Tag Archives: Metal

Science Research Technology

Premiere at TUBE/WIRE: Inline geometry measurements pay off quickly, also for production lines with low throughput

Measuring systems for wire rolling and drawing

Premiere at TUBE/WIRE:  Inline geometry measurements pay off quickly, also for production lines with low throughput

CONTOUR CHECK WIRE systems are available with several measuring axes for contour measurements.

At TUBE/WIRE 2018, LAP is going to introduce its new optical measuring system CONTOUR CHECK WIRE. This high-precision system is particularly suitable for inline geometry measurements in production lines with low production volumes. It enables wire producers to comply exactly with the tolerances specified by their customers, while optimizing material use.

In wire rolling mills and wire drawing shops, multi-axes LAP systems have long become established for diameter and contour measurements. In these applications, the systems are often exposed to extremely harsh operating conditions.

LAP has developed a new product line, CONTOUR CHECK WIRE, for geometry measurements in process stages with less challenging ambient conditions.

In many forming stages, one-axis inline measurements of the diameter of the cold wire already help to achieve significant improvements in the quality of the finished product and in the efficiency of production.

Being a moderate investment and an easy-to-use system, CONTOUR CHECK WIRE is a highly attractive option for factories with lower throughputs. The systems measure the diameter and ovality with exactly the same precision as the systems of LAP“s proven CONTOUR CHECK family, yet are smaller and, apart from power, need no other media supply.

CONTOUR CHECK WIRE systems are designed for inline measurements of wire with diameters between 0.5 and 30 mm. They measure with a precision of +/- 8 µm. If operated at temperatures not exceeding 40 °C, they do not require any cooling.

The compactness of the hardware allows the sensor units to be easily integrated into existing lines or used as mobile units at several positions within a factory. Like all LAP systems, they are designed for harsh steel mill environments. They are made to reliably operate under the conditions typically found in rolling mills, they come with a sturdy housing and are ready to use in virtually no time.

For Dr. Ralph Föhr, head of LAP“s Business Unit „Industry Systems“, it was very important to develop a system that could be sold at an affordable price: „Customers using the new CONTOUR CHECK WIRE system can save between 50,000 to 200,000 euros on material and production costs yearly. As the systems cost much less than the amounts saved, the return on investment occurs very fast, especially in factories operating several lines.“

The measured values are displayed both numerically and graphically on the touch screen of the Panel PC that comes with the system. Integration into the factory infrastructure is possible via optional interfaces.

Background information: The CONTOUR CHECK family

The new systems are based on LAP“s CONTOUR CHECK family of products which measure diameters and contours of long products in the metals industry, for example, of wire, bars, sections and tubes. Depending on the complexity of a product, they may measure the contour in several axes, either with METIS laser scanners or with the light-sectioning method.

During the last 25 years, LAP has installed more than 300 laser-optical contour measuring systems at customers in the steel industry.

LAP at TUBE/WIRE 2018:
Düsseldorf, Germany, 16 – 20 April 2018
Halle 7a/ Stand E16

About LAP

Since 1984 LAP has supplied laser-based systems for high-precision measurements of geometric dimensions, such as width, thickness, length, diameter and flatness, in industrial production. LAP systems excel at providing ultra-precise measurement results under harshest operating conditions. Hundreds of LAP systems are tried and tested every day in steel and rolling mills worldwide.

Among the customers of the company, which today employs more than 300 people, are leading steel makers such as Baosteel, Posco, ThyssenKrupp Steel and Vallourec.

The LAP staff support the company“s worldwide customer base from the headquarters in Lüneburg/Germany and through an international network of branches and technical agencies.

LAP GmbH Laser Applikationen
Marianna Schroeter
Zeppelinstraße 23
21337 Lüneburg/Germany
Phone: +49.4131.9511-222
Fax: +49.4131.9511-96
E-Mail: m.schroeter@lap-laser.com
Url: http://www.lap-laser.com

VIP Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen/Germany
Phone: +49.241.89468-24
Fax: +49.241.89468-44
E-Mail: reinhardt@vip-kommunikation.de
Url: http://www.vip-kommunikation.de

English Press Releases

Heinrich GEORG Maschinenfabrik: New slitting line for Eisen + Stahl Service Center

High efficiency through short non-productive times

Heinrich GEORG Maschinenfabrik: New slitting line for Eisen + Stahl Service Center

GEORG slitting lines excel in terms of winding accuracy; photo shows a plant, delivered in the past

GEORG has received an order to manufacture and supply a new slitting line to the German steel service center E + S Eisen + Stahl Service GmbH. With the new line, the Mannheim-based company will be adding the sale of slit strip out of its own facilities to its portfolio, thus taking another important step towards metal product processing in addition to trading.

Eisen + Stahl sells steel, stainless steel and aluminum sheet and plate, which the company cuts in its own facilities to the sizes demanded by its customers. To date, slit strip ordered by customers has been sourced from third parties. With the new slitting line supplied by GEORG, Eisen + Stahl will in the future be able to slit the strip at its own facilities in Mannheim. Thus the company will be able to cater to call-off orders much more flexibly. Additionally, the new line will reduce the company“s dependency on third-party supplies.

The new line will be designed to handle up to 1,650 mm wide and up to 5 mm thick steel strip, or up to 2 mm thick strip in stainless grades. It will be able to produce up to 30 slit coils from one mother coil at speeds of up to 400 m/min. The new line will be designed to optionally pay the strip off from above or below. Thus slitting can be performed with the inside or outside coil surface up, whatever may be requested by the customer.

Thanks to the high degree of automation, the GEORG slitting line will have much shorter non-productive times than traditional lines. For example, removal of the slit coils from the recoiler and placement of the coils on the payoff reel will take place synchronically. Any knife changes that may be necessary will also be performed in the process.

The scrap chopper features GEORG“s „shimless tooling“ technology, which dispenses with the necessity to insert shims while the knives are being reground.

