PIM Metals Dec '22 - Jan '23

elcome to the December issue of PIM Metals, as we come to the end of yet another year of publishing PIM Metals (incorporating IMT) we would like to thank all those readers around the world who took the time to complete the re-

Re-registration comes as direct cost to us but it is something we have done since 2008, it is only possible to absorb this cost every year thanks to those who place advertising and marketing messages within the magazineWithout there support we would not be able to report on the news coming from those who support and supply the metal production and processing industry we serve.

As we look forwards to 2023 one of the key areas of concern will remain spiralling energy costs, being an energy intensive industry, efficient production and processing of metals will be high on the list for managers to address and how to reduce energy consumption and ensure process

Looking to our next issue February we will be looking at Inspection, testing & quality control, Strip metal processing and Applications for Laser technology.

All that remains is wish you all a Merry Xmas and Happy Email: imtmagazine@virginmedia.com

Aluminium packaging recycling rate on track to surpass 2022 target

According to Q3 data published by the Environment Agency in November, aluminium packaging recycling rates have increased for the third quarter in a row and remain firmly on track to exceed their annual target.

The period July to September 2022 saw a total of 37,815 tonnes of aluminium packaging collected for recycling.

Material collected through kerbside, bring and on-the-

go systems totalled 28,003 tonnes, while 9,491 tonnes were recovered from incinerator bottom ash (IBA) and 322 tonnes were collected through other routes.

With a net annual requirement of 147,632 tonnes, taking into consideration a carry-in of 8,212 tonnes from 2021, the United Kingdom has already surpassed 80% of its annual collection and recycling target with three months of the year – and the busy Christmas period - still to go.

Tom Giddings, general

manager of Alupro, commented:

“The UK’s PRN data for Q3 shows another strong performance for separately collected aluminium packaging, material recovered from IBA and other local protocol fractions. It’s positive news indeed that PRNs issued to date this year are already well ahead of target.

“While many had suggested that the high recycling rates experienced during the COVID-19 pandemic were just a short-term trend, it’s reassuring to see that impressively high volumes of aluminium packaging

have continued.

“As we move into Q4, assuming volumes remain high, we could see recycling rates hit record levels – a huge achievement for the industry. This, alongside the news that targets for 2023 are set to remain constant, puts us in a positive position to maintain progress into the New Year.”

For more information about Alupro, visit www.alupro.org. uk. To access the National Packaging Waste Database, visit www.npwd.environment-agency. gov.uk.

Messner takes off

In 2020, right in the middle of the Corona Pandemic, Michael Messner, Austrian entrepreneur and creative metalworker, dared to start over by founding MTM MetallTechnik Messner in Ragnitz near Graz. He is rewarded for his courage and innovative ideas. He attributes part of his still young success story to his “Messer Experience”.

Especially today, in economically difficult times, a success story like that of Michael Messner gives hope. Having only started his company MTM MetallTechnik Messner in 2020, he can already show an increase in sales of almost 500% in the third financial year.

“I am very happy about the high demand for our products and the associated excellent order situation,” says Michael Messner, owner and Managing Director of the young company proudly. “We attribute a significant part of this success to our CNC flame cutting machine from Messer Cutting Systems and our positive experiences with Messer.“

Messner’s goal was to deliver high-quality to customers in the field of metal technology at marketable prices. The contract manufacturer for sheetmetal technology and blanks started looking for suitable equipment at an early stage. Messner started asking various manufacturers at the end of 2019. “It was important for me to be able to cover as many different customer requirements as possible with the machine park,” Messner explains his selection process.

The ability to deliver, service technicians nearby, manufacture of the machine in Germanspeaking countries, customer service, availability of employees,

professionalism, brand awareness and quality were the decisive criteria for him. “In addition, the expenses for starting the company should remain within reasonable limits.”

Messner opted for the MetalMaster 2.0 from Messer Cutting Systems. The MetalMaster is an economical CNC flame cutting machine that shows full power in a small space. Quick and easy to install and operate, the compact and spacesaving plasma cutting system is the economical entry-level machine for plasma or oxy-fuel cutting, or both combined. High positioning speeds and intelligent height adjustment reduce nonproductive times.

