Historic Cover Archive
2014 to 2012
2014 to 2012
Caption: The Lotus Evora sports car features a multi-material structure utilizing aluminum, steel, and composite materials. The chassis is primarily constructed of aluminum sheet and extrusions joined using adhesive bonding and self-piercing rivets (a process called riv-bonding) for the front and center modules and a steel rear structure to support the engine and suspension. Lotus uses a variety of innovative joining technologies in the design of its multi-material vehicles. For more information on automotive joining, see the article on page 18.
Caption: SMS Meer's Axel Bauer (left), general manager of extrusion press sales, and Uwe Muschalik (right), general manager of hydraulic press R&D and technology, in front of the newly built HybrEx 25, the radically different 25 MN extrusion press designed by the SMS Meer R&D and Technology Group headed by Muschalik. See story on page 24.
Caption: Take-charge extruder Bonnell Aluminum in Newnan, GA, installed a new start-of-the-art extrusion line engineered to automotive specifications. The newly installed double runout table is part of a complete handling system supplied by Turla, Italy. For the complete story of the $17 million expansion project see page 6.
Caption: This 39 hollow aluminum extrusion for a heat exchanger 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.)
Caption: Aluminicaste is an aluminum greenfield remelt facility located in Central Mexico now close to full production capacity. The plant casts mainly extrusion billet as well as rolling ingot and forging/large press billet on two DC casting lines, in both hard and soft alloys. An initial phase has been completed but expansion potential is expected to take the plant to become one of the largest operations of the kind in North America. Pictured is the Aluminicaste team.
Caption: The new Diamond cold mill installed at Aleris Duffel in Belgium is a single stand 6-Hi mill specifically tailored for production of wide auto body sheet (WABS). Supplied by Danieli in cooperation with Innoval Technology, the new mill meets all of the criteria for production of WABS, including the ability to produce both standard mill finishes and electric discharge (EDT) finishes. For more information, see article on page 10.
Caption: The 2013 McLaren 12C GT high-performance sports car achieves light weight, high power, and high efficiency. Use of aluminum in the 12C for the crashbox, engine, engine mount, and other parts provides more than just weight reduction. Extrusions in the crash box are fabricated with the optimal structural shape in order to absorb impact during an accident (see story page 22). Technologies used in the premium market tend to lead mass-market development, according to Mark White, Jaguar Land Rover (JLR). White shows how aluminum is paving the way, as exemplified in JLR’s latest entry level premium sedan to roll out in 2015 (see story page 48).
Caption: This large, 6 x 7 inch aluminum extruded rectangular bar is one of Service Center Metals (SCM) 6061 Manifold Thunder Bar products. The Virginia extruder tailors its soft alloy extrusion products solely for service center customers. Premium bar products are designed for superior machineability with elevated mechanical properties and commercial dimensional tolerances. At their ten year anniversary mark, SCM has also begun building a compact remelt plant. See story on page 18.
Caption: This large friction stir welding machine, located at the Rock Island Arsenal in Illinois, can weld extrusions that are as much as 55 ft long and is the only machine in North America capable of two-sided panel welds.
Caption: The sheared face of a “hub” extrusion die used to connect several drawn tubes together to form a tent system. This is the first die that was run at the Alfiniti drawn tube operation in Winton, NC. Alfiniti expanded through investment in equipment to supply their internal tube bloom feedstock. See story beginning on page 6. (Photo by J.D. Schloz)
Caption: View down potline 6 of UC Rusal’s Volgograd smelter in Russia. There are 84 pots in this potroom, each pot producing 1.2 tonnes of aluminum per day. Volgograd has been undergoing a modernization, set to be complete in the first quarter of 2013, that will enable the smelter to increase slab output. Learn about this and other developments in the primary aluminum industry, beginning on page 9.
Caption: The hot roughing mill at Xiamen Xiashun Aluminum Foil Co. Ltd. is located in Fujian province in southeastern China. Xiashun has a 1+1 hot mill with a roughing and finishing stand, as well as a single-stand cold mill for the production of 2,150 mm wide strip. Xiashun mills provide an annual production capacity of 200,000 tons. For more information go to page 50.
Caption: Assembly of the all-new Range Rover at the Jaguar Land Rover manufacturing facility in Solihull, U.K., showing the aluminum stamped side structure. The 2013 Range Rover is now the first SUV with an all-aluminum body structure. Novelis supplied AC-300 alloy aluminum sheet for body structural components in crash relevant areas, including the longitudinal beams in the front end assembly, the reinforcements of the underbody, and structural components in the rear end of the vehicle. For more information about the use of aluminum in the new Range Rover, and other light vehicles, see page 32. (Photo: ©Jaguar Land Rover)
Caption: "Aluminum Man" emerges from an aluminum ingot. Sculpture made of 100% recycled aluminum unveiled at the inauguration of Novelis Global R&T Center in Atlanta, GA.
Caption: Inside the paint booth at Frontera Aluminios looking up at extrusions newly painted by the just installed vertical disk painting system in the Tecate, Mexico facility.
Caption: COVER: Before billets are removed from the new casting pit at Sapa's Cressona facility, the chief caster stencils the cast order number onto the cast log. At a time when demand for billet is increasing, Sapa is making significant investments to increase their casting capacity.
Caption: View of the entrance of a hollow extrusion die. Photo courtesy of Compes Group.