PIM Metals October/November 2023 issue by ASTAC

PIM METALS INCORPORATING IMT

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VOLUME 2 l ISSUE 10 l OCTOBER/NOVEMBER 2023

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25 Years State of the Art

PIM Metals October/November 2023

COMMENT/IN THIS NEWS ISSUE

COMMENT

IN THIS ISSUE

elcome to the October issue of PIM Metals, as the metals industry strives to achieve government targets to reduce both emissions and energy reduction costs can be a serious factor. Achieving these targets can be restrictive in the short term, but the long-term benefits especially in energy reduction can show a return on investment. Suppliers to the metals industry are making significant investments in developing new products and services that can assist our industry in meeting these targets, this for example ranges from process controls to optimise energy consumption to new low energy tube bending machine technology.

Global Aluminum Associations welcome new OECD analysis...

WELDING

Perfect symbiosis of welding technology and kinematics

Recyclability of metals is a major benefit when we look for example at the use of plastic tube/pipe, we can also see a surge in the use of metals when looking to the beverage industry and the switch from plastic to aluminium due to the ability for consumers to recycle. For our final issue in 2023 we will be looking at Tube and pipe production & processing, Energy management and reduction plus Tube & Pipe mills. Contributions and news should be with us no later than November 20th and sent to imtmagazine@virginmedia.com

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Vince Maynard KVJ Enterprises, Tralee, Hillcrest Road, Edenbridge, Kent, TN8 6JS, UK

PRODUCTION Anthony Wiffen ASTAC Business Publishing Tel: +44 (0) 1460 261011

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Automatic laser technology: with ‘Micro Briges’ for macro productivity gains

Cover picture: Fronius p.10

PUBLISHER & EDITORIAL DIRECTOR

Huge opportunity for supply chain collaboration in the metalworking sector

Vince Maynard, Publisher Email: imtmagazine@virginmedia.com

VOLUME 2, NUMBER 11 – OCTOBER/NOVEMBER 2023 Contact information

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MasterMover launches world’s most powerful electric tug solution

EVENTS

Convincing premiere for wire and Tube Middle East Africa in Cairo

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Editorial and advertising deadline for the December 2023/January 2024 issue of PIM is:

November 20th

PIM Metals October/November 2023

NEWS

Global Aluminum Associations welcome new OECD analysis of climate impact of subsidies across aluminum supply chains

he aluminum associations of the United States, Europe, Canada and Japan welcome a new report by the Organisation for Economic Cooperation and Development (OECD), The climate implications of government support in aluminum smelting and steelmaking. The report examines current government support provided to aluminum smelting and steelmaking firms. It finds that support has both increased output and greenhouse gas (GHG) emissions in the two sectors and shifted production to less efficient and higher GHG emitting plants, most notably in China and India. The report also highlights the expected benefits of alternative support measures that target the development and adoption of new climate technologies that are essential for the transition

to net zero emissions (NZE) globally. The OECD report simulates removing existing government support and estimates that doing so would decrease global GHG emissions by 1%, while reducing global output by just 0.3%. These results are driven by China and India, which account for 96% and 89% of the emissions and output reductions, respectively. This is largely because China and India have a ratio of support to output between 1.8 and 7 times the world average, and GHG emission intensities that are one and a half to three times larger than in OECD economies. In welcoming the report, Charles Johnson, President & CEO of The Aluminum Association; Paul Voss, Director General of European Aluminium; Jean Simard, President & CEO of the Aluminium Association of Canada; and Yasushi Noto, Executive Director of the

Japan Aluminium Association emphasized: “The report highlights that addressing excessive subsidies and thereby ensuring a level playing field globally can be a cost-effective strategy to reduce emissions in hard-toabate sectors like aluminum. Across aluminum supply chains today, high levels of support in China displace output from lower GHG emitting production systems, resulting in a much higher carbon footprint globally. Removing such harmful support is an essential element of the aluminum industry making the transition to net zero emissions globally.” “Finding the right balance between government support and private sector spending on research, development and technology adoption at industrial scale is key to enabling a viable aluminum industry pathway to a sustainable future. The transition to NZE

globally will require massive new investments, but the costs cannot be borne by governments alone. Additional private sector investments in electricity decarbonization, near zero GHG emission smelting systems, and near 100% aluminum recycling rates are also needed. These investments are contingent on aluminum markets being fair, open to competition and free of aggressive state capitalism.” “On behalf of our member companies and the 1.75 million workers they directly and indirectly support across the United States, Europe, Canada and Japan, we are fully committed to working with international organisations and with governments to ensure that responsibly and sustainably produced aluminum contributes to a clean energy economy globally.”

Italian job for Corinth Pipeworks Corinth Pipeworks was awarded a contract, by Snam to manufacture and supply approximately 13 km of longitudinally submerged arcwelded steel pipes (LSAW) for the development of an offshore and onshore natural gas pipeline for the Floating Storage and Regasification Unit (FSRU). The contract is valued at over €10 million. The greenfield FSRU based

PIM Metals October/November 2023

LNG terminal project in the port of Ravenna is a strategic project to help ensuring Italy’s energy needs, increasing security of supply and diversification. Furthermore, the project will provide critical infrastructure, with a capacity of 170,000 cubic meters and a nominal throughput of 5 billion cubic meters of natural gas per year. The 26-inch, pipeline, will be certified to transport up to 100%

hydrogen. Corinth Pipeworks is utilizing cutting-edge technology and infrastructure, providing solutions for hydrogen certification of new pipelines. As such steel pipes produced today and installed in the current gas network shall cover the energy mix of tomorrow. Steel pipes will be manufactured at Corinth Pipeworks’ facilities and will include internal and three-

layer polypropylene, external coating, as well as concrete weight coating (CWC), applied at the same location as pipe manufacturing at Thisvi, Greece. This award to Corinth Pipeworks is the latest from Snam, with the assistance of its Italian business partner PIPEX, and builds on the company’s successful long-term relationship and a succession of earlier pipeline developments.

NEWS

ALFED report investigates impact of global conflict on the UK aluminium industry

LFED, the aluminium federation, has launched a new report examining the impact of the Russia/Ukraine war on the UK aluminium industry. Developed in partnership with CRU International Ltd, the document explores the short, medium and long-term consequences of government import sanctions, as well as suggesting alternative future options to maintain primary aluminium supply. With the objective of protecting the UK’s thriving aluminium supply chain, supporting domestic production and minimising the effects of geopolitical issues, the report considers how

removing Russian material from imports will directly impact UK businesses, as well as how changing market dynamics will likely hit future export demand. The opportunities to increase uptake of recycled content and reduce the industry’s carbon footprint are also covered in detail, alongside the wider supply chain issues presented by a weakening global forecast.

