Technical Papers

The following papers that have been published in print in previous editions of APT ALUMINIUM Process & Product Technology Intrnational magazine will be available as pdf files from 23 April 2006 to all AluminumI members

APT ALUMINIUM Process & Product Technology
Volume II, Issue I

Contents
Foreword
Introduction

Fifty seven Years of Achievement—a Profile of Roy Woodward
By APT ALUMINIUM, UK

Keynote Speech at the Aluminum Association Spring Meeting
By Alain Belda, Alcoa, USA

Sustainable Development—Making the Economic Case
By The European Aluminium Association and APT ALUMINIUM, Belgium and UK

Alcan Sees Opportunity to Establish Aluminium Industry as Global Benchmark of Sustainability
By Cynthia Carroll, Alcan Primary Metal Group, Canada*

VAW-IMCO GmbH—a European Light Metal Recycling Powerhouse
By APT ALUMINIUM, UK 
(From an interview with Roland Scharf-Bergmann)

Chalco Seeks Growth Through Science and Technology
By Liu Xiangmin, Chalco, China*

Aluminium Supply Increases and Demand Softens
By Basemetals.com, UK

Primary Processes

Model-Based Digester Temperature Control at Alpart Jamaica Refinery
By Astley Forrester and Terry Snow,
Alpart Alumina Refinery and Comalco Alumina Refinery, Jamaica and Australia*

Fundamental Research on Alumina Production for the Future
By Zhao Qingjie, Yin Zhoulan, Chen Qiyuan, and Yang Qiaofang, Qi Lijuan and, Zhang Lingxian,
Central South University, Zhengzhou Research Institute Aluminum Corporation of China, Ltd and Aluminum Corporation of China Ltd., China

Manufacturing Control for Aluminium Smelters
By M P Taylor and John Chen, University of Auckland, New Zealand

Molten Metal and Forming Processes

A Technical and Commercial Comparison of Alloying Products for the Aluminium Casthouse
By David Evans, Steven Munnoch and Steve Martin, Avon Metals, UK

Automation Control of Metal Flow and Level
By Hans G. Wilhelm, DeltaConsult, Germany

Influence of Manufacture and Ingot Structure on Die Forgings
By Juliusz Senderski, Tomasz Stuczynski, Andrzej Klyszewski, Bartlomiej Plonka, The Institute of Non-Ferrous Metals, Light Metal Division, Poland

SMS Demag leaps forward with “Virtual reality”
By APT ALUMINIUM, UK

Microstructural Gradients in Twin Roll Cast AA3105
By Naiyu Sun and Burton R. Patterson (1), Jaakko P. Suni, Eider A. Simielli and Hasso Weiland (2), and Larry F. Allard (3)
(1) University of Alabama at Birmingham,
(2) Alcoa Technical Center and
(3) Oak Ridge National Laboratory, USA*

Precision Spray Control Strategies for shape-control systems
By David Tucker and Hubert Wenig,
Lechler UK Limited and Lechler GmbH, UK and Germany

Achieving the ‘Perfect’ Cut on Modern Extrusion Presses
By Matteo Crosti, Danieli Breda Officine Meccaniche SpA, Italy

Increasing the Productivity of Extrusion Presses
By Martin Turesson, Hydratech AB, Sweden

Corporate Feature

Metra Targets Future Aluminium Extrusion Growth in Railway Sector

Stress and Layer Corrosion in 2xxx and 7xxx Series Extruded Transport Alloys
By Mieczyslaw Opyrchal, Juliusz Senderski and Andrzej Klyszewski,
The Institute of Non-Ferrous Metals, Light Metal Division, Poland

End Product Manufacturing Processes

TWI Develops Comeld TM To Boost Metal-to-Composite Bond Strengths
By Faye Smith, TWI World Centre for Materials Joining Technology, UK

Aluminium in Construction and Environmental Technologies

Energy and Sustainability of Aluminium Fabricated Products
By Jurg Gerber, Global Projects Alcan Inc., and APT ALUMINIUM, UK

Aluminium To Play Key Role in Sustainable Building
By Laura Berneri, EAA and, APT LUMINIUM, Belgium and UK

Hydro Launches Innovative Aluminium Façade Concept
By Lars H. Ringvold, Hydro Aluminium Building Systems

APT ALUMINIUM Process & Product Technology
Volume I, Issue II & APT ALUMINIUM Interactive CD II