The automatic, patented CNC-based system for arranging the separators saves setup times. While in the past, the separator discs used to be installed manually, this system now automatically sets the separator discs precisely at the correct positions, without any manual intervention. With four separator shafts in place, the new machine achieves optimally wound coils.

Against the backdrop of high energy costs, GEORG will equip the machine with highly energy-efficient motors and drives. Certain plant components, such as the brake rollers, will be operated in generator mode, allowing them to feed excessive energy into a link.

Axel Sturm, Head of Sales of GEORG“s Finishing Lines division, emphasizes that the lines made by GEORG are of interest not only for the big strip producers: „The order for E + S demonstrates that investing in quality-equipment from GEORG also pays for small and medium-size businesses. Last but not least the high degree of automation and proven longevity make our machines extremely attractive for steel producers and steel service centers as well.“

Dominik Naber, Managing Director of E + S, explains why he decided to buy a GEORG slitting line: „GEORG equipment is known for excellent precision, short non-productive times and long lifetimes. Of course, also costs mattered. But considering its overall duration of service, the new machine also provided major advantages in terms of total cost of ownership.“

The new line is expected to start producing at the E + S facilities in Mannheim in September 2018.

About EISEN + STAHL Service Center GmbH

Eisen + Stahl Service GmbH, based in Mannheim, Germany, is an owner-managed steel trading company looking back on more than 40 years of business. The family-owned company sells sheets, plates and slit strip made of hot or cold-rolled, hot-dip galvanized or zinc-plated steels, stainless steel grades or aluminum, in standard or customized sizes.

The current facilities include as key assets a cut-to-length line for 6,000-mm-long sheets, a recoiling plant and a fully automatic plate shear. Its extensive stock of items stored over an area of more 10,000 square meters allows E + S to instantly deliver products to customers all over Europe.

The company is certified to DIN EN ISO 9001:2008.

About Heinrich GEORG Maschinenfabrik

GEORG is a business partner worldwide well-reputed for reliable and powerful high-tech mechanical engineering solutions. The company“s cutting-edge finishing lines and machine tools as well as production lines, machines and equipment for the transformer industry are in operation in numerous renowned companies around the world.

The various product areas of the family-owned company, which employs more than 450 people and is now in its third generation, cater to most diverse markets and customers throughout the world. The company structure is based on a divisional setup, with three divisions acting on the market as independent profit centers.

The divisions GEORG Finishing Lines, GEORG Transformer Lines and GEORG Machine Tools are supported by the company“s own manufacturing facilities at the headquarters in Kreuztal, Germany. The GEORG Corporate Services division completes the portfolio with a wide range of value adding services. The company maintains a worldwide network of sales and service branches to be within easy reach for its international customers.

GEORG Finishing Lines

The Finishing Lines division manufactures a wide range of slitting and cut-to-length lines as well as multi-blanking, side trimming, inspection, recoiling and packaging lines and high-precision heavy-duty roller levelers. The lines provide long-term efficiency, as they are characterized by very short setup times, ease of operation, low HR requirements and perfect, process-controlled operation.

For more information please visit www.georg.com

Heinrich Georg GmbH Maschinenfabrik
Thomas Kleb
Langenauer Straße 12
57223 Kreuztal / Germany
Phone: +49.2732.779-539
Fax: +49.2732.779-39171
E-Mail: thomas.kleb@georg.com
Url: http://www.georg.com

Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen / Germany
Phone: +49.241.89468-24
Fax: +49.241.89468-44
E-Mail: reinhardt@vip-kommunikation.de
Url: http://www.vip-kommunikation.de

English Press Releases

3tn and GIPA under one roof

Warehouse and transport management in the metals industry: 3tn adds crane automation to product portfolio

3tn and GIPA under one roof

Harmonization between 3tn’s TWMS/metals warehouse management systems and the underlying basic

3tn, providers of the TWMS/metals warehouse management system, have taken over GIPA – Gesellschaft für Industrie- und Prozessautomation mbH. As from May 29, 2017, GIPA has been operating as a subsidiary of 3tn. With this transaction, the two companies have consolidated their long-standing partnership. Now they can offer efficient warehouse management solutions for the metals industry from a single source.

3tn and GIPA can look back on 18 years of successful cooperation. Numerous 3tn TWMS/metals projects in the steel industry implemented with crane automation systems from GIPA at any automation level testify to the long-standing partnership between the two companies.

On May 29, 3tn acquired all of the assets of GIPA mbH in order to further foster the successful relationship and be able in the future to offer innovative warehouse management systems complete with perfectly tailored automation solutions. GIPA will offer the same product and service portfolio as before and continue to serve customers separate from 3tn, for example as supplier of crane equipment for in the environment of nuclear power generation.

Thorsten Tönjes and Thomas Niepmann, the founders and managing directors of 3tn, will also be managing directors of GIPA. They will be supported by Wolfgang Hagedorn, who will continue to act as GIPA managing director and provide his technological know-how in order to ensure maximum continuity of business.

3tn customers will benefit from the new situation in various ways: TWMS/metals systems and the underlying basic automation will be even better harmonized, resulting in smoother interfaces, easier coordination during the project phase and a shorter supply chain.

Thorsten Tönjes sees great potential for both companies: „For our joint customers, this means that hardware and software will come from the same source. With both companies operating under the same roof, it will be easier for us to offer innovative and cost-efficient solutions and to join forces to bring forward developments in the field of intralogistics in the metals industry.“

As in the past, the customers may choose between buying 3tn warehouse management systems complete with all associated automation or sourcing the automation systems from a third party.

About GIPA

GIPA – Gesellschaft für Industrie- und Prozessautomation mbH, founded in 1996, specializes in engineering and software solutions for electrical and automation systems in industrial plants.

