />
A large contact area between alumina<br />
and bath is obviously important<br />
in or<strong>de</strong>r to ensure rapid heating and<br />
dissolution of the alumina, since the<br />
dissolution process, which is strongly<br />
endothermic, has been found to be<br />
mass transfer controlled [3]. The importance<br />
of this becomes even more<br />
evi<strong>de</strong>nt if the alumina is ad<strong>de</strong>d to a<br />
low-melting bath rich in aluminium<br />
fluori<strong>de</strong>, where the alumina solubility<br />
is lower [1].<br />
One remedy would be to establish<br />
a large contact area between alumina<br />
and bath. Beck and Brooks [4] have<br />
patented a process where very finegrained<br />
alumina is used in low-melting<br />
baths, keeping the particles in<br />
suspension in a bath agitated by gasinduced<br />
convection.<br />
The purpose of the present work was<br />
to study the dissolution rate of finegrained<br />
alumina when ad<strong>de</strong>d batchwise<br />
to a low-melting bath with the<br />
composition given above. The results<br />
are compared with the well-documented<br />
behaviour of regular alumina<br />
in conventional baths at around<br />
960°C.<br />
experimental<br />
As mentioned above the process of<br />
alumina dissolution in cryolite-based<br />
melts involves the formation and<br />
break-up of agglomerates. In a laboratory<br />
cell for studies of alumina dissolution,<br />
the convection pattern in the<br />
melt should be as close as possible to<br />
that existing in industrial cells. That<br />
is difficult to achieve on a laboratory<br />
scale. In industrial cells the ano<strong>de</strong> gas<br />
escaping up along the ano<strong>de</strong> si<strong>de</strong> sets<br />
up strong convection, making the bath<br />
move upwards close to the ano<strong>de</strong> si<strong>de</strong><br />
and down in the middle of the channel<br />
between two ano<strong>de</strong>s. At the same time<br />
the bubbles, when reaching the bath<br />
surface, create an undulating surface<br />
with bath splashing over newly<br />
formed alumina agglomerates.<br />
effect of convection in the bath<br />
The objective with the laboratory<br />
set-up was to combine the effects of<br />
convection and an undulating bath<br />
surface. Convection in the bath was<br />
ensured by mechanical stirring of the<br />
melt with an impeller. Bubbling of argon<br />
gas through the bath was inten<strong>de</strong>d<br />
to simulate the surface effect created<br />
by escaping gas bubbles. A <strong>de</strong>scription<br />
of the gas stirrer arrangement is<br />
given elsewhere [5].<br />
The inner diameter of the crucible<br />
was 20 cm. The amount of bath was<br />
6500 g, and the composition of the<br />
industrial type electrolyte that was<br />
tested initially was 10 wt% AlF 3 , 5<br />
wt% CaF 2 , and the initial Al 2 O 3 concentration<br />
was 2 wt%, the balance be-<br />
52 ALUMINIUM · 9/2009
Fig. 1: Sketch of the cell used for the dissolution experiments. Dimension:<br />
Graphite crucible i. d. = 200 mm<br />
ing cryolite. In Figure 1 a sketch of the<br />
experimental arrangement is shown.<br />
The in situ alumina probe measured<br />
the so-called critical current<br />
<strong>de</strong>nsity by a linear sweep voltammetric<br />
method [6, 7]. The critical current<br />
<strong>de</strong>nsity is correlated to the alumina<br />
concentration. A few bath samples<br />
were taken and analysed for alumina,<br />
to serve as a control and calibration in<br />
each experiment. The advantage of the<br />
alumina probe was that it gave quick<br />
and instantaneous results, yielding up<br />
to one measurement per second.<br />
To test out the method industrial<br />
gra<strong>de</strong> alumina was used initially. The<br />
alumina was ad<strong>de</strong>d in one batch since<br />
the intention was to simulate the operation<br />
of point fee<strong>de</strong>rs. The batch<br />
size was 0.45 g/cm 2 bath surface corresponding<br />
to an increase in alumina<br />
concentration in the bath by 2.2 wt%.<br />
Dissolution curves for one experiment<br />
with mechanical stirring only<br />
and one experiment with gas bubbling<br />
together with mechanical stirring are<br />
ALUMINIUM · 9/2009<br />
shown in Figures 2 and 3 respectively.<br />
Data from the sweep measurements<br />
show how much of the alumina is<br />
dissolved as a function of time. The<br />
bath temperature recor<strong>de</strong>d during<br />
the dissolution run is also given on<br />
the graphs (right hand axis), showing<br />
a marked drop in temperature upon<br />
addition.<br />
As can be seen from the dissolution<br />
curves, gas bubbling enhanced<br />
the dissolution rate. This appears<br />
to be due both to an increase in the<br />
quantity which was dissolved initially<br />
and an increase in the dissolution rate<br />
of the remain<strong>de</strong>r of the batch. The increase<br />
in the initial dissolution rate is<br />
reflected in a faster and higher temperature<br />
drop in the case when gas<br />
bubbling was applied (Fig. 3).<br />
experiments<br />
in low-melting baths<br />
Fig. 2: Dissolution curve from an experiment with no gas stirring.<br />
Bath convection maintained by mechanical stirring only<br />
As indicated above the composition<br />
of the low-melting bath was 55 mol%<br />
r e s e a r c h<br />
NaF and 45 mol% AlF3 , which corresponds<br />
to a NaF/AlF3 molar ratio (CR)<br />
of 1.22. The alumina sensor was not<br />
applied in these initial experiments.<br />
Frequent bath samples were taken<br />
for 20 minutes, and sampling was<br />
continued at less frequent intervals<br />
up until 2 hours after the addition. In<br />
some experiments a second batch was<br />
ad<strong>de</strong>d at this time (2 hours after the<br />
first batch), and sampling was continued<br />
for another 2 hours. Tests were<br />
performed with fine-grained ‘superground’<br />
Alcoa A152 <strong>Alu</strong>mina (grain<br />
size ~ 1 µm). For comparison experiments<br />
with industrial gra<strong>de</strong> primary<br />
alumina (grain size 30-150 µm) were<br />
also performed.<br />
Visual observations were ma<strong>de</strong><br />
when a batch of alumina was ad<strong>de</strong>d. It<br />
was observed that the part of the batch<br />
that was dispersed quickly on the surface<br />
was rapidly soaked by bath, and<br />
it was no longer visible after about 10<br />
seconds. However, some lumps could<br />
form and remain as floating ‘rafts’ on<br />
the surface for up to 1 to 3 minutes<br />
before they were soaked by bath and<br />
started to sink as one piece.<br />
Figures 4 and 5 shows the results<br />
from sample analysis and recor<strong>de</strong>d<br />
temperatures for two samples of finegrained<br />
(~1 µm) alumina. In addition<br />
dissolution rates were calculated<br />
for the initial rapid phase. After the<br />
first jump in alumina concentration<br />
a slower dissolution took place, and<br />
the dissolution rate was estimated for<br />
the next 30 minutes as well. After 2<br />
hours only 60% of the ad<strong>de</strong>d alumina<br />
had been dissolved, indicating very<br />
slow dissolution of the remaining agglomerates.<br />
Table 1 summarises results from<br />
five experiments for the initial ➝<br />
Fig. 3: Dissolution curve from an experiment with both gas bubbling<br />
and mechanical stirring<br />
53
e s e a r c h<br />
Experiment 1<br />
CR = 1.22 Adding 2 wt% Al 2 O 3 at time 0<br />
Fig. 4: Dissolution curves, only one addition ma<strong>de</strong> of 2 wt% finegrained<br />
alumina. Squares: alumina concentration. Line: electrolyte<br />
temperature<br />
rapid stage of alumina dissolution,<br />
where 1 to 4 represent fine-grained<br />
alumina and 5 represents regular<br />
industrial metallurgical gra<strong>de</strong> (MG)<br />
alumina. This rapid dissolution occurred<br />
within a time frame of 30 to<br />
85 seconds.<br />
The data show a marked difference<br />
between experiments no 1 to 4 and<br />
experiment no 5 (primary industrial<br />
alumina). With the exception of experiment<br />
1 (2 wt% addition), experiment<br />
5 shows the highest initial dissolution<br />
rate and by far the highest percentage<br />
of initially dissolved material. An<br />
explanation for this difference can be<br />
the ten<strong>de</strong>ncy of the fine-grained material<br />
to form clumps/agglomerates of<br />
sintered alumina on the surface of the<br />
bath, which then dissolved slowly in<br />
the bath. The relatively coarse-grained<br />
regular alumina (experiment no 5)<br />
showed a different behaviour on the<br />
surface of the bath. It was free-flow-<br />
Experiment 2<br />
CR = 1.22 Adding 1 wt% Al2O3 at time 0 and time 120<br />
Fig. 5: Dissolution curves, two subsequent additions ma<strong>de</strong> of 1 wt%<br />
fine-grained alumina. Squares: alumina concentration. Line: electrolyte<br />
temperature<br />
Experiment Wt% ad<strong>de</strong>d<br />
Batch 1<br />
Dissolution rate [g/min] Percent of batch dissolved<br />
Batch 2<br />
Dissolution rate [g/min] Percent of batch dissolved<br />
1 2 53 21.5 - -<br />
2 1 32 25 22 17<br />
3 2 17 19 - -<br />
4 1 25 25 26 22<br />
5 1 44 72 53 63<br />
Table 1: Dissolution in first rapid phase of the dissolution process<br />
Experiment<br />
Dissolution rate<br />
[g/min]<br />
ing and it spread across the surface of<br />
the melt, so it did not stick together<br />
forming clumps, as experienced for<br />
the fine-grained material.<br />
The proportion of the batches<br />
which had dissolved after 2 hours is<br />
shown in Table 2.<br />
The results show that the 2 wt%<br />
additions in experiments 1 and 3 were<br />
less efficient than the 1 wt% additions.<br />
In the case of the 2 wt% batch sizes<br />
the alumina took longer to get wetted<br />
and sink into the bath, so it may<br />
have formed more strongly sintered<br />
agglomerates.<br />
For the second batch ad<strong>de</strong>d in experiments<br />
2, 4 and 5 there was also a<br />
marked difference in the dissolution,<br />
in the sense that the fine-grained<br />
alumina dissolved more slowly. The<br />
regular alumina was completely dissolved<br />
after 30-60 minutes.<br />
Previous studies [5] of the dissolution<br />
of regular primary aluminas in<br />
Batch 1 Batch 2<br />
Percent of batch<br />
dissolved after 2 hours<br />
Dissolution rate<br />
[g/min]<br />
normal baths at around 975°C show<br />
typically that more than 50% of the<br />
sample was dissolved initially, and<br />
the sample was completely dissolved<br />
after about 12 minutes. If we compare<br />
with experiment 5 in the present<br />
work, it seems that the portion that<br />
dissolves initially was about the same,<br />
but the remaining part dissolved more<br />
slowly. The time for total dissolution<br />
of the samples in the low-melting bath<br />
un<strong>de</strong>r study was more than one hour,<br />
which means that the time for total<br />
dissolution was increased by a factor<br />
of five or more compared to conventional<br />
baths.<br />
addition of large batches of 6<br />
wt-% industrial gra<strong>de</strong> alumina to<br />
low-melting baths (cr=1.22) and<br />
to industrial type bath (cr=2.3)<br />
In these experiments the concentration<br />
of dissolved alumina was moni-<br />
Percent of batch<br />
dissolved after 2 hours<br />
1 0.71 60 - -<br />
2 0.81 94 0.49 48<br />
3 0.55 44.5 - -<br />
4 0.50 75 0.34 55<br />
5 0.46 100 0.65 82<br />
Table 2: Dissolution rates in the period from 2 to 30 minutes after alumina addition and the total percentage that was dissolved after 2 hours<br />
54 ALUMINIUM · 9/2009
Fig. 6: Dissolution curve, industrial electrolyte and industrial gra<strong>de</strong><br />
alumina. Small points: alumina concentration measured by the<br />
alumina probe. Squares: bath samples analysed for alumina concentration<br />
(Leco). Line: bath temperature<br />
tored by the alumina probe in addition<br />
to control analysis of bath samples<br />
taken at regular intervals during<br />
the runs. Figures 6 and 7 show the<br />
dissolution behaviour in ‘standard’<br />
bath and in low-melting bath respectively.<br />
The results in Figure 6 show that<br />
the sandy, industrial gra<strong>de</strong> primary<br />
alumina was completely dissolved<br />
after approximately 30 minutes. This<br />
is about 2.5 times longer than in the<br />
comparable experiment in Figure<br />
3, where only 2 wt-% alumina was<br />
ad<strong>de</strong>d.<br />
When comparing the results shown<br />
in Figures 6 and 7 there is a striking<br />
difference in the initial dissolution.<br />
The fine-grained alumina showed a<br />
<strong>de</strong>layed response, and as expected it<br />
did not dissolve completely, but levelled<br />
off after 50 minutes at about 3<br />
wt-%, which is close to saturation [1].<br />
The undissolved alumina remained<br />
partly as a sludge at the bottom of the<br />
crucible and partly in suspension in<br />
the bath.<br />
The conclusion of these experiments<br />
is the same as for the previous<br />
tests, i. e. the dissolution rate in the<br />
low-melting electrolyte was consi<strong>de</strong>rably<br />
slower than the dissolution of<br />
regular alumina in normal Hall-Heroult<br />
bath. This is not surprising in<br />
view of the following facts,<br />
• Less driving force (lower<br />
concentration gradient)<br />
• Expected lower mass transfer<br />
coefficient (due to lower<br />
temperature)<br />
• Greater ten<strong>de</strong>ncy to clumping.<br />
The ten<strong>de</strong>ncy to clumping is probably<br />
related to the ‘fineness’ of the pow-<br />
ALUMINIUM · 9/2009<br />
<strong>de</strong>r. This also makes it more difficult<br />
to handle (low fluidity, dusting, etc). If<br />
it is <strong>de</strong>sired to maintain a permanent<br />
suspension of alumina in the electrolyte,<br />
it would be preferable if it could<br />
be achieved with a coarser-grained<br />
alumina.<br />
Visual observations<br />
of alumina dissolution in<br />
well-stirred, low melting baths<br />
The background for these experiments<br />
was the unexpected slow dissolution<br />
observed for fine-grained alumina in<br />
low-melting baths. One hypothesis<br />
was that the alumina calcination temperature<br />
could be an important factor,<br />
since the fine-grained material had<br />
been calcined at 1,600°C. The objective<br />
of these experiments was to test<br />
this hypothesis to see if the <strong>special</strong><br />
quality alumina was suited as a feed<br />
material for<br />
a l u m i n i u m<br />
electrolysis.<br />
The experiments<br />
were<br />
carried out in<br />
an open furnace,<br />
where<br />
the low-melting<br />
bath was<br />
kept in a platinumcrucible.<br />
The bath<br />
composition<br />
was as before<br />
45 mol%<br />
AlF 3 and 55<br />
mol% NaF,<br />
i. e. CR = 1.22.<br />
The experi-<br />
r e s e a r c h<br />
Fig. 7: Dissolution curve for the first 60 minutes after addition of<br />
industrial gra<strong>de</strong> alumina to low-melting electrolyte. Small points:<br />
alumina concentration measured by the alumina probe. Squares:<br />
bath samples analysed for alumina concentration (Leco). Line: bath<br />
temperature<br />
mental set-up is sketched in Figure 8.<br />
The melt was agitated by a propellershaped<br />
platinum stirrer placed in the<br />
centre of the crucible, operating at 254<br />
rpm. A Pt/Pt10Rh (Type S) thermocouple<br />
was also immersed in the melt,<br />
as shown in Figure 8. The amount of<br />
bath was 140 g, and the temperature<br />
was 740 ± 3°C prior to each addition.<br />
The experiments were carried out as<br />
visual observation of the time nee<strong>de</strong>d<br />
for a batch of 0.5 wt-% alumina to dissolve.<br />
The melt became opaque immediately<br />
after the addition. The time<br />
counted from the moment of addition<br />
till the bottom of the crucible became<br />
visible again, was taken as a measure<br />
of the time of dissolution.<br />
Table 3 lists the various types of<br />
alumina that were tested in these experiments.<br />
An interesting parameter<br />
gleaned from these curves is the ‘cut<br />
size’ (d0.5 ), meaning that 50% of ➝<br />
Fig. 8. Experimental set-up for visual study of alumina dissolution in<br />
low-melting bath<br />
55
e s e a r c h<br />
the mass has particle diameter less<br />
than d 0.5 ).<br />
The results showed that there was<br />
a marked difference in dissolution<br />
time of the various aluminas; in fact<br />
more than one or<strong>de</strong>r of magnitu<strong>de</strong>.<br />
The best dissolution behaviour was<br />
observed for the ‘normal’ metal gra<strong>de</strong><br />
alumina, as shown in Figure 9. In this<br />
case relatively short dissolution times<br />
were observed, similar to those previously<br />
observed for commercial aluminas<br />
in cryolite. The longest dissolution<br />
times were observed for crushed<br />
MG alumina, calcined at 1,600°C,<br />
where the dissolution time was of<br />
the or<strong>de</strong>r of 5 to 20 minutes in the<br />
alumina concentration range of 1 to 2<br />
wt-% (see. Fig. 9). Even crushed MG<br />