Tom Jones, chief executive officer of ALFED, commented: “Politically, and morally, pressure is increasing to ensure that all materials used within the UK have a clear path of origin and do not – in any way – support the Russian state. While Russiansourced aluminium was only ever responsible for a small fraction of the import market, it is still important to consider the longerterm picture to ensure minimal disruption to the supply chain. “Our latest report investigates the widespread impact of global conflict, identifying both challenges and opportunities, but also raising a number of highly pertinent questions. Firstly, what does a viable future solution

for material sourcing look like? Secondly, what support should the UK government offer to support the wider agenda? And, finally, what are the immediate priorities that we – as an industry – must be tackling to maintain global competitiveness? “It’s fair to suggest that this report is a hugely important resource for any business involved in the UK aluminium supply chain and I’d implore industry professionals to take the time to read it in further detail.” “Impacts to UK aluminium industry following Russia/Ukraine war” is available for members to download via the ALFED website. To become a member of ALFED, visit www.alfed.org.uk.

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PIM Metals October/November 2023

NEWS

Wired for success: Unison Ltd acquires UK wire bending machinery manufacturer, Pneuform

nison Ltd, the UKbased inventor of all-electric tube manipulation, has acquired Dorking-based wire and small tube bending machinery maker, Pneuform, for an undisclosed sum. The acquisition further underpins Unison Ltd’s position as a leading manufacturer of tube and pipe bending technologies and paves the way for the company to become a key provider of machinery to the international wire bending and coil forming sectors. As a member of the Unison family, Pneuform will benefit from direct access to the many advancements that Unison Ltd has brought to tube and pipe manipulation – innovations that will help Pneuform achieve even greater sales success going forward. “We have known the team at Pneuform for many years and are hugely impressed by their product range, extensive knowledge of wire-forming technologies, and high levels of customer care,” comments Unison Ltd’s joint managing director, Alan Pickering. “In welcoming Pneuform to the Unison family, we look forward to enhancing the business’s existing, excellent machine tool range with our advanced, user-friendly control systems and simulation

Unison Ltd’s joint managing director, Alan Pickering. software. With our locations in the north of the UK and in the Midlands, and with Pneuform’s HQ in the south of the country, we also look forward to providing Pneuform’s British customers with even higher levels of service. “The Pneuform name will be retained, as will its rich heritage,” adds Alan Pickering. “While to ensure that Pneuform is able to further develop its position as a leader in wire and small tube bending machines, we have a number of new

machine tool technologies in the pipeline. We are convinced these new machines will be of particular interest to organisations producing tubular components for the automotive, EV, electronics, solar energy and refrigeration industries. Further announcements will be made in due course.” Pneuform was a pioneer of CNC 3D wire bending. Today its wire and small diameter tube bending machines have become the industry standard

with manufacturers of beer coolers, drink dispensers and HVAC equipment, as well as with makers of small diameter automotive parts. Pneuform’s range of wire bending machines includes rotary head models, flat rotary line bending machines and enamelled wire bending machines. Available in 2-axis and 3-axis versions, Pneuform machines cater for outside tube diameters ranging from 3 mm to 11 mm in stainless steel and 3 mm to 15 mm in copper.

Unison Ltd: intelligent tube technology Unison Ltd is the UK’s leading manufacturer of tube and pipe bending machines and continually innovates the tube and pipe bending marketplace. The company manufactured the world’s first all-electric tube bender in 1994, followed by the world’s first all-electric multi-stack tube bender, then the world’s largest all-electric tube bender for the shipbuilding industry. Available in single-stack, multi-stack and right/left varieties, Unison machines are delivered to more than 20 countries globally. Unison’s tube bending software is recognised as the most userfriendly control system for tube bending machines. The software is written and supported by Unison, ensuring complete control of its evolution, with no need for third party support. www.unisonltd.com PIM Metals October/November 2023

NEWS

Corinth Pipeworks is awarded pipe manufacturing contract for the Porthos offshore CCS project

orinth Pipeworks has been awarded a more than €30 million contract, to manufacture and supply High Frequency Welded (HFW) steel pipes for the Porthos CO2 transport and storage project. Carbon Capture and Storage (CCS) is a low-cost method of preventing huge volumes of CO2 from entering the atmosphere with permanent storage in geological reservoirs. CCS is a crucial strategy to help accomplish climate targets, particularly if industry has few options for making major shortterm CO2 emission reductions. Once operational, the Porthos project intends to permanently store CO2 from industry in the Port of Rotterdam in empty gas fields

deep beneath the North Seabed. The 16-inch, 22-kilometer offshore pipeline will include anti-corrosion coating, thermal insulation, as well as concrete weight coating (CWC). The pipeline will transfer CO2 from a compressor station to the P18-A platform in the North Sea. The existing gas platform P18-A will be repurposed for CO2 storage. The platform will be outfitted with the necessary equipment for transporting the collected CO2 to the injection wells. The pipes will be manufactured at Corinth Pipeworks’ facilities in Greece, and offshore installation work will commence according to schedule within 2026. Carbon Capture and Storage (CCS) technologies have the

potential to play a significant and diverse role in achieving global energy and climate goals. The European Union has recognised Porthos as an important project in meeting climate targets, designated it a Project of Common Interest and made €102 million in funding available for it. For the past 15 years, Corinth

Pipeworks has manufactured pipelines transporting CO2 totaling over 1,150 km in length. The company’s North American onshore and now European offshore CO2 pipeline experience demonstrates its readiness to contribute to the development of many planned CCS projects around the world.