Productivity and flexibility increase thanks to the touch screen CNC control Global Control 2.0, which requires a total of three clicks from loading the part program to cutting, and a safety concept that enables clearing during the cutting operation.

“The MetalMaster is a compact, very dynamic machine thanks to its lightweight construction. In my opinion, it is one of the fastest machines in the plasma product segment,” explains Messner. “Its speed, accuracy, quality and versatility make it a machine that fits our needs perfectly.”

In addition to the MetalMaster and Global Control, the CAD/CAM software OmniWin and the use of Messer gases as well as service and training round off the overall package.

“It was important to us to provide MTM with a highly flexible machine concept that would make it easy for newcomers to quickly and sustainably establish themselves

The efficient and cost-effective machine covers around 98% of MTM’s requirements in the 2D area with plasma, oxy-fuel, carrier processing and calculation with quotations via OmniWin.

Despite the difficult global situation, Messer Cutting Systems kept to the delivery date. Construction, training, testing, acceptance and commissioning took place within five days. The machine was already running productively at MTM on the fifth day.

“The on-site commissioning with Messer Cutting Systems was very successful. I’m very satisfied,” says Messner, pleased about the successful project and his positive Messer Experience.

The purchase of the machine has increased both his overall market and his sales potential. With the support of the machine, he has significantly expanded the portfolio of services and components. This has led to greater customer satisfaction and numerous new customers.

“The decisive factor is the accuracy and quality, our high speed and efficiency with a low error rate. From planning to the

finished product, we are now much faster thanks to the CAD/ CAM software OmniWin from Messer. It is user-friendly, has suitable interfaces for importing from planning programs, enables error-tolerant operation and runs perfectly,” says Messner. “I would definitely choose the complete package again!“

Of course, despite numerous challenges, he plans to remain on the road to success. In the business customer area, the company is under constant pressure compared to the competition. In the private sector, MTM has to adapt to individualized consumer products. In order to keep quality high and prices low, the use of machines and software solutions such as those from Messer Cutting Systems is indispensable.

Due to high demand, he is looking for at least one full-time employee, other employees not excluded. “If growth continues, I will also consider investing in an additional laser machine from Messer Cutting Systems,” says Messner.

In doing so, he will continue to take quality and costs into account in the future as well as continue to pay attention to service, advice and the availability of suppliers.

on the market,” says Gerhard Wimmer, head of the Messer Cutting Systems department at Messer Austria GmbH.

New start succeeds despite the pandemic

Family owned since 1957, Zumbach is a global leader in the industry. Driven by innovation and experience. We are here for you and ready to build the future together.

LOTTE ALUMINIUM places order with SMS group for high-bay storage system for aluminium coils

As part of its strategic expansion plans, LOTTE ALUMINIUM Materials USA LLC is investing in a new production plant for aluminium cathode foils in the US state of Kentucky. A core section of the overall plant is the logistics and storage system, which is where LOTTE relies on the innovative strength and expertise of AMOVA, a subsidiary of SMS group. SMS was contracted to supply a smart, fully automated high-bay store with transport system. The high-bay storage system, which has around 500 storage spaces, is connected to the various process lines by the relevant conveying equipment and will be provided with warehouse management software specially developed by SMS.

The LOTTE group is one

of the largest conglomerates in South Korea and employs more than 80,000 people in over 90 business units worldwide. The group’s highly diversified product portfolio includes aluminium foils, printed packaging materials, corrugated cardboard boxes, as well as basic chemicals and highly advanced materials such as polymers, monomers, and petrochemical feedstocks.

The group’s target is to produce 36,000 tons of cathode foils annually to meet the sharp increase in demand. Aluminium cathode foils are used, for example, in the production of lithium-ion batteries for electric cars. The new high-bay storage system will accommodate coils on paper and steel spools as well as separator racks.

As LOTTE produces very thin-rolled, sensitive coils, SMS

c 500 coil storage spaces for smooth material logistics

c Direct access to various process lines in the plant

c Cantilever racking system ensures the materialfriendly storage of a vast range of different-size materials

c Optimized process flow thanks to digitalization

was faced in the project planning phase with the challenge of developing a system that was as flexible and material-friendly as possible. An important aspect for LOTTE when awarding the contract was that SMS has a successful reference facility, a fully automated, intelligently controlled highbay storage system, in the US

state of Kentucky, one of many references all over the world.