A main business activity is the development of software solutions and the supply of functional units for cranes used in production processes, for example in the metals industry, in shipyards or in the environment of nuclear power generation. Functionalities implemented in the systems include tracking of the crane positions and the associated sensor equipment, data transfer into warehouse management systems, visualization at all levels of automation and fully automatic, driver-less crane operation.

The service offer covers all project stages from consulting, planning, software development and supply of the control cabinets to after-sales and maintenance services.

About 3tn

Thomas Niepmann and Thorsten Tönjes founded 3tn in 1999, after working together for several years on warehouse management projects in the metals industry.

Their business plan was to develop customized warehouse optimization software, specifically tailored to the requirements of the metals industry. This philosophy has been consistently followed ever since.

The 3tn team consists of software developers, computer scientists, electrical technicians and engineers. They bring expertise in all stages of a project: analyses and feasibility studies, software development, project management, commissioning, and user training. Experienced technicians ensure comprehensive after-sales support and 24/7 service.

3tn Industriesoftware GmbH
Thorsten Tönjes
Gottlieb-Daimler-Straße 17
59439 Holzwickede/Germany

VIP Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen / Germany

Computer IT Software

OVH exklusiv Deep Dive Webinar: Automatisiertes Bare-Metal Provisioning für IT-Infrastrukturen

OVH exklusiv   Deep Dive Webinar: Automatisiertes Bare-Metal Provisioning für IT-Infrastrukturen

Das Thema „Cloud“ ist hochaktuell. Mit Cloudlösungen ist oft eine „Delokalisierung“ oder sogar die Vorstellung einer „Dematerialisierung“ von Hardware verbunden. Natürlich müssen auch Cloud Services durch Hardware funktionieren – nur befindet sich diese woanders.

Im OVH -Webinar am 03. Juni von 10:00 – 11:00 Uhr wirft Felix Krohn, SysAdmin bei OVH, einen Blick „unter die Wolken“ – das heißt auf die Hardware, deren Inbetriebnahme und grundlegende Konfiguration als Basis für die weitere Verwendung dient. Sei es zum Bereitstellen von Cloud-Dienstleistungen oder auch anderen hoch automatisierten Umgebungen.

Darüber hinaus wird im Webinar gezeigt, wie Bare-Metal eingesetzt wird, um solche Services immer weiter zu vereinfachen, und mit welchen Lösungen die Teilnehmer volle Kontrolle über ihr System haben und ihre Ziele verwirklichen können.

Das Webinar ist als Deep Dive Veranstaltung konzipiert und richtet sich an Anwender auf Experten-Level.

Hier geht es zur Anmeldung:

Mit rund 250.000 Servern ist OVH europäischer Marktführer und einer der führenden Anbieter von IT-Infrastrukturen weltweit.* Das nach ISO/IEC 27001 und SOC zertifizierte Unternehmen betreibt 17 hochmoderne Rechenzentren in Europa und Nordamerika sowie ein eigenes Glasfasernetzwerk mit einer Gesamtbandbreite von 5,5 TB/s und 32 Präsenzpunkten auf 3 Kontinenten. Außerdem unterhält OVH eine eigenständige Server-Produktion. OVH wurde 1999 in Frankreich von Octave Klaba gegründet. Das inhabergeführte Familienunternehmen ist in 17 Ländern weltweit vertreten und beschäftigt derzeit rund 1.200 Mitarbeiter. In Deutschland ist OVH seit 2006 am Markt. Sitz der deutschen Niederlassung ist Saarbrücken.
*Quelle: Netcraft

Jens Zeyer
Dudweiler Landstraße 5
66123 Saarbrücken
+49 (681) 90673216

Alpha & Omega PR
Dr. Oliver Schillings
Schloßstraße 86
51429 Bergisch Gladbach
+49 (2204) 9879930
+49 (2204) 9879938

Science Research Technology

Aluminum for blasting aluminum

The new Trowal continuous feed machines have been specially adapted for aluminum blast media.

Aluminum for blasting aluminum

Raw and finished part: Brass fitting

At the Gifa exhibition Walther Trowal displays the new continuous feed tumblast machines, which have been specially adapted for shot blasting of light metals like aluminum or magnesium. For weight reasons these 2 metals are more and more replacing steel as the material of choice for the production of a wide range of components. The soft and, therefore, gentle aluminum media has proven to be the most suitable blast media for treating components made from light metals.

The continuously increasing sales of the Walther Trowal THM shot blast systems show a clear trend toward aluminum blast media becoming more popular for blast cleaning of die-cast and forged aluminum and magnesium components. Its obvious advantage over stainless steel media is the drastic reduction of the overall operating costs due to the wear rate of the blast turbines in particular and the machine in general trending to nearly zero.

Of course, because of the lower mass of aluminum media, the turbines must throw a much larger media quantity to achieve the same processing results. For this reason, Walther Trowal re-engineered the THM troughed belt shot blast machines to ensure that they can easily cope with the higher media quantities. A highlight of the new THM shot blast machine range is the innovative electric media dosing system, which will be presented to the public at Gifa. These machines were specially adapted for gentle blast cleaning of aluminum and magnesium. But of course, they also produce excellent results on steel, zinc and brass components.

Troughed belt continuous shot blast machines: Extremely gentle work piece transport

The THM continuous troughed belt machines can handle large quantities of bulk produced small parts as well as large, delicate single work pieces with complex shapes. Because of the much simpler and gentler work piece handling they frequently replace conventional batch tumblast machines. THM continuous feed machines are especially advantageous for treating very delicate components: Contrary to batch tumblast machines, where the parts are continuously tumbling over each other with a high risk of nicking, in the Walther Trowal THM machines the work pieces are spread out throughout the length of the trough, ensuring a gentle, nick-free processing. The work pieces are not tumbling over each other but gently roll over the polyurethane coating of the transport rods. This is extremely important for highly complex thin-walled parts, which must increasingly undergo an intensive blast cleaning process. The results are perfectly cleaned parts without any nicking or other damage.