The Sustainability Ratings are in! Inductotherm Heating & Welding are delighted to announce that they have been awarded the Silver - Ecovadis Sustainability Rating. This new accolade follows hot on the heels of Inductotherm Heating & Welding’s triple BSI ISO accreditation awarded in June 2022 which included ISO9001 for Quality, ISO45001 for Occupational Health & Safety and ISO14001 for the Environment. Inductotherm Heating & Welding are undertaking a process of developing and improving their environmental and sustainability practices to ensure they are sensitive and responsible to the local and wider environment. Implementing a wide range of changes in all areas of the business from adopting renewable energy to changing to eco-friendly supplies and

PIM Metals October/November 2023

engaging with suppliers as an on-going commitment by the company. In addition to their commitment of social and environmental responsibility these accolades provide their customer base with the reassurance that they are engaging with a forward thinking and ethical company committed to providing their customers with the environmentally sound and

continually improving service. Achieving the Silver rating has already allowed Inductotherm Heating and Welding to attain “Preferred Supplier Status” with existing Tier 1 customers who highly value sustainability across all areas of their business. Ecovadis was founded in 2007 and has grown to become the world largest and most trusted provider of business sustainability rating. The Ecovadis sustainability methodology evaluates how well a company has integrated the principles of sustainability/ CSR into their business and management systems based on seven founding principles: l Assessment by international experts. l Tailored to industry sector, country and company size.

l Source diversification to ensure

rich stakeholder input for reliable scoring. l Utilize technology to ensure a secure and confidential process and accelerated cycle time. l Traceability and transparency of documentation l Evidence-based. l Excellence through continuous improvement. The methodology is built on internationally sustainability standards, including the Global Reporting Initiative, the United Nations Global Compact and the ISO26000 with performance measure across 21 indicators in four themes: l Environment l Labor & Human Rights l Ethics l Sustainable Procurement.

NEWS

Unison enjoys a fantastic FABTECH 2023

ABTECH 2023 Chicago proved to be a huge success for Unison Ltd, the UK-based inventor of all-electric tube manipulation, and its North American division, Unison Tube LLC. Over the course of the fourday event in September, the tube and pipe bending machinery manufacturer secured a significant number of high-quality enquiries. Paul Krickeberg, CEO of Sharpe Products, one of North America’s leading specialists in custom tube and pipe bending and tube laser cutting, also visited Unison Ltd’s show booth to view the all-electric Unison Breeze CNC tube bender that would soon be on its way to his company. The machine purchased by Sharpe Products - a 100 mm (4”) single-stack Breeze model - formed the centrepiece of Unison Ltd’s FABTECH display. It is the ninth Unison Breeze to be bought by Sharpe Products since 2003, and will be used to provide additional capacity for bending tubular components for the business’s extensive customer base. “We’re absolutely delighted that Sharpe Products has chosen to purchase yet another Unison Breeze all-electric tube bending machine,” says Stuart Singleton, VP of Unison Tube LLC. “As you can imagine, such impressive

From left: Stuart Singleton, VP – Unison Tube LLC; John Nimmons, Plant Manager – Sharpe Products; Paul Krickeberg – CEO, Sharpe Products; Alan Pickering – Joint Managing Director, Unison Ltd repeat orders are an incredible testimony to the faith a customer places in our machine tool technologies, operating software and product support.” UK-based Unison Ltd invented ultra-precise, all-electric tube and pipe bending, and the Breeze 100 mm (maximum tube diameter) machine is one of its flagship models. Just like all Unison Breeze tube bending machines, the 100 mm Breeze offers rapid setup, fast tooling changes, exceptional power, rigid mechanical design, and all-electric control for right-firsttime repeat sub-contract work, or immediately after producing

a single trial part. These are all attributes that Unison Ltd believes make its Breeze models the ultimate tube manipulation machines for businesses specialising in frequently changing, small-to-medium batch production runs. Other highlights for Unison Ltd during FABTECH 2023 included the considerable interest shown in its EvBend range of manually operated, CNC-controlled 3-axis tube bending machines. Typically used for low-volume, highaccuracy production and prototyping, Unison EvBend machines provide accurate multi-

plane bending at a much lower cost than many CNC benders. Two models are currently available – the EvBend 1000 for bending tube of up to 16 mm in diameter, and the EvBend 2000, a machine featuring powerassisted operation and capable of bending tube of up to 50 mm in diameter. Unison EvBend machines are widely used across the aerospace and motorsport sectors for bending precision components. For more product information, please contact: Alan Pickering – Joint Managing Director, Unison Ltd. T: +44(0) 1723 582 868 E: sales@unisonltd.com

PIM Metals October/November 2023

NEWS

Tata Steel and Gestamp UK nearly double recycled steel content with new circularity partnership

new agreement between Gestamp and Tata Steel UK will see the percentage of recycled steel in the components they supply to the automotive sector nearly double, as the two companies work to increase the circularity of steel in the automotive supply chain. The initiative will allow Gestamp to pass the benefits of increasing its recycled content, such as a reduced carbon footprint, to vehicle manufacturers. OEMs need low-emission steel to meet their decarbonisation targets with guaranteed quality and safety. This new circularity concept contributes to achieving sustainability goals by using high-quality scrap as a secondary raw material for the production of low-emissions steel. Tata Steel’s automotive steel grades already include 17% recycled content – made up of scrap steel that re-enters the steel production process. The recycled content provided by Gestamp will be additional to the existing recycled content. This new partnership sees the percentage of recycled content associated with the steel provided to Gestamp jump to 30% with no impact on quality, strength or formability. This is, in turn, passed on to automotive manufacturers, reducing the overall carbon footprint of their supply chain and production process. Steel is 100% circular, it can be re-melted to produce material of the same quality an infinite amount of times. When a component, for example a bumper bar, is processed from steel, it is typical for the manufacturing process to generate some scrap

PIM Metals October/November 2023

material. Normally, this high quality scrap is sold on to a third party scrap buyer and mixed with steel grades of different qualities. In this new partnership, Gestamp will channel its high quality scrap (through efficient collection and transport management) to Tata Steel’s steelworks in Port Talbot so that it can be used again in future steelmaking. By using the mass balance principle1, the returned steel will then be accounted for as part of the component’s recycled content. The traceability and quality of pre-consumer scrap provided by Gestamp will enable the recycled content of new steel to be increased and the quality of the steel to be preserved. To ensure accountability, Tata Steel will provide evidence to demonstrate the volume of high quality scrap supplied and the associated CO2 savings by setting up a Gestamp Recycled Content Bank, which will be independently audited. Peter Quinn, Director of Sustainability & Environment at Tata Steel UK, said: “Reducing the automotive supply chain’s carbon footprint is a priority for us and many of our customers,

