Historic Cover Archive
1989 to 1987
1989 to 1987
Caption: New, Japanese billet caster near Toyama, illustrates industry trend toward larger capacity DC casting stations. Toyama Alloys Limited's new billet caster casts 108 strands of 6" diameter billet The facility was successfully commissioned on October 17, 1989, and has an operating capacity of 120,000 MT per annum. The casting machine shown was built by the Misawa-Van Company (Tokyo, Japan), and is equipped with the AirSlip billet casting technology supplied by Wagstaff Engineering, Inc., (Spokane, Washington, USA).
Caption: Aluminum holding furnace completely lined with monolithic nonwetting low cement refractory castables.
Caption: A rolling ingot sawing line at Howmet Aluminum (Alumax) in Lancaster, Pennsylvania.
Caption: Aluminum mill photos courtesy of Achenbach Buschhutten: (1) 1888 first complete rolling mill. (2) 1918 first complete aluminum two-high rolling milltrain. (3) 1919 first lift-over type two-high sheet rolling mill. (4) 1921 first three-high sheet rolling mill. (5) 1924 first aluminum two-high reversing mill with cable pullers. (6) 1927 first three-high strip rolling mill. (7) modifications of two-high to three-high mills. (8) 1934 first foil rolling mill wilh friction coilers. (9)1938 heavy duty two-high cold rolling mill with (10) jumping jacks. (11) 1950 the uncompleted foil mill. (12 and 13 not shown). (14) 1952 first modern four-high aluminum strip rolling mill. (15) 1954 first four-high reversing strip mill lor copper and brass. (16) 1956 first complete aluminum rolling plant installation.
Caption: Production of new aluminum-based composite material. Top row: Casting of MMC foundry ingots; close-up of the first-ever direct-chill (DC) casting of an MMC extrusion billet. Bottom row: Cast billet being head-stamped; MMC materials staged for shipment. The background is a photomicrograph (320X) of a polished specimen, showing the uniform distribution of particles in the matrix (15 vol% A1203 in 6061 aluminum). (Dural Aluminum Composites Corporation, San Diego.)
Caption: Artist's rendition of the National Aerospace Plane (NASP) in flight. The colors shown reflect the actual temperatures to be encountered by this vehicle. Titanium based materials will account for a large proportion of the airframe and engine.
Caption: Hoisted aloft by a crane operator at Warrick Operations, this 14-ton aluminum ingot will be rolled into thin sheet. Produced in an electromagnetic caster (EMC) which uses a powerful magnetic field to confine the molten metal until it cools, this new technology provides a smoother ingot surface which requires little or no scalping. (Photograph courtesy of the Aluminum Company of America.)
Caption: Aluminum alloy extrusion billet "Air Slip" mold system by Wagstaff Engineering on "Loma-Mann" direct chill casting machine supplied by Wellman Furnaces to Dubai Aluminum. (Courtesy of Dubai Aluminum Company, Dubai, United Arab Emirates).
Caption: The new AX-S hard aluminum spacesuit developed by NASA Ames researcher, Hubert E. "Vic" Vykukal.
Caption: Euramax's new 2500 metric ton extrusion press in The Netherlands. This plant is considered one of Europe's most sophisticated. Computer software integrates and controls every step of the extrusion process, from billet preparation to profile out-transport.
Caption: Withdrawing rolling ingot from the electromagnetic casting installation in the South Ingot plant of Alcoa's Tennessee operations.
Caption: Accumulator at Alcoa's Tennessee operations stores 4 minutes of sheet with mill running at 5000 fpm.
Caption: Euramax Coated Products' new 63 inch paint line in The Netherlands. Seen from the coil-payoff end it can handle aluminum, galvalume, or steel substrates.
Caption: National Aluminum's computerized paint line at Anniston, Alabama. The paint line is capable of painting vertical extrusions up to 30 feet in length. (Picture courtesy of Edward J. Klein, National Intergroup Inc., Pittsburg, Pennsylvania.)
Caption: Sheet ingots are cast by direct chill at Commonwealth Aluminum, Lewisport. Kentucky. Having a capacity of 90,000 lbs. per cast, the casters employ a tilt-type mold carriage and an internally guided singleacting hydraulic main cylinder of 21" bore. Each casting machine is powered by a 50 hp hydraulic drive. The casting stations were built by Loma Machine, a Hill Acme Company.
Caption: An operator checks a monitor displaying thickness of aluminum strip on a light-gauge slitting line at the new Logan Aluminum plant at Russellville, Kentucky. Accuracy of strip thickness is held to within ±0.1 percent with the use of AccuRay 7000 Micro measuring system.
Caption: This 50,000-ton forging press at Wyman-Gordon Company's Worcester, Massachusetts, plant produces large airframe components from aluminum and titanium. Put in operation in 1955, it is one of the largest in the world and was a part of the Air Force's heavy press program. It was purchased by Wyman-Gordon in 1982. See story on filtration of ingot poured for the press.