alumina pre-dried to 300°C, showed<br />
dissolution times 4 to 10 times higher<br />
than the ‘normal’ gra<strong>de</strong> alumina in<br />
this concentration range.<br />
In view of the observations ma<strong>de</strong><br />
in these experiments it appears that<br />
the fineness of the alumina is a <strong>de</strong>termining<br />
factor for the dissolution<br />
process. A high content of the alpha<br />
phase seem to have an additional<br />
<strong>de</strong>trimental effect, i. e. it increases the<br />
time of dissolution. It has previously<br />
been found that high alpha alumina<br />
dissolves somewhat more slowly than<br />
the gamma phase alumina in cryolitic<br />
melts at 1,030°C [2] and it is possible<br />
that this difference is enhanced in lowmelting<br />
baths, where the solubility of<br />
alumina is lower. However, no simple<br />
relationship could be found between<br />
Type, <strong>de</strong>scription Term d 0.5 /µm<br />
Metal gra<strong>de</strong>, commercial alumina MG 82.95<br />
A-152, fine, 1 µm, highly calcined alumina, from Alcoa A152 1.86<br />
Crushed MG * alumina, calcined at 1600°C CMG 1600 4.51<br />
Crushed MG alumina, pre-dried at 300°C<br />
* MG – Metal Gra<strong>de</strong><br />
CMG 300 5.45<br />
Table 3: Materials tested and cut sizes (see text)<br />
these parameters and the time of dissolution.<br />
For example, the slowest dissolving<br />
alumina in these experiments<br />
was the CMG 1600 material. Table 3<br />
shows that 50% of the mass of this material<br />
has particles with diameter 4.5<br />
µm or less (d 0.5 =4.507 µm), compared<br />
to 1.86 µm for the A152 material.<br />
These materials have both been calcined<br />
at 1,600°C and have thus been<br />
converted to 100% α-alumina, but the<br />
finer A152 (d 0.5 =1.86) dissolves more<br />
rapidly than the coarser CMG 1600<br />
(d 0.5 =4.5 µm).<br />
conclusion<br />
It can be conclu<strong>de</strong>d from this investigation<br />
that if the only selection<br />
criterion is the rate of dissolution in<br />
low-melting baths, the normal industrial<br />
gra<strong>de</strong> alumina is the best choice.<br />
The main concern will probably be<br />
the ability to operate the bath at near<br />
saturation concentration with respect<br />
to alumina. Hence, the problem of<br />
maintaining slurry and avoiding forming<br />
sludge, i. e. alumina <strong>de</strong>posits, must<br />
be given high priority, and operating<br />
with fine-grained alumina might be<br />
Fig. 9: Results from three parallel runs with ‘normal’ MG alumina in low-melting bath.<br />
Time observed to obtain transparent melt after addition of batches of 0.5 wt-% alumina.<br />
Time plotted as a function of the concentration of alumina dissolved in the bath, <strong>de</strong>termined<br />
from bath samples taken before the addition<br />
the only option. In that case finely<br />
ground low-calcined alumina appears<br />
to be the best choice.<br />
acknowledgement<br />
Permission to publish given by Gol<strong>de</strong>n<br />
Northwest <strong>Alu</strong>munum Holding Company,<br />
is gratefully acknowledged.<br />
references<br />
[1] E.J. Frazer and J. Thonstad, “<strong>Alu</strong>mina<br />
solubility and diffusion coefficient in lowtemperature<br />
fluori<strong>de</strong> electrolytes”, to be<br />
published.<br />
[2] J. Thonstad, F. Nordmo, J. B. Paulsen,<br />
“Dissolution of <strong>Alu</strong>mina in Molten Cryolite”.<br />
Met Trans. 1972, pp. 403-408.<br />
[3] J. Thonstad, A. Solheim, S. Rolseth,<br />
O. Skaar, “The Dissolution of <strong>Alu</strong>mina in<br />
Cryolite Melts”, Light Metals 1988, pp.<br />
655-661.<br />
[4] T. Beck and R. J. Brooks. “Non-Consumable<br />
Ano<strong>de</strong> and Lining for <strong>Alu</strong>minum<br />
Electrolytic Reduction Cell”, United States<br />
Patent No. 5,284,562, 1994.<br />
[5] S. Rolseth, R. Hovland, O. Kobbeltvedt,<br />
”<strong>Alu</strong>mina Agglomeration and Dissolution<br />
in Cryolitic melts”, Light Metals 1994,<br />
pp.351-357.<br />
[6] O. Kobbeltvedt, S. Rolseth and<br />
J. Thonstad, “On the Mechanism of <strong>Alu</strong>mina<br />
Dissolution with Relevance to Point<br />
Feeding <strong>Alu</strong>minium Cells”, Light Metals<br />
1996, pp. 421-427.<br />
[7] R. G. Haverkamp, B. J. Welch and<br />
J. B. Metson, ”An Electrochemical Method<br />
for Measuring the Dissolution Rate of<br />
<strong>Alu</strong>mina in Molten Cryolite”, Bulletin<br />
of Electrochemistry, Vol.8, pp.334-340,<br />
1992.<br />
authors<br />
S. Rolseth, H. Gudbrandsen, K.S. Osen and<br />
J. Kvello are from SINTEF Materials and<br />
Chemistry, Trondheim, Norway.<br />
J. Thonstad is from Department of Materials<br />
Technology and Electrochemistry,<br />
Norwegian University of Science and<br />
Technology, Trondheim, Norway.<br />
56 ALUMINIUM · 9/2009
ALUMINIUM CHINA 2009 exceedingly successful<br />
Those who atten<strong>de</strong>d ALUMINIUM<br />
CHINA 2009 some weeks ago, the<br />
fifth time that the event has taken<br />
place in China, could be forgiven<br />
for thinking that the industrial<br />
downturn and economic crisis<br />
have never spread as far as China.<br />
Shanghai is still buzzing with<br />
exhilarating business activities,<br />
entertainment and the spending<br />
spree mentality, and the world’s<br />
most important aluminium industry<br />
gathering of the year, ALU-<br />
MINIUM CHINA, was atten<strong>de</strong>d by<br />
8,786 qualified tra<strong>de</strong> visitors and<br />
over 4,000 exhibiting staff from 61<br />
countries and regions, a recordbreaking<br />
result <strong>de</strong>spite the difficult<br />
economic situation.<br />
ALUMINIUM CHINA 2009 brought<br />
together 265 exhibitors from 30 countries<br />
and regions, and 8,786 tra<strong>de</strong> visitors,<br />
including 480 VIPs and 30 <strong>de</strong>legations<br />
from 32 provinces in China<br />
and 61 countries around the world.<br />
The number of visitor was up by 30%<br />
compared with the 2008 event and<br />
also a record compared to 2007 when<br />
the industry was at its peak. 47% of<br />
the visitors were from aluminium applications<br />
industries such as building<br />
and construction, transportation,<br />
electronics and machinery manufacturing,<br />
while nearly 66% of visitors<br />
had purchasing recommendation and<br />
<strong>de</strong>cision-making authority.<br />
Leading the exhibitors this year<br />
were some of the industry’s top companies<br />
such as the <strong>Alu</strong>minium Corporation<br />
of China, Nanshan <strong>Alu</strong>minium,<br />
Dubal, Novelis, SMS Metallurgy,<br />
Siemens VAI, Wagstaff, Pyrotek, Jieru<br />
Heavy Industry Equipment, Fata<br />
Hunter, Achenbach, Toshiba Mitsubishi-Electric<br />
Industrial Systems<br />
and others, who presented the latest<br />
products and leading technologies<br />
and, taken together, inspired the<br />
Asian and the global community with<br />
confi<strong>de</strong>nce in an imminent recovery.<br />
The performance of the show in<br />
Shanghai generated superb feedback<br />
from participants, and three-quarters<br />
of the international hall space had<br />
already been booked for the 2010<br />
tra<strong>de</strong> fair by the end of the event. The<br />
ALUMINIUM · 9/2009<br />
on-site exhibitor survey showed that<br />
more than 92% of the exhibitors were<br />
satisfied or completely satisfied with<br />
their participation, 86% were satisfied<br />
with the number of visitors, while 87%<br />
are satisfied with the visitor quality.<br />
The marketing manager from Emmegi<br />
China commented: “We received a<br />
huge number of professional visitors<br />
this year, who were genuinely interested<br />
in our products. We rebooked<br />
our stand for 2010 as soon as we could<br />
and expect to expand our market activities<br />
even more next year.”<br />
The on-site visitor survey showed the<br />
same encouraging results, with 97%<br />
of those attending being content with<br />
their visit this year. The <strong>de</strong>puty plant<br />
manager for the casting unit of the<br />
Chinalco Luoyang branch <strong>de</strong>clared:<br />
“I was able to achieve all my goals<br />
this year: to meet old friends, find<br />
out about the latest technologies, and<br />
reach agreements with a number of<br />
suppliers at the show.”<br />
The associated 2009 China <strong>Alu</strong>minium<br />
Fabrication Forum, organised<br />
by the China Non Ferrous Metal<br />
Industry Association along with<br />
China’s aluminium information and<br />
consultancy provi<strong>de</strong>r Antaike, was<br />
mo<strong>de</strong>rated by experts and senior executives<br />
from IAI, AA, JAA, London<br />
Metal Exchange and provi<strong>de</strong>d important<br />
information on the latest trends in<br />
More than 8,700 business people visited the <strong>Alu</strong>MiniuM ChinA 2009 fair<br />
Schweißen & Schnei<strong>de</strong>n 2009<br />
Die ganze Welt <strong>de</strong>r Schweißtechnik<br />
steht im Mittelpunkt <strong>de</strong>r Fachmesse<br />
„Schweißen & Schnei<strong>de</strong>n. Vom 14. bis<br />
19. September 2009 präsentiert die international<br />
wichtigste und umfassendste<br />
Messe <strong>de</strong>r Branche in Essen einen lückenlosen<br />
Überblick zu aktuellen Entwicklungen<br />
und Innovationen rund um das<br />
Fügen, Trennen und Beschichten. Alle<br />
namhaften Hersteller sowie die Anbieter<br />
von Dienstleistungen wer<strong>de</strong>n ihre Inno<br />
the global aluminium market. In light<br />
of the positive feedback from exhibitors,<br />
organiser Reed Exhibitions has<br />
confirmed that ALUMINIUM CHINA<br />
2010 will again be held at the Shanghai<br />
New International Expo Centre,<br />
from 9 to 11 June.<br />
■<br />
vationen vorstellen. Zur mittlerweile 17.<br />
Auflage dieser Messe wer<strong>de</strong>n rund 1.000<br />
Aussteller aus über 30 Nationen erwartet.<br />
Aus circa 90 Län<strong>de</strong>rn wer<strong>de</strong>n die<br />
Fachbesucher nach Essen reisen, um sich<br />
über das Weltmarktangebot zu informieren<br />
und Investitionen zu realisieren.<br />
Kontakt:<br />
Messe Essen GmbH<br />
www.messeessen.<strong>de</strong><br />
E v E N t S<br />
57<br />
Reed Exhibitions
p A t E N t E<br />
patentblatt Juni 2009<br />
Fortsetzung aus 7/8 2009<br />
Verfahren zur herstellung eines leichtmetall-Verbundgussteils<br />
sowie leichtmetall-Verbundgussteil.<br />
BMW AG,<br />
80809 München, DE. (B22D 19/00, EP 1<br />
433 552, EP-AT: 04.11.2003)<br />
Verfahren zur herstellung von Gussteilen<br />
aus leichtmetalllegierungen<br />
mit Kühlung vor <strong>de</strong>m Pressen. Process<br />
Conception Ingenierie S.A., Meudon, FR.<br />
(C22F 1/04, PS 601 34 207, EP 1213367,<br />
EP-AT: 16.11.2001)<br />
Verfahren zum herstellen von Zylin<strong>de</strong>rblöcken<br />
aus leichtmetall mit eingeschweißtenleichtmetall-Zylin<strong>de</strong>rbüchsen<br />
und Einrichtung zur Durchführung<br />
<strong>de</strong>s Verfahrens. Volkswagen AG, 38440<br />
Wolfsburg, DE. (B23P 13/00, PS 100 19<br />
783, AT: 20.04.2000)<br />
legierung umfassend Mg und Sr und<br />
hieraus gefertigte galvanische Opferano<strong>de</strong>.<br />
Magontec GmbH, 46240 Bottrop,<br />
DE. (C23F 13714, OS 10 2007 061 561,<br />
AT: 18.12.2007<br />
Metallpulverherstellung durch Reduktion<br />
<strong>de</strong>r Oxi<strong>de</strong> mit gasförmigem<br />
Magnesium. H.C. Starck GmbH, 38642<br />
Goslar, DE; H.C. Starck Inc., Newton Massachusetts<br />
02161-1951, US. (B22F 1/00,<br />
EPA 2055412, EP-AT: 05.05.1999)<br />
Verfahren zum löten von einem Werkstück<br />
aus einer Magnesiumlegierung<br />
unter Verwendung einer stromfreien<br />
Plattierung von nickel-Phosphor, eines<br />
Flüssigmittels und einem bleifreien<br />
Zinnlegierungs-lotmaterial. Magtech<br />
Technology Co., Ltd, Taipei Hsi 236,<br />
TW. (B23K 1/00, EPA 2055419, EP-AT:<br />
20.05.2008)<br />
Bauteil aus einer Magnesiumlegierung<br />
und Verfahren zu <strong>de</strong>ssen herstellung.<br />
Hon Hai Precision Industry Co. Ltd., Tucheng<br />
City, Taipei Hsien, TW. (F16S 5/00,<br />
OS 10 2008 060 794, AT: 05.12.2008<br />
hochresistente <strong>Alu</strong>miniumbasis-legierungen<br />
und daraus hergestellte Artikel.<br />
Fe<strong>de</strong>ralnoe Gosudarstvennoe Unitarnoe<br />
Predpryatie „Vserossiysky“ Nauchno-Issledovatelsky<br />
Institut Neorganicheskikh<br />
Materialov, Moskau/Moscow, RU; Joint-<br />
Stock Co. „Samara Metallurgical Plant“,<br />
Samara, RU. (C22C 21/10, PS 600 19 803,<br />
EP 1241275, EP-AT: 28.09.2000)<br />
längliches halteelement. Corus Bausysteme<br />
GmbH, 56070 Koblenz, DE. (E04D<br />
3/362, PS 603 20 126, EP 1552081, EP-<br />
AT: 29.08.2003)<br />
Wärmetauscherprofil. Erbslöh <strong>Alu</strong>minium<br />
GmbH, 42553 Velbert, DE. (F28F 1/02,<br />
GM 20 2006 005 013, AT: 29.03.2006)<br />
Verfahren zur herstellung geprägter<br />
Deckelelemente für Behälter und<br />
Deckelelemente für Behälter. Alcan<br />
Technology & Management Ltd., Neuhausen<br />
am Rheinfall, CH. (B41F 19/02,<br />
EP 1 892 096, EP-AT: 28.09.2006)<br />
Verfahren zum Auftragen einer<br />
Schutzbeschichtung auf Kohlenstoff<br />
enthalten<strong>de</strong>n Bestandteilen von Elektrolysezellen.<br />
Alcan International Ltd.,<br />
Montreal, Quebec, CA. (C25C 3/08, EP 1<br />
693 486, EP-AT: 09.02.2001)<br />
Konstruktionselement für die luftfahrt<br />
mit Variation <strong>de</strong>r anwendungstechnischen<br />
Eigenschaften. Alcan Rhenalu,<br />
Courbevoie, FR. (C22F 1/053, PS<br />
60 2005 006 764, EP 1727921, EP-AT:<br />
21.03.2005)<br />
Verbundprofil für Fenster, Türen o<strong>de</strong>r<br />
<strong>de</strong>rgleichen mit einem Aufsatzprofil.<br />
Alcoa <strong>Alu</strong>minium Deutschland, Inc.,<br />
58642 Iserlohn, DE.(E06B 3/30, EPA<br />
2055884, EP-AT: 14.11.2007)<br />
Verkleidungsprofil. Corus Bausysteme<br />
GmbH, 56070 Koblenz, DE. (E04F 19/02,<br />
GM 201 01 392, AT: 26.01.2001)<br />
Aus leichtmetall bestehen<strong>de</strong>s Profilrohr.<br />
RK Rose & Krieger GmbH Verbindungs-<br />
und Positioniersysteme, 32423<br />
Min<strong>de</strong>n, DE. (F16S 3/02, GM 299 10 111,<br />
AT: 10.06.1999)<br />
Verfahren zur Reinigung eines schmelzflüssigen<br />
Metalls. Aleris Switzerland<br />
GmbH, Schaffhausen, CH. (C22B 21/06,<br />
PS 60 2005 006 254, EP 1727917, EP-AT:<br />
17.02.2005)<br />
Verfahren zur herstellung einer Baustrebe<br />
durch Crimpen, und so erhaltene<br />
Baustrebe. Norsk Hydro ASA, 0240<br />
Oslo, NO. (E06B 3/273, EPA 2055883,<br />
EP-AT: 23.10.2008)<br />
Verbindungsstück und Verbindung<br />
von Profilen mit diesem Stück. Norsk<br />
Hydro ASA, 0240 Oslo, NO. (E06B 3/96,<br />
EPA 2055885, EP-AT: 31.10.2008)<br />
Vorrichtung zur Betätigung einer Tür<br />
o<strong>de</strong>r einem ähnlichem Element, das<br />
aus Profilen erstellt ist. Norsk Hydro<br />
ASA, 0240 Oslo, NO. (E05B 1/00, EPA<br />
2050899, EP-AT: 17.10.2008)<br />
Verfahren zur herstellung eines Absorberblechs<br />
für Sonnenkollektoren.<br />
Hydro <strong>Alu</strong>minium Deutschland GmbH,<br />
51149 Köln, DE. (F24J 2/48, EPA 2054676,<br />
EP-AT: 24.08.2007)<br />
Verfahren und Vorrichtung zum Erzeugen<br />
einer Konversionsschicht. Hydro<br />
<strong>Alu</strong>minium Deutschland GmbH, 51149<br />
Köln, DE. (C25D 11/04, EPA 2055809,<br />
EP-AT: 03.11.2008)<br />
Beheizbare Ba<strong>de</strong>- o<strong>de</strong>r Duschwanne.<br />
Hydro <strong>Alu</strong>minium Deutschland GmbH,<br />
51149 Köln, DE. (F24 H 1/00, OS 10 2007<br />
062 526, AT: 20.12.2007)<br />
Druckplattenträger und Verfahren zur<br />
herstellung eines Druckplattenträgers<br />
o<strong>de</strong>r einer Offsetdruckplatte. Hydro<br />
<strong>Alu</strong>minium Deutschland GmbH, 51149<br />
Köln, DE. (B41N 1/08, PS 199 02 527,<br />
AT: 22.01.1999)<br />
Vorrichtung zum Rotationsgießen. Hydro<br />
<strong>Alu</strong>minium Mandl & Berger GmbH,<br />
Linz, AT. (B22D 23/00, GM 201 22 596,<br />
AT: 06.03.2001)<br />
lamellenanordnung für Fassa<strong>de</strong>n. Hydro<br />
Building Systems GmbH, 89077 Ulm,<br />
DE. (E04F 13/21, GM 20 2006 003 166,<br />
AT: 01.03.2006)<br />
Verfahren und Einrichtung zum kontinuierlichen<br />
o<strong>de</strong>r halbkontinuierlichen<br />
Stranggießen von Metall. Norsk Hydro<br />
ASA, Oslo, NO. (B22D 11/06, EP 1 648<br />
635, EP-AT: 25.06.2004)<br />
Fresnel-Spiegel und Verfahren zu <strong>de</strong>ssen<br />
herstellung. Erbslöh <strong>Alu</strong>minium<br />
GmbH, 42553 Velbert, DE. (F21V 7/04,<br />
OS 10 2007 061 153, AT: 17.12.2007)<br />
Zweiteiliger Kolben für einen Verbrennungsmotor.<br />
Mahle International<br />
GmbH, 70376 Stuttgart, DE. (F02F 3/00,<br />
OS 10 2007 060 472, AT: 14.12.2007)<br />
Kühlkörper für halbleiterbauelemente<br />
o<strong>de</strong>r dgl. Geräte sowie Verfahren zu<br />
seiner herstellung. Alcan Technology<br />
& Management AG, 8212 Neuhausen<br />
am Rheinfall, CH. (H01L 23/367, EPA<br />
2054930, EP-AT: 09.08.2007)<br />
Rahmen mit Fenster- o<strong>de</strong>r Türflügel.<br />
Norsk Hydro ASA, 0240 Oslo, NO. (E06B<br />
3/46, EPA 2053189, EP-AT: 23.10.2008)<br />
ALUMINIUM veröffentlicht unter<br />