Contents
Foreword
Introduction

19. Continental Shift—Aluminium Use Worldwide with Soaring Asian Production
By J. Stephen Larkin, The Aluminum Association, USA

Aluminium Makes Inroads into Mass Transport Sector
By Bernard Gilmont, EAA, Belgium

Growing Automotive Aluminium Demand—A Total Supply Chain Effort
By Werner A. Stelzer, Alcan Automotive

CRU. New Smelting Capacity: Where is the Power?
By Mark Fraser, CRU Strategies, UK

CRU. China, the New Global Locomotive—The Implications for Aluminium
By John Martin, CRU International, UK

Developments in Aluminium Extrusion
By Frank F. Kraft and James Sanderson, Ohio University and Kaiser Aluminum, USA

Primary Processes

Inert Anodes in Aluminium Production Cells
By Vittorio de Nora, MOLTECH S.A., Switzerland

Defined Cooling of Cryolite
By Matthias Moritz, Aumund Foerdertechnik GmbH, Germany TMS.

Chinese Smelter Project Takes Shape in Yichuan, Henan
By She Haibo, Chen Shichang and Zhang Juanzhang,
Shenyang Aluminum & Magnesium Engineering & Research Institute (SAMI),
Yichuan, Henan HongKong Longquan Aluminium Co., Ltd. (LQAL) and
Luoyang Longquan Tiansong Carbon Co., Ltd., China

Solios 1p Corporate Feature
ALOUETTE PHASE II Project—Solios Meets the Challenge Once More
Solios, France

High Performance Dry and Wet Scrubbing systems for Potlines
By Geir Wedde, Terje Opsahl and Parto Pakdel Henriksen, ALSTOM Norway AS, Norway

Optimal Anode Rod and Stub Repair for Improved Primary Smelter Efficiency
By Jon H Magnusson, ALTECH SMV ehf, Iceland

Modernisation of Smelter and Casthouse at Sayanogorsk
By Rusal and APT Aluminium,

Molten Metal Processing

TMS. In-Furnace Refining Using Pyrotek’s Rotary Injector Systems
By Robert A. Frank and Peter J. Flisakowski, Pyrotek, Inc., USA

TMS. Investigation of Grain Refinement Fading in Hypoeutectic Silicon Alloys
By Zbigniew Zamkotowicz, Tomasz Stuczynski, Boguslaw Augustyn,
Marzena Lech-Grega and Wladyslaw Wezyk,
The Institute of Non-Ferrous Metals, Light Metal Division, Poland

Analysis of Aluminium and its Alloys by a New CCD-based Spectrometer
By E. Halász, J.-M. Böhlen and E. Muller, Thermo Electron Corporation, Switzerland

Ceramic Foam Filter Technology in Aluminium Cast Houses
By Leonard S. Aubrey, SELEE Corporation, USA

Innovative Gas Solutions for the Aluminum Industry
By Linde Gas, Germany

Wagstaff Senses the Future of Casting, Minimises Customers’ Risk
By Anna Henry, Headline Ink, USA

Semi-fabricated Product Processes

TMS. Incremental Forming of Aluminium Blanks
By Sergey Golovashchenko and Al Krause, Ford Motor Company, USA

Advanced Controls for Cold Rolling Mills—OPTIROLL® i2
By W.F. Sommer, Achenbach Buschhütten, Germany

Roll Aluminium Surface Preparation for Packaging Applications
By Rory Wolf, Enercon Industries Corporation, USA

Shape Technology 1p Corporate Profile
Technological Advances in Spray Coolant Systems,
Shape Technology Ltd., UK

Automated Inspection System for Casters and Mill Rolls
By Borja Lopez, Innerspec Technologies, Inc., USA

ET 2004

Wagstaff NuMax™ Technology—Improving Billet Casting and Extrusion Performance
J.D. Schloz*, R.M. Kelly** and G. A. Jones**, *Wagstaff, Inc., and **Werner Company, USA

HIPEX: Controling Temperature in the Extrusion Process
By Matteo Crosti, Danieli Breda Officine Meccaniche Spa, Italy

ET. Extrudability and Mechanical Properties of Alcan’s High Performance Al-Mg-Si alloys
By Alex Brassard, Nick Parson, T (Ram) Ramanan, Greg Lea, Gary Hay and Christopher W. Jowett, Alcan, Canada and USA

Special Purpose Extrusion Press to Produce Curved Profiles
By Markus König and Uwe Muschalik, SMS Eumuco GmbH, Germany