Applying its decades of experience, SMS worked with the customer to develop an ideal solution tailored to his needs. With the cantilever system (load-carrying beam supported at one end) that is now being implemented, all products can be supplied damage-free for the next stage in the process.

LOTTE is relying on SMS’s digitalization expertise and rounding off its portfolio with the warehouse management software. This software, specially developed over decades, is a core component of the high-bay storage systems and is subject to continual optimization to ensure end-to-end material tracking and user-friendly visualization.

The system is scheduled to go into service at the end of 2024.

From left to right: Changhyun Park, CTO, LOTTE ALUMINIUM, USA; Eunseong Chang, CEO, LOTTE ALUMINIUM, USA; Bernd Klein, CEO, AMOVA; Daniel Opitz, Commercial Project Manager, AMOVA (PresseBox) (Düsseldorf, 29.11.2022)

North West manufacturer celebrates Golden Jubilee

North West manufacturer Dean Group celebrates 50 years of high-quality manufacturing services.

Eighty guests attended the Black Swan in Warrington to celebrate the company’s past achievements and bright future. As well as employees and their families, the event included many influential members, such as key suppliers and executives who witnessed the founding of Dean Group. In addition, current managing Director Graham Stubbs gave an impassioned speech about the company’s journey that was emotionally well-received by everyone, including Chairman Christopher Dean.

In 1982, Christopher Dean joined the company, followed shortly after by his sister Carol Hutchison as in 1985. This familyrun business grew significantly over the last 50 years from Dean Groups’ initial UK facility in Stretford in 1972. Before moving the company to a purpose-built facility in Irlam, Manchester, with

no loss of production.

With this full-fledged foundry established next to a major UK city, Dean Group has spent decades creating made-in-UK castings with superior precision and short lead times.

Christopher became managing director of Dean Group in 1995 and led his team to several accreditations and award nominations over the years. With Dean Group recently being shortlisted for ‘Made in the North West 2022’, the company has also won several prestigious awards, such as: Prestigious Salford business award for Technology (2010)and Gold

Environmental award (2019).

Dean Group is now a threegeneration company with Sam Dean supporting this family business as an Estimating Engineer and Jack Hutchison recently promoted to deputy production manager

All attendants enjoyed the vibrant celebration as the close-knit teams shared stories, anecdotes, and memories of Dean Group’s long journey to reach this golden jubilee moment. With any landmark event about past achievements, thoughts inevitably turn toward the future.

Graham Stubbs, Managing

Director at Dean Group, commented: “Dean Group is energised to welcome the next decade and our plans for the next ten years. We are heavily investing in the UK Foundry whilst continuing to develop our partner route further.”

Dean Group has a past worth celebrating with a future that is just as bright. Over the last 50 years, the company has developed innovative solutions to maintain its position as a manufacturing industry leader. Developing new processes has been the company’s focus whilst maintaining the highest quality investment casting and diecasting services.

A significant part of Dean Groups’ recent commitment to their UK facility was the £200,000 investment they made in a highly advanced 3D printing room. These machines significantly improve daily operations, such as providing the ability to create accurate prototypes much more efficiently.

Dean Group is set to continue investing in UK foundry, ensuring they are reliably supplying the highest quality results for all its made-in-UK castings for the next 50 years and beyond.

SMS group installs its first AI-based Integrated Operating Center at Daye Special Steel

SMS group has completed its first X-Pact® IOC (Integrated Operating Center), a central monitoring room for the entire 460-millimeter tube plant, at Daye Special Steel in Hubei Province, China. With the Daye 460 project, which also includes the enhancement of the tube plant’s existing automation systems, SMS group has achieved a breakthrough in its Integrated Operating Center (IOC) application, an important milestone on the path to X-Pact® Lights-out.