dieser Rubrik regelmäßig einen Überblick<br />
über wichtige, <strong>de</strong>n Werkstoff<br />
<strong>Alu</strong>minium betreffen<strong>de</strong> Patente. Die<br />
ausführlichen Patentblätter und auch<br />
weiterführen<strong>de</strong> Informationen dazu<br />
stehen <strong>de</strong>r Redaktion nicht zur Verfügung.<br />
Interessenten können diese<br />
beziehen o<strong>de</strong>r einsehen bei <strong>de</strong>r<br />
Mittel<strong>de</strong>utschen Informations-, Patent-,<br />
Online-Service GmbH (mipo),<br />
Julius-Ebeling-Str. 6,<br />
D-06112 Halle an <strong>de</strong>r Saale,<br />
Tel. 0345/29398-0<br />
Fax 0345/29398-40,<br />
www.mipo.<strong>de</strong><br />
Die Gesellschaft bietet darüber hinaus<br />
weitere Patent-Dienstleistungen an.<br />
58 ALUMINIUM · 9/2009
Kolben für einen Verbrennungsmotor<br />
sowie Verfahren zu seiner herstellung.<br />
Mahle International GmbH, 70376 Stuttgart,<br />
DE. (F02F 3/00, OS 10 2007 061 601,<br />
AT: 20.12.2007)<br />
Mehrteiliger Kolben für einen Verbrennungsmotor.<br />
Mahle GmbH, 70376<br />
Stuttgart, DE. (F02F 3/00, EP 1 660 769,<br />
EP-AT: 19.08.2004)<br />
Vorrichtung zum kontinuierlichen Gießen<br />
von Metallblöcken. Novelis Inc., Toronto,<br />
Ontario M5J 1S9, CA. (B22D 11/14,<br />
EPA 2058064, EP-AT: 09.12.2004)<br />
Plattiertes Blechprodukt und herstellungsverfahren<br />
dafür. Novelis Inc., Toronto,<br />
Ontario M5J 1S9, CA. (B32B 15/01,<br />
EPA 2055473, EP-AT: 05.11.2007)<br />
Bauelement mit Al-Papier-Schicht. Novelis<br />
Deutschland GmbH, 37075 Göttingen,<br />
DE. (E04 2/02, OS 10 2007 060<br />
239, AT: 14.12.2007)<br />
Wärmegedämmtes Verbundprofil, insbeson<strong>de</strong>re<br />
für Fenster, Türen, Fassa<strong>de</strong>n<br />
und <strong>de</strong>rgleichen. Norsk Hydro A/S,<br />
Oslo, NO. (E06B 3/263, PS 501 14 114, EP<br />
1170454, EP-AT: 23.05.2001)<br />
Verfahren und System zur automatischen<br />
Analyse von Partikeln. Norsk<br />
Hydro ASA, Oslo, NO. (G01N 15/02,<br />
PS 601 34 013, EP 1287330, EP-AT:<br />
23.04.2001)<br />
Gießpulver für das Stranggießen und<br />
Verfahren zur Verwendung <strong>de</strong>s Pulvers.<br />
Sumitomo Metal Industries, Ltd.,<br />
Osaka, JP. (B22D 11/10, PS 698 09 659,<br />
EP 0899041, EP-AT: 26.08.1998)<br />
patentblatt Juli 2009<br />
Al-Mg-legierungsextrusionsmaterial<br />
mit hervorragen<strong>de</strong>n Kaltverfestigungseigenschaften<br />
für Kaltverformungsverfahren.<br />
Denso Corp., Kariya-shi, Aichiken,<br />
JP; Kabushiki Kaisha Kobe Seiko<br />
Sho, Kobe, Hyogo, JP. (C22C 21/06, OS<br />
10 2008 054 436, AT: 09.12.2008)<br />
Verfahren zur herstellung von Flugzeugstrukturelementen<br />
aus Al-Si-Mglegierung.<br />
Alcan Rhenalu, Courbevoie,<br />
FR. (C22F 1/05, PS 601 34 357, EP<br />
1143027, EP-AT: 03.04.2001)<br />
Dach eines Kraftfahrzeuges aus einem<br />
an einem Stahlrahmen befestigten<br />
Blech aus einer Al-Si-Mg-legierung.<br />
Alcan Rhenalu, Paris, FR. (C22C 21/08,<br />
EP 1 633 900, EP-AT: 17.06.2004)<br />
leichtmetallrad. Sumitomo Rubber<br />
Industries Ltd., Kobe, Hyogo, JP. (B60B<br />
3/10, PS 602 27 440, EP 1241023, EP-AT:<br />
14.03.2002)<br />
ALUMINIUM · 9/2009<br />
Al-ni-Seltenerdmetall Sputtertarget.<br />
Kabushiki Kaisha Kobe Seiko Sho, Kobe,<br />
Hyogo, JP; Kobelco Research Institute,<br />
Inc., Kobe, Hyogo, JP. (C23C 14/34, PS<br />
60 2006 001 532, EP 1700928, EP-AT:<br />
30.01.2006)<br />
Anorganisches Alpha-<strong>Alu</strong>minium-<br />
Membransubstrat und herstellungsverfahren<br />
dafür. Corning Inc., Corning<br />
NY 14831, US. (C04B 38/06, EPA<br />
2061734, EP-AT: 11.12.2007)<br />
Sammeln von <strong>Alu</strong>minium in Elektrolysezellen.<br />
Moltech Invent S.A., 2134 Luxembourg,<br />
LU. (C25C 3/08, EPA 2064370,<br />
EP-AT: 20.06.2007)<br />
Rüttelmaschine zur Abformung von<br />
ungebrannten Ano<strong>de</strong>nblöcken, insbeson<strong>de</strong>re<br />
für die <strong>Alu</strong>minium-Schmelzflusselektrolyse.<br />
Outokumpu Oyj, Espoo,<br />
FI. (C25C 3/12, PS 100 44 677, AT:<br />
09.09.2000)<br />
Verfahren zur Ausbildung und Feinverteilung<br />
feiner Wasserstoffbläschen<br />
in Wasserstoff enthalten<strong>de</strong>n <strong>Alu</strong>minium-Gusslegierungsschmelzen.<br />
Schäfer<br />
Chemische Fabrik GmbH, 53773 Hennef,<br />
DE. (C22C 1/08, PS 10 2004 006 034, AT:<br />
06.02.2004)<br />
Werkstoff auf <strong>de</strong>r Basis einer <strong>Alu</strong>miniumlegierung,<br />
Verfahren zu seiner<br />
herstellung sowie Verwendung hierfür.<br />
Mahle GmbH, 70376 Stuttgart, DE;<br />
PEAK Werkstoff GmbH, 42553 Velbert,<br />
DE. (C22C 21/02, OS 10 2004 007 704,<br />
AT: 16.02.2004)<br />
Druckgussbauteile aus <strong>Alu</strong>minium- und<br />
Magnesiumlegierungen mit mechanischen<br />
Verbindungen und Verfahren<br />
zum Verbin<strong>de</strong>n. Daimler AG, 70327<br />
Stuttgart, DE. (F16B 4/00, OS 10 2004<br />
039 748, AT: 17.08.2004)<br />
Rapid-Prototyping durch Al/Mg-3D-<br />
Druck. General Motors Corp., Detroit,<br />
Mich., US. (B22F 7/00, OS 11 2005 002<br />
040, WO-AT: 16.05.2005)<br />
Tür- und Fensterprofile, außen holz<br />
und innen liegend <strong>Alu</strong>minium. Noka<br />
Holzverarbeitungs-GmbH, 26683 Saterland,<br />
DE. (E06B 3/08, GM 201 04 502,<br />
AT: 14.03.2001)<br />
Schweißloses Verbindungselement,<br />
Stütze für Sanitär und Möbel aus <strong>Alu</strong>minium,<br />
E<strong>de</strong>lstahl. Schikoff, Robert,<br />
90471 Nürnberg, DE. (F16B 19/02, GM<br />
20 2009 001 743, AT: 11.02.2009)<br />
Verbessertes Verfahren zur herstellung<br />
von Filterhilfsmitteln in <strong>Alu</strong>miniumraffinerien.<br />
BHP Billiton Worsley<br />
<strong>Alu</strong>mina Pty. Ltd., Collie, Western Australia,<br />
AU. (B01D 37/02, EP 1 301 260,<br />
EP-AT: 20.07.2001)<br />
p A t E N t E<br />
Kolben mit einem <strong>Alu</strong>miniumeinsatzstück<br />
und Verfahren zur seiner herstellung.<br />
Renault S.A.S., Boulogne Billancourt,<br />
FR. (F02F 3/00, PS 60 2004 014<br />
825, EP 1439301, EP-AT: 14.01.2004)<br />
Verfahren zur Behandlung von <strong>Alu</strong>minium<br />
in einem Ofen. L’Air Liqui<strong>de</strong>,<br />
Société Anonyme pour l‘Etu<strong>de</strong> et<br />
l‘Exploitation <strong>de</strong>s Procédés Georges<br />
Clau<strong>de</strong>, Paris, FR. (C22B 21/00, EP 1 625<br />
241, EP-AT: 30.03.2004)<br />
Verfahren zur Verarbeitung von <strong>Alu</strong>minium<br />
in einem Rotations- o<strong>de</strong>r Flammofen.<br />
L’Air Liqui<strong>de</strong>, Société Anonyme<br />
pour l‘Etu<strong>de</strong> et l‘Exploitation <strong>de</strong>s Procédés<br />
Georges Clau<strong>de</strong>, Paris, FR. (F27B<br />
7/20, PS 60 2005 007 710, EP 1721111,<br />
EP-AT: 07.02.2005)<br />
Stranggepresstes Produkt aus <strong>Alu</strong>miniumlegierung,<br />
Verfahren zu seiner<br />
herstellung, Mehrfachleitungsrohr<br />
für Wärmetauscher und Verfahren<br />
zur herstellung vom Wärmetauscher<br />
mit <strong>de</strong>m Mehrfachleitungsrohr. Denso<br />
Corp., Kariya, Aichi, JP; Sumitomo Light<br />
Metal Industries, Ltd., Tokio/Tokyo, JP.<br />
(C22C 21/00, PS 60 2006 001 552, EP<br />
1746174, EP-AT: 21.07.2006)<br />
Verfahren zum Diffusionsfügen von<br />
Mg/Al-Bauteilen. General Motors Corp.,<br />
Detroit, Mich., US. (B23K 35/28, PS 602<br />
16 369, EP 1273385, EP-AT: 08.05.2002)<br />
Beschichtetes, <strong>Alu</strong>minium enthalten<strong>de</strong>s<br />
Material und Verfahren zur <strong>de</strong>ssen<br />
herstellung. Denso Corp., Kariya, Aichi,<br />
JP; Nihon Parkerizing Co., Ltd., Tokio/<br />
Tokyo, JP. (B05D 7/16, PS 695 28 854,<br />
EP 0676250, EP-AT: 07.04.1995)<br />
Verfahren zur Oberflächenbehandlung<br />
von <strong>Alu</strong>minium enthalten<strong>de</strong>n Metallen.<br />
Denso Corp., Kariya, Aichi, JP; Nihon Parkerizing<br />
Co., Ltd., Tokio/Tokyo, JP. (C23C<br />
22/83, PS 698 11 818, EP 0911427, EP-<br />
AT: 22.10.1998)<br />
Verfahren zum Vollformgießen von<br />
<strong>Alu</strong>minium mit beschichtetem Mo<strong>de</strong>ll.<br />
General Motors Corp., Detroit, Mich., US.<br />
(B22C 3/00, PS 698 18 379, EP 0899038,<br />
EP-AT: 31.07.1998)<br />
hubkolbenmaschine mit <strong>Alu</strong>miniumblock<br />
und <strong>Alu</strong>miniumkolben. General<br />
Motors Corp., Detroit, Mich., US. (F02F<br />
3/10, PS 699 08 837, EP 0937889, EP-AT:<br />
21.01.1999)<br />
Verfahren zur simultanen elektrolytischen<br />
Abscheidung von Zink und Magnesium<br />
auf einem Substrat aus Blech<br />
und Verfahren zur herstellung eines<br />
korrosionsgeschützten, lackierten Formteils<br />
aus Blech. ThyssenKrupp Steel AG,<br />
47166 Duisburg, DE. (C25D 3/56, PS 10<br />
2004 037 673, AT: 04.08.2004) ➝<br />
59
p A t E N t E<br />
<strong>Alu</strong>miniumlegierung vom Typ Al-Zn-Mg<br />
und Verfahren zu <strong>de</strong>ren herstellung.<br />
<strong>Alu</strong>minium Lend GmbH & Co.Kg., 5651<br />
Lend, AT. (C22C 21/10, EPA 2061912,<br />
EP-AT: 03.09.2007)<br />
<strong>Alu</strong>miniumlegierung für Motorbauteile.<br />
GM Global Technology Operations,<br />
Inc., Detroit, Mich., US. (C22C 21/12, OS<br />
10 2007 042 099, AT: 05.09.2007)<br />
Verfahren zum herstellen eines Gegenstan<strong>de</strong>s<br />
aus Metall, insb. aus einer<br />
hochfesten <strong>Alu</strong>miniumlegierung sowie<br />
Verfahren zum Richten eines solchen<br />
Gegenstan<strong>de</strong>s. Otto Fuchs KG, 58540<br />
Meinerzhagen, DE. (B23P 13/00, OS 10<br />
2008 003 882, AT: 10.01.2008)<br />
<strong>Alu</strong>miniumlegierung für Motorblöcke.<br />
General Motors Corp., Detroit, Mich., US.<br />
(C22C 21/02, OS 11 2004 001 160, WO-<br />
AT: 26.03.2004)<br />
Verfahren zur Streckformung von ausgehärteten<br />
Blechen aus <strong>Alu</strong>miniumlegierung.<br />
General Motors Corp., Detroit,<br />
Mich., US. (B21D 22/22, PS 699 23 742,<br />
EP 0992300, EP-AT: 02.09.1999)<br />
Verfahren zum herstellen von Gussteilen<br />
aus leichtmetall mit Einsätzen.<br />
Georg Fischer GmbH, 58791 Werdohl,<br />
DE. (B22D 19/00, EPA 2070612, EP-AT:<br />
11.12.2007)<br />
Verfahren zum leichtmetall-legierungs-Sintern.<br />
Schwäbische Hüttenwerke<br />
Automotive GmbH & Co. KG, 73433<br />
Aalen, DE. (C22C 1/04, PS 50 2004 007<br />
370, EP 1709209, EP-AT: 26.11.2004)<br />
Preform für Verbundwerkstoffe mit einer<br />
Metallmatrix aus Magnesium. Her<br />
Majesty in Right of Canada AS represented<br />
by the Minister of Natural Resources,<br />
Ottawa, Ontario, CA. (C22C 47/06, PS<br />
100 34 631, AT: 17.07.2000)<br />
Druckgussbauteile aus Al- und Mg-legierungen<br />
mit mechanischen Verbindungen<br />
und Verfahren zum Verbin<strong>de</strong>n.<br />
Daimler AG, 70327 Stuttgart, DE.<br />
(F16B 4/00, OS 10 2004 039 748, AT:<br />
17.08.2004)<br />
Verfahren zum Diffusionsfügen von<br />
Mg/Al-Bauteilen. General Motors Corp.,<br />
Detroit, Mich., US. (B23K 35/28, PS 602<br />
16 369, EP 1273385, EP-AT: 08.05.2002)<br />
Verfahren zur elektrolytischen herstellung<br />
von Magnesium und <strong>de</strong>ssen<br />
legierungen. General Motors Corp., Detroit,<br />
Mich., US. (C25C 3/04, PS 696 03<br />
668, EP 0747509, EP-AT: 13.05.1996)<br />
Verkleidungselement. Hermann Gutmann<br />
Werke AG, 91781 Weißenburg,<br />
DE. (E04F 13/08, EPA 1854938, EP-AT:<br />
27.04.2007)<br />
hochfeste, nicht brennbare Magnesiumlegierung.<br />
National Institute of Advanced<br />
Industrial Science and Technology,<br />
Tokio/Tokyo, JP. (C22C 23/00, WO<br />
2008 026333, WO-AT: 28.02.2007)<br />
Druckgussteile aus einer kriechbeständigen<br />
Magnesiumlegierung. General<br />
Motors Corp. (n.d.Ges.d. Staates Delaware),<br />
Detroit, Mich., US. (C22C 23/02,<br />
PS 600 09 783, EP 1048743, EP-AT:<br />
31.01.2000)<br />
Zusammensetzung und Verfahren zur<br />
Behandlung von Magnesiumlegierungen.<br />
Université Pierre et Marie Curie,<br />
Paris, FR. (C23C 22/57, PS 602 27 065, EP<br />
1390565, EP-AT: 31.05.2002)<br />
Folienverpackung. Alcan Technology<br />
& Management Ltd., 8212 Neuhausen<br />
am Rheinfall, CH. (B65D 75/28, EPA<br />
2065316, EP-AT: 27.11.2007)<br />
Gegenstand aus einer mit Kunststoff<br />
hinterspritzten <strong>Alu</strong>miniumfolie. Alcan<br />
Technology & Management Ltd.,<br />
8212 Neuhausen am Rheinfall, CH.<br />
(C25D 11/08, EPA 2063001, EP-AT:<br />
20.11.2007)<br />
Flächige Beleuchtungseinrichtung. Alcan<br />
Technology & Management Ltd.,<br />
Neuhausen am Rheinfall, CH. (F21K<br />
7/00, EP 1 861 651, EP-AT: 08.03.2006)<br />
Geschweißtes Strukturelement mit<br />
min<strong>de</strong>stens zwei <strong>Alu</strong>miniumlegierungsteilen,<br />
die verschie<strong>de</strong>ne metallurgische<br />
Zustän<strong>de</strong> haben, und Verfahren zur<br />
herstellung eines solchen Elements.<br />
Alcan Rhenalu, Paris, FR. (B23K 20/12,<br />
EP 1 799 391, EP-AT: 12.09.2005)<br />
Reibrührschweißteile sowie Systeme<br />
und Verfahren zu ihrer herstellung.<br />
Alcoa Inc., Pittsburgh, PA 15212-5858,<br />
US. (B23K 20/12, EPA 2067563, EP-AT:<br />
12.11.2008)<br />
Vorrichtung und Verfahren zur kontinuierlichen<br />
Metallschmelzezuführung<br />
unter Druck. Alcoa Inc., Alcoa Center,<br />
Pa., US. (B22D 17/20, PS 602 27 580, EP<br />
1714718, EP-AT: 18.04.2002)<br />
<strong>Alu</strong>miniumlegierungsprodukt mit<br />
verbesserten Eigenschaftskombinationen.<br />
Alcoa Inc., Pittsburgh, Pa., US.<br />
(C22C 21/10, EP 1 565 586, EP-AT:<br />
17.11.2003)<br />
unterstruktur für ein Dach o<strong>de</strong>r eine<br />
Fassa<strong>de</strong>. Corus Bausysteme GmbH,<br />
56070 Koblenz, DE. (E04D 3/36, OS 102<br />
97 074, WO-AT: 09.08.2002)<br />
Dachkonstruktion und Befestigungsvorrichtung<br />
dafür. Corus Bausysteme<br />
GmbH, 56070 Koblenz, DE. (E04D 3/362,<br />
GM 203 05 954, AT: 11.04.2003)<br />
hochfestes <strong>Alu</strong>miniumlegierungshartlötblech.<br />
Aleris <strong>Alu</strong>minum Koblenz<br />
GmbH, 56070 Koblenz, DE. (B32B 15/01,<br />
PS 60 2004 013 327, EP 1648694, EP-AT:<br />
09.07.2004)<br />
Aus einem profilgewalzten Metallprodukt<br />
hergestelltes Rohr und herstellungsverfahren<br />
dafür. Aleris <strong>Alu</strong>minum<br />
Koblenz GmbH, 56070 Koblenz,<br />
DE. (F28D 1/03, EP 1 802 932, EP-AT:<br />
04.10.2005)<br />
<strong>Alu</strong>miniumband für lithografische<br />
Druckplattenträger und <strong>de</strong>ssen herstellung.<br />
Hydro <strong>Alu</strong>minium Deutschland<br />
GmbH, 51149 Köln, DE. (C22F 1/04, EPA<br />
2067871, EP-AT: 30.11.2007)<br />
Elektrolysezelle und Verfahren zu ihrem<br />
Betrieb. Norsk Hydro ASA, 0240<br />
Oslo, NO. (C25C 3/16, EPA 2066831,<br />
EP-AT: 12.09.2007)<br />
lamelle, insbeson<strong>de</strong>re Sonnenschutzlamelle.<br />
Hydro Building Systems GmbH,<br />
89077 Ulm, DE. (E06B 9/386, PS 10 2006<br />
005 240, AT: 06.02.2006)<br />
Fahrzeugkarosserie mit einem Karosserieelement.<br />
BMW AG, 80809 München,<br />
DE; Norsk Hydro ASA, Oslo, NO.<br />
(B62D 65/02, OS 10 2007 058 783, AT:<br />
06.12.2007)<br />
Schiebetür o<strong>de</strong>r Schiebefenster mit<br />
thermisch isolierter Führungsschiene.<br />
Norsk Hydro ASA, Oslo, NO. (E06B 3/46,<br />
PS 60 2006 001 448, EP 1772582, EP-AT:<br />
03.10.2006)<br />
Glashalteleiste, Rahmenkonstruktion<br />
sowie Verfahren zur Montage einer<br />
Glashalteleiste. Hermann Gutmann<br />
Werke AG, 91781 Weissenburg,<br />
DE. (E06B 3/58, EPA 2060728, EP-AT:<br />
10.11.2008)<br />
Verfahren zur herstellung einer leichtmetalllaufbuchse<br />
mit einer äußeren<br />
rauen Oberfläche. Mahle GmbH, 70376<br />
Stuttgart, DE. (B22C 9/02, OS 102 18 714,<br />
AT: 26.04.2002)<br />
Kolben für einen Verbrennungsmotor<br />
und Verfahren zur Beschichtung seiner<br />
nabenbohrungen. Mahle International<br />
GmbH, 70376 Stuttgart, DE. (F02F 3/10,<br />
EP 1 877 659, EP-AT: 09.12.2005)<br />
Einteiliger Kühlkanalkolben für einen<br />
Verbrennungsmotor. Mahle GmbH,<br />
70376 Stuttgart, DE. (F02F 3/22, EP 1 546<br />
536, EP-AT: 19.09.2003)<br />
legierungen auf Magnesiumbasis mit<br />
hoher Festigkeit / Duktilität für konstruktive<br />
Anwendungen. GM Global<br />
Technology Operations, Inc., Detroit,<br />
Mich., US. (C22C 23/02, OS 11 2007 001<br />
169, WO-AT: 16.05.2007)<br />
60 ALUMINIUM · 9/2009
Bauelement mit Al-Papier-Schicht. Novelis<br />
Deutschland GmbH, 37075 Göttingen,<br />
DE. (E04C 2/02, EPA 2071094, EP-<br />
AT: 20.12.2007)<br />
Magnesiumlegierungselement und<br />
herstellungsverfahren dafür. Sumitomo<br />
Electric Industries, Ltd., Osaka-shi,<br />
L. H. Kallien, Chr. Böhnlein<br />
Druckgießen<br />
Giesserei 96, 07/2009, S. 18-26<br />
Großabnehmer von Gussteilen haben vermehrt begonnen, ihre<br />
erlangte Marktstärke gegenüber <strong>de</strong>n Metallgießern zu nutzen,<br />
um Einkaufsbedingungen und Zahlungsmodalitäten zu ihren<br />
Gunsten durchzusetzen. Aufkommen<strong>de</strong> Lieferkonzepte wie<br />
„Just in time“ verlangten vom Druckgießer ein <strong>de</strong>utlich hohes<br />
Maß an Flexibilität. Die Einhaltung stetig steigen<strong>de</strong>r Qualitätsanfor<strong>de</strong>rungen<br />
stellte die gesamte Branche auf eine harte<br />
Probe – etwa die gefor<strong>de</strong>rte Null-Fehler-Produktion mit 99,994<br />
Prozent korrekten Teilen En<strong>de</strong> <strong>de</strong>r achtziger Jahre. Aus heutiger<br />
