Foundry Daily News

The Newsletter of Alumotive

Pircher - Wheels on display at Alumotive
Pircher Alfred SAS, based in Lana (Bolzano), has a 50-year experience in the industrial wheel sector and is the sole importer for Italy of the WICKE brand, world-renowned German manufacturer of wheels and rollers for manual and automated handling.
The corporate product range includes polyamide, cast iron, and steel core wheels coated in black or trace-proof rubber, in several polyurethane types featuring different hardness, and also in Vulkollan.
Pircher Alfred SAS offers both standard and customized products to meet the customers' needs. In-house qualified consultants support the customers and help developing whatever projects where wheels are used. Pircher is an exhibitor at Alumotive 2014.

Forging Group Monale - A young yet specialized company
Forging Group Monale S.r.l. - affiliated company of the German-based WÖSSNER Group, international manufacturer of pistons - is a new company specialized in light alloy forging. Even though FGM has been founded recently, their high quality production facility and knowledgeable staff have a high level of experience and technical ability in forging design and manufacturing.
Forging manufacturing is a very ancient metals hot processing. Since their adoption little more than one century ago, aluminium alloys are especially adapted for this kind of processing. The plastic deformation obtained by this technique enables the manufacturing of lightweight aluminium products having complex geometry, suitable for high-stress applications yet lightweight, compact and extremely workable.

Each product results from a close relationship between the Customer and FMG staff, which offers its experience to meet the single production requirements and to provide support during the study and designing phase.
In force of this experience, the company has fast expanded in the prestigious sector of structural forged products. In fact FGM has been collaborating for some time with a piston manufacturer whose products are assembled on the engines of well-known carmakers that won or are winning races and the F1 World Constructors' Championship.
The Quality Department supervises the entire process in compliance with the UNI EN ISO 9001:2008 standard.

BM Anodizzazione - The region Veneto works at record time
For 40 years BM Anodizzazione Alluminio has been a leading company in the sector of aluminium product anodizing, processing items having different shapes and dimensions. Customer-oriented philosophy and processing quality are the pillars that the corporate strategy is based on as well as an all-round customer service ranging from alloy consultancy to free estimates and advice on the best treatments to adopt. The company is equipped with pre-treating machinery that allows for better finishing.
The corporate flexible organization can handle urgent overnight deliveries while the regular lead time is of 3 to 5 days, even for large quantities. In order to reduce collection and delivery time, BM has company-owned transport means or avails itself of couriers. New cutting-edge machinery has consolidated BM Anodizzazione Alluminio's position on the domestic market and gives momentum to expand on foreign markets.

Kiwa Cermet Italia partner to Alumotive's sustainable innovation
In the last 25 years CERMET has been developing and providing services to support the organizations' value. Last August CERMET has joined the Kiwa Group - an established international organization in the certification, inspection, test and training Sector - thus changing its company name into KIWA CERMET ITALIA.
Benefiting from this experience, which is an opportunity to develop and strengthen the company's operational skills on the domestic and foreign market, this year too KIWA CERMET ITALIA will contribute to the ALUMOTIVE project with its know-how, especially in terms of management of the technical quality along the supply chain, also including product and process environmental quality.
KIWA CERMET ITALIA is committed to promote the value not only of a single firm but most of all of the production chains and company networks.

With an outstanding experience in quality, environment and safety management system certification, KIWA CERMET ITALIA is also specialized in certification that complies with the standards set by the automotive (ISO TS 16949) and aeronautical industry as for lab activities and, via UNAVIAcert - another company of the Group - as for certification in accordance with the EN 9100, EN 9110 and EN 9120 standards.
Over time, KIWA CERMET ITALIA has developed several interesting projects for the Supply Chain Operations (SCO):

• PEC - Prevention and Control for the car and agricultural machinery sector.
• DIMOTER - Telematic District serving the car and motorcycle industry in the Region Emilia Romagna.
• ECOIMPRESA - Technical meeting to promote sustainable mobility, ELV, eco-compatible production.
• TRACES - Transnational Calibration Expert System.
• ISML - Innovation centre in the field of energy and environmental efficiency materials.

ALUMOTIVE is a new chance for KIWA CERMET ITALIA to discuss the crucial role of added-value services in supporting the relationship between buyers and supply chains with the aim to establish systems that expand business opportunities while limiting exposure.

Smartdress Project - Innovative, fast, eco-friendly
European researchers have found a way to make the automotive sector more eco-friendly, while at the same time cutting production costs. The EU-funded project SMARTDRESS ('Adaptive tip dress control for automated resistance spot welding') is developing a fully automated control system to improve crucial welding processes.
The global automotive sector produces around 60 million vehicles per year. In the primary stages of vehicle construction, manufacturers rely heavily on resistance spot-welding (RSW), a process in which steel or other metal surfaces are joined by heat generated by electric current. In this phase of car production, manufacturers use RSW guns with electrode 'tips' - the elements that are placed directly in contact with the metal pieces to transmit current. When these tips get worn, weld quality can suffer, resulting in interruptions in production, and, by extension, loss of revenues.
According to project partners, most spot weld quality problems can be traced to poor electrode tip dressing. This is a major cause of interruptions in the manufacturing process.

With a new vehicle typically rolling off a production line every one to two minutes, a welding tip issue causing even a five-minute line stoppage, once per day, can result in a loss of 10 vehicles per week, equating to about EUR 7 million in lost revenue per year.
Dresser systems for maintaining tip quality are already in use on many production lines, but current solutions require manual set-up, optimisation and continued monitoring during production, which cannot be efficiently performed for large production lines. In addition, today's tip dress systems cannot be used in the high-volume production of aluminium assemblies, preventing the use of RSW and requiring high-cost technologies such as self-pierced riveting.
The SMARTDRESS system will be intelligent, automatically optimising, monitoring and maintaining RSW electrode tip quality. The new technology will allow for the first time aluminium welding, which until now was not done on a commercial scale. This technique will lower the cost of manufacturing vehicles made from aluminium.
SMARTDRESS has received over EUR 1.1 million in EU funding and will complete its work before the end of 2013.

Titanium metal
In the metallurgical sector titanium has a place of absolute importance for its outstanding characteristics that distinguish it. Some of its alloys in fact reach tensile strengths similar to those of the best steel alloys that are used in the mechanical field for highly stressed parts. The density of titanium, however, is 42% lower (4.5 kg/m3 against 7.7 kg/m3) and this allows to create lighter components. The modulus of elasticity is significantly lower than that of steel, but this is offset by adopting major sections and more generous ribs. In practice, one can obtain a weight reduction of around 30-35%, which constitutes a considerable advantage, particularly when it comes to parts that must move very quickly.

Among other characteristics of titanium is its extraordinary resistance to corrosion. The distribution of this metal has been hampered by its high cost, but a lot of work is being done to reduce this handicap.
Today there is a large number of titanium alloys, suitable for a variety of uses, the most used is Ti 6Al 4V. The first applications were in the field of aeronautics, where until today, still has wide spread use. In the motoring segment titanium finds applications in cars and competition motorbikes and in some high performance series models; components that are made include connecting rods, valves, bolts, springs and rods. The excellent biocompatibility of titanium means that it is widely used in orthopaedic implants.

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