Conform™- the use of alternative feedstock materials
By Philip M. Thomas Outokumpu Holton Ltd., UK

ET. Isothermal Extrusion of Aluminium Alloys
By Masaya Takahashi and Takeshi Yoneyama,
Sumitomo Light Metal Industry Co. Ltd. and Kanazawa University, Japan

ET. Travelling Billet Homogenizing Furnace—a New Option
By William R. Weyand, Seco/Warwick, USA

ET. Quenching Performance Maximised in Minimum Space
By David Jenista, Granco Clark, Inc., USA

ET. Analysis and Design Optimization of Aluminium Extrusion Dies
By Mahender P. Reddy*, Ravisankar Mayavaram*, David Durocher*, Håkan Carlsson**and Ola Bergqvist**
*Altair Engineering and **Altair Engineering AB, USA and Sweden

Front-loading Technology With Tandem Cylinder Design
By Jürgen Sturm, TECALEX Aluminium Technology, Spain

End Product Manufacturing Processes

Advancements in Powder Coating Applications
By Greg Bocchi, The Powder Coating Institute, USA

Development of Profiles for Structural Applications
By Alberto Pomari, METRA SpA, Italy

New Developments Within the Aluminium Shipbuilding Industry
By Tony Anderson, AlcoTec Wire Corporation, USA

Machining Process of Aluminium Profiles for Trains
By Giovanni Barbareschi, TEKNA srl, Italy

Automotive Aluminium and Light Weighting

End-of-Life Recycling of Aluminium in Trucks
By Bernard Gilmont, EAA and APT Aluminium, Belgium and UK

Increased Growth Rate Forecast for Automotive High-Strength Steels
By Dennis Urban, Dennis Witmer and Ron Krupitzer,
Ispat Inland, Inc., United States Steel Corporation and American Iron and Steel Institute, USA

‘Alumaximised Car’—EAA Study Points To Light Weighting
By EAA Automotive and APT Aluminium

Jaguar Presents R & D Challenges to Lightweight Vehicle Suppliers
By Peter Standring, University of Nottingham, UK

Innovative Material Supply for the Lamborghini Gallardo
By Tom Vertommen, Corus Aluminium Rolled Products, Belgium

New Aluminium Laser Robot Welding for Lamborghini
By Tony van der Veldt, Corus Research Centre, The Netherlands

Opel Eco-Speedster—Saving Fuel at High Speed
By Hydro Aluminium, Norway and UK

Corporate Features

Solios 1p Corporate Feature
ALOUETTE PHASE II Project—Solios Meets the Challenge Once More
Solios, France

Shape Technology 1p Corporate Profile
Technological Advances in Spray Coolant Systems
Shape Technology Ltd., UK

APT ALUMINIUM Process & Product Technology
Volume I, Issue II & APT ALUMINIUM Interactive

Contents
Foreword
Introduction

Growing Automotive Aluminium Demand—A Total Supply Chain Effort
By Werner A. Stelzer, Alcan Automotive

CRU. New Smelting Capacity: Where is the Power?
By Mark Fraser, CRU Strategies, UK

CRU. China, the New Global Locomotive—The Implications for Aluminium
By John Martin, CRU International, UK

Developments in Aluminium Extrusion
By Frank F. Kraft and James Sanderson, Ohio University and Kaiser Aluminum, USA

Primary Processes

Defined Cooling of Cryolite
By Matthias Moritz, Aumund Foerdertechnik GmbH, Germany

Modernisation of Smelter and Casthouse at Sayanogorsk
By Rusal and APT Aluminium

Molten Metal Processing

In-Furnace Refining Using Pyrotek’s Rotary Injector Systems
By Robert A. Frank and Peter J. Flisakowski, Pyrotek, Inc., USA

Innovative Gas Solutions for the Aluminium Industry
By Linde Gas, Germany

Wagstaff Senses the Future of Casting, Minimises Customers’ Risk
By Anna Henry, Headline Ink, USA

Semi-fabricated Product Processes

Incremental Forming of Aluminium Blanks
By Sergey Golovashchenko and Al Krause, Ford Motor Company, USA

Automated Inspection System for Casters and Mill Rolls
By Borja Lopez, Innerspec Technologies, Inc., USA

ET04 Presentations Republished with permission from the Eighth International Aluminium Extrusion Technology Seminar (ET’04),
first published by the Extrusion Technology for Aluminium Profiles Foundation, USA.

