Historic Cover Archive
2009 to 2007
2009 to 2007
Caption: Erection of the new aluminum hot strip mill and cold rolling complex in progress at Xiamen Xiashun located in China’s southeastern province of Fujian. Xiamen Xiashun will increase its upstream rolling facilities by 200,000 tpy with this expansion coming onstream in 2010.
Caption: Photo shows the V8 aluminum engine (weighing 204 lbs) for the 2010 Chevrolet Camaro (printed with permission ©GM Comp.). Engines continue to be the highest volume component for aluminum in automotive applications. The Camaro contains 10% aluminum by vehicle curb weight, including engine blocks and heads, pistons, hood, wheels, transmission housing, differential housings, and brake calipers. Both aluminum and magnesium have shown steady growth in automotive since the 1970s. A number of forming technologies as well as improvements in material properties and cost will increase their greater use inthe future.
Caption: The F-35 Lightning II Joint Strike Fighter (JSF) is a highly advanced stealth aircraft. Its development program represents the largest defense project to date with nine partnering countries. As titanium is a key component in the JSF, the program is primed to boost the titanium industry, particularly in Australia. (Photo courtesy of Lockheed Martin.)
Caption: While billets are removed from the pit at Alexin’s new casthouse in Bluffton, Indiana, casting personnel perform routine between-cast tasks, such as inspecting billet molds, checking the casting rings for imperfections, and coating the t-plates with a release agent. The novel casting station configuration allows access to the molds by tilting the table away from the casting pit, improving pit turnaround efficiency and enhancing operator safety. The Alexin greenfield facility is the newest aluminum extrusion billet casthouse in North America.
Caption: Weseralu GmbH installed the first magnetic billet heater put into industrial operation at their extrusion facility in Minden, Germany.
Caption: The new 170,000 tpy potline at UC Rusal’s Irkutsk smelter installed February 2008 not only boosts capacity, but also improves the overall environmental performance of the smelter.
Caption: From rolled sheet to valuable recycled content, used beverage cans (UBCs) are a major source of supply for the U.S. aluminum industry. However, too many UBCs have ended up in landfill as the current U.S. recycling rate of 54% attests. Due to the culmination of industry wide efforts, which include new technology to extract UBCs before they become part of the waste stream, The Aluminum Association has now, with confidence, announced a new target goal of 75% by 2015.
Caption: Photo shows the Tesla Roadster, designed by Tesla Motors Inc. The Roadster features an aluminum extruded chassis, and the company’s new Model S will carry even more aluminum. (Printed with permission, courtesy of Tesla Motors Inc.)
Caption: Photo shows a common and daily practice of removing dross from an aluminum melting furnace by means of skimming with a forklift operated cleaning rake. Location: Jackson, Tennessee. (Photographer: John Peterman.)
Caption: Quality control check at exit of recently rebuilt press #9, a 5,700 ton indirect press, at the Cressona extrusion operation in Pennsylvania. Cressona is one of 11 plants in the U.S., many of which are undergoing upgrades, that are now part of Sapa North American Extrusions, Inc. Sapa’s new entry into the domestic market is shifting the landscape of the North American extrusion industry.
Caption: Australian shipbuilder Austal is the designer and builder of the 127-meter aluminum seaframe for the Littoral Combat Ship (LCS), which is being built at the company’s U.S. shipyard in Mobile, Alabama.
Caption: This simulation image shows the load (effective stress) on the mandrel of an aluminum extrusion die. The mandrel’s weak points are clearly shown. This is one of the simulations that Compes Italy created in an effort to optimize leg design on a port-hole die that ultimately led to the Compes Blade Die design. The software used for the simulation is QForm 3D. This issue features a review of the Extrusion Workshop and 2nd Extrusion Benchmark in Bologna, Italy in September. Leg shape in die design was one of the topics covered in the Benchmark portion of the workshop in which Compes participated.
Caption: Coiled aluminum sheet from the hot mill awaiting further reduction on the cold mill at Koenig & Vits in Wisconsin.
Caption: The latest Shinkansen Series N700 train “Nozomi” features lightweight aluminum construction. (Photo courtesy JR Central)
Caption: View of the mouth of the new Ube press and Cometal puller at Frontier Aluminum in Corona, California. Frontier recently expanded their existing facilities in California and constructed a new anodizing plant in Mexico. With Italian handling equipment built in China and a Chinese anodizing line, assembled in Mexico, Frontier has found a successful strategy to compete globally.
Caption: Inside Elixir Industries’ new facility in Douglas, Georgia, AlumiCore side rails are ready to undergo five successive bending operations prior to aging. Further value-added processing completes Elixir’s manufacture of the platform frame for the Club Car’s Precedent golf cart
Caption: Image of a 3-D solid model of an extrusion main cylinder and main cylinder housing (ram is shown in blue). Precisely sized models allow for pre-manufacture visualization of mating parts, virtual assembly of planned components, FEA, and stress analysis. In the hands of a capable engineer, 3-D modeling represents the next step forward in the modern extrusion design process. (Image courtesy of Butech Bliss.)
Caption: New fully equipped Wagstaff casting pit at Krasnoyarsk for production of 12 meter long slabs. The newly modernized casting complex is the largest in Russia and the CIS for aluminum rolling slabs.