Sicht lässt sich diesbezüglich jedoch eine klare Aussage treffen.<br />
Aufgrund dieser geän<strong>de</strong>rten Rahmenbedingungen sahen sich<br />
viele Betriebe einer Marktsituation gegenüber, die nur durch<br />
konsequente Steigerung von Produktivität, Flexibilität, Prozesssicherheit<br />
und Qualität zu bewältigen war. Auch <strong>de</strong>r Blick über<br />
die Grenzen nach Japan En<strong>de</strong> <strong>de</strong>r achtziger Jahre bestätigte die<br />
geringe Kapazitätsauslastung <strong>de</strong>r heimischen Druckgießereien<br />
und führte Anfang <strong>de</strong>r neunziger Jahre zu einem verstärkten<br />
Interesse an Lean Production. Behan<strong>de</strong>lt wer<strong>de</strong>n im Einzelnen:<br />
Druckgießverfahren, Werkstoffverbün<strong>de</strong>, Druckgießprozess,<br />
Druckgießmaschine, Druckgießwerkzeug, Trenn- und Schmierstoffe,<br />
Schmelze, Qualität, Simulation, Gusswerkstoffe. 11 Abb.,<br />
125 Qu.<br />
ALUMINIUM 9 (2009) <strong>Alu</strong>minium-industrie, Druckguss<br />
W. Lori<br />
Störfaktor Reibung. Die Be<strong>de</strong>utung<br />
<strong>de</strong>r Reibung in Schraubenverbindungen<br />
Konstruktionspraxis 7/2009, S. 50-51<br />
Der Ingenieur hat ständig mit Reibung zu tun – bewusst und<br />
unbewusst. In <strong>de</strong>r Praxis zeigt sich immer wie<strong>de</strong>r, dass die Be<strong>de</strong>utung<br />
<strong>de</strong>r Reibung falsch eingeschätzt wird. Beim drehmomentgesteuerten<br />
Anziehen kann dies fatale Folgen haben. Der<br />
Zusammenhang zwischen Anziehmoment und <strong>de</strong>r Zielgröße<br />
Montagevorspannkraft ist wesentlich von <strong>de</strong>r Reibung abhängig.<br />
In <strong>de</strong>r Schraubenverbindung ist eine Reibung unvermeidbar<br />
und kann zum Fluch o<strong>de</strong>r Segen wer<strong>de</strong>n. Schließlich entstehen<br />
durch Reibung und Verschleiß jährlich Verluste in Höhe von<br />
etwa fünf Prozent <strong>de</strong>s Bruttosozialproduktes. Doch was ist Reibung<br />
und wie wirkt sie sich aus? 3 Abb., 3 Tab.<br />
ALUMINIUM 9 (2009) Verbin<strong>de</strong>n<br />
H. Zak, B. Tonn, S. Kores<br />
Warmfeste <strong>Alu</strong>miniumgusslegierungen<br />
für Zylin<strong>de</strong>rköpfe in direktem Wettbewerb<br />
Giesserei-Praxis 6/2009, S. 199-202<br />
In dieser Arbeit wur<strong>de</strong>n die warmfesten Zylin<strong>de</strong>rkopflegierungen<br />
AlSi6Cu4, AlSil2CuNiMg, AlCu5NiSbZr und AlMg3Sil-<br />
ScZr unter einheitlichen Bedingungen getestet, um ein<strong>de</strong>utige<br />
Aussagen über die tatsächlichen Eigenschaftsprofile dieser<br />
Werkstoffe zu treffen. Die beste Kombination aus gießtech-<br />
ALUMINIUM · 9/2009<br />
Osaka 541-0041, JP. (C22C 23/02, EPA<br />
2060642, EP-AT: 10.07.2007)<br />
hartlötblech mit sehr langer haltbarkeit<br />
und großer Formbarkeit. Alcoa<br />
Inc., Pittsburgh, PA 15212-5858, US.<br />
(B32B 15/20, EPA 2065180, EP-AT:<br />
17.04.2003<br />
Alpha-<strong>Alu</strong>miniumoxid-Pulver. Sumitomo<br />
Chemical Co., Ltd., Tokyo 104-8260,<br />
JP. (C01F 7/44, EPA 2070873, EP-AT:<br />
18.09.2007)<br />
Strukturelement. Norsk Hydro ASA,<br />
0240 Olso, NO. (B62D 25/08, EPA<br />
2070807, EP-AT: 02.12.2008)<br />
nischen und mechanischen Eigenschaften sowie ein attraktives<br />
Preisleistungsverhältnis verleiht <strong>de</strong>r Legierung AlSil2CuNiMg<br />
die größte Chance, sich im Einsatz bei hoch belasteten <strong>Alu</strong>miniumzylin<strong>de</strong>rköpfen<br />
in naher Zukunft durchzusetzen. Die<br />
kontinuierliche Zunahme <strong>de</strong>r Motorleistung in Verbindung mit<br />
höheren Leistungsdichten stellt permanent wachsen<strong>de</strong> technische<br />
Anfor<strong>de</strong>rungen an die Zylin<strong>de</strong>rkopflegierungen. Der<br />
anhalten<strong>de</strong> Zwang zur Gewichts- und Kostenreduzierung sowie<br />
die Gewährleistung einer prozesssicheren Herstellbarkeit<br />
<strong>de</strong>r Zylin<strong>de</strong>rköpfe verschärft das Spannungsfeld für die Weiterentwicklung<br />
von diesen Motorenkomponenten noch weiter.<br />
Das am Zylin<strong>de</strong>rkopf auftreten<strong>de</strong> Lastkollektiv wird in statische<br />
und dynamische Beanspruchungen unterteilt. 7 Abb., 6 Tab.,<br />
16 Qu.<br />
ALUMINIUM 9 (2009) legierungen<br />
J. Zähr, M. Schnick, U. Fussel,<br />
M. Sen<strong>de</strong>, S. Rose, M. Speise<strong>de</strong>r, A. Lang, G. Wilhelm<br />
untersuchungen zur Oberflächenreinigung<br />
beim lichtbogenschweißen von <strong>Alu</strong>miniumlegierungen<br />
mit nicht abschmelzen<strong>de</strong>r Elektro<strong>de</strong><br />
Schweißen und Schnei<strong>de</strong>n 61 (2009), Heft 6, S. 302-311<br />
Vorgestellt wer<strong>de</strong>n Untersuchungen zum Einfluss <strong>de</strong>r Schweißparameter<br />
sowie <strong>de</strong>r Zusammensetzung von Prozessgas und<br />
Grundwerkstoff auf die Breite und Regelmäßigkeit <strong>de</strong>r Reinigungszone<br />
beim WIG-Schweißen von <strong>Alu</strong>minium mit Gleichstrom<br />
und plusgepolter Elektro<strong>de</strong>. Die Untersuchungen belegen<br />
einen großen Einfluss <strong>de</strong>r Schutzgasab<strong>de</strong>ckung, <strong>de</strong>r verwen<strong>de</strong>ten<br />
Prozessgase sowie <strong>de</strong>r Zusammensetzung <strong>de</strong>s Grundwerkstoffs.<br />
Außer<strong>de</strong>m wer<strong>de</strong>n durch Hochgeschwindigkeitskinematographie<br />
sowie Rasterelektronenmikroskopaufnahmen zwei<br />
unterschiedliche Lichtbogenansätze am katodisch gepolten<br />
<strong>Alu</strong>minium i<strong>de</strong>ntifiziert. Es wer<strong>de</strong>n die Ursachen <strong>de</strong>r unterschiedlichen<br />
Ansatzmodi erläutert und Möglichkeiten dargestellt,<br />
wie <strong>de</strong>r Lichtbogenansatz und die Reinigungswirkung<br />
gezielt beeinflusst wer<strong>de</strong>n können. 16 Abb., 3 Tab., 21 Qu.<br />
ALUMINIUM 9 (2009) Schweißen<br />
A. Pithan, H. Fuchs, S. Röpke<br />
Potenziale von <strong>Alu</strong>miniumlegierungen<br />
für hoch belastete Zylin<strong>de</strong>rköpfe<br />
Giesserei-Praxis 6/2009, S. 203-207<br />
L I t E r A t U r S E r v I C E<br />
Steigen<strong>de</strong> spezifische Leistungen von Verbrennungsmotoren<br />
– insbeson<strong>de</strong>re von mo<strong>de</strong>rnen Dieselmotoren – stellen an<br />
<strong>de</strong>n Zylin<strong>de</strong>rkopf immer höhere Anfor<strong>de</strong>rungen Ein typisches<br />
Beispiel ist <strong>de</strong>r aktuelle 2,0l-4V-TDI-Motor mit Common-Rail-<br />
Einspritzung von Volkswagen. Die Belastungen äußern sich<br />
vor allem in hohen Zünddrücken und Temperaturen. Mo<strong>de</strong>rne<br />
Dieselmotoren arbeiten heute mit Zünddrücken bis zu 180 bar,<br />
aber auch solche von 200 bar und mehr sind bereits in <strong>de</strong>r<br />
Automobilindustrie im Gespräch. Die Betriebstemperaturen<br />
bei <strong>de</strong>n Zylin<strong>de</strong>rköpfen betragen dabei im Brennraum 220 bis<br />
250 °C. Aufgabe ist es, Bauteile zu entwickeln, die diesen Belastungen<br />
zuverlässig standhalten. Dabei ist die optimale ➝<br />
61
L I t E r A t U r E S E r v I C E<br />
Kombination von Konstruktion, Gießverfahren und Werkstoff<br />
gefor<strong>de</strong>rt. Untersuchungen zum Einsatz geeigneter Zylin<strong>de</strong>rkopflegierungen<br />
haben gezeigt, dass die Legierung allein die<br />
For<strong>de</strong>rungen nicht erfüllen kann. Ein funktionieren<strong>de</strong>s Bauteil<br />
erhält man nur durch geeignete Konstruktion und ein werkstoffgerechtes<br />
Herstellungsverfahren. Dies beinhaltet neben <strong>de</strong>m<br />
Gießen vor allem auch die Wärmebehandlung. Bei <strong>de</strong>n Bauteilfestigkeiten<br />
ist zu beobachten, dass die nominellen statischen<br />
Werte durch Eigenspannungen – z.B. aus <strong>de</strong>r Warmbehandlung<br />
– überlagert wer<strong>de</strong>n können. Dies kann dazu führen, dass das<br />
nominelle Potenzial <strong>de</strong>s Werkstoffs nicht immer genutzt wird.<br />
13 Abb., 3 Tab.<br />
ALUMINIUM 9 (2009) Anwendung<br />
R. A. P. Fielding<br />
homogenization of <strong>Alu</strong>minium Alloy Extrusion Billet<br />
Part iii: The Application of the Continuous<br />
homogenization Process to AA6xxx Series Alloys<br />
Light Metal Age, April 2009, S. 8-17<br />
The majority of AA6xxx extrusion alloy billets are homogenized<br />
in one of the 90 continuous furnaces manufactured by Hertwich<br />
Engineering since their first prototype was supplied to<br />
Amag in Austria in 1980. The advantages of this technology<br />
and issues specific to the <strong>de</strong>sign, operation and control of these<br />
furnaces are discussed. The productivity and, to a large <strong>de</strong>gree,<br />
the recovery from the extrusion of an aluminium alloy billet<br />
is <strong>de</strong>pen<strong>de</strong>nt on its thermal history from alloying and casting<br />
through homogenization until its entry to the extrusion die. As<br />
was pointed out by Reiso, an optimum billet structure for one<br />
extru<strong>de</strong>r may not be the optimum for another. Whether a prime<br />
or a secondary producer supplies the extrusion billet, variations<br />
in the chemical composition, the preparation of the melt,<br />
or the casting and homogenization processes, can be <strong>de</strong>tected<br />
at the extrusion press. Additionally, in the extrusion plant, the<br />
specific pressure of the presses and the <strong>de</strong>sign of the extrusion<br />
dies affect the choice of die, billet and container temperatures.<br />
The rate of heating the billet before entering the extrusion press<br />
varies between induction and gas-fired furnaces. All of these<br />
factors have an influence on the optimum billet structure. As a<br />
consequence, the production of extrusions, from molten metal<br />
to the age ovens, must be looked upon as a whole. What happens<br />
at one stage of the production process is not in<strong>de</strong>pen<strong>de</strong>nt of the<br />
other stages. 5 figures, 27 sources<br />
ALUMINIUM 9 (2009) Strangpressen<br />
J. C. LaBelle, T. Dolby<br />
hex Washer-head Fastener<br />
Pull-Over in Mo<strong>de</strong>rately Thin <strong>Alu</strong>minium<br />
Light Metal Age, April 2009, S. 40-43<br />
Pull-over, also termed pull-through, is a mo<strong>de</strong> of failure for a<br />
tension-loa<strong>de</strong>d fastener in which the sheet, plate or extrusion<br />
locally tears and/or <strong>de</strong>forms sufficiently to allow the head to<br />
pass completely through. Screws are used to resist tensile <strong>de</strong>sign<br />
loads in a variety of aluminium structures including skylights,<br />
curtain walls, and window framing. The <strong>Alu</strong>minium Design<br />
Manual (ADM) inclu<strong>de</strong>s equation 5.4.2.2-1 for pull-over of tapping<br />
screws installed in aluminium. This formula, however, was<br />
based on testing of relatively thin aluminium, 1.02 mm (0.040“)<br />
maximum, using hex-head fasteners with loose washers that<br />
were a metal/rubber combination. Subsequently, limited testing<br />
indicated that this equation was likely conservative for greater<br />
thicknesses. Thus, a testing programme was initiated in or<strong>de</strong>r to<br />
study behaviour and provi<strong>de</strong> <strong>de</strong>sign guidance for the pull-over<br />
mo<strong>de</strong> for hex-head screws with integral or loose metal-washers,<br />
and pan-head screws, installed in mo<strong>de</strong>rately thin aluminium.<br />
Thicknesses ranged from about 1.02 mm (0.040“) to 6.35 mm<br />
(0.25“). Testing covered a range of fastener-plate combinations<br />
(sets) including four screw diameters, five plate thicknesses, and<br />
several alloy-tempers. In total, 162 specimens were tested (Fig.<br />
1), usually with eight tests for each combination (set) of screw<br />
size, plate thickness, and alloy-temper. Pull-over occurred in all<br />
of the tests except for those with nominal 6.35 mm (1/4“) thick<br />
plates. In these tests, screw failure occurred.<br />
Data analysis inclu<strong>de</strong>d comparisons between test results and<br />
predicted (nominal) values based on the ADM. In all cases, the<br />
ADM pull-over prediction was substantially less than the test<br />
average for the new data. A simple <strong>de</strong>sign equation was <strong>de</strong>veloped<br />
to more accurately, yet conservatively, mo<strong>de</strong>l pull-over<br />
behaviour for screws installed in aluminium with a minimum<br />
thickness of 1.02 mm (0.040“) and prescribed hole sizes. 4 figures,<br />
5 tables, 7 sources.<br />
ALUMINIUM 9 (2009) Verarbeitung, erste Stufe<br />
Sh. Akhtar, G. Timelli, F. Bonollo, L. Arnberg, M. Di Sabatino<br />
A comparative study of <strong>de</strong>fects and mechanical properties in<br />
high pressure die cast and gravity die cast aluminium alloys<br />
International Foundry Research/Giessereiforschung 61 (2009)<br />
No. 2, S. 36-48<br />
Defects such as pores, hot tears, entrained oxi<strong>de</strong>s or macrosegregation<br />
may occur in aluminium die castings, impairing their<br />
mechanical properties. The nature, extent and distribution of<br />
such <strong>de</strong>fects will, however, differ between die casting processes.<br />
To investigate these differences, a comparative study between<br />
gravity castings of an A356 alloy and high pressure die castings<br />
of an A380 alloy was carried out. The <strong>de</strong>fect distributions of<br />
the castings were investigated by metallography, radiography<br />
and fractography, and the tensile properties were measured.<br />
The gravity die castings were produced in a step mould with<br />
and without filter and at different controlled hydrogen concentrations<br />
in the melt. The U-shaped pressure die castings were<br />
produced with systematic variations of process parameters<br />
such as plunger speed, commutation point between first and<br />
second phase and pouring temperature. It has been found that<br />
both castings contain <strong>de</strong>fects, primarily pores and oxi<strong>de</strong>s, and<br />
that the presence and distribution of these <strong>de</strong>fects are highly<br />
sensitive to the process conditions. Significant variations of the<br />
<strong>de</strong>fect distribution have, however, also been found in castings<br />
produced un<strong>de</strong>r the same conditions, particularly in the pressure<br />
die castings indicating the stochastic nature of <strong>de</strong>fects in<br />
die castings. The dominating <strong>de</strong>fect type in the gravity die casting<br />
is hydrogen porosity mainly at high hydrogen melt concentrations,<br />
whereas in the high pressure die castings, oxi<strong>de</strong>s and<br />
entrapped air porosity dominate. The tensile properties in both<br />
types of castings are affected by the amount and distribution of<br />
<strong>de</strong>fects. This effect is particularly prominent for the pressure<br />
die castings where the <strong>de</strong>fect area fraction has been found to<br />
<strong>de</strong>termine the tensile strength. In the gravity castings, hydrogen<br />
porosity <strong>de</strong>creases the tensile strength, but this effect becomes<br />
significant only at quite high hydrogen melt concentrations. The<br />
tensile properties as well as the porosity also <strong>de</strong>pen<strong>de</strong>d on the<br />
cross section of the castings. 26 figures, 4 tables, 27 sources<br />
ALUMINIUM 9 (2009) Formguss, Gusslegierungen<br />
Für Schrifttum zum Thema „<strong>Alu</strong>minium“ ist <strong>de</strong>r Gesamtverband <strong>de</strong>r <strong>Alu</strong>miniumindustrie e.V. (GDA)<br />
<strong>de</strong>r kompetente Ansprechpartner. Die hier referierten Beiträge repräsentieren lediglich einen Ausschnitt<br />
aus <strong>de</strong>m umfassen<strong>de</strong>n aktuellen Bestand <strong>de</strong>r GDA-Bibliothek.<br />
Die von <strong>de</strong>r <strong>Alu</strong>minium-Zentrale seit <strong>de</strong>n dreißiger Jahren kontinuierlich aufgebaute Fach-Bibliothek<br />
wird duch <strong>de</strong>n GDA weitergeführt, ausgebaut und auf die neuen Medien umgestellt. Sie steht allen<br />
interessenten offen.<br />
Ansprechpartner ist Dr. Karsten hein, E-Mail: karsten.hein@aluinfo.<strong>de</strong><br />
62 ALUMINIUM · 9/2009
International Journal for Industry, Research and Application<br />
How do your products and services come to appear every month in the<br />
list of supply sources, on the internet – www.<strong>Alu</strong>-<strong>web</strong>.<strong>de</strong> – and in the<br />
annual list of supply sources published by ALUMINIUM ?<br />
� Please mark the main group relevant to you<br />
q Smelting technology q Rolling technology<br />
q Extrusion q Foundry<br />
� Indicate the sub-group and/or key word<br />
(if necessary, ask us for the list of key words)<br />
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� … and send this form to us by fax or post:<br />
Fax number For information Giesel Verlag GmbH, ALUMINIUM<br />
+49-511/7304-157 Tel.: -142 Rehkamp 3, D-30916 Isernhagen<br />
We will gladly send you a quotation!