Wagstaff NuMax™ Technology—Improving Billet Casting and Extrusion Performance
J.D. Schloz *, R.M. Kelly** and G. A. Jones**, *Wagstaff, Inc., and **Werner Company, USA

Extrudability and Mechanical Properties of Alcan’s High Performance Al-Mg-Si alloys
By Alex Brassard, Nick Parson, T (Ram) Ramanan, Greg Lea, Gary Hay and Christopher W Jowett, Alcan, Canada and USA

Isothermal Extrusion of Aluminium Alloys
By Masaya Takahashi and Takeshi Yoneyama,
Sumitomo Light Metal Industry Co. Ltd. and Kanazawa University, Japan

Travelling Billet Homogenizing Furnace—a New Option
By William R. Weyand, Seco/Warwick, USA

Quenching Performance Maximised in Minimum Space
By David Jenista, Granco Clark, Inc., USA

Analysis and Design Optimization of Aluminium Extrusion Dies
By Mahender P. Reddy*, Ravisankar Mayavaram*, David Durocher*, Håkan Carlsson**and Ola Bergqvist**
*Altair Engineering and **Altair Engineering AB, USA and Sweden

Special Purpose Extrusion Press to Produce Curved Profiles
By Markus König and Uwe Muschalik, SMS Eumuco GmbH, Germany

Conform™—the use of alternative feedstock materials
By Philip M. Thomas, Outokumpu Holton Ltd., UK

HIPEX: Controling Temperature in the Extrusion Process
By Matteo Crosti, Danieli Breda Officine Meccaniche Spa, Italy

Front-loading Technology With Tandem Cylinder Design
By Jürgen Sturm, TECALEX Aluminium Technology, Spain

Automotive Aluminium and Light Weighting

End-of-Life Recycling of Aluminium in Trucks
By Bernard Gilmont, EAA and APT Aluminium, Belgium and UK

‘Alumaximised Car’—EAA Study Points To Light Weighting
By EAA Automotive and APT Aluminium, Belgium and UK

Jaguar Presents R & D Challenges to Lightweight Vehicle Suppliers
By Peter Standring, University of Nottingham, UK

Innovative Material Supply for the Lamborghini Gallardo
By Tom Vertommen, Corus Aluminium Rolled Products, Belgium

New Aluminium Laser Robot Welding for Lamborghini
By Tony van der Veldt, Corus Research Centre, The Netherlands

New “Highclad” Material with Aluminium and Titanium
By Corus Aluminium, The Netherlands

Opel Eco-Speedster—Saving Fuel at High Speed
By Hydro Aluminium, Norway and UK

Aluminium Use in Tomorrow’s Automotive Industry
By Joel Le Gal, Renault Company, France

Corporate Features

ALOUETTE PHASE II Project—Solios Meets the Challenge Once More
Solios, France

Technological Advances in Spray Coolant Systems
Shape Technology Ltd., UK

Linde Gas—Leader in Gas Solutions for the Aluminium Industry
By Linde Gas, Germany

Iceland’s Increased Role in Global Aluminium Production
By Jon H Magnusson, Altech SMV ehf., Iceland.

APT ALUMINIUM Process & Product Technology
Volume I, Issue I

Contents
Foreword
Introduction Section

Interview with Chris Bark-Jones,
EAA Chairman

US Aluminium Industry Mulls Slimmed Down Energy Strategy
By Robin King, The Aluminum Association*, USA

Finite Element Modeling (FEM)—An ET 2004 Preview
By Nancy E. Klein, Writer and Editor, USA

China’s Expanding Appetite for Alumina
By Yisha Xue, China Business Consultancy UK

Indian Aluminium Industry Targets Three Sectors for Growth
By The Aluminiun Association of India (AAI)

Continuous Innovation is Key to Success at SAG
Interview with Josef Woehrer, Chairman & CEO of Salzburger Aluminium AG, Austria

Primary Processes

The Supply of Bauxite in Australia
By Michael Ison, Australian Aluminium Council (AAC)

Smelter Integration of Automation and Information Systems
By Ben Peters, Rockwell Automation, Belgium

Improvement Of Anodic Stems Using Bimetallic ETJ 2000
By John Banker, DMC Clad Metal Division, USA, Antoine Nobili and
Stéphane Pauly, DMC Nobelclad Division, France