including Gestamp. We believe that improving circularity in the supply chain is an effective and immediate way to reduce overall CO2 emissions in the automotive sector, as well as the most efficient way to recycle steel. The approach we have taken with Gestamp demonstrates the innovative and collaborative thinking possible, not only in our two organisations, but in the UK automotive supply chain as a whole.” Ernesto Barceló, Chief ESG Officer at Gestamp, said: “This agreement strengthens our circular economy model and benefits our customers on their way to neutrality and net-zerocar thanks to the use of high quality scrap as a secondary raw material while guaranteeing the quality and safety of our products”, says Ernesto Barceló, Gestamp Chief ESG Officer. “The excellent management of Gestamp in collection, sorting and transport this high quality scrap, will provide Tata Steel with (the possibility of) lower emissions steel”. Any additional revenue earned by Tata Steel UK as a result of this partnership will be reinvested into further decarbonisation projects,

in turn accelerating the company’s path to net zero. So far, Tata Steel UK has reduced the amount of energy required to make one tonne of steel by 30% since 1990. Steelmakers, including in Europe, are looking to reduce their carbon emissions, such as by recycling scrap to create new high-quality steel for customers. Earlier this month (September) Tata Steel announced the proposed route to decarbonise its UK operations by switching to electric arc furnace steelmaking (EAF) technology which produces new steel from scrap steel. The proposal is subject to relevant regulatory approvals, information and consultation processes, and finalising detailed terms & conditions. Bringing back steel scrap from customers like Gestamp to its Port Talbot steelworks is, therefore, an important step helping to secure raw materials for steel products both now and in the future. It also means recycled, reduced carbon steel is available to automotive manufacturers in the short term until EAF steel is in production. Last year Tata Steel UK launched Optemis® Carbon Lite, which enables steel users to reduce products’ carbon footprint by up to 90% by drawing upon credits in its CO2 bank, earned from independentlyverified CO2 savings made by its decarbonisation projects. For more information about Tata: Alex Michaelides on + 44 (0)7802 865 732 amichaelides@ torqueagencygroup.com For more information about Gestamp: Miguel Bañón Penalba on +34 619 406 058 / +34 658 508 731 mbanonpenalba@gestamp.com

NEWS

Hasçelik selects Tenova and ABB technology for steelmaking line at new plant in northwest Türkiye

BB has partnered with Tenova, a leading developer and provider of sustainable solutions for the green transition of the metals industry, to install and commission equipment in a new Hasçelik Sanayi ve Ticaret A.S. steel plant in Osmaneli (Bilecik, Türkiye). Hasçelik is one of Türkiye’s leading manufacturers of special steel with a total of five manufacturing plants and other locations worldwide. The new line will comprise Consteel® Electric Arc Furnace (EAF) equipped with Consteerrer® electromagnetic liquid steel stirring system, a ladle furnace and a twin vacuum degasser. All units are linked and governed by an extensive, state-of-the-art automation system to optimize the whole process and guarantee high quality steel grades. The unit selected by Hasçelik will be the first continuously charged EAF in Türkiye and will allow the steelmaker to leverage the inherent flexibility of the Consteel EAF to tackle declining scrap availability and quality. The continuous charge makes the process robust to the variation of the scrap density, quality and content of volatile compounds. At the heart of the system is the new Consteel Evolution based on a full-platform EAF with singlepoint roof lifting system, a combination that brings the benefits of energy efficiency, reduced workforce, increased reliability, improved productivity and reduced environmental impact.

The new Consteel furnace will be equipped with Consteerrer, a technology jointly developed by ABB and Tenova as part of an exclusive global partnership agreement. Consteerrer is an application of ABB’s unique ArcSave® non-contact electromagnetic stirring technology designed specifically for continuous charging EAFs. It reduces thermal losses, increases melt rate, rapidly homogenizes the liquid steel and reduces oxygen content in the bath. The technology can be customized to match the needs of different EAFs and retrofitted on existing units. “In light of rising commodity and energy costs as well as a greater focus on sustainability, process efficiency is more important than ever,” said Zaeim Mehraban, Global Sales Manager, Metallurgy Products

at ABB. “Using the unique and proven ABB ArcSavebased electromagnetic stirring technology found at the core of Consteerrer, Hasçelik will be able increase productivity and energy efficiency in their electric arc furnace process and accelerate financial gains as well as progress to sustainability goals.” “With this project, Hasçelik is investing to increase its competitiveness within the market of high steel grades,” said Davide Masoero, Tenova Area Manager Europe Electric Arc & Ladle Furnace. “Scrap characteristics in terms of purity and density are, in fact, worsening and the Consteel technology is fundamental to maintaining high quality production.” “Together with Tenova experts and drawing on ABB technology,

we have designed a tailormade solution that also makes provision for future expansion of the current facility. The specific technologies of Consteel and Consteerrer perfectly fit with our needs,” said Naci Faydasiçok, Hasçelik chairman of the board. With production facilities in İstanbul and Konya and a total of nine warehouses in seven provinces, Hasçelik Sanayi ve Ticaret A.S. produces and supplies hot-rolled special steel and cold-worked special bright steel and sells and distributes seamless pipes. It is the flagship in the Faydasiçok Holding group of companies and comprises bright steel production facility Hasçelik Cold Processing Center with an annual production capacity of 170,000 tons and Hasçelik Special Steel Rolling Mill with a production capacity of 300,000 tons per year. PIM Metals October/November 2023

WELDING

Perfect symbiosis of welding technology and kinematics Welding engineers all over the world associate the name Fronius with innovative welding technology. Above all, the innovators are known for providing high-performance, high-tech welding systems. The name Fronius is also associated with revolutionary welding processes such as Cold Metal Transfer (CMT), intelligent seam detection sensors such as WireSense, and the brandnew DynamicWire wirefeeder. However, there is little awareness across all industries that Fronius Welding Automation supplies automated welding systems from a single source. Only in the oil and gas offshore sector does the company have a strong profile among potential customers as a renowned manufacturer of cladding systems.

here is a long tradition of plant construction at Fronius. Take, for example, the longitudinal seam welding system from 1979 for welding sheet metal sections made of steel. The company has been developing sustainably designed welding systems that have future potential since 1975. That’s why most of their solutions can be upgraded and expanded by adding extra features such as welding processes, sensor technology, and software updates. Today, more than 3,500 installed systems are in use across 45 different countries with over 2,000 active customers. Covering an area of more than 11,000 square meters, around 150 employees (a number that is increasing) take on the welding technology challenges presented by their customers.