L i e f e r v e r z e i c h n i s<br />
1<br />
Smelting technology<br />
Hüttentechnik<br />
1.1 Raw materials<br />
1.2 Storage facilities for smelting<br />
1.3 Ano<strong>de</strong> production<br />
1.4 Ano<strong>de</strong> rodding<br />
1.4.1 Ano<strong>de</strong> baking<br />
1.4.2 Ano<strong>de</strong> clearing<br />
1.4.3 Fixing of new ano<strong>de</strong>s to the ano<strong>de</strong>s bars<br />
1.5 Casthouse (foundry)<br />
1.6 Casting machines<br />
1.7 Current supply<br />
1.8 Electrolysis cell (pot)<br />
1.9 Potroom<br />
1.10 Laboratory<br />
1.11 Emptying the catho<strong>de</strong> shell<br />
1.12 Catho<strong>de</strong> repair shop<br />
1.13 Second-hand plant<br />
1.14 <strong>Alu</strong>minium alloys<br />
1.15 Storage and transport<br />
1.16 Smelting manufactures<br />
1.1 Raw Materials/Rohstoffe<br />
� Raw Materials / Rohstoffe<br />
trIMet ALuMINIuM AG<br />
<strong>Alu</strong>miniumallee 1<br />
D-45356 Essen<br />
Tel.: +49 (0) 201 / 3660<br />
Fax: +49 (0) 201 / 366506<br />
E-Mail: info@trimet.<strong>de</strong><br />
Internet: www.trimet.<strong>de</strong><br />
1.2 Storage facilities for<br />
smelting<br />
Lagermöglichkeiten i.d. Hütte<br />
FLSmidth MöLLer GmbH<br />
Ha<strong>de</strong>rslebener Straße 7<br />
D-25421 Pinneberg<br />
Telefon: 04101 788-0<br />
Telefax: 04101 788-115<br />
E-Mail: moeller@flsmidth.com<br />
Internet: www.flsmidthmoeller.com<br />
Kontakt: Herr Dipl.-Ing. Timo Letz<br />
outotec GmbH<br />
Albin-Köbis-Str. 8, D-51147 Köln<br />
Phone: +49 (0) 2203 / 9921-0<br />
E-mail: aluminium@outotec.com<br />
www.outotec.com<br />
� Conveying systems bulk materials<br />
För<strong>de</strong>ranlagen für Schüttgüter<br />
(Hüttenaluminiumherstellung)<br />
FLSmidth MöLLer GmbH<br />
Internet: www.flsmidthmoeller.com<br />
see Storage facilities for smelting 1.2<br />
1.1 Rohstoffe<br />
1.2 Lagermöglichkeiten in <strong>de</strong>r Hütte<br />
1.3 Ano<strong>de</strong>nherstellung<br />
1.4 Ano<strong>de</strong>nschlägerei<br />
1.4.1 Ano<strong>de</strong>nbrennen<br />
1.4.2 Ano<strong>de</strong>nschlägerei<br />
1.4.3 Befestigen von neuen Ano<strong>de</strong>n an <strong>de</strong>r -stange<br />
1.5 Gießerei<br />
1.6 Gießmaschinen<br />
1.7 Stromversorgung<br />
1.8 Elektrolyseofen<br />
1.9 Elektrolysehalle<br />
1.10 Labor<br />
1.11 Ofenwannenentleeren<br />
1.12 Katho<strong>de</strong>nreparaturwerkstatt<br />
1.13 Gebrauchtanlagen<br />
1.14 <strong>Alu</strong>miniumlegierungen<br />
1.15 Lager und Transport<br />
1.16 Hüttenerzeugnisse<br />
� Unloading/Loading equipment<br />
Entla<strong>de</strong>-/Bela<strong>de</strong>einrichtungen<br />
FLSmidth MöLLer GmbH<br />
www.flsmidthmoeller.com<br />
see Storage facilities for smelting 1.2<br />
ALuMINA ANd pet coke SHIpuNLoA<strong>de</strong>rS<br />
Contact: Andreas Haeuser, ha@neuero.<strong>de</strong><br />
1.3 Ano<strong>de</strong> production<br />
Ano<strong>de</strong>nherstellung<br />
see Storage facilities for smelting 1.2<br />
� Auto firing systems<br />
Automatische Feuerungssysteme<br />
rIedHAMMer GmbH<br />
D-90411 Nürnberg<br />
Phone: +49 (0) 911 5218 0, Fax: -5218 231<br />
E-Mail: frank.goe<strong>de</strong>@riedhammer.<strong>de</strong><br />
Internet: www.riedhammer.<strong>de</strong><br />
� Exhaust gas treatment<br />
Abgasbehandlung<br />
ALStoM Norway AS<br />
Tel. +47 22 12 70 00<br />
Internet: www.environment.power.alstom.com<br />
� Hydraulic presses for prebaked<br />
ano<strong>de</strong>s / Hydraulische Pressen zur<br />
Herstellung von Ano<strong>de</strong>n<br />
LAeIS GmbH<br />
Am Scheerleck 7, L-6868 Wecker, Luxembourg<br />
Phone: +352 27612 0<br />
Fax: +352 27612 109<br />
E-Mail: info@laeis-gmbh.com<br />
Internet: www.laeis-gmbh.com<br />
Contact: Dr. Alfred Kaiser<br />
� Mixing Technology for<br />
Ano<strong>de</strong> pastes<br />
Mischtechnologie für Ano<strong>de</strong>nmassen<br />
Buss AG<br />
CH-4133 Pratteln<br />
Phone: +41 61 825 66 00<br />
E-Mail: info@busscorp.com<br />
Internet: www.busscorp.com<br />
� Open top and closed<br />
type baking furnaces<br />
Offene und geschlossene Ringöfen<br />
rIedHAMMer GmbH<br />
D-90411 Nürnberg<br />
Phone: +49 (0) 911 5218 0, Fax: -5218 231<br />
E-Mail: frank.goe<strong>de</strong>@riedhammer.<strong>de</strong><br />
Internet: www.riedhammer.<strong>de</strong><br />
64 ALUMINIUM · 9/2009
1.4 Ano<strong>de</strong> rodding<br />
Ano<strong>de</strong>nanschlägerei<br />
see Storage facilities for smelting 1.2<br />
� Removal of bath residues from<br />
the surface of spent ano<strong>de</strong>s<br />
Entfernen <strong>de</strong>r Badreste von <strong>de</strong>r Ober -<br />
fläche <strong>de</strong>r verbrauchten Ano<strong>de</strong>n<br />
GLAMA Maschinenbau GmbH<br />
Hornstraße 19<br />
D-45964 Gladbeck<br />
Telefon 02043 / 9738-0<br />
Telefax 02043 / 9738-50<br />
� Transport of finished ano<strong>de</strong><br />
elements to the pot room<br />
Transport <strong>de</strong>r fertigen Ano<strong>de</strong>nelemente<br />
in Elektrolysehalle<br />
Hovestr. 10 . D-48431 Rheine<br />
Telefon + 49 (0) 59 7158-0<br />
Fax + 49 (0) 59 7158-209<br />
E-Mail info@windhoff.<strong>de</strong><br />
Internet www.windhoff.<strong>de</strong><br />
1.4.1 Ano<strong>de</strong> baking<br />
Ano<strong>de</strong>nbrennen<br />
� Ano<strong>de</strong> charging<br />
Ano<strong>de</strong>nchargieren<br />
SerMAS INduStrIe<br />
E-Mail: sermas@sermas.com<br />
see Casting Machines 1.6<br />
� Ano<strong>de</strong> storage<br />
Ano<strong>de</strong>nlager<br />
SerMAS INduStrIe<br />
E-Mail: sermas@sermas.com<br />
see Casting Machines 1.6<br />
1.4.2 Ano<strong>de</strong> clearing<br />
Ano<strong>de</strong>nschlägerei<br />
� Separation of spent ano<strong>de</strong>s<br />
from the ano<strong>de</strong> bars<br />
Trennen von <strong>de</strong>n Ano<strong>de</strong>nstangen<br />
SerMAS INduStrIe<br />
E-Mail: sermas@sermas.com<br />
see Casting Machines 1.6<br />
ALUMINIUM · 9/2009<br />
1.4.3 Fixing of new ano<strong>de</strong>s<br />
to the ano<strong>de</strong>s bars<br />
Befestigen von neuen<br />
Ano<strong>de</strong>n a. d. Ano<strong>de</strong>nstange<br />
� Fixing the nipples to the<br />
ano<strong>de</strong>s by casting in<br />
Befestigen <strong>de</strong>r Nippel mit <strong>de</strong>r<br />
Ano<strong>de</strong> durch Eingießen<br />
SerMAS INduStrIe<br />
E-Mail: sermas@sermas.com<br />
see Casting Machines 1.6<br />
1.5 Casthouse (foundry)<br />
Gießerei<br />
HertWIcH eNGINeerING GmbH<br />
Maschinen und Industrieanlagen<br />
Weinbergerstraße 6, A-5280 Braunau am Inn<br />
Phone +437722/806-0<br />
Fax +437722/806-122<br />
E-Mail: info@hertwich.com<br />
Internet: www.hertwich.com<br />
INotHerM INduStrIeoFeN-<br />
uNd WÄrMetecHNIk GMBH<br />
Konstantinstraße 1a<br />
D 41238 Mönchengladbach<br />
Telefon +49 (02166) 987990<br />
Telefax +49 (02166) 987996<br />
E-Mail: info@inotherm-gmbh.<strong>de</strong><br />
Internet: www.inotherm-gmbh.<strong>de</strong><br />
see Equipment and accessories 3.1<br />
SIGNo<strong>de</strong>® SySteM GMBH<br />
Packaging Equipment<br />
Non-Ferrous Specialist Team DSWE<br />
Magnusstr. 18, 46535 Dinslaken/Germany<br />
Telefon: +49 (0) 2064 / 69-210<br />
Telefax: +49 (0) 2064 / 69-489<br />
E-Mail: g.laks@signo<strong>de</strong>-europe.com<br />
Internet: www.signo<strong>de</strong>.com<br />
Contact: Mr. Gerard Laks<br />
Stopinc AG<br />
Bösch 83 a<br />
CH-6331 Hünenberg<br />
Tel. +41/41-785 75 00<br />
Fax +41/41-785 75 01<br />
E-Mail: interstop@stopinc.ch<br />
Internet: www.stopinc.ch<br />
L i e f e r v e r z e i c h n i s<br />
� Clay / Toner<strong>de</strong><br />
trIMet ALuMINIuM AG<br />
<strong>Alu</strong>miniumallee 1<br />
D-45356 Essen<br />
Tel.: +49 (0) 201 / 3660<br />
Fax: +49 (0) 201 / 366506<br />
E-Mail: info@trimet.<strong>de</strong><br />
Internet: www.trimet.<strong>de</strong><br />
� Degassing, filtration and<br />
grain refinement<br />
Entgasung, Filtern, Kornfeinung<br />
drache umwelttechnik<br />
GmbH<br />
Werner-v.-Siemens-Straße 9/24-26<br />
D 65582 Diez/Lahn<br />
Telefon 06432/607-0<br />
Telefax 06432/607-52<br />
Internet: www.drache-gmbh.<strong>de</strong><br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
� Dross skimming of liquid metal<br />
Abkrätzen <strong>de</strong>s Flüssigmetalls<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Dross skimming of the melt<br />
Abkrätzen <strong>de</strong>r Schmelze<br />
E-Mail: sermas@sermas.com<br />
see Casting machines 1.6<br />
� Furnace charging with<br />
molten metal<br />
Ofenbeschickung mit Flüssigmetall<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Melting/holding/casting furnaces<br />
Schmelz-/Halte- und Gießöfen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5<br />
65
L i e f e r v e r z e i c h n i s<br />
Sistem teknik Ltd. Sti.<br />
DES San. Sit. 102 SOK No: 6/8<br />
Y.Dudullu, TR-34775 Istanbul/Turkey<br />
Tel.: +90 216 420 86 24<br />
Fax: +90 216 420 23 22<br />
E-Mail: info@sistemteknik.com<br />
Internet: www.sistemteknik.com<br />
� Metal treatment in the<br />
holding furnace<br />
Metallbehandlung in Halteöfen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
� Transfer to the casting furnace<br />
Überführung in Gießofen<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
drache umwelttechnik<br />
GmbH<br />
Werner-v.-Siemens-Straße 9/24-26<br />
D 65582 Diez/Lahn<br />
Telefon 06432/607-0<br />
Telefax 06432/607-52<br />
Internet: www.drache-gmbh.<strong>de</strong><br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
Windhoff Bahn- und<br />
Anlagentechnik GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Transport of liquid metal<br />
to the casthouse<br />
Transport v. Flüssigmetall in Gießereien<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
MArx GmbH & co. kG<br />
www.marx-gmbh.<strong>de</strong><br />
see Melt operations 4.13<br />
Windhoff Bahn- und<br />
Anlagentechnik GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Treatment of casthouse<br />
off gases<br />
Behandlung <strong>de</strong>r Gießereiabgase<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
1.6 Casting machines<br />
Gießmaschinen<br />
� Pig casting machines (sow casters)<br />
Masselgießmaschine (Sowcaster)<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
see Storage facilities for smelting 1.2<br />
� Rolling and extrusion ingot<br />
and T-bars<br />
Formatgießerei (Walzbarren o<strong>de</strong>r<br />
Pressbolzen o<strong>de</strong>r T-Barren)<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
� Horizontal continuous casting<br />
Horizontales Stranggießen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
� Scales / Waagen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
� Sawing / Sägen<br />
343 Chemin du Sta<strong>de</strong><br />
38210 Saint Quentin sur Isère<br />
Tel. +33 (0) 476 074 242<br />
Fax +33 (0) 476 936 776<br />
E-Mail: sermas@sermas.com<br />
Internet: www.sermas.com<br />
� Heat treatment of extrusion<br />
ingot (homogenisation)<br />
Formatebehandlung (homogenisieren)<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5 HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5<br />
HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5<br />
HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5<br />
see Billet Heating Furnaces 1.5<br />
� Vertical semi-continuous DC<br />
casting / Vertikales Stranggießen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
Wagstaff, Inc.<br />
3910 N. Flora Rd.<br />
Spokane, WA 99216 USA<br />
+1 509 922 1404 phone<br />
+1 509 924 0241 fax<br />
E-Mail: info@wagstaff.com<br />
Internet: www.wagstaff.com<br />
1.8 Electrolysis cell (pot)<br />
Elektrolyseofen<br />
� Calcium silicate boards<br />
Calciumsilikatplatten<br />
promat GmbH – techn. Wärmedämmung<br />
Scheifenkamp 16, D-40878 Ratingen<br />
Tel. +49 (0) 2102 / 493-0, Fax -493 115<br />
verkauf3@promat.<strong>de</strong>, www.promat.<strong>de</strong><br />
66 ALUMINIUM · 9/2009
� Pot feeding systems<br />
Beschickungseinrichtungen<br />
für Elektrolysezellen<br />
FLSmidth MöLLer GmbH<br />
www.flsmidthmoeller.com<br />
see Storage facilities for smelting 1.2<br />
1.9 Potroom<br />
Elektrolysehalle<br />
t.t. tomorrow technology S.p.A.<br />
Via <strong>de</strong>ll’Artigianato 18<br />
Due Carrare, Padova 35020, Italy<br />
Telefon +39 049 912 8800<br />
Telefax +39 049 912 8888<br />
E-Mail: gmagarotto@tomorrowtechnology.it<br />
Contact: Giovanni Magarotto<br />
� Ano<strong>de</strong> changing machine<br />
Ano<strong>de</strong>nwechselmaschine<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Ano<strong>de</strong> transport equipment<br />
Ano<strong>de</strong>n Transporteinrichtungen<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Crustbreakers / Krustenbrecher<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
2 Extrusion<br />
Strangpressen<br />
2.1 Extrusion billet preparation<br />
2.1.1 Extrusion billet production<br />
2.2 Extrusion equipment<br />
2.3 Section handling<br />
2.4 Heat treatment<br />
2.5 Measurement and control equipment<br />
2.6 Die preparation and care<br />
2.7 Second-hand extrusion plant<br />
2.8 Consultancy, expert opinion<br />
2.9 Surface finishing of sections<br />
2.10 Machining of sections<br />
2.11 Equipment and accessories<br />
2.12 Services<br />
2.1 Extrusion billet<br />
preparation<br />
Pressbolzenbereitstellung<br />
SIGNo<strong>de</strong>® SySteM GMBH<br />
Packaging Equipment<br />
Non-Ferrous Specialist Team DSWE<br />
Magnusstr. 18, 46535 Dinslaken/Germany<br />
Telefon: +49 (0) 2064 / 69-210<br />
Telefax: +49 (0) 2064 / 69-489<br />
E-Mail: g.laks@signo<strong>de</strong>-europe.com<br />
Internet: www.signo<strong>de</strong>.com<br />
Contact: Mr. Gerard Laks<br />
ALUMINIUM · 9/2009<br />
� Dry absorption units for<br />
electrolysis exhaust gases<br />
Trockenabsorptionsanlage für<br />
Elektrolyseofenabgase<br />
ALStoM Norway AS<br />
Tel. +47 22 12 70 00<br />
Internet: www.environment.power.alstom.com<br />
� HF Measurementtechnology<br />
HF Messtechnik<br />
opSIS AB<br />
Box 244, S-24402 Furulund, Schwe<strong>de</strong>n<br />
Tel. +46 (0) 46-72 25 00, Fax -72 25 01<br />
E-Mail: info@opsis.se<br />
Internet: www.opsis.se<br />
� Tapping vehicles<br />
Schöpffahrzeuge<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
1.11 Emptying the<br />
catho<strong>de</strong> shell<br />
Ofenwannenentleeren<br />
� Catho<strong>de</strong> bar casting units<br />
Katho<strong>de</strong>nbarreneingießanlage<br />
E-Mail: sermas@sermas.com<br />
see Casting machines 1.6<br />
2.1 Pressbolzenbereitstellung<br />