Compared to spinner hanger machines the THM continuous shot blast systems have also significant technical advantages: Because the work pieces are gently tumbling through the troughed belt, they are exposed to the blast stream from all sides and, especially, always at the same distance from the turbines, ensuring all around, even shot blasting results.

Aluminum: The gentle shot blasting media

Generally the blast cleaning of die-cast or forged aluminum components, for example, steering knuckles, requires a relatively soft blast media. But there is also an increasing trend towards the use of aluminum blast media for processing magnesium components, especially in the automobile industry. Many structural automotive components, for example, dashboard mountings, are made from magnesium. This material has not only a low weight, but at the same time, is also very tough.

Due to the fact that in the Walther Trowal THM shot blast systems the distance between the work pieces and the turbines is very short, the aluminum blast media – despite its low density — has still a very high kinetic energy when hitting the work pieces. This is ideal for processing components made from aluminum and magnesium. The THM continuous shot blast machines can be equipped with a different number of turbines. For example, for forged aluminum components the THM 700/4/E with four (4) turbines with 15 kW each offers an optimum performance.

A design that is totally adapted to aluminum

To ensure the proper handling of the aluminum shot blasting media, the Walther Trowal engineering team has completely redesigned many key equipment components like the media dosing system and the blast turbines. Just one of the many details: Since a rough surface on the throwing blades would quickly wear down the aluminum blast media, the surface of the blades is smoothed in a vibratory finishing machine before they are installed in the turbine. The result is drastically reduced media consumption, lower dust emissions and a significantly higher uptime of the turbines.

Continuous feed or batch processing

For integrating the THM systems into automated manufacturing systems Walther Trowal offers a range of part feeding and handling systems like, for example, vibratory conveyors or angled belt conveyors. Many customers link the Walther Trowal blast cleaning systems directly with their forging line or die-casting machines.

But the THM systems can also be operated in batch mode. In such cases the work pieces arrive at the blast machine in special part bins and are transferred into the machine with lift & tip loaders.

Large work pieces are placed manually on a special belt conveyor.

Safety comes first

Since aluminum and magnesium dust is flammable and can be highly explosive, it is of utmost importance that the dust concentrations generated by shot blasting of light metal components with aluminum remain low.

In numerous design details the Walther Trowal engineers made sure that only small dust quantities are produced during the shot blast operation and dust deposits in the machine are prevented. One example are vibratory conveyors for transporting the blast media, which totally preclude the formation of dust pockets. In addition, the dust-loaded air is cleaned in special explosion protected dust collectors, and the air speed in the machine and the ductwork is constantly monitored.

Walther Trowal at Gifa
(Düsseldorf, June 16 – 20, 2015): Hall 15 / Booth A35)

Facts about Walther Trowal

For more than 80 years Walther Trowal has been a pioneer and market leader in various surface treatment technologies. The company offers modular and custom engineered solutions for a wide range of surface treatment problems.

Initially only making vibratory finishing equipment, over the years Walther Trowal has continuously broadened its product range and today offers a wide portfolio of equipment and services for improving all kinds of surfaces, e.g. mass finishing, part cleaning, shot blasting and drying of a wide spectrum of work pieces, last but not least, the coating of mass produced small parts.

Walther Trowal offers not only various types of equipment but complete surface treatment systems: By linking the various equipment modules and automating the complete process, we are able to precisely adapt our process technologies to the technical requirements of our customers. This also includes various types of peripheral equipment and process water cleaning and recycling systems. Of course, we also offer comprehensive pre- and after-sale service like sample processing in one of our demonstration labs and global repair and maintenance service.

Walther Trowal serves many customers in many industries around the world. For example, in the automotive and aerospace industry, medical engineering and wind power generation.

Walther Trowal GmbH & Co.KG
Georg Harnau
Rheinische Str. 35-37
42781 Haan/Germany
+49 2129.571-209
+49 2129.571-225

Regina Reinhardt
Süsterfeldstrasse 83
52072 Aachen/Germany

Science Research Technology

Schwartz: Three hardness zones in the same blank

Two new techniques boost heat treatment flexibility in press hardening structural parts made of 22MnB5

Schwartz: Three hardness zones in the same blank

A sheet metal part after heat treatment in the thermal printer

At the Thermprocess trade fair, Schwartz will be premiering two innovations developed in-house for the press hardening of sheet metal: tailored tempering with a „thermal printer“ produces different hardness zones in the part, while a dew point control system for the air atmosphere of roller-hearth furnaces reduces the risk of oxygen-induced embrittlement.

Tailored tempering

The new „thermal printer“ enables the user to create multiple regions of different hardness in the same sheet metal blank. A targeted, localized heat treatment exposes the part to a locally varying time/temperature curve. Thus, in addition to the hard martensitic areas obtained by conventional press hardening, it is possible to produce soft zones with a microstructure comprising ferrite, pearlite and bainite.

By this accurately focused heat treatment, Schwarz achieves a very narrow hardness transition area in the product. The thermal printer can provide a 250 °C temperature differential over a width of only 60 mm. On a tailored tempered blank subjected to a 550 °C holding temperature, hardness measurements in the soft zone revealed a bainitic microstructure having a hardness of 350 HV. The area of transition to the hard zone was only 30 mm wide.

The printer is integrated into a press-hardening line in the furnace-to-press transfer section. In a dual configuration using two printers, cycle times of around 20 seconds can be achieved with this process.

Schwartz uses a mathematical model based on finite-difference modeling to model the temperature pattern across the blank, from which the parameters for temperature distribution in the printer are then derived.

Dew point control

At Thermprocess, Schwartz will also present their three-zone dew point control system for roller-hearth furnaces for the first time. The technology manages the dew point in three separate, individually controlled zones via the supply of very dry air.

This development was driven by the observation that in aluminium-silicon (AlSi) coated parts, cracks due to hydrogen embrittlement may occur in the base material after the press hardening process. Accordingly, even loads below the material’s limit of elasticity may result in its fracture. The phenomenon is likely to be caused by sub-dew point conditions during heat treatment.

