Historic Cover Archive
2015 to 2013
2015 to 2013
Caption: Installation of a ShurCast™ 450S casting machine in 2014 at the new R&D Center at Wagstaff, Inc. in Spokane, WA is shown. The R&D Center was largely under wraps until the recent Casting Confidence Week in September 2015 when an industry first occurred. Attendees at the convention center in downtown Spokane were able to view the first ever automated casting of an ingot at the R&D Center using a video monitoring system initiated from a remote location (see article page 32). The casting cylinder (pictured) accommodates a 7 m cast. Production size billet and ingot in common and aerospace alloys can be cast in the 2,322 sq m center, which also includes a state-of-the-art furnace, filtration, casting, and water quality systems.
Caption: The multitude of useful, versatile, and attractive aluminum applications/markets present in our every day lives are pictured in this scene of Detroit, MI. From top left, clockwise: planes/aerospace, skyscrapers/buildings and construction, space launch vehicles, bicycles, smart watches, automobiles, cans, cameras, boats/marine, cellular phones, and trains. Aluminum is truly an extraordinary metal! (Artist: Thomas Fielding)
Caption: View inside Air Products’ Combustion Lab test furnace during adjustable heat release oxyfuel burner firing. Oxyfuel burner modeling at various set points helped determine the burner best suited for Sapa Extrusions. Sapa used oxyfuel technology in a novel application to boost productivity of a regen-fired reverb furnace in their casthouse in Cressona, PA. See story beginning on page 20.
Caption: The London Gateway Port Terminal in Essex, U.K., utilizes an external frameless aluminum curtainwall system that allows sunlight within the building, reducing reliance on interior lights during the daylight hours. Daylighting is just one of the ways aluminum windows can improve the environmental performance of a structure in the aim to construct zero energy buildings. See article beginning on page 6. (Photo: Sapa Group.)
Caption: Collaboration between Litelab Corporation and Almag Aluminum of Brampton, ON, Canada, yielded this highly engineered heatsink for a high-powered LED. Designed to handle thermal loads over 40 W without forced convection, this fixture is capable of producing 5,000 lumens. The complex extrusion shown in both clear and black anodized utilizes a tailored alloy, serrated cooling fins, and enhanced geometry to achieve optimal heat dissipation.
Caption: Pot tending machine using the crust breaker during an anode change at Qatalum.
Caption: Only 15 µm thick but completely free from grease in the as-rolled condition, the aluminum foil pictured was produced at Hydro's Grevenbroich rolling mill in Germany. Previously material could only be cleaned of residual rolling oil by undergoing heat treatment. Hydro announced earlier this year a sophisticated bath process whereby foil can be chemically degreased yet still retain the original degree of hardness. (Photo credit: Hydro Aluminium)
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.