2.1.1 Pressbolzenherstellung<br />
2.2 Strangpresseinrichtungen<br />
2.3 Profilhandling<br />
2.4 Wärmebehandlung<br />
2.5 Mess- und Regeleinrichtungen<br />
2.6 Werkzeugbereitstellung und -pflege<br />
2.7 Gebrauchte Strangpressanlagen<br />
2.8 Beratung, Gutachten<br />
2.9 Oberflächenveredlung von Profilen<br />
2.10 Profilbearbeitung<br />
2.11 Ausrüstungen und Hilfsmittel<br />
2.12 Dienstleistungen<br />
� Billet heating furnaces<br />
Öfen zur Bolzenerwärmung<br />
Am großen Teich 16+27<br />
D-58640 Iserlohn<br />
Tel. +49 (0) 2371 / 4346-0<br />
Fax +49 (0) 2371 / 4346-43<br />
E-Mail: verkauf@ias-gmbh.<strong>de</strong><br />
Internet: www.ias-gmbh.<strong>de</strong><br />
L i e f e r v e r z e i c h n i s<br />
1.15 Storage and transport<br />
Lager und Transport<br />
SMS Siemag Aktiengesellschaft<br />
Logistiksysteme<br />
see Rolling mill technology 3.0<br />
1.16 Smelting manufactories<br />
Hüttenerzeugnisse<br />
� Rolling ingots<br />
Walzbarren<br />
Alcan <strong>Alu</strong>minium Valais SA<br />
CH-3960 Sierre<br />
Telefon: 0041 27 / 4575111<br />
Telefax: 0041 27 / 4576425<br />
MArx GmbH & co. kG<br />
www.marx-gmbh.<strong>de</strong><br />
see Melt operations 4.13<br />
67
L i e f e r v e r z e i c h n i s<br />
Sistem teknik Ltd. Sti.<br />
DES San. Sit. 102 SOK No: 6/8<br />
Y.Dudullu, TR-34775 Istanbul/Turkey<br />
Tel.: +90 216 420 86 24<br />
Fax: +90 216 420 23 22<br />
E-Mail: info@sistemteknik.com<br />
Internet: www.sistemteknik.com<br />
2.1.1 Extrusion billet<br />
production<br />
Pressbolzenherstellung<br />
� Billet transport and storage<br />
equipment<br />
Bolzen-Transport- u. Lagereinricht.<br />
SerMAS INduStrIe<br />
E-Mail: sermas@sermas.com<br />
See Casting Machines 1.6<br />
2.2 Extrusion equipment<br />
Strangpresseinrichtungen<br />
oilgear towler GmbH<br />
Im Gotthelf 8<br />
D 65795 Hattersheim<br />
Tel. +49 (0) 6145 3770<br />
Fax +49 (0) 6145 30770<br />
E-Mail: info@oilgear.<strong>de</strong><br />
Internet: www.oilgear.<strong>de</strong><br />
SMS Meer GmbH<br />
Schloemann Extrusion<br />
Ohlerkirchweg 66<br />
D-41069 Mönchengladbach<br />
Tel. +49 (0) 2161 / 3500<br />
Fax +49 (0) 2161 / 3501667<br />
E-Mail: info@sms-meer.com<br />
Internet: www.sms-meer.com<br />
� Containers / Rezipienten<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Press control systems<br />
Pressensteuersysteme<br />
oilgear towler GmbH<br />
see Extrusion Equipment 2.2<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Temperature measurement<br />
Temperaturmessung<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Heating and control<br />
equipment for intelligent<br />
billet containers<br />
Heizungs- und Kontrollausrüstung<br />
für intelligente Blockaufnehmer<br />
MArx GmbH & co. kG<br />
www.marx-gmbh.<strong>de</strong><br />
see Melt operations 4.13<br />
2.3 Section handling<br />
Profilhandling<br />
SIGNo<strong>de</strong>® SySteM GMBH<br />
Packaging Equipment<br />
Non-Ferrous Specialist Team DSWE<br />
Magnusstr. 18, 46535 Dinslaken/Germany<br />
Telefon: +49 (0) 2064 / 69-210<br />
Telefax: +49 (0) 2064 / 69-489<br />
E-Mail: g.laks@signo<strong>de</strong>-europe.com<br />
Internet: www.signo<strong>de</strong>.com<br />
Contact: Mr. Gerard Laks<br />
� Packaging equipment<br />
Verpackungseinrichtungen<br />
H+H HerrMANN + HIeBer GMBH<br />
För<strong>de</strong>rsysteme für paletten<br />
und schwere Lasten<br />
Rechbergstraße 46<br />
D-73770 Denkendorf/Stuttgart<br />
Tel. +49 (0) 711 / 9 34 67-0<br />
Fax +49 (0) 711 / 3 46 0911<br />
E-Mail: info@herrmannhieber.<strong>de</strong><br />
Internet: www.herrmannhieber.<strong>de</strong><br />
Vollert Anlagenbau<br />
GmbH + co. kG<br />
Stadtseestraße 12<br />
D-74189 Weinsberg<br />
Tel. +49 (0) 7134 / 52-220<br />
Fax +49 (0) 7134 / 52-222<br />
E-Mail intralogistik@vollert.<strong>de</strong><br />
Internet www.vollert.<strong>de</strong><br />
� Puller equipment<br />
Ausziehvorrichtungen/Puller<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Section cooling<br />
Profilkühlung<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Section saws<br />
Profilsägen<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
68 ALUMINIUM · 9/2009
� Section store equipment<br />
Profil-Lagereinrichtungen<br />
H+H HerrMANN + HIeBer GMBH<br />
För<strong>de</strong>rsysteme für paletten<br />
und schwere Lasten<br />
Rechbergstraße 46<br />
D-73770 Denkendorf/Stuttgart<br />
Tel. +49 (0) 711 / 9 34 67-0<br />
Fax +49 (0) 711 / 3 46 0911<br />
E-Mail: info@herrmannhieber.<strong>de</strong><br />
Internet: www.herrmannhieber.<strong>de</strong><br />
kASto Maschinenbau GmbH & co. kG<br />
Industriestr. 14, D-77855 Achern<br />
Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300<br />
kasto@kasto.<strong>de</strong> / www.kasto.<strong>de</strong><br />
Hersteller von Band- und Kreissägemaschinen<br />
sowie Langgut- und Blechlagersystemen<br />
Vollert Anlagenbau<br />
GmbH + co. kG<br />
see Packaging equipment 2.3<br />
� Section transport equipment<br />
Profiltransporteinrichtungen<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
Nijverheidsweg 3<br />
NL-7071 CH Ulft Netherlands<br />
Tel.: +31 315 641352<br />
Fax: +31 315 641852<br />
E-Mail: info@unifour.nl<br />
Internet: www.unifour.nl<br />
Sales Contact: Paul Overmans<br />
� Stackers / Destackers<br />
Stapler / Entstapler<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
ALUMINIUM · 9/2009<br />
� Stretching equipment<br />
Reckeinrichtungen<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Transport equipment for<br />
extru<strong>de</strong>d sections<br />
Transporteinrichtungen<br />
für Profilabschnitte<br />
H+H HerrMANN + HIeBer GMBH<br />
För<strong>de</strong>rsysteme für paletten<br />
und schwere Lasten<br />
Rechbergstraße 46<br />
D-73770 Denkendorf/Stuttgart<br />
Tel. +49 (0) 711 / 9 34 67-0<br />
Fax +49 (0) 711 / 3 46 0911<br />
E-Mail: info@herrmannhieber.<strong>de</strong><br />
Internet: www.herrmannhieber.<strong>de</strong><br />
Vollert Anlagenbau<br />
GmbH + co. kG<br />
see Packaging equipment 2.3<br />
2.4 Heat treatment<br />
Wärmebehandlung<br />
BSN Thermprozesstechnik GmbH<br />
Kammerbruchstraße 64<br />
D-52152 Simmerath<br />
Tel. 02473-9277-0 · Fax: 02473-9277-111<br />
info@bsn-therm.<strong>de</strong> · www.bsn-therm.<strong>de</strong><br />
Ofenanlagen zum Wärmebehan<strong>de</strong>ln von <strong>Alu</strong>miniumlegierungen,<br />
Buntmetallen und Stählen<br />
Seco/WArWIck S.A.<br />
Sobieskiego 8, 66-200 Swiebodzin PL<br />
tel./fax +48 68 4111 600 (655)<br />
Fax +49 (0) 711 / 3 46 0911<br />
info@secowarwick.com.pl<br />
www.secowarwick.com.pl<br />
L i e f e r v e r z e i c h n i s<br />
� Annealing furnaces<br />
Glühöfen<br />
see Equipment and accessories 3.1<br />
� Heat treatment furnaces<br />
Wärmebehandlungsöfen<br />
INotHerM INduStrIeoFeN-<br />
uNd WÄrMetecHNIk GMBH<br />
see Casthouse (foundry) 1.5<br />
see Billet Heating Furnaces 2.1<br />
� Custom <strong>de</strong>signed heat<br />
processing equipment<br />
Kun<strong>de</strong>nspezifische<br />
Wärmebehandlungsanlagen<br />
Sistem teknik Ltd. Sti.<br />
see Billet Heating Furnaces 2.1<br />
� Homogenising furnaces<br />
Homogenisieröfen<br />
HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5<br />
Seco/WArWIck S.A.<br />
see Heat treatment 2.4<br />
see Billet Heating Furnaces 2.1<br />
69
L i e f e r v e r z e i c h n i s<br />
2.5 Measurement and<br />
control equipment<br />
Mess- und Regeleinrichtungen<br />
� Extrusion plant control systems<br />
Presswerkssteuerungen<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
2.6 Die preparation and care<br />
Werkzeugbereitstellung<br />
und -pflege<br />
� Die heating furnaces<br />
Werkzeuganwärmöfen<br />
MArx GmbH & co. kG<br />
www.marx-gmbh.<strong>de</strong><br />
see Melt operations 4.13<br />
Sistem teknik Ltd. Sti.<br />
see Billet Heating Furnaces 2.1<br />
Nijverheidsweg 3<br />
NL-7071 CH Ulft Netherlands<br />
Tel.: +31 315 641352<br />
Fax: +31 315 641852<br />
E-Mail: info@unifour.nl<br />
Internet: www.unifour.nl<br />
Sales Contact: Paul Overmans<br />
� Extrusion dies<br />
Strangpresswerkzeuge<br />
Haarmann Holding GmbH<br />
Karmeliterstraße 6<br />
D-52064 Aachen<br />
Telefon: 02 41 / 9 18 - 500<br />
Telefax: 02 41 / 9 18 - 5010<br />
E-Mail: info@haarmann-gruppe.<strong>de</strong><br />
Internet: www.haarmann-gruppe.<strong>de</strong><br />
� Har<strong>de</strong>ning technology<br />
Härtetechnik<br />
Haarmann Holding GmbH<br />
see Die preparation and care 2.6<br />
2.7 Second-hand<br />
extrusion plant<br />
Gebr. Strangpressanlagen<br />
Qualiteam International/extruprex<br />
Champs Elyséesweg 17, NL-6213 AA Maastricht<br />
Tel. +31-43-3 25 67 77<br />
Internet: www.extruprex.com<br />
2.10 Machining of sections<br />
Profilbearbeitung<br />
� Processing of Profiles<br />
Profilbearbeitung<br />
tensai (International) AG<br />
extal division<br />
Steinengraben 40<br />
CH-4051 Basel<br />
Telefon +41 (0) 61 284 98 10<br />
Telefax +41 (0) 61 284 98 20<br />
E-Mail: tensai@tensai.com<br />
2.11 Equipment and<br />
accessories<br />
Ausrüstungen und<br />
Hilfsmittel<br />
� Inductiv heating equipment<br />
Induktiv beheizte<br />
Erwärmungseinrichtungen<br />
Am großen Teich 16+27<br />
D-58640 Iserlohn<br />
Tel. +49 (0) 2371 / 4346-0<br />
Fax +49 (0) 2371 / 4346-43<br />
E-Mail: verkauf@ias-gmbh.<strong>de</strong><br />
Internet: www.ias-gmbh.<strong>de</strong><br />
� Ageing furnace for extrusions<br />
Auslagerungsöfen für<br />
Strangpressprofile<br />
see Billet Heating Furnaces 2.1<br />
Nijverheidsweg 3<br />
NL-7071 CH Ulft Netherlands<br />
Tel.: +31 315 641352<br />
Fax: +31 315 641852<br />
E-Mail: info@unifour.nl<br />
Internet: www.unifour.nl<br />
Sales Contact: Paul Overmans<br />
2.12 Services<br />
Dienstleistungen<br />
Haarmann Holding GmbH<br />
see Die preparation and care 2.6<br />
could not find your „keywords“?<br />
please ask for our complete<br />
„Supply sources for the aluminium industry“.<br />
e-Mail: p.kapsali@giesel.<strong>de</strong><br />
70 ALUMINIUM · 9/2009
3<br />
Rolling mill technology<br />
Walzwerktechnik<br />
3.1 Casting equipment<br />
3.2 Rolling bar machining<br />
3.3 Rolling bar furnaces<br />
3.4 Hot rolling equipment<br />
3.5 Strip casting units and accessories<br />
3.6 Cold rolling equipment<br />
3.7 Thin strip / foil rolling plant<br />
3.8 Auxiliary equipment<br />
3.9 Adjustment <strong>de</strong>vices<br />
3.10 Process technology / Automation technology<br />
3.11 Coolant / lubricant preparation<br />
3.12 Air extraction systems<br />
3.13 Fire extinguishing units<br />
3.14 Storage and dispatch<br />
3.15 Second-hand rolling equipment<br />
3.16 Coil storage systems<br />
3.17 Strip Processing Lines<br />
3.18 Productions Management Systems<br />
3.0 Rolling mill technology<br />
Walzwerktechnik<br />
SMS Siemag Aktiengesellschaft<br />
Eduard-Schloemann-Straße 4<br />
D-40237 Düsseldorf<br />
Telefon: +49 (0) 211 881-0<br />
Telefax: +49 (0) 211 881-49 02<br />
E-Mail: communications@sms-siemag.com<br />
Internet: www.sms-siemag.com<br />
Geschäftsbereiche:<br />
Warmflach- und kaltwalzwerke<br />
Wiesenstraße 30<br />
D-57271 Hilchenbach-Dahlbruch<br />
Telefon: +49 (0) 2733 29-0<br />
Telefax: +49 (0) 2733 29-2852<br />
Bandanlagen<br />
Wal<strong>de</strong>rstraße 51/53<br />
D-40724 Hil<strong>de</strong>n<br />
Telefon: +49 (0) 211 881-5100<br />
Telefax: +49 (0) 211 881-5200<br />
elektrik + Automation<br />
Ivo-Beucker-Straße 43<br />
D-40237 Düsseldorf<br />
Telefon: +49 (0) 211 881-5895<br />
Telefax: +49 (0) 211 881-775895<br />
Logistiksysteme<br />
Obere Industriestraße 8<br />
D-57250 Netphen<br />
Telefon: +49 (0) 2738 21-0<br />
Telefax: +49 (0) 2738 21-1299<br />
E-Mail: info@siemag.com<br />
Internet: www.siemag.com<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
ALUMINIUM · 9/2009<br />
3.1 Gießanlagen<br />
3.2 Walzbarrenbearbeitung<br />
3.3 Walzbarrenvorbereitung<br />
3.4 Warmwalzanlagen<br />
3.5 Bandgießanlagen und Zubehör<br />
3.6 Kaltwalzanlagen<br />
3.7 Feinband-/Folienwalzwerke<br />
3.8 Nebeneinrichtungen<br />
3.9 Adjustageeinrichtungen<br />
3.10 Prozesstechnik / Automatisierungstechnik<br />
3.11 Kühl-/Schmiermittel-Aufbereitung<br />
3.12 Abluftsysteme<br />
3.13 Feuerlöschanlagen<br />
3.14 Lagerung und Versand<br />
3.15 Gebrauchtanlagen<br />
3.16 Coil storage systems<br />
3.17 Bandprozesslinien<br />
3.18 Produktions Management Systeme<br />
3.1 Casting equipment<br />
Gießanlagen<br />
� Filling level indicators and controls<br />
Füllstandsanzeiger und -regler<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
Wagstaff, Inc.<br />
see Casting machines 1.6<br />
� Melting and holding furnaces<br />
Schmelz- und Warmhalteöfen<br />
Gautschi<br />
engineering GmbH<br />
Geschäftsbereich <strong>Alu</strong>minium<br />
Konstanzer Straße 37<br />
Postfach 170<br />
CH 8274 Tägerwilen<br />
Telefon +41/71/6666666<br />
Telefax +41/71/6666688<br />
E-Mail: aluminium@gautschi-engineering.com<br />
Kontakt: Stefan Blum, Tel. +41/71/6666621<br />
LoI thermprocess GmbH<br />
Am Lichtbogen 29<br />
D-45141 Essen<br />
Germany<br />
Telefon +49 (0) 201 / 18 91-1<br />
Telefax +49 (0) 201 / 18 91-321<br />
E-Mail: info@loi-italimpianti.<strong>de</strong><br />
Internet: www.loi-italimpianti.com<br />
Seco/WArWIck S.A.<br />
see Heat treatment 2.4<br />
L i e f e r v e r z e i c h n i s<br />
� Melt purification units<br />
Schmelzereinigungsanlagen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
� Metal filters / Metallfilter<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
3.2 Rolling bar machining<br />
Walzbarrenbearbeitung<br />
� Band saws / Bandsägen<br />
SMS Meer GmbH<br />
Ohlerkirchweg 66<br />
D-41069 Mönchengladbach<br />
Tel. +49 (0) 2161 / 3500<br />
Fax +49 (0) 2161 / 3501667<br />
E-Mail: info@sms-meer.com<br />
Internet: www.sms-meer.com<br />
� Slab milling machines<br />
Barrenfräsmaschinen<br />
SMS Meer GmbH<br />
see Rolling bar machining 3.2<br />
71
L i e f e r v e r z e i c h n i s<br />
3.3 Rolling bar furnaces<br />
Walzbarrenvorbereitung<br />
BSN Thermprozesstechnik GmbH<br />
see Heat Treatment 2.4<br />
� Homogenising furnaces<br />
Homogenisieröfen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5<br />
� Annealing furnaces<br />
Glühöfen<br />
eBNer Industrieofenbau Ges.m.b.H.<br />
Ruflinger Str. 111, A-4060 Leonding<br />
Tel. +43 / 732 / 68 68<br />
Fax +43 / 732 / 68 68-1000<br />
Internet: www.ebner.cc<br />
E-Mail: sales@ebner.cc<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
schwartz GmbH<br />
see Equipment and accessories 3.1<br />
� Bar heating furnaces<br />