With the new dew point control system, the dew point inside the roller hearth furnace can be precisely controlled and brought down to as low as -20 °C. One central element of this system is an automatically self-„tuning“ laser measuring cell developed specifically for this application case. Unlike capacitive systems, it delivers precise results in a few seconds‘ time.

For the measurement the laser light is reflected by a mirror. Since the system evaluates the diffuse reflection, it provides precise measurements even when the mirror is dirty, in contrast to conventional sensors. A window is the only optical component with exposure to the sample chamber. This design makes for a reliable and maintenance-friendly measurement.

Schwartz at Thermprocess 2015 (Düsseldorf, 16 – 20 June):
Hall 09, Stand F42

About Schwartz
Schwartz develops and manufactures high-efficiency heat treatment systems for annealing, hardening, forging, sintering and tempering ferrous and nonferrous metals. In each of these processes, the heat treatment can be carried out under air, protective gas and/or reactive atmospheres.

Especially for the heat treatment of aluminium, Schwartz designs and builds equipment based on high-convection heating, e.g. by the jet heating method.

Over the decades, Schwartz GmbH has come into the spotlight time and again for its innovative systems. One example is the technology of press-hardening sheet metal, which was pioneered by Schwartz along with the associated environmental protection solutions. At one German automotive manufacturer, equipment supplied ex Simmerath saves huge amounts of CO2 each year – the cuts are equivalent to the emissions of a small city with a population of 32,000.

At the Simmerath headquarters site, around 3,000 sq.m. of floorspace are dedicated to the manufacture, assembly and commissioning of heat treatment equipment. There are currently 110 people employed at the Simmerath factory; the company has a total workforce of 150 employees worldwide.

In 2011, the manufacturing subsidiary Schwartz Heat Treatment Systems Asia (Kunshan) Co. Ltd. was founded in Shanghai, PR China. Another subsidiary, Schwartz Inc. of Oswego, Illinois (U.S.A.), has been active since 2012. Now as before, all equipment is fully erected, heated up before shipment, and subjected to pre-commissioning at the production facility (Simmerath and Kunshan).

Schwartz GmbH
Elke Müller
Edisonstraße 5
52152 Simmerath / Germany

Regina Reinhardt
Süsterfeldstraße 83
52072 Aachen / Germany

Science Research Technology

Siempelkamp: Order for two isothermal forging presses

Complete solution for the forging of turbine blades made of titanium aluminide

Siempelkamp: Order for two isothermal forging presses

The complete plant is enclosed and operates under an inert gas atmosphere.

Leistritz Turbinentechnik GmbH ordered from Siempelkamp the design and supply of two 8 MN isothermal forging plants for the manufacture of turbine blades made of titanium aluminide. The customer will use these forging presses to manufacture a new generation of aircraft engines which are, compared to the nickel-base alloys currently used, up to 50% lighter while offering the same strength. Thus, they allow for significantly reduced fuel consumption.

Due to its intermetallic structure titanium aluminide is characterized by its high strength and excellent creep resistance at high temperatures. At the same time, at a density of 4 grams per cubic meter, it is very light. Therefore, it is ideally suited for aircraft engines. The material provides the potential to reduce the weight of turbine blades for aircraft engines by up to 50% which also goes along with a significant reduction of the centrifugal forces. The lighter design of the engines, made possible with the new components, will contribute decisively to reduced fuel consumption.

Intermetallic titanium aluminide was considered as not forgeable for a long time. Compared to casting, forging generates a special re-crystallization structure which is necessary for safety reasons for the rotating engine parts. In addition, the process stability during forging is higher than during casting and consequently, the turbine blades meet the extremely high quality requirements of the aircraft industry.

Leistritz has developed a new process where the blanks can be formed without cracks under carefully defined conditions at temperatures between 1,150 and 1,300 °C. The high forming temperature and the long dwell time of the forgings in the die, due to forming speeds of less than 0.1 mm/s, require heating the tools to forging temperature.

The extremely low press speeds require the hydraulic drive control to be especially accurate and uniform. Special guide and sealing systems assure uniform compression and thus avoid the undesired stick-slip effect. The symmetrical press design with a cross thread guide located on the outside allows for high precision forging. Because the guide elements are isolated from the heat source there is no thermal influence on the guide. The large distance between the guidance elements and the high rigidity of the press frame also contribute to precisely opposite aligned upper and lower dies during the forging process.

Leistritz has been operating a Siempelkamp 50 MN isothermal forging press since 1984. Due to the positive experiences and Siempelkamp’s expertise in the technologically sophisticated isothermal forging process, Leistritz contacted Siempelkamp early on and discussed different concepts. During pilot production, engineering talks about the design of the later production line started. In the beginning of 2014 both companies cooperated to develop the requirement profile for the plant allowing series operation. In November 2014 Leistritz commissioned Siempelkamp with the development and production of two manufacturing plants for the series production of turbine blades. Since the molybdenum contained inside the dies sublimates in the open air at temperatures over 600 °C oxygen has to be prevented from entering the dies. Therefore, the entire plant is enclosed which allows the complete automatic process, starting with the inserting of the blank at room temperature to the unloading of the forged turbine blades, to take place in an inert gas atmosphere.

Siempelkamp supplies both presses from a single source. The scope of supply for both presses includes a rotary hearth furnace, a loading manipulator, the forging press, the tool heating system, the hydraulic drive system and the complete electrical system. The process control monitors and documents the process parameters according to the certification standards in the aircraft industry.

The first press will start series production in March 2016, the second press one year later.

About Siempelkamp

During several decades, Siempelkamp has accumulated vast experience in engineering and manufacturing metal forming presses. These include sheet metal forming presses for the production of large pipes and half shells, straightening presses, presses for the production of side members, presses for heat exchanger plates, hydroforming presses, presses for the production of rear axle housing as well as the full line of closed and open-die forging presses. The company specializes in customized presses with high press forces.