Longitudinal welding system (seam welder) from 1979 for welding sheet metal tolerances. Last but not least, smart data documentation systems assist in perfecting the welding process.

Cost-Effective from Batch Sizes of One Collaborative systems, intelligent sensor technology,

software solutions for data management, and offline programming including welding simulation open up profitable welding opportunities for metal processing companies starting with a single batch. That is why Fronius robotic welding cells prove profitable not only for large

Technological Advantage Since the invention of the “cold” MAG welding process, Cold Metal Transfer (CMT), if not earlier, Fronius has continuously achieved technological leadership in many welding-related areas, resulting in state-of-the-art mechanized and automated welding systems. Advanced power source technology stabilizes the arc and ensures perfect welding results. Modern monitoring sensors optimize guidance of the welding torch and compensate for component 10

PIM Metals October/November 2023

Robotic welding cell welds aluminum inverter housing, welding process: PMC Ripple Drive

Anton Leithenmair MBA, Head of Fronius Welding Automation companies, but also for smalland medium-sized enterprises.

Modular System and Project Management The specific requirements for the welding technology are analyzed together with the customer. This is followed by the creation of an individual solution. To do this, Fronius has an extensive construction kit of standardized components at its disposal. Starting with the feasibility study and continuing with planning, engineering, manufacturing, and start-up, the sale of welding systems is handled as a project. During this time, customers have one main point of contact: the project manager. He or she takes care of the entire project process and acts as the interface between the customer and all the Fronius sections involved.

WELDING

FRW compact double-headed circular seam welding system

Offline programming and simulation with Fronius Pathfinder In doing so, the project manager ensures that processes run smoothly, cooperation is effective, and projects are successfully completed. “The platform concept is at the heart of our engineering process. We define this as an intelligent matrix of management, technology, modular system, partnerships, and service.”

Anton Leithenmair, Head of Fronius Welding Automation Automation from a Single Source Almost every project starts with a feasibility study, which determines the entire engineering process. It forms the basis for a solution that is tailored both in terms of technical and commercial viability. The integration of welding technology into the kinematic elements depends on the following factors: component conditions, process accuracy, and profitability. Welding Automation sources specialized components such as robots, sensors, clamping systems, and shelving systems from qualified cooperation partners.

Offline Programming and Welding Data Management Fronius provides and relies on

software solutions that enable a high degree of control and optimal interaction between all system components. Pathfinder provides all customers with an offline programming and simulation solution that significantly increases the profitability of welding systems. WeldCube is programmed for the evaluation of welding data. The innovative software seamlessly records welding data, makes welds reproducible without any limitations, and supports users in identifying optimization potential and maintenance intervals.

Fronius Welding Automation is there to help its customers wherever they are in the world: providing support with everything from planning to feasibility studies, welding tests, commissioning, user training, remote maintenance, calibration, predictive maintenance, and onsite maintenance work.

All-inclusive Service

One Range for All Industries

Right from the start and throughout the entire service life of a welding system,

Mechanized Welding Systems: All welding torch movements are controlled automatically without

LaserHybrid robotic welding cell

Endless torch rotation cladding system (ETR) with SpeedClad welding torch

the use of robots. Examples include boiler welding systems, seam welders, orbital welding systems, and magnetic or railguided welding carriages. Robotic Welding Cells: Robots are used to control the movement axes. They are ideal for automating complex welding tasks on a variety of components. In combination with intelligent offline programming and simulation software for batch sizes as small as one. Overlay Welding Systems (Cladding Systems): Overlay welding is used primarily in the cladding of metals to protect against abrasion and corrosion. Typical fields of application include rising pipes as well as valves for the oil and gas industry or membrane walls for power plants and waste incinerators. Click here for more information on Fronius Welding Automation: https://www.fronius. com/en/welding-technology/ product-list?filter=2862 Photos: Fronius International GmbH

PIM Metals October/November 2023

NEW PRODUCTS SUPPLY CHAIN

Huge opportunity for supply chain collaboration in the metalworking sector

nly a quarter (24%) of metal workers say that there is enough supply chain collaboration in the industry, according to new research from SAIT Abrasives. SAIT, specialist manufacturer of bonded and coated abrasives for industrial use, wanted to understand the extent to which the metalworking sector is collaborating to source solutions throughout the supply chain, as it embarks on its own collaborative initiatives to support its end12

PIM Metals October/November 2023

users and distributors. Despite this lack of collaboration, just over half (54%) of those surveyed say they value when a supplier can create a tailored solution to their business need and a further half (56%) say that it is important that their suppliers are innovative. Yet, only half (51%) say that their suppliers are collaborating with them to offer tailored solutions. Respondents state that they value supply chain collaboration because it helps increase efficiencies within their business

(52%), adapt to business needs (47%), and innovate (46%). Chris Ingman, managing director at SAIT Abrasives, said: “Our research shows that while half the industry does value supply chain collaboration, over three quarters feel that the industry isn’t maximising the potential of taking a more cohesive approach to working together. “Collaboration is vital to innovation, while our industry is ultimately very traditional and relies on traditional

processes, there is still a need for innovation. This could be changes that speed up processes, right through to large-scale digital innovations. No matter the scale, a joined-up approach is essential to understanding the challenge and developing the solution. “At SAIT, our technical team works with customers to understand their needs and challenges. We go on-site to see how customers are using our products and we analyse their workplaces to see how we can provide the right product

NEW PRODUCTS SUPPLY CHAIN

for them. Often this results in bespoke solutions. This agility is invaluable to our customers, leading to greater workplace efficiencies and productivity.” While just under half (44%) say that it is important to them that their suppliers are present in their buying journey, less than a quarter (21%) say that they buy directly through people, instead opting to buy from suppliers’ websites. On top of this, only a third (30%) say that they make choices over which supplier to use quicker when they can speak to the potential supplier directly. RB Tools & Fixings, a specialist in single source and supply for customers ranging across construction, fabrication, manufacturing and production has been working with SAIT to provide surface finishing solutions to the metalworking industry. Matt Walsh, operations director at RB Tools & Fixings, said: “In general, the desire to collaborate is growing but the

research suggests we need greater industry awareness of the long-term health and safety, and cost benefits that can be gained from working with the supply chain. “As a distributor, we find it really important because it gives us the best opportunity to synergise with manufacturers while bringing innovation to end users, enabling them to improve efficiencies and processes while securing an overall cost saving. “Collaboration also enhances the relationship and trust throughout the supply chain, from manufacturer to end user, and builds a line of communication that allows manufacturers to bring new innovations to market from customer feedback.” Chris concludes: “Collaboration isn’t just crucial to how we solve issues today, it’s vital to how we solve future challenges too. At the moment, all industries are facing big questions from how do we work

safer, to how do we work more sustainably. These are huge questions and the answers lie in greater collaboration. Only then will we see useful innovations that lead to more streamlined processes.”