Barrenanwärmanlagen<br />
see Heat treatment 2.4<br />
eBNer Industrieofenbau Ges.m.b.H.<br />
see Annealing furnaces 3.3<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
� Roller tracks<br />
Rollengänge<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
3.4 Hot rolling equipment<br />
Warmwalzanlagen<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
see Cold rolling units / complete plants 3.6<br />
� Coil transport systems<br />
Bundtransportsysteme<br />
Vollert Anlagenbau<br />
GmbH + co. kG<br />
see Packaging equipment 2.3<br />
Windhoff Bahn- und<br />
Anlagentechnik GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Drive systems / Antriebe<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Rolling mill mo<strong>de</strong>rnisation<br />
Walzwerksmo<strong>de</strong>rnisierung<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Spools / Haspel<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Hot rolling units /<br />
complete plants<br />
Warmwalzanlagen/Komplettanlagen<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
3.5 Strip casting units<br />
and accessories<br />
Bandgießanlagen und<br />
Zubehör<br />
� Cores & shells for continuous<br />
casting lines<br />
Cores & shells for continuous<br />
casting lines<br />
Bruno presezzi SpA<br />
Via per Ornago 8<br />
I-20040 Burago Molgora (Mi) – Italy<br />
Tel. +39 039 63502 229<br />
Fax +39 039 6081373<br />
E-Mail: aluminium.<strong>de</strong>pt@brunopresezzi.com<br />
Internet: www.brunopresezzi.com<br />
Contact: Franco Gramaglia<br />
� Revamps, equipments & spare parts<br />
for continuous casting lines<br />
Revamps, equipments & spare parts<br />
for continuous casting lines<br />
Bruno presezzi SpA<br />
Via per Ornago 8<br />
I-20040 Burago Molgora (Mi) – Italy<br />
Tel. +39 039 63502 229<br />
Fax +39 039 6081373<br />
E-Mail: aluminium.<strong>de</strong>pt@brunopresezzi.com<br />
Internet: www.brunopresezzi.com<br />
Contact: Franco Gramaglia<br />
� Twin-roll continuous casting<br />
lines (complete lines)<br />
Twin-roll continuous casting lines<br />
(complete lines)<br />
Bruno presezzi SpA<br />
Via per Ornago 8<br />
I-20040 Burago Molgora (Mi) – Italy<br />
Tel. +39 039 63502 229<br />
Fax +39 039 6081373<br />
E-Mail: aluminium.<strong>de</strong>pt@brunopresezzi.com<br />
Internet: www.brunopresezzi.com<br />
Contact: Franco Gramaglia<br />
72 ALUMINIUM · 9/2009
3.6 Cold rolling equipment<br />
Kaltwalzanlagen<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
BSN Thermprozesstechnik GmbH<br />
see Heat Treatment 2.4<br />
SIGNo<strong>de</strong>® SySteM GMBH<br />
Packaging Equipment<br />
Non-Ferrous Specialist Team DSWE<br />
Magnusstr. 18, 46535 Dinslaken/Germany<br />
Telefon: +49 (0) 2064 / 69-210<br />
Telefax: +49 (0) 2064 / 69-489<br />
E-Mail: g.laks@signo<strong>de</strong>-europe.com<br />
Internet: www.signo<strong>de</strong>.com<br />
Contact: Mr. Gerard Laks<br />
� Coil annealing furnaces<br />
Bundglühöfen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
see Equipment and accessories 3.1<br />
Seco/WArWIck S.A.<br />
see Heat treatment 2.4<br />
� Coil transport systems<br />
Bundtransportsysteme<br />
Vollert Anlagenbau<br />
GmbH + co. kG<br />
see Packaging equipment 2.3<br />
Windhoff Bahn- und<br />
Anlagentechnik GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
ALUMINIUM · 9/2009<br />
� Cold rolling units /<br />
complete plants<br />
Kaltwalzanlagen/Komplettanlagen<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Drive systems / Antriebe<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Heating furnaces / Anwärmöfen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
Hier könnte Ihr<br />
Bezugsquellen- <br />
Eintrag<br />
stehen.<br />
Rufen Sie an:<br />
Tel. 0511 / 73 04-148<br />
Beate Schaefer<br />
L i e f e r v e r z e i c h n i s<br />
� Process optimisation systems<br />
Prozessoptimierungssysteme<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
� Process simulation<br />
Prozesssimulation<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Revamps, equipments & spare parts<br />
Revamps, equipments & spare parts<br />
Bruno presezzi SpA<br />
Via per Ornago 8<br />
I-20040 Burago Molgora (Mi) – Italy<br />
Tel. +39 039 63502 229<br />
Fax +39 039 6081373<br />
E-Mail: aluminium.<strong>de</strong>pt@brunopresezzi.com<br />
Internet: www.brunopresezzi.com<br />
Contact: Franco Gramaglia<br />
� Roll exchange equipment<br />
Walzenwechseleinrichtungen<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
Vollert Anlagenbau<br />
GmbH + co. kG<br />
see Packaging equipment 2.3<br />
Windhoff Bahn- und<br />
Anlagentechnik GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
73
L i e f e r v e r z e i c h n i s<br />
� Rolling mill mo<strong>de</strong>rnization<br />
Walzwerkmo<strong>de</strong>rnisierung<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
see Cold rolling units / complete plants 3.6<br />
� Slitting lines-CTL<br />
Längs- und Querteilanlagen<br />
see Cold rolling units / complete plants 3.6<br />
� Strip shears<br />
Bandscheren<br />
see Cold rolling units / complete plants 3.6<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Trimming equipment<br />
Besäumeinrichtungen<br />
see Cold rolling units / complete plants 3.6<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
3.7 Thin strip /<br />
foil rolling plant<br />
Feinband-/Folienwalzwerke<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
see Cold rolling units / complete plants 3.6<br />
SIGNo<strong>de</strong>® SySteM GMBH<br />
Packaging Equipment<br />
Non-Ferrous Specialist Team DSWE<br />
Magnusstr. 18, 46535 Dinslaken/Germany<br />
Telefon: +49 (0) 2064 / 69-210<br />
Telefax: +49 (0) 2064 / 69-489<br />
E-Mail: g.laks@signo<strong>de</strong>-europe.com<br />
Internet: www.signo<strong>de</strong>.com<br />
Contact: Mr. Gerard Laks<br />
� Coil annealing furnaces<br />
Bundglühöfen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
see Equipment and accessories 3.1<br />
schwartz GmbH<br />
see Cold colling equipment 3.6<br />
Seco/WArWIck S.A.<br />
see Heat treatment 2.4<br />
� Heating furnaces<br />
Anwärmöfen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
INotHerM INduStrIeoFeN-<br />
uNd WÄrMetecHNIk GMBH<br />
see Casthouse (foundry) 1.5<br />
� Thin strip / foil rolling mills /<br />
complete plant<br />
Feinband- / Folienwalzwerke /<br />
Komplettanlagen<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Revamps, equipments<br />
& spare parts<br />
Revamps, equipments & spare parts<br />
Bruno presezzi SpA<br />
Via per Ornago 8<br />
I-20040 Burago Molgora (Mi) – Italy<br />
Tel. +39 039 63502 229<br />
Fax +39 039 6081373<br />
E-Mail: aluminium.<strong>de</strong>pt@brunopresezzi.com<br />
Internet: www.brunopresezzi.com<br />
Contact: Franco Gramaglia<br />
� Rolling mill mo<strong>de</strong>rnization<br />
Walzwerkmo<strong>de</strong>rnisierung<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
3.9 Adjustment <strong>de</strong>vices<br />
Adjustageeinrichtungen<br />
� Sheet and plate stretchers<br />
Blech- und Plattenstrecker<br />
SMS Meer GmbH<br />
see Rolling bar machining 3.2<br />
� Cable sheathing presses<br />
Kabelummantelungspressen<br />
SMS Meer GmbH<br />
see Rolling bar machining 3.2<br />
74 ALUMINIUM · 9/2009
� Cable undulating machines<br />
Kabelwellmaschinen<br />
SMS Meer GmbH<br />
see Rolling bar machining 3.2<br />
� Transverse cutting units<br />
Querteilanlagen<br />
SerMAS INduStrIe<br />
E-Mail: sermas@sermas.com<br />
See Casting Machines 1.6<br />
3.10 Process technology /<br />
Automation technology<br />
Prozesstechnik /<br />
Automatisierungstechnik<br />
� Process control technology<br />
Prozessleittechnik<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
Wagstaff, Inc.<br />
ALUMINIUM · 9/2009<br />
see Casting machines 1.6<br />
Hier könnte Ihr<br />
Bezugsquellen- <br />
Eintrag<br />
stehen.<br />
Rufen Sie an:<br />
Tel. 0511 / 73 04-148<br />
Beate Schaefer<br />
� Strip thickness measurement<br />
and control equipment<br />
Banddickenmess- und<br />
-regeleinrichtungen<br />
ABB Automation technologies AB<br />
Force Measurement<br />
S-72159 Västeras, Swe<strong>de</strong>n<br />
Phone: +46 21 325 000<br />
Fax: +46 21 340 005<br />
E-Mail: pressductor@se.abb.com<br />
Internet: www.abb.com/pressductor<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Strip flatness measurement<br />
and control equipment<br />
Bandplanheitsmess- und<br />
-regeleinrichtungen<br />
ABB Automation technologies AB<br />
Force Measurement<br />
S-72159 Västeras, Swe<strong>de</strong>n<br />
Phone: +46 21 325 000<br />
Fax: +46 21 340 005<br />
E-Mail: pressductor@se.abb.com<br />
Internet: www.abb.com/pressductor<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
L i e f e r v e r z e i c h n i s<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
3.11 Coolant / lubricant<br />
preparation<br />
Kühl-/Schmiermittel-<br />
Aufbereitung<br />
� Rolling oil recovery and<br />
treatment units<br />
Walzöl-Wie<strong>de</strong>raufbereitungsanlagen<br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Filter for rolling oils and<br />
emulsions<br />
Filter für Walzöle und Emulsionen<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
� Rolling oil rectification units<br />
Walzölrektifikationsanlagen<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
75
L i e f e r v e r z e i c h n i s<br />
3.12 Air extraction systems<br />
Abluft-Systeme<br />
� Exhaust air purification<br />
systems (active)<br />
Abluft-Reinigungssysteme (aktiv)<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Siemag Aktiengesellschaft<br />
see Rolling mill technology 3.0<br />
� Filtering plants and systems<br />
Filteranlagen und Systeme<br />
dantherm Filtration GmbH<br />
Industriestr. 9, D-77948 Friesenheim<br />
Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245<br />
E-Mail: info.<strong>de</strong>@danthermfiltration.com<br />
Internet: www.danthermfiltration.com<br />
3.14 Storage and dispatch<br />
Lagerung und Versand<br />
SMS Siemag Aktiengesellschaft<br />
Logistiksysteme<br />
see Rolling mill technology 3.0<br />
3.16 Coil storage systems<br />
Bundlagersysteme<br />
SMS Siemag Aktiengesellschaft<br />
Logistiksysteme<br />
see Rolling mill technology 3.0<br />
Vollert Anlagenbau<br />
GmbH + co. kG<br />
see Packaging equipment 2.3<br />
3.17 Strip Processing Lines<br />
Bandprozesslinien � Strip Processing Lines<br />
Bandprozesslinien<br />
� Colour Coating Lines<br />
Bandlackierlinien<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
� Lithographic Sheet Lines<br />
Lithografielinien<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
see Cold rolling units / complete plants 3.6<br />
� Stretch Levelling Lines<br />
Streckrichtanlagen<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
� Strip Annealing Lines<br />
Bandglühlinien<br />
BWG Bergwerk- und Walzwerk-<br />
Maschinenbau GmbH<br />
Mercatorstraße 74 – 78<br />
D-47051 Duisburg<br />
Tel.: +49 (0) 203-9929-0<br />
Fax: +49 (0) 203-9929-400<br />
E-Mail: bwg@bwg-online.<strong>de</strong><br />
Internet: www.bwg-online.com<br />
could not find your „keywords“?<br />
please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
e-Mail:<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
3.18 Production<br />
Management systems<br />
Produktions Management<br />
Systeme<br />
4production AG<br />
Production Optimising Solutions<br />
Carlo-Schmid-Str. 12, D-52146 Würselen<br />
Tel.: +49 (0) 2405 4135-0<br />
info@4production.<strong>de</strong>, www.4production.com<br />
A PSI Group Company<br />
p.kapsali@giesel.<strong>de</strong><br />
76 ALUMINIUM · 9/2009
4 Foundry<br />
Gießerei<br />
4.1 Work protection and ergonomics<br />
4.2 Heat-resistant technology<br />
4.3 Conveyor and storage technology<br />
4.4 Mould and core production<br />
4.5 Mould accessories and accessory materials<br />
4.6 Foundry equipment<br />
4.7 Casting machines and equipment<br />
4.8 Handling technology<br />
4.9 Construction and <strong>de</strong>sign<br />
4.10 Measurement technology and materials testing<br />
4.11 Metallic charge materials<br />
4.12 Finshing of raw castings<br />
4.13 Melt operations<br />
4.14 Melt preparation<br />
4.15 Melt treatment <strong>de</strong>vices<br />
4.16 Control and regulation technology<br />
4.17 Environment protection and disposal<br />
4.18 Dross recovery<br />
4.19 Gussteile<br />
4.2 Heat-resistent technology<br />
Feuerfesttechnik<br />
� Refractories<br />
Feuerfeststoffe<br />
promat GmbH – techn. Wärmedämmung<br />
Scheifenkamp 16, D-40878 Ratingen<br />
Tel. +49 (0) 2102 / 493-0, Fax -493 115<br />
verkauf3@promat.<strong>de</strong>, www.promat.<strong>de</strong><br />
4.3 Conveyor and storage<br />
technology<br />
För<strong>de</strong>r- und Lagertechnik<br />
Vollert Anlagenbau<br />
GmbH + co. kG<br />
see Packaging equipment 2.3<br />
4.5 Mold accessories and<br />
accessory materials<br />
Formzubehör, Hilfmittel<br />
� Fluxes<br />
Flussmittel<br />
Solvay Fluor GmbH<br />
Hans-Böckler-Allee 20<br />
D-30173 Hannover<br />
Telefon +49 (0) 511 / 857-0<br />
Telefax +49 (0) 511 / 857-2146<br />
Internet: www.solvay-fluor.<strong>de</strong><br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
ALUMINIUM · 9/2009<br />
4.6 Foundry equipment<br />
Gießereianlagen<br />
� Casting machines<br />
Gießmaschinen<br />
� Heat treatment furnaces<br />
Wärmebehandlungsöfen<br />
see Foundry equipment 4.6<br />
� Solution annealing furnaces/plant<br />
Lösungsglühöfen/anlagen<br />
erNSt reINHArdt GMBH<br />
Postfach 1880, D-78008 VS-Villingen<br />
Tel. 07721/8441-0, Fax 8441-44<br />
E-Mail: info@ernstreinhardt.<strong>de</strong><br />
Internet: www.Ernst-Reinhardt.com<br />
L i e f e r v e r z e i c h n i s<br />
4.1 Arbeitsschutz und Ergonomie<br />
4.2 Feuerfesttechnik<br />
4.3 För<strong>de</strong>r- und Lagertechnik<br />
4.4 Form- und Kernherstellung<br />
4.5 Formzubehör, Hilfsmittel<br />
4.6 Gießereianlagen<br />
4.7 Gießmaschinen und Gießeinrichtungen<br />
4.8 Handhabungstechnik<br />
4.9 Konstruktion und Design<br />
4.10 Messtechnik und Materialprüfung<br />
4.11 Metallische Einsatzstoffe<br />
4.12 Rohgussnachbehandlung<br />
4.13 Schmelzbetrieb<br />
4.14 Schmelzvorbereitung<br />
4.15 Schmelzebehandlungseinrichtungen<br />
4.16 Steuerungs- und Regelungstechnik<br />
4.17 Umweltschutz und Entsorgung<br />
4.18 Schlackenrückgewinnung<br />
4.19 Cast parts<br />
see Equipment and accessories 3.1<br />
HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5<br />
see Billet Heating Furnaces 2.1<br />
Seco/WArWIck S.A.<br />
see Heat treatment 2.4<br />
4.7 Casting machines<br />