With the three business areas Machinery and Plant Manufacturing, Foundry and Nuclear Technology, the Siempelkamp Group is a leading technology provider with international scope.

The company enjoys worldwide reputation as systems supplier of presses and press lines for the metals industry as well as turn-key plants for the wood-working industry.


Siempelkamp Maschinen- und Anlagenbau GmbH
Ralf Griesche
Siempelkampstraße 75
47803 Krefeld / Germany

Regina Reinhardt
Süsterfeldstr. 83
52072 Aachen / Germany

Science Research Technology

Harmonized integrated solutions from the liquid steel down to the semi-finished product

Alpine Metal Tech for the first time at Metec with the brands Numtec, Gega, Magnemag, Koch H&K and Knorr.

Harmonized integrated solutions from the liquid steel down to the semi-finished product

GEGA torch cutting machine

At Metec, Alpine Metal Tech will introduce the „Alpine Metal Tech Continuous Casting Machine Package (AMT CCM Package)“, a complete solution of harmonized integrated systems which optimize the continuous casting process from the liquid steel down to the semi-finished product. The package comprises equipment for ladle and tundish preheating, a shroud manipulator, powder feeding equipment, a torch cutting machine and deburrer, marking and reading equipment as well as optical devices for measuring and inspecting slabs, blooms or billets.

The AMT CCM Package consists of perfectly harmonized machinery of the brands Numtec, Gega, Magnemag, Koch H&K and Knorr. The equipment optimizes the continuous casting process at various phases from the steel ladle down to the inspection of the cast slabs, blooms or billets.

The harmonized interaction of all individual components perfects the casting process, for example, by adjusting the parameters of the torch cutting machine with the deburrer and optimizing the processing for downstream process steps such as the marking of the material with high-resolution systems. Uniform visualization and consistent user guidance make the process transparent, assisting the personnel in the control room.

In addition, the AMT CCM Package reduces the implementation effort when building a new plant or revamping an existing one because there is only one interface connecting the individual systems of the package with the process control and level-2 automation systems.

According to Dr. Andreas Pichler, CEO of Alpine Metal Tech, the package gives operators of continuous casting plants a clear added value: „Being a one-stop solution, the AMT CCM Package harmonizes the various components of equipment that make up a continuous casting machine and are crucial to the quality of the cast products. But the AMT CCM Package also means: only one person of contact for various key plant components and clear responsibilities in all matters of plant construction, commissioning and service.“

In long production, the one-stop solutions offered by Alpine Metal Tech also cover equipment that is even further down the process chain: for example, group company Knorr will show measuring and testing systems for sections at Metec; Koch H&K will present plants and equipment for rolling mills and finishing facilities as far down the process chain as the loading of finished products.

Alpine Metal Tech with
Numtec, Gega, Magnemag, Koch H&K and Knorr
at Metec 2015 (June 16 – 20, 2015 in Düsseldorf, Germany):
Hall 04, stand 4E18

About Alpine Metal Tech Holding

Alpine Metal Tech develops, engineers and manufactures specialist equipment for rolling mills, for product identification and inspection as well as complete package solutions for continuous casting plants in the steel industry. Beyond that, the company provides dedicated solutions for the testing, manufacturing and handling of aluminium wheels. Based in the Austrian town of Regau, Alpine Metal Tech Holding is active worldwide with the following companies:

Alpine Metal Tech (Regau, Austria)
– shroud manipulators, casting powder feeders
– deburrers as well as marking and reading & tracking systems
– customized solutions for wheel production

Alpine Metal Tech Gega GmbH (Hofheim-Wallau and Bonefeld, Germany)
– autogenous technology for preheating, torch cutting and scarfing

KNORR Technik GmbH & Co. KG (Kapfenberg, Austria)
– optoelectronic measuring systems for inspection and measurement of sections

KOCH H&K Industrieanlagen GmbH (Dillingen, Germany)
– rolling mill plants, automation, control and network systems

MAKRA Manfred Kratzmeier GmbH (Forst, Germany)
– customized solutions for wheel production

With sales and service set-ups in the USA, Brazil, China, South Africa, UK, Spain and Denmark, and service offices in many other steel and aluminium producing countries, Alpine Metal Tech is present and close to its customers all over the world. Through this global network, Alpine Metal Tech has established a worldwide concept for close-to-the customer life cycle services and ensures reliable and high-performance operation of its supplied equipment.

Alpine Metal Tech Holding
Günter Kienast
Buchbergstraße 11
A-4844 Regau, Österreich
+43.76 72.78 134-14

Regina Reinhardt
Süsterfeldstraße 83
52072 Aachen / Germany


Von Hip-Hop bis Metal: Hamburger Musikpreis HANS verliehen

Von Hip-Hop bis Metal: Hamburger Musikpreis HANS verliehen

Marcus Wiebusch gewann gleich in zwei Kategorien einen HANS _ Foto (c)Public Address

Die Preise sind verliehen, die Gewinner stehen fest: Marcus Wiebusch, Trümmer, Mantar und das Team um Deine Freunde zählen zu den Gewinnern des Hamburger Musikpreis HANS 2014. Vor rund 500 geladenen Gästen aus der Musikbranche fand am Mittwoch, 26. November, in der Markthalle Hamburg die Preisverleihung statt. Als Gäste waren unter anderen Axel Bosse, FC St. Pauli-Präsident Oke Göttlich, Jupiter Jones-Gitarrist Sascha Eigner und Moderatorin Madita van Hülsen vor Ort. In insgesamt acht Kategorien wurden die Auszeichnungen vergeben. Live-Acts des Abends waren Marcus Wiebusch, Rhonda, Trümmer, Deine Freunde und das Duo Michel van Dyke und Nils Wülker. Götz Bühler moderierte den Abend. Eine zweistündige Zusammenfassung der HANS-Verleihung ist am Donnerstag, 27. November, im digitalen Radioprogramm NDR Blue ab 20.00 Uhr zu hören.