Read the full insights from the survey on SAIT UK’s blog here: https://www.saitabrasives.co.uk/blog/post/ bringing-the-uk-metalworkingsector-together-through-supplychain-collaboration-

PIM Metals October/November 2023

NEW PRODUCTS LASERS

Automatic laser technology: with ‘Micro Briges’ for macro productivity gains Bevel cutting head Bevel-U for high presicion parts for automated robot welding

he machine platform ELEMENT from Messer Cutting Systems is, thanks to its impressive wealth and flexibility of possibilities, the basis for individually customised system configuration. Thus, for example, the laser machine ELEMENT L: it can be adapted optimally to the special needs of each user with many innovative design features such as the bevel cutting head “Bevel U” as well as the nozzle changer “Laser Nozzle Control”. A special cutting technology with micro bridges significantly shortens the otherwise necessary handling times. The laser machine ELEMENT L combines simultaneous hole piercing and faster cuts with laser precision cutting, all in one machine. It cuts Mild Steel, Stainless Steel and Aluminium with O2 and N2as well the optimum automatic gas mixing unit. With positioning speeds up to 140 m/min (combination X-/Y axes) and a high acceleration, the unit scores with high speeds and, thanks to linear guides in the X and Y axes, with outstanding positioning accuracy. The productivity has been significantly increased using high-speed lifters and modern process optimisation techniques. Independent tools, driven by servomotors, offer a range of processing possibilities. The CNC control has been developed to increase the efficiency significantly, eliminate unnecessary information and to make production operations 14

PIM Metals October/November 2023

The ELEMENT L scores with remarkably high dynamics, the newest laser technology, and the ability to process XXL plates economically. ZURÜCKVOR (PresseBox) more transparent. Set-up times can be reduced by the automatic positioning of multiple tools from the part program or the optionally available control.

Plasma and Laser combined Multiple tools can be integrated in the ELEMENT L. Both the number of torches and their space can be programmed. The user can combine the newest laser technology (maximum two stations) with advanced plasma technology here. Ingo Staudinger, Product Manager, Laser and Material Handling: “Highlight of the Element 400 L is the bevel cutting head Bevel-U, specially developed for the laser process. With its design, the Bevel-U is perfectly suited to produce precise and consistently accurate bevel parts – a great advantage in weld preparation

for automated robot welding.” Bevels between -50° and +50° are possible in workpieces, as are different edge shapes for a subsequent welding process. The bevel angle can be continuously, steplessly varied during the laser cutting process. A magnetic collision protection for the cutting head is also included in the design of the Bevel-U as is a manual operating console for all drives, to be able to carry out set-up work directly on the machine.

Solutions for more Automation Ingo Staudinger: “Bearing in mind the lack of skilled craftspeople and the urge for higher productivity, quality and sustainability, plate processers are increasingly seeking automated solutions, which, amongst other things, make a low manning operation possible.

There is an enormous potential in this area which we can tap into for the user.” With the newest developments in laser cutting technology, Messer Cutting Systems has created outstanding prerequisites for an automated production. Often it is the little things which give the decisive advantage, for example with handling: To be able to handle a part better after processing, the Messer cutting technology makes it possible to leave micro bridges between the cut part and the scrap frame. So each part does not have to be handled individually, but the plate can be simply removed as one piece by the loading/unloading system or a shuttle table. This significantly reduces non-productive times. The bridges are so fine that they can be easily parted from the frame later.

NEW PRODUCTS LASERS

“One feature for the automation of the ELEMENT L is the nozzle changer “Laser Nozzle Control” (LNC). It automates the set-up quickly and reliably and thus ensures maximum processing quality and productivity – for every material, every thickness and every process – and that with no manual intervention”, states Ingo Staudinger. The LNC ensures reliably high cut quality and shortens set-up times. Machine idle time is prevented, and the plate processor gets reliable planning and optimisation.

High precision in the production process The plate position is decisive for an accurate cut. There are always deviations here. With the ELEMENT L that is

no problem. Before cutting, the actual orientation of the plate is determined with the cutting nozzle sensing and the CNC program is rotated correspondingly – manually from the operating console or fully automatically from the program. This drastically reduces the effort when placing the plate on the machine and helps to achieve optimum plate utilisation. Just as important for the processing quality of the production process is a uniform motion of the machine. The ELEMENT L is equipped with a helical geared drive and precision linear guides. These provide the basis for fluid movements. Powerful AC servomotors ensure fast acceleration of the cutting tool in and around holes and corners.

Thus, an outstanding cut quality is achieved.

and minimises down-time but, above all, gives optimum protection to the operator.”

Marking included Additionally, different marking tools can be integrated in the ELEMENT L: to produce nonpermanent labels such as layout lines or a simple part identification on the plate, Messer Cutting Systems offer an Inkjet marker. For permanent marking a stylus marker is available for the ELEMENT L.

Safety first “High protection of person and machine is the first commandment for us in the design of a machine”, affirms Ingo Staudinger. “The functional safety technology of the integrated, internationally certified, TwinSAFE systems not only prevents damage to the machine

Digitalisation in the production The ELEMENT L is complemented by the powerful software solutions from Messer Cutting Systems. They ensure maximum transparency in production operations, production planning and control. To smooth the way further for a continuous networking, the Global Connect can process production orders directly and achieve maximum productivity, especially in combination with the products of the OmniFab family. That the operator interface is clearly and simply structured helps the user to call and use all features with no problems.