and equipment<br />
Gießereimaschinen<br />
und Gießeinrichtungen<br />
Molten Metall Level control<br />
Ostra Hamnen 7<br />
SE-430 91 Hono / Schwe<strong>de</strong>n<br />
Tel.: +46 31 764 5520, Fax: +46 31 764 5529<br />
E-Mail: info@precimeter.com<br />
Internet: www.precimeter.com<br />
Sales contact: Jan Strömbeck<br />
Wagstaff, Inc.<br />
see Casting machines 1.6<br />
� Mould parting agents<br />
Kokillentrennmittel<br />
Schrö<strong>de</strong>r kG<br />
Schmierstofftechnik<br />
Postfach 1170<br />
D-57251<br />
Freu<strong>de</strong>nberg<br />
Tel. 02734/7071<br />
Fax 02734/20784<br />
www.schroe<strong>de</strong>r-schmierstoffe.<strong>de</strong><br />
77
L i e f e r v e r z e i c h n i s<br />
4.8 Handling technology<br />
Handhabungstechnik<br />
Vollert Anlagenbau<br />
GmbH + co. kG<br />
see Packaging equipment 2.3<br />
� Manipulators<br />
Manipulatoren<br />
SerMAS INduStrIe<br />
E-Mail: sermas@sermas.com<br />
See Casting Machines 1.6<br />
4.9 Construction and<br />
Design<br />
Konstruktion und Design<br />
THERMCON OVENS BV<br />
� <strong>Alu</strong>minium alloys<br />
<strong>Alu</strong>miniumlegierungen<br />
ALerIS recycling (German Works) GmbH<br />
<strong>Alu</strong>miniumstraße 3<br />
D-41515 Grevenbroich<br />
Telefon +49 (0) 2181/16 45 0<br />
Telefax +49 (0) 2181/16 45 100<br />
E-Mail: recycling@aleris.com<br />
Internet: www.aleris-recycling.com<br />
MetALLHAN<strong>de</strong>LSGeSeLLScHAFt<br />
ScHooF & HASLAcHer MBH & co. kG<br />
Postfach 600714, D 81207 München<br />
Telefon 089/829133-0<br />
Telefax 089/8201154<br />
E-Mail: info@metallhan<strong>de</strong>lsgesellschaft.<strong>de</strong><br />
Internet: www.metallhan<strong>de</strong>lsgesellschaft.<strong>de</strong><br />
� Pre alloys / Vorlegierungen<br />
see Extrusion 2<br />
4.11 Metallic charge<br />
materials<br />
Metallische Einsatzstoffe<br />
MetALLHAN<strong>de</strong>LSGeSeLLScHAFt<br />
ScHooF & HASLAcHer MBH & co. kG<br />
Postfach 600714, D 81207 München<br />
Telefon 089/829133-0<br />
Telefax 089/8201154<br />
E-Mail: info@metallhan<strong>de</strong>lsgesellschaft.<strong>de</strong><br />
Internet: www.metallhan<strong>de</strong>lsgesellschaft.<strong>de</strong><br />
� Recycling / Recycling<br />
trIMet ALuMINIuM AG<br />
Nie<strong>de</strong>rlassung Gelsenkirchen<br />
Am Stadthafen 51-65<br />
D-45681 Gelsenkirchen<br />
Tel.: +49 (0) 209 / 94089-0<br />
Fax: +49 (0) 209 / 94089-60<br />
Internet: www.trimet.<strong>de</strong><br />
trIMet ALuMINIuM AG<br />
Nie<strong>de</strong>rlassung Harzgero<strong>de</strong><br />
<strong>Alu</strong>miniumallee 1<br />
06493 Harzgero<strong>de</strong><br />
Tel.: 039484 / 50-0<br />
Fax: 039484 / 50-100<br />
Internet: www.trimet.<strong>de</strong><br />
4.13 Melt operations<br />
Schmelzbetrieb<br />
� Heat treatment furnaces<br />
Wärmebehandlungsanlagen<br />
see Billet Heating Furnaces 2.1<br />
� Melting furnaces<br />
Schmelzöfen<br />
Büttgenbachstraße 14<br />
D-40549 Düsseldorf/Germany<br />
Tel.: +49 (0) 211 / 5 00 91-43<br />
Fax: +49 (0) 211 / 50 13 97<br />
E-Mail: info@bloomeng.<strong>de</strong><br />
Internet: www.bloomeng.com<br />
Sales Contact: Klaus Rixen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5<br />
see Equipment and accessories 3.1<br />
MArx GmbH & co. kG<br />
Lilienthalstr. 6-18<br />
D-58638 Iserhohn<br />
Tel.: +49 (0) 2371 / 2105-0, Fax: -11<br />
E-Mail: info@marx-gmbh.<strong>de</strong><br />
Internet: www.marx-gmbh.<strong>de</strong><br />
Seco/WArWIck S.A.<br />
see Heat treatment 2.4<br />
� Holding furnaces<br />
Warmhalteöfen<br />
Büttgenbachstraße 14<br />
D-40549 Düsseldorf/Germany<br />
Tel.: +49 (0) 211 / 5 00 91-43<br />
Fax: +49 (0) 211 / 50 13 97<br />
E-Mail: info@bloomeng.<strong>de</strong><br />
Internet: www.bloomeng.com<br />
Sales Contact: Klaus Rixen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
see Equipment and accessories 3.1<br />
Seco/WArWIck S.A.<br />
see Heat treatment 2.4<br />
78 ALUMINIUM · 9/2009
� Heat treatment furnaces<br />
Wärmebehandlungsanlagen<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
HertWIcH eNGINeerING GmbH<br />
see Casthouse (foundry) 1.5<br />
see Equipment and accessories 3.1<br />
Seco/WArWIck S.A.<br />
see Heat treatment 2.4<br />
4.14 Melt preparation<br />
Schmelzvorbereitung<br />
ceraflux India pvt. Ltd.<br />
F - 59 & 60, MIDC, Gokul Shirgaon,<br />
Kolhapur - 416 234. Maharastra (India)<br />
E-Mail: cerafluxindia@dataone.in<br />
cerafluxindia@gmail.com<br />
Web: www.ceraflux.com<br />
� Degassing, filtration<br />
Entgasung, Filtration<br />
drache umwelttechnik<br />
GmbH<br />
Werner-v.-Siemens-Straße 9/24-26<br />
D 65582 Diez/Lahn<br />
Telefon 06432/607-0<br />
Telefax 06432/607-52<br />
Internet: http://www.drache-gmbh.<strong>de</strong><br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
� Melt treatment agents<br />
Schmelzebehandlungsmittel<br />
Gautschi<br />
engineering GmbH<br />
see Casting equipment 3.1<br />
ALUMINIUM · 9/2009<br />
4.15 Melt treatment <strong>de</strong>vices<br />
Schmelzbehandlungseinrichtungen<br />
Metaullics Systems europe B.V.<br />
Ebweg 14<br />
NL-2991 LT Barendrecht<br />
Tel. +31-180/590890<br />
Fax +31-180/551040<br />
E-Mail: info@metaullics.nl<br />
Internet: www.metaullics.com<br />
4.16 Control and<br />
regulation technology<br />
Steuerungs- und<br />
Regelungstechnik<br />
� HCL measurements<br />
HCL Messungen<br />
opSIS AB<br />
Box 244, S-24402 Furulund, Schwe<strong>de</strong>n<br />
Tel. +46 (0) 46-72 25 00, Fax -72 25 01<br />
E-Mail: info@opsis.se<br />
Internet: www.opsis.se<br />
do you need<br />
more<br />
information?<br />
5<br />
E-Mail:<br />
P.Kapsali@giesel.<strong>de</strong><br />
L i e f e r v e r z e i c h n i s<br />
4.17 Environment protection<br />
and disposal<br />
Umweltschutz und<br />
Entsorgung<br />
� Dust removal / Entstaubung<br />
NeotecHNIk GmbH<br />
Entstaubungsanlagen<br />
Postfach 110261, D-33662 Bielefeld<br />
Tel. 05205/7503-0, Fax 05205/7503-77<br />
info@neotechnik.com, www.neotechnik.com<br />
� Flue gas cleaning<br />
Rauchgasreinigung<br />
dantherm Filtration GmbH<br />
Industriestr. 9, D-77948 Friesenheim<br />
Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245<br />
E-Mail: info.<strong>de</strong>@danthermfiltration.com<br />
Internet: www.danthermfiltration.com<br />
4.19 Cast parts / Gussteile<br />
trIMet ALuMINIuM AG<br />
Nie<strong>de</strong>rlassung Harzgero<strong>de</strong><br />
<strong>Alu</strong>miniumallee 1<br />
06493 Harzgero<strong>de</strong><br />
Tel.: 039484 / 50-0<br />
Fax: 039484 / 50-100<br />
Internet: www.trimet.<strong>de</strong><br />
Materials and Recycling<br />
Werkstoffe und Recycling<br />
<strong>Alu</strong>-<strong>web</strong>.<strong>de</strong><br />
<strong>de</strong>r ALUMINIUM-<br />
Branchentreff.<br />
Haben Sie schon Ihren<br />
Basiseintrag bestellt?<br />
Nein, dann sofort anrufen:<br />
0511/73 04-142<br />
Panagiota Kapsali<br />
� Granulated aluminium<br />
<strong>Alu</strong>miniumgranulate<br />
eckA Granulate Austria GmbH<br />
Bürmooser Lan<strong>de</strong>sstraße 19<br />
A-5113 St. Georgen/Salzburg<br />
Telefon +43 6272 2919-12<br />
Telefax +43 6272 8439<br />
Kontakt: Ditmar Klein<br />
E-Mail: d.klein@ecka-granules.com<br />
79
L i e f e r v e r z e i c h n i s<br />
6<br />
Machining and Application<br />
Bearbeitung und Anwendung<br />
� Machining of aluminium<br />
<strong>Alu</strong>miniumbearbeitung<br />
Haarmann Holding GmbH<br />
see Die preparation and care 2.6<br />
6.1 Surface treatment<br />
processes<br />
Prozesse für die<br />
Oberflächenbehandlung<br />
Henkel AG & co. kGaA<br />
D-40191 Düsseldorf<br />
Tel. +49 (0) 211 / 797-30 00<br />
Fax +49 (0) 211 / 798-23 23<br />
Internet: www.henkel-technologies.com<br />
� Adhesive bonding / Verkleben<br />
Henkel AG & co. kGaA<br />
siehe Prozesse für die Oberflächentechnik 6.1<br />
� Anodising / Anodisation<br />
Henkel AG & co. kGaA<br />
siehe Prozesse für die Oberflächentechnik 6.1<br />
� Cleaning / Reinigung<br />
Henkel AG & co. kGaA<br />
siehe Prozesse für die Oberflächentechnik 6.1<br />
� Joining / Fügen<br />
Henkel AG & co. kGaA<br />
siehe Prozesse für die Oberflächentechnik 6.1<br />
� Pretreatment before coating<br />
Vorbehandlung vor <strong>de</strong>r Beschichtung<br />
Henkel AG & co. kGaA<br />
siehe Prozesse für die Oberflächentechnik 6.1<br />
6.2 Semi products<br />
Halbzeuge<br />
� Wires / Drähte<br />
drAHtWerk eLISeNtAL<br />
W. erdmann GmbH & co.<br />
Werdohler Str. 40, D-58809 Neuenra<strong>de</strong><br />
Postfach 12 60, D-58804 Neuenra<strong>de</strong><br />
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044<br />
E-Mail: info@elisental.<strong>de</strong><br />
Internet: www.elisental.<strong>de</strong><br />
could not find your „keywords“?<br />
please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
telefon:<br />
0411/7304-142<br />
panagiota kapsali<br />
6.3 Equipment for forging<br />
and impact extrusion<br />
Ausrüstung für Schmie<strong>de</strong>und<br />
Fließpresstechnik<br />
� Hydraulic Presses<br />
Hydraulische Pressen<br />
LASco umformtechnik GmbH<br />
Hahnweg 139, D-96450 Coburg<br />
Tel. +49 (0) 9561 642-0<br />
Fax +49 (0) 9561 642-333<br />
E-Mail: lasco@lasco.<strong>de</strong><br />
Internet: www.lasco.com<br />
8 Literature<br />
Literatur<br />
� Technikcal literature<br />
Fachliteratur<br />
taschenbuch <strong>de</strong>s Metallhan<strong>de</strong>ls<br />
Fundamentals of extrusion technology<br />
Giesel Verlag GmbH<br />
Verlag für Fachmedien<br />
ein unternehmen <strong>de</strong>r klett-Gruppe<br />
Rehkamp 3 · 30916 Isernhagen<br />
Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157<br />
Internet: www.alu-bookshop.<strong>de</strong>.<br />
� Technical journals<br />
Fachzeitschriften<br />
Giesel Verlag GmbH<br />
ein unternehmen <strong>de</strong>r klett-Gruppe<br />
Rehkamp 3 · 30916 Isernhagen<br />
Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157<br />
80 ALUMINIUM · 9/2009
International<br />
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Nielsen-Gebiet 3 b (Ba<strong>de</strong>n-Württemberg):<br />
G. Fahr, Verlags- und Pressebüro e. K.<br />
Marktplatz 10, 72654 Neckartenzlingen<br />
Tel: 0 71 27/30 84<br />
Fax: 07127/2 14 78<br />
E-Mail: info@verlagsbuero-fahr.<strong>de</strong><br />
Nielsen-Gebiet 4 (Bayern):<br />
G. Fahr, Verlags- und Pressebüro e.K.<br />
Marktplatz 10, 72654 Neckartenzlingen<br />
I M P R E S S U M / I M P R I N T<br />
Tel: 0 8362/5054990<br />
Fax: 08362/5054992<br />
E-Mail: info@verlagsbuero-fahr.<strong>de</strong><br />
Nielsen-Gebiet 5, 6 + 7 (Berlin, Mecklenburg-Vorpommern,<br />
Bran<strong>de</strong>nburg,<br />
Sachsen-Anhalt Sachsen, Thüringen):<br />
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Scandinavia, Denmark,<br />
Netherlands, Belgium, Luxembourg<br />
multilexa GmbH, publisher services<br />
Linsenhofer Straße 51, 98529 Suhl,<br />
Germany<br />
Tel: +49 (0)3681/4550478<br />
Fax: +49 (0)3681/4553042<br />
E-Mail: thomas.werner@multilexa.com<br />
www.multilexa.com<br />
Switzerland<br />
JORDI PUBLIPRESS<br />
Postfach 154 · CH-3427 Utzenstorf<br />
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Fax +41 (0)32 666 30 99<br />
E-Mail: info@jordipublipress.ch<br />
www.jordipublipress.ch<br />
Austria<br />
Verlagsbüro Katrin Forstner<br />
Wiengasse 6/7/3, A-1140 Wien<br />
Tel: +43(0)1 9235352<br />
Fax: +43(0)1 9 797189<br />
E-Mail: katrin.forstner@chello.at<br />
Italy<br />
MEDIAPOINT & COMMUNICATIONS<br />
SRL<br />
Corte Lambruschini – Corso Buenos<br />
Aires, 8<br />
Vo piano – Interno 7, I-16129 Genova<br />
Tel: +39(0)10 5 70 49 48,<br />
Fax: +39(0)10 5 53 00 88<br />
E-Mail: info@mediapointsrl.it<br />
www.mediapointsrl.it<br />
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GCC countries etc.<br />
Marketing Xpertise Rieth<br />
Dipl.-Ing. Bernhard Rieth<br />
Strümper Berg 10, D-40670 Meerbusch<br />
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Fax: +49 (0)2159 962 644<br />
E-Mail: marketing.xpertise@t-online.<strong>de</strong><br />
United Kingdom<br />
Marketing Xpertise Rieth<br />
Dipl.-Ing. Bernhard Rieth<br />
Strümper Berg 10, D-40670 Meerbusch<br />
Tel: +49 (0)2159 962 643<br />
Fax: +49 (0)2159 962 644<br />
E-Mail: marketing.xpertise@t-online.<strong>de</strong><br />
France<br />
DEF & Communication<br />
Axelle Chrismann<br />
48 boulevard Jean Jaurès<br />
F-92110 Clichy<br />
Tel: +33 (0)1 47 30 71 80,<br />
Fax: +33 (0)1 47 30 01 89<br />
E-Mail: achrismann@wanadoo.fr<br />
Der ALUMINIUM-Branchentreff <strong>de</strong>s<br />
Giesel Verlages: www.alu-<strong>web</strong>.<strong>de</strong><br />
81
V O R S C H A U / P R E V I E W<br />
IM NÄCHSTEN HEFT<br />
Special: <strong>Alu</strong>miniumbearbeitung<br />
Neue Entwicklungen und Trends. Verfahren, Werkzeuge<br />
und Maschinen. Geplante Beiträge:<br />
• Portalfräsmaschine für die Bearbeitung von<br />
<strong>Alu</strong>miniumblöcken und -blechen<br />
• Kombinierte Bohr-/Fräsanlage zur Endbearbeitung<br />
von Karosserien<br />
• Halb- und vollautomatische Gehrungssägen in<br />
größeren Abmessungen<br />
Technologie<br />
• Energieeffizienz bei <strong>de</strong>r Erzeugung und <strong>de</strong>m<br />
Verbrauch von Druckluft, am Beispiel <strong>Alu</strong>norf<br />
Weitere Themen<br />
• Aktuelles aus <strong>de</strong>r Branche; Kurzberichte<br />
Erscheinungstermin: 5. Oktober 2009<br />
Anzeigenschluss: 18. September 2009<br />
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IN THE NEXT ISSUE<br />
Special: Machining of aluminium<br />
New <strong>de</strong>velopments and trends. Process technology,<br />
tools and machinery. Subjects covered inclu<strong>de</strong>:<br />
• Portal milling machine for aluminium slabs<br />
and sheet<br />
• Combined milling and drilling facility for the<br />
final machining of car body<br />
• Semi and fully automatic vertical miter bandsaws<br />
for precise mitre cuts<br />
Technology<br />
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Other topics<br />
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Fax: +49 (0) 511 73 04 157<br />
Date of publication: 5 October 2009<br />
Advertisement <strong>de</strong>adline: 18 September 2009<br />
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82 ALUMINIUM · 9/2009
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Postco<strong>de</strong>, city<br />
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Giesel Verlag GmbH<br />
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30907 Isernhagen · Germany<br />
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