Billet stacked and ready for shipment
at Aluminicaste, Guanajuato State, Mexico.
The February 2014 issue of Light Metal Age features an article on the new aluminum greenfield remelt facility located in Guanajuato State, Mexico. Aluminicaste is close to full production capacity, producing primarily extrusion billet, but also capable of manufacturing world class rolling ingot and forging/large press billet, in both hard and soft alloys on their two DC casting lines. This product mix and the ability to cast both hard and soft alloys make the Aluminicaste plant unique in the flexibility of products it can produce.
This article, which Aluminicaste has made this article available as a free download via its website, describes the concepts of the location, plant configuration, and market focus for what has been completed in this initial phase, as well as the expansion potential that will take the plant from the largest remelt in Mexico to being one of the largest operations of its kind on the entire North America continent.
Keep informed about the aluminum casting, extrusion, and flat rolled aluminum industry by subscribing to Light Metal Age!
Ford has performed extreme testing on the new aluminum bodied F-150 trucks to ensure the durability of the trucks over long term, rugged use. These tests range from acid baths to slamming its doors and tailgates to towing trailers over mountain passes. “We wanted to build the toughest, most capable F-150, while making it as much as 700 pounds lighter,” said Pete Reyes, Ford F-150 chief engineer. “We challenged the team to torture the truck harder than any F-150 before it.”
Before the first 2015 F-150 rolls off the assembly line at the end of the year, it will have been subjected to 10 million miles of combined real-world and simulated durability testing. A few of the torture tests performed are presented below.
Torture Tests: Seven Channel
Ford built a special torture rack that violently twists and shakes the truck seven ways – simultaneously – for five days, simulating the equivalent of 225,000 miles. This testing isn’t random. After running a fully instrumented truck through durability courses, engineers recorded the forces the road surface put on various vehicle components. Those forces are replicated in seven channels – four up and down, two side to side and one lengthwise down the center. The frame and body are stressed to see how well the truck performs in situations that might bend the frame.
Torture Tests: Drum Drop
Ford engineers dropped 55-gallon drums into the bed of the truck on an angle, making sure all of the force came down on the sharp rim of the drum. Engineers in Dearborn, Michigan, then measure the impact and make adjustments until the cargo box floor is suitably tough.
Torture Tests: Corrosion Bath
An advantage aluminum has over steel is that it doesn’t produce red rust. So Ford had to go beyond the usual tests that include driving vehicles through countless salt baths and soaking them in high-humidity chambers. The company developed a modified corrosion test using an acidified spray to be more aggressive on the high-strength, aluminum alloy. After simulating 10 years of exposure, the aluminum material showed virtually no signs of degradation.
More information on the torture tests performed, along with videos can be found on Ford’s media website.
The Blue Planet features Novelis aluminum cladding.
The Blue Planet
National Aquarium Denmark, Den Blå Planet (the Blue Planet), is Northern Europe’s largest aquarium with more than 20,000 animals and seven million litres of water. Inspired by the circulating currents of a whirlpool, the10,000-square meter building’s architecture is clad with Novelis aluminum. More than 27,000 square meters of coated aluminum were processed into 40,000 uniformly shaped shingles for use in the construction of the Blue Planet. Thee shingles were attached to the building using stainless steel clips, which allow it to form a continuous, flowing façade.
Aluminum was selected to clad the building due to the quality and durability of the material. The seawater-resistant alloy Novelis C4S, used for decades in extreme climates, was an essential feature that impacted the architects’ decision. For a natural aluminum look, a clear lacquer was used on the coil-coated aluminum. Also, aluminum also poses no risk for ground water pollution and can collect rain water for use in the aquarium without the need for purification.
When it opened its doors in early 2013, the Blue Planet replaced Denmark’s original aquarium, which was constructed in 1939.
Novelis announced at the 2014 Craft Brewers Conference in Denver that Red Hare Brewing Company will launch the world’s first commercial use of evercan, the company’s independently certified high-recycled content (90%) aluminum sheet for beverage cans (certified by by SCS Global Services). Red Hare craft beer packaged exclusively in cans made of evercan sheet is expected to be on store shelves beginning in May 2014 throughout the southeastern U.S.
“Novelis’ evercan is a perfect fit for Red Hare,” noted Roger Davis, founder and ceo of Red Hare Brewing Company. “The independent certification of the closed-loop recycling process behind evercan strengthens our commitment to employing the best in sustainable business practices, making evercan a natural extension of the Red Hare brand.”