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NEW PRODUCTS

MasterMover launches world’s most powerful electric tug solution

asterMover, the global leader in electric tug solutions, has announced the launch of its new remote controlled PS7000+ model, featuring an impressive weight capacity of 70,000kg and patented MultiLink technology. Designed to enable a single operator to safely move loads of up to 70,000kg with a single machine, the PS7000+ is the ideal solution for heavy industrial manufacturing industries, where the movement of large, heavy loads presents serious challenges around operational efficiency and safety. Featuring a remote control operation, the PS7000+ allows an operator to take up the ideal vantage point when conducting the movement of a load, delivering unparalleled visibility and maximising safety. With the launch of the PS7000+, a single machine can move up to 70,000kg. Through MasterMover’s innovative MultiLink technology – a patented system enabling the multiple electric tugs to work together under the control of a single operator – this weight capacity is increased, meaning the PS7000+ is equipped to take on the most extreme movements of heavy wheeled loads. The PS7000+ adds additional weight-moving capacity to the PowerSteered range of remotecontrolled electric tugs from MasterMover. Offering a more compact and flexible alternative to traditional material handling systems, such as overhead cranes, fixed rail systems and large, high capacity forklift 16

PIM Metals October/November 2023

solutions, the PS7000+ helps industrial manufacturers discover greater efficiency and flexibility, whilst driving safer operations. The launch of the PS7000+ comes after MasterMover was recognised with the King’s Award for Enterprise in Innovation earlier in the year, demonstrating commitment to continuous innovation and product development. “The launch of the PS7000+ once again reflects our dedication to product development and

evolution. The PS7000+ is a natural evolution of our PowerSteered range, with our PS800+ and PS3000+ models already available to move 8,000kg and 30,000kg, respectively,” said James Jones, Partner & Director. “The PS7000+ enhances our ability to help our customers take on the toughest load movement challenges they face. Typically, customers moving the heaviest loads rely on large, cumbersome equipment, but with the launch of the PS7000+, they can benefit

from a significantly more compact alternative. We’re excited to see what opportunities the PS7000+ presents for our global customer base.” MasterMover offers the widest range of electric tugs and tows on the market, with pedestrian operated, remote controlled and fully autonomous (AGV) solutions available. The company’s products are used globally in over 70 countries, across industrial manufacturing, retail and logistics, and facilities management.

NEW PRODUCTS

GV Stamperie reduces energy consumption and eliminates downtime with the ELGi EG series

Local channel partner support and industry-leading warranty critical for Italian company’s precision forged and machined metal operations.

V STAMPERIE (GVS), one of the leading Italian brass and aluminum forging and machining companies, chose four EG Series (EG110V, EG90 Premium, and EG132) oil-lubricated air compressors from ELGi to improve efficiency. The installation resulted in energy savings of approximately 10% and zero downtime at its production plant in Brescia, Italy. GVS was looking for a new compressed air solution to replace the aging equipment driving the machining of its brass, aluminum, and copper forged parts used in a wide range of OEM components for the HVAC (Heating Ventilation Air Conditioning), DHW (Domestic Hot Water), Head Pumps, and Automotive sectors. The company contacted the Verardi Group S.r.l, one of ELGi’s Channel Partners in Italy and a trusted compressed air service partner to GVS for over 45 years. Verardi installed four ELGi EG Series oil-lubricated screw air compressors, one of them with variable speed, to meet GVS’ efficiency and reliability requirements. “The precise forging and machining of metals requires quality and reliable compressed air, and we needed a solution for a reliable source of air that would simultaneously deliver better efficiency and energy savings,” said Giovanni Biondi, Production Manager at GVS. “Our decades of experience with Verardi and trust in their professionalism and support were also important factors in our decision to

install four ELGi EG Series air compressors. Since installing the ELGi units in September 2022, we have recorded energy savings of 10% compared to previous units, resulting in a significant reduction in our energy costs,” concluded Biondi. Founded in 1964 as Gallus Romano Lumezzane, one of the first companies in Italy to own brass hot forging presses, the company acquired GV Stamperie in 1990. GVS makes brass, aluminum, and copper forged parts with high-precision machines. The company supplies a wide range of OEM components to various sectors. “At ELGi, we seek to meet customer needs by offering them a portfolio of solutions characterized by high performance, reliability, and one of the lowest total costs of

ownership,” said Graziano Dal Tio, Regional Manager Italy at ELGi. “Through close collaboration with our channel partners, we can offer heavy industrial customers like GVS a unique combination of reliability, efficiency, and peace of mind. The EG Series chosen by GVS stands out for its patented technology, high efficiency, and ten-year market-leading warranty on the airend.” The sturdy design of the EG Series compressor range enables operations at extreme temperatures – from cold to hot and from dry to extremely humid conditions- leading to improved compressed air system reliability. ELGi’s high-efficiency airends are equipped with in-house developed η-V profile rotors, with the 4/5 lobe combination, designed to run at low rotor speeds. This unique design reduces pressure

losses, and together with the OSBIC (Oil separation by impact and centrifugal action), 3-stage separation provides best-in-class energy efficiency.   The in-built ELGi Variable Frequency Drive (VFD) matches the compressor output with the demand by varying motor speed, reducing the power consumption and resulting in savings. The EG Series comes with ELGi’s industry-leading warranty program, which includes no limitation of running hours and comes with a 10-year warranty on the airend, a 5-year warranty on the compressor package, three years on the VFD, and one year on electrical, rubber, and plastic parts. Jennifer Gerold Marketing Manager – Europe T +32 496 28 09 38 E jennifer.gerold@elgi.com PIM Metals October/November 2023

NEW PRODUCTS

New surface fault detection algorithms for PROFILEMASTER SPS Monitoring Systems from ZUMBACH ®

ue to the continuous success and the growing demand of surface inspection, ZUMBACH Electronics has launched two new main features on the PROFILEMASTER® SPS product family. The latest generation of high-speed cameras allow the acquisition of full product contours at a rate of 2000Hz. This allows a stable and reliable measurement even on very high line speeds and challenging products like rebar. In addition, the new surface fault detection algorithm (software option “SFD”) also benefits from the faster cameras as smaller surface faults can be detected. It is also possible to inspect any kind of complex products such as rails and profiles. Since the launch of the PROFILEMASTER SPS family, the monitoring systems have proven their reliability under harsh environments of rolling mills for hot and cold steel rods, bars, profiles and much more. Various models are available with 4 up to 8 laser/camera modules and

different measuring field sizes to cover product dimensions from 5 mm (.2 in.) up to 720 mm (28.3 in.). All relevant dimensions

such as width, height, angle and radius or other geometric characteristics are displayed in an operator-friendly graphical

user interface. Changes in speed and twist within normal limits have no influence on the measurement precision.