Si3N4 Bonded SiC Refratories For Higher Al Cell Performance
By E. Jorge & O. Marguin, Saint-Gobain CREE, Germany

Anode Baking Furnaces—Recent Developments
By Frank Goede, Riedhammer GmbH, Germany

Purification of Potroom Metal in Transport Crucibles
By Jon H. Magnusson, Altech SMV, Iceland

The Ideal Green Anode Paste Mixer
By Joseph E. Flynn, B&P Process Equipment, LLC, USA and Stephen J. Colvin Technical Writer, USA

Improved HF Detection in Primary Aluminium Smelters
By Hamish Adam, Boreal Laser, Canada

Molten Metal & Semi-fabricated Processes

EU and European Aluminium Industry Conclude Groundbreaking VIR[*] Project

Automated Level Control For Molten Aluminium Pouring
By Walt Pastorius, LMI Technologies, (USA) and Johan Ahlgren,
LHI Technologies AB, Sweden

Filtration of Molten Aluminium—Metallurgical and Practical Aspects
By Karl Venås, Sør-Trøndelag, University College, Norway and
Hans Christian Ly, ALMEQ Norway AS, Norway

Cycle Time & Production Data In The Aluminium Fabrication Industry
By Jean Bonhomme, Engineering Consultant and Luc Chouinard
McGill University, Montreal, Canada

VAntage Advances with New Products for the Rolling Industry
By Dennis Meech, VAI (UK)Ltd, UK

Quantitative Study Into Aluminium Hot Rolling—Coolant Sprays
By David Tucker, Lechler Limited, UK

Closed Circuit—Automated Materials Flow
By Georg Papadopoulos, Herrmann+Hieber & Co. GmbH, Germany

Alcoa Green Sand Casting—Improving the DISAmatic Process
By Andreas Kiebel and Holger Haddenhorst, Alcoa Europe
Automotive Castings & Finished Extrusions, Germany

Molten-metal Resistant Fabrics Made of Lenzing FR®
Lenzing Fibers

MicroStream Technology for Light Aluminium Dies
By Fred Schmid, Microtecnica Technologies, Germany

End Product Manufacturing Processes

New Cutting Lines for Nanshan Group Corp—China
By Detlef Neumann, Danieli Fröhling, Germany

Surface Treatment Options for Aluminium and its Alloys
By E. P. Short, Aluminium Finishing Consultant, UK

Filler Alloy Selection for Aluminium Welding
By Tony Anderson AlcoTec Wire Corporation, USA

High Speed Inline Weld Inspection
By Norbert Stein, Vitronic GmbH, Germany

Automotive Aluminium & Light Metals

VIR[*] Industry Partners Look to ‘Virtu-Al’ High Quality Manufacturing
By The European Commission

Thixalloy® Components for Innovative Design Solutions
By Josef Woehrer, Salzburger Aluminium AG Group and Hans Luechinger, Aluminium Lend GmbH and Thixalloy® Components GmbH, Austria

Single Engine Blocks Mould With Low-Pressure Aluminium Casting
By Thomas Muehleck, Kurtz Group, Germany

Production of Quality Castings With Welding and Heat Treatment
By H. Haddenhorst, and H. Böhmer, Alcoa Advanced Transportation Systems, Germany

Taylor Welded blanks (TWB) by Friction Stir Welding (FSW)
By Kari Erik Lahti, ESAB AB, Sweden

Cadillac Sixteen—a Radical Approach to Aluminium Content
By Jeff Holland, GM Design & Performance Division Communications and Debbie Frakes, GM Powertrain Communications, USA

Advanced Aluminium Concepts for Ferrari 360 And Enzo
By Maurizio Rossi & Carlo Carcioffi, Ferrari and Maserati Group, Italy

Sophisticated Structure for 21st Century Rolls-Royce Phantom
By BMW AG, Germany, and APT Aluminium

Developing The New Aluminium Jaguar XJ Saloon
By Mark White, Whitley Engineering Centre, Jaguar Cars Limited, UK

BMW Upgrades Dingolfing Plant for New Generation Aluminium Axle
By BMW AG, Germany and APT Aluminium

New Designer Systems for Zinc and Galvanizing Baths
By John Fryatt and Dennis Been, Metaullics Systems Europe B.V, The Netherlands

Aluminium Wheels—Lightweight Solution For Red Planet Rovers
By NASA Jet Propulsion Laboratory, USA

 

 

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