In gleich zwei Kategorien setzte sich Marcus Wiebusch durch. Mit seinem Solo-Projekt überzeugte der Kettcar-Sänger die Jury. In der Kategorie „Hamburger Künstler des Jahres“ erhielt er ebenso einen HANS wie in der Kategorie „Hamburger Song des Jahres“ für „Der Tag wird kommen“. „Seine Texte sind zu Versen eines Stadtchronisten geworden. In dieser Stadt das Plattenlabel Grand Hotel Van Cleef und die Band Kettcar mitbegründet zu haben, ist ein Verdienst um Pop und Rock, mit dem sich bestenfalls Berry Gordy Jr. in Detroit mit Motown messen könnte“, so die Jury.

Zum „Hamburger Nachwuchs des Jahres“ wurde die Band Trümmer gekürt. Ihr Debüt-Album, das im Sommer erschien, sorgte bundesweit für Aufsehen. Für ihre eigenständige Mischung aus Poesie und Wut, Punk und großen Melodien wurden Paul Pötsch, Tammo Kasper und Maximilian Fenski jetzt ausgezeichnet. Die Kategorie „Hamburger Nachwuchs des Jahres“ wird von der TownTalker Media AG präsentiert.

Der ehemalige Echt-Schlagzeuger Florian Sump, der Live-DJ von Fettes Brot Markus Pauli und der Tigerentenclub-Moderator Lukas Nimscheck machen als Deine Freunde Hip-Hop für Kinder. Ihr Team erhielt den HANS 2014 in der Kategorie „Herausragende Hamburger Künstlerentwicklung des Jahres“. Das Trio ließ es sich nicht nehmen, die Laudatio auf ihr Team selbst zu halten.

Weil sie zurzeit durch Finnland tourt, konnte die Band Mantar nicht vor Ort sein. Stellvertretend nahm Co-Produzent Timo Höcke die Auszeichnung entgegen. Ihr Album „Death By Burning“ erhielt einen HANS in der Kategorie „Hamburger Produktion des Jahres“. Die Jury: „Mit den Mitteln der White Stripes oder Black Keys gelingen ihnen Werke fernab des an jede Reduktion gewöhnten Genres Blues. Das Konzept dahinter hört auf den Namen DIY, Do It Yourself: die Produktion, das Songwriting, das Packaging, ihr Label – alles hausgemacht.“

Die Zeitschrift „Das Wetter – Magazin für Text und Musik“ wurde mit dem HANS in der Kategorie „Hamburger Medienformat des Jahres“ ausgezeichnet. Magazin-Macher Sascha Ehlert nahm den Preis in der Markthalle entgegen. Die Jury lobte die „Liebe zur Sprache“ und die „Unabhängigkeit“ des Magazins.

„Die Macher des Überjazz Festivals haben auf Kampnagel ein Festival installiert, um welches Hamburg längst schon von den Musikern des Mutterlandes dieses Genres beneidet wird. Dem Mut, der Chuzpe und dem Selbstverständnis, Jazz als eine moderne Kunst- und Lebensform zu begreifen gebührt jede Ehre“, so die Jury in ihrer Begründung, den HANS in der Kategorie „Hamburger Programmmacher des Jahres“ an die Initiatoren des Überjazz Festivals zu verleihen. Heiko Jahn, Kurator des Festivals, dankte in seiner Rede vor allem den vielen Helferinnen und Helfern.

Eine feste Institution im Hamburger Nacht- und Kulturleben ist der von Rocko Schamoni und Schorsch Kamerun betriebene Golden Pudel Club. Seit zehn Jahren gestaltet Axel Solman die Poster der legendären Reihe „MFOC“. Für seine beständig kreativen und künstlerischen Leistungen zeichnete die Jury den Grafik-Designer in der Kategorie „Hamburger Gestaltung des Jahres“ aus.

„Wir haben heute wieder gesehen, wie vielfältig, lebhaft und spannend die Hamburger Musikszene ist: Hip-Hop, Metal, Indie, Pop und Jazz – und das alles in beeindruckender Qualität“, so der Jury-Vorsitzende Alexander Maurus.

Die Preisverleihung mit allen Live-Auftritten, Dankesreden und Laudatoren ist am Donnerstag, 27. November, nachzuhören: Das digitale Radioprogramm NDR Blue überträgt ab 20.00 Uhr eine zweistündige Sondersendung zum diesjährigen HANS.

Seit der ersten Verleihung 2009 unterstützt, begleitet und fördert der Norddeutsche Rundfunk den HANS als Medienpartner für Hörfunk, Fernsehen und Internet. Weiterhin engagieren sich die Hamburger Volksbank, die Hamburg Kreativ Gesellschaft mbH und die TownTalker Media AG für den HANS.

Die Gewinner des HANS 2014 in der Übersicht:

„Hamburger Künstler des Jahres“
Marcus Wiebusch

„Herausragende Hamburger Künstlerentwicklung“
Das Team um Deine Freunde

„Hamburger Medienformat des Jahres“
Das Wetter – Magazin für Text und Musik

„Hamburger Produktion des Jahres“
Death By Burning von Mantar

„Hamburger Programmmacher des Jahres“
Überjazz Festival

„Hamburger Gestaltung des Jahres“
Axel Solman für die Gestaltungen zum Golden Pudel Club

„Hamburger Nachwuchs des Jahres“

„Hamburger Song des Jahres“
Der Tag wird kommen von Marcus Wiebusch

Christoph Kohlhöfer
Maria-Louisen-Str. 96
22301 Hamburg

Science Research Technology

Walther Trowal offers more reliable finishing results

Walther Trowal offers more reliable finishing results

After being “trowalized” a grease retaining disk is perfectly cleaned.