Customer benefits / main features l Provides 100% inspection in real time

l Integrates in a seamless way to your network or higher-level systems

l Reduces start-up time

l Simple cleaning requirements, giving short maintenance needs

l Increases the repeatability and precision of your end product

l Logging of all production data for QC department

l Improves process control

l Makes post production measurements irrelevant

l Reduces scrap

l Surface fault detection (SFD) thanks to high sampling rate

l Saves raw material and post processing costs

l Compilation of a 3D model thanks to high sampling rate

l Detects process problems at an early stage

l Reliable operation in harsh conditions, product temperatures up to 1200°C

PIM Metals October/November 2023

NEW PRODUCTS

Unison launches new consumable tooling service, to help manufacturers reduce stockholding and cut costs

nison Ltd, the UK’s leading manufacturer of tube and pipe bending machinery, has launched a new bend tooling service to make it simple and straightforward for businesses in Britain and further afield to receive the quality consumable tooling they require, precisely when they need it. The result of a £500,000 investment to date, with a further £250,000 spend planned by Christmas 2023, at the heart of the service is a new tooling manufacturing centre at Unison’s Scarborough HQ. From here, fully tailored tooling agreements are prepared and around one hundred thousand pounds worth of tooling, including mandrel balls and wiper dies, is held in stock. “We’ve been aware of a gap in the consumable bend tooling market for some time,” says Unison Sales Applications Engineer, Luke Gibson. “As such, we wanted to extend our already extensive tooling service to provide even greater convenience to Unison customers, while also giving users of other makes of tube bending machines rapid access to our consumable and long-life products. Equipped with the latest manufacturing technologies, our new tooling centre allows us to do just that.” By holding pre-agreed stocks of consumable tooling on behalf of its customers, Unison ensures much faster delivery times than for tooling that is made to order. Unison’s consumable tooling agreements enable customers to

minimise the volume of tooling they would typically keep on site and benefit from the associated cost savings. On-demand, next day and scheduled deliveries eliminate the risk of a tooling shortage stopping production and provide the opportunity to standardise tooling across

different manufacturing sites. As part of the service, Unison also offers volume discounts and the convenience of easy budgeting through regular payment plans. “Regardless of a customer’s consumable bend tool requirements, be it wiper dies, mandrel balls or other goods,

we’ll create an agreement that meets their needs perfectly,” adds Luke Gibson. “No matter where they’re based, we’ll hold ample stocks of the bend tools they frequently require at one of our UK, USA or partner facilities around the world, for dispatch as and when they’re needed.” As well as aluminium bronze consumable bend tooling, Unison also produces long-life precision tooling for the most challenging of tool manipulation applications. “Choosing Unison tooling means de-risking your processes, as we ensure every tool fits perfectly and makes parts accurately,” adds Luke Gibson. “We can also customise tool mounts so that new tooling can be used with existing machines, while our quick-change collets and mandrels, and bar-coded tooling further streamline the tube manipulation process and help businesses save time and money.” PIM Metals October/November 2023

EVENTS

Convincing premiere for wire and Tube Middle East Africa in Cairo

successful appearance for Messe Düsseldorf’s four new foreign satellites in Cairo: from 2 to 4 September, wire and Tube Middle East Africa, together with GIFA and METEC Middle East Africa, presented themselves for the first time at the Egyptian trade fair METAL & STEEL EGYPT at the Egypt International Exhibition Center in Cairo/Egypt. The regions of Egypt, the Middle East and North Africa offered many first-time exhibitors the opportunity to invest in these growth markets. 383 exhibitors from 19 countries took the opportunity to show their colors in Cairo. In addition to local companies, exhibitors from the UK, France, Austria, Belgium,

Turkey, Spain, Switzerland, Morocco, the USA and Germany, among others, also came to Egypt. The Egyptian trade fair organizer AGEX (Arabian German Exhibitions & Publishing Ltd) has already been holding its METAL & STEEL EGYPT trade fair since 2010. The cooperation with Messe Düsseldorf results in valuable synergies for all sectors involved. There was noticeable interest in the exhibition halls right from the start of the five trade fairs. Over 7,000 professionals (around 10% international) traveled to Cairo over three days to network and find out about trends and innovations from the industries and discover the latest machinery, equipment, products and services from the metal and

steel industry and the wire, cable, tube, foundry and metallurgy sectors. There will be another edition of the trade fairs in the first half of 2025. At that time, the five industry players will once again present themselves in Cairo. The exact date will be found

with the regional organizer and in consideration of all satellites of the metal trade fair portfolio made by Messe Düsseldorf. In the meantime, up-to-date information will be shared here: www.wire-mea.com, www.tubemea.com, www.gifa-mea.com and www.metec-mea.com.

Lively industry interest in Bangkok: Metal trade fair quartet hits the road together for the second time in Thailand More than 400 exhibitors from 30 countries presented their technological highlights at the leading regional trade fairs for the wire, cable and raw industries, wire and Tube Southeast Asia, which took place for the second time together with GIFA Southeast Asia and METEC Southeast Asia at BITEC in Bangkok from 20 to 22 September 2023. Joint participations from six countries complemented the lineup with their national pavilions. wire and Tube Southeast Asia are regarded in Thailand as leading regional information and trade platforms for their 20

PIM Metals October/November 2023

industries. Over 80% of the 245 exhibiting companies were international. wire Southeast Asia showcased machinery and equipment for wire production, wire processing and wire finishing, accessories, measuring, control and testing technology as well as new and further developed special wires and cables. Machines and technologies from the fields of tube manufacturing, tube processing and tube finishing complete the range of products at Tube Southeast Asia. 7,400 trade fair visitors, around

30 % of them international, came to Bangkok to find out about industry trends at all four trade fairs and to expand their business relationships. The visitors were manufacturers, buyers and suppliers from the wire, cable, tube, foundry and metallurgy

industries, as well as from the automotive, oil and gas, construction, energy, building and electrical industries. From 17 to 19 September 2025, wire and Tube Southeast Asia will once again join forces with GIFA and METEC Southeast Asia in Bangkok. wire and Tube Southeast Asia Press contact in Germany: Petra Hartmann-Bresgen M.A. Ulrike Osahon Tel: +49 (0) 211/45 60 -541/ -992 E-mail: HartmannP@messeduesseldorf.de www.wire-southeastasia.com, www.tube-southeastasia.com

The ONLY event that brings together the entire metals supply chain

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x250+ Supply Chain Exhibitors x5,000+ visitors x120+ Speakers x50+ Seminars x4 Theatres

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