Red Hare, one of the fastest-growing micro-breweries in the U.S., selected evercan aluminum as part of its commitment to reduce the company’s environmental footprint, while preserving the freshness and taste of its finely crafted beer. It was the first craft brewery in Georgia to package its products in aluminum cans, following a trend in the micro-brewery industry to move from bottles to cans as a way to expand distribution and appeal to on-the-go consumers. Nearly 400 craft brewers in nearly every state in the U.S. are canning more than 1,300 different beers.
“Novelis’ evercan is an excellent model for sustainability-based innovation, which will enable beverage brands and retailers to advance their own sustainable packaging goals,” said Stuart L. Hart, the S.J. Johnson professor emeritus in Sustainable Global Enterprise, Cornell University, founder of the Enterprise for a Sustainable World and author of Capitalism at the Crossroads. “This introduction also serves as an important catalyst to educate other brand holders and consumers about the value of closed-loop aluminum recycling and engage them to take action themselves.”
Davis further explains to use Red Hare Brewing’s choice to use evercan sheet in the following video.
The April 2014 annual aluminum extrusion issue of Light Metal Age is now available. The digital edition has been released to subscribers and the print edition will be shipped next week.
The cover features a 39 hollow aluminum extrusion for a heat exchanger that was made by Almag Aluminum in Brampton, Ontario, Canada, an extruder known for designing and extruding complex shapes. The extrusion die was manufactured by Exco Canada in Markham, Ontario. (Photo: Robert Ciolfi.)
Feature Articles include:
- “What Kind of Extruder Are You? – Self Planning Matrix for Benchmarking Extrusion Operations,” by Craig Werner, Werner Extrusion Solutions, LLC
- “Southern Aluminum Finishing Goes West – New Anodizing Line Opened in Redding, CA”
- “The Impact of Methodological Choices on the LCA Results of Aluminum Extrusion Products,” by Marshall Jinlong Wang, The Aluminum Association
- “Outlook on Aluminum Extrusion Die Industry from an Italian Die Maker, Interview with Tommaso Pinter, Alumat & Almax Mori“
- “Saws for Billet and Extrusion Operations,” by Roger A.P. Fielding, BENCHMARKS
- “Arabal 2013 – Part II: Downstream Development in the Gulf,” by contributing editor, Andrew Hall (photos of exhibitors are online)
- “Gearing Up Aluminum Extrusions for Automotive, Interview with Matthias Kapp, Sapa Extrusions North America“
- “Global Flat Rolled Product Long Term Outlook: Automotive and Aerospace to Drive Growth,” by Goran Djukanovic, Aluminum Market Analyst
- “Novatec Celebrates 20 Years of Service to Aluminum Extruders”
- “AEC 2014 Annual Meeting Illuminates N.A. Extrusion“
- Directory of Aluminum Extrusion Equipment Manufacturers & Suppliers
Editorial departments include a story on the American Lightweight Metals Manufacturing Initiative announced by President Obama and a Product Spotlight on the ExtSTAR™ quoting module. Other coverage include the Extruder News and Contracts & Expansions, as well as our International Patent Calendar.
If you would like to receive a copy of the April issue, as well as future issues of Light Metal Age, you can subscribe online.
Titanium 2014, the 30th Anniversary Conference, will be held September 21-24, 2014 at the Hilton Chicago in Chicago, IL. The gathering offers a full spectrum of information on the latest business, technology, and market trends and developments in the global titanium industry and is designed to suit the needs of titanium industry professionals, suppliers, customers, and stakeholders. It provides an excellent forum for expert discussions, continuing education, networking opportunities, and more.
Conference attendees typically hold executive positions in areas such as management, sales and marketing, product development, procurement, engineering and design, purchasing and quality control. The 2013 event drew a record attendance of 1,180 guests from 28 countries.
Call for Papers
International Titanium Association (ITA) invites ITA members, non-members, and acedemia to submit abstracts by e-mail to firstname.lastname@example.org for consideration by the conference organizing committee. Only abstracts written in English will be considered.
Sufficient detail for fair evaluation of the proposed paper and presentation should be included along with an indication which of the following session(s) the presenter would prefer to participate in: Raw Materials; Alternative Energy; Commercial Aerospace; Military/Defense; Automotive; Medical; Industrial Markets; Economy/Finance; Energy Exploration and Production; Manufacturing Technology; New Materials; Consumer Markets; Architectural; Welding & Joining; Medical Applications.
Call for Papers Deadline is June 16, 2014.
Questions may be directed to the ITA at 1-303-404-2221 or by email at email@example.com.