No matter what water hardness you must work with, the newly developed broadband compounds are considerably less foaming.

Walther Trowal is the only supplier in the industry offering compounds for the surface finishing of metal parts which work entirely independent from the hardness of the process water and produce practically no foam. This is great news for the users, because their „trowalizing“ processes run now absolutely stable irrespective of the ambient operating conditions. Since they contain synthetically manufactured raw materials instead of soap, the new compounds also contribute to a cleaner environment.

With soap-based compounds the optimum balance between a good cleaning effect and acceptable foaming has been limited to a very narrow water hardness range. Even minor fluctuations of the water hardness could jeopardize the stability of the entire finishing process.

The solution – Special surfactants

With the new broadband compounds trowal KRA, trowal SGK and trowal KRS Walther Trowal was able to completely eliminate the negative effects of the water hardness. This guarantees absolutely stable finishing processes over a wide range of process water hardness.

The new compounds contain special surfactants instead of different types of soaps. The result: Very little foaming under practically any operating condition and extremely simple handling. Auxiliary compounds like de-foamers, hardness-augmenting agents or, for some applications, additional machinery are no longer required. „Foam parties“ are a thing of the past, at least in the field of mass finishing.

With their wide application range relative to the water hardness the new compounds offer a high degree of operational stability: The hardness of the process water is not a limiting factor anymore. This means that the user does no longer have to choose between different water supply companies, install an in-house water softener or deal with fluctuating water characteristics – his mass finishing processes remain unaffected by the water hardness!

Of course, this means also that the new compounds can be utilized at any location without the risk of jeopardizing the specified finishing results. This offers a big advantage for users with multiple manufacturing facilities. And at the same time it ensures that the results of processing trials run at the Walther Trowal demonstration lab in Haan during the pre-sale phase are absolutely repeatable at the customer premises.

The new Trowal compounds have excellent cleaning, degreasing and corrosion protection characteristics. They produce bright and shiny surfaces. In addition, they emulsify oil very efficiently resulting in excellent degreasing results. They also effectively disperse the metal and media fines generated by the finishing process, thus allowing the process water to easily flush them out of the processing bowl. Additional low foaming inhibitors provide excellent corrosion protection.

Customer feedback highly positive

Users who switched to the new compounds report that their mass finishing processes are running absolutely free of any trouble and that since the changeover no service support from Walther Trowal was required.

A manufacturer of needles for textile machinery was the first customer using the new Walther Trowal compounds. Although the process water used at this customer“s premises is very soft, the addition of hardness augmenting agents is no longer necessary. Another significant benefit of the new compounds is the fact that the process water can now be recycled over a very long period requiring only fresh water replenishment due to evaporation loss.

„Green compounds“ protect our environment and save valuable resources.

When developing the new broadband compounds Walther Trowal focused to a large extent on environmental protection: The basic ingredients are synthetically produced materials replacing palm oil which is the major substance for soap production and is also found in many food items. In recent years palm oil has become highly controversial because of environmentally hazardous growing and harvesting methods.

For many mass finishing applications the new compounds aIlow recycling of the process water for the very first time resulting in significant cost savings for fresh water and waste water disposal.

The new broadband compounds

trowal KRA: An all-round compound

trowal KRA is a universal cleaning and degreasing compound with excellent corrosion protection characteristics. It is suitable for all metals and is mostly used for deburring of work pieces that may contain some surface oil but do not require intensive degreasing.

trowal SGK: Excellent degreasing characteristics

Walther Trowal developed the trowal SGK compound specifically for degreasing and cleaning of parts made from aluminum, stainless steel and zinc. It has excellent degreasing characteristics and can also be used for the removal of stubborn surface contaminations.

trowal KRS: Vey good corrosion protection

trowal KRS is ideal for finishing of ferritic work pieces that tend to rust easily. It contains special surfactants that effectively disperse the metal and media fines and, thus, protect the surface of the parts against corrosion.

The detrimental relationship between soap and water

The reason for the negative impact of water hardness in conjunction with soap-based compounds is the fact that soap reacts completely different in operating conditions with varying degrees of water hardness. In soft water soap has excellent cleaning characteristics and emulsifies oil very well. However, when the process water is recycled, it produces a lot of foam necessitating the use of de-foamers. Furthermore, the soap does not adhere to the surface, i.e. it does not create a protective surface film insulating the surface from the environment. The result: Poor corrosion protection.

On the other hand, in hard water the corrosion protection of soap-based compounds is quite good, and very little foam is generated. But this comes at the price of diminished cleaning capabilities. In addition, the soap in connection with hard water hinders the emulsification of oil resulting in an insufficient degreasing effect.

Facts about Walther Trowal

For more than 80 years Walther Trowal has been a pioneer and market leader in various surface treatment technologies. The company offers modular and custom engineered solutions for a wide range of surface treatment problems.

Initially only making vibratory finishing equipment, over the years Walther Trowal has continuously broadened its product range and today offers a wide portfolio of equipment and services for improving all kinds of surfaces, e.g. mass finishing, part cleaning, shot blasting and drying of a wide spectrum of work pieces, last but not least, the coating of mass produced small parts.

Walther Trowal offers not only various types of equipment but complete surface treatment systems: By linking the various equipment modules and automating the complete process we are able to precisely adapt our process technologies to the technical requirements of our customers. This also includes various types of peripheral equipment and process water cleaning and recycling systems. Of course, we also offer comprehensive pre- and after-sale service like sample processing in one of our demonstration labs and global repair and maintenance service.

Walther Trowal serves customers all over the world in many industries, for example, automotive, aerospace, medical implants and wind energy.

Walther Trowal GmbH & Co.KG
Georg Harnau
Rheinische Str. 35-37
42781 Haan/Germany
+49 2129.571-209
+49 2129.571-225

Regina Reinhardt
Süsterfeldstrasse 83
52072 Aachen/Germany