Cameras installed along the production line provide the basis for centralized

operator monitoring, thus eliminating the need for operating activities in the harsh environmental conditions commonly found in the metallurgical industry. The automation system utilizes AI video analytics to respond to abnormal situations during production. The line’s level of automation has been improved and a breakthrough in intelligent manufacturing with centralized remote control has been achieved with the help of AI technology. Consequently, Daye is able to optimize its tube mill production processes from one control station.

With the demand for smart factories increasing worldwide, the Integrated Operating

c Centralized operator monitoring of the entire 460 millimeter tube plant using AI video analytics

c Only six operators are required to supervise the entire rolling line

Center has taken on a key role. An entire plant, from ironmaking to finished product, can be integrated into a central operating center, not only for greenfield factories, but for existing complexes too. The IOC represents the pinnacle of excellence of the production complex, facilitating plant

and logistics management by concentrating information and thereby significantly reducing the required manpower.

Following implementation of the Integrated Operating Center, the 460-millimeter tube plant at Daye Special Steel can be operated with the highest possible degree of automation. The number of discrete control elements across the entire rolling line has been reduced from 550 to only 50. Today, only six operators manage the entire rolling line, instead of 15 previously.

The new IOC and the introduction of autonomous operation play an important part in improving both product yield and quality.

R&M improves reliability for stainless steel producer

Application

Based in Fort Wayne, Indiana, Valbruna Slater Stainless, Inc. (VSSI) is part of the Valbruna Group. Founded in 1925, Valbruna has 2,500 employees and an annual output of approximately 250,000 tons of specialty steels. Production is primarily focused on stainless steels and specialty alloys, such as nickel alloys and titanium long products.

As part of its investment in continuous improvement, Valbruna is constantly updating its production capabilities and experience. For VSSI, this included upgrading its overhead cranes, which are used to move finished goods and raw materials for stainless steel processing.

Challenge

VSSI wanted to replace two older DC-powered cranes with more powerful AC cranes - but still retain the existing bridge structure. The older cranes

had become unreliable, and the hoists were heavy compared to more modern solutions. Getting new cranes to work on the current bridge would ensure that the upgrade was highly costeffective.

Solution

VSSI turned to Hoosier Crane Service Co. for expert assistance. HCS, founded by Tom and Cherie Schmidt, is a familyowned business headquartered in Elkhart, IN. Hoosier Crane

has grown throughout the last 20 years from 4 employees to approximately 100 employee and is presently providing overhead crane material handling solutions throughout the USA.

The older DC cranes were

Overhead cranes from R&M Materials Handling, Inc. have provided a cost-effective and more reliable solution for a producer of stainless steel.

Hoosier Crane removed the two existing hoists and replaced them with new R&M 10 ton hoists

each equipped with 20 ton and 7 ton dual hoists on one trolley. Hoosier Crane’s original plan was to keep a center line bridge drive motor on both but replace the DC motors with larger AC motors. However, Hoosier Crane decided that the more viable solution was side mounted SEW Euro Drive gearboxes with motors.

Hoosier Crane removed the two existing hoists and replaced them with new R&M 10 ton hoists. Hoosier Crane installed the new hoists on a new ASCE rail. These new hoists were one third of the weight of the old hoists.

Results

Using the R&M 10t hoists, Hoosier Crane was able to deploy a more reliable, lightweight and modern system without

replacing the bridges.

Patrick Hilger, Engineering and Maintenance Manager at Valbruna Slater Stainless, Inc. said: “Hoosier Crane has been a reliable service vendor for Valbruna for years. We were

looking for a reliable, costeffective solution that could still be designed to fit on the existing bridge structure. Using the existing bridge structure saved cost on install and material.”

Derek Bukrajewski, Director

of Service for Hoosier Crane, said: “R&M has always been a reliable option in the past. In this case, it fit the footprint for what both HCS and the customer were trying to accomplish.”

Getting new cranes to work on the current bridge kept the upgrade cost-effective.

Cladding 12-meter-high finned walls with CMT technology

SHI FW Energia

FAKOP (FAKOP) can look back over a century of history and tradition. Its origins trace back to 1880, when Wilhelm Fitzner and Konrad Gamper founded a steam boiler factory in the

Polish city of Sosnowiec. Just two decades later, in 1900, the Polish boilermakers achieved true world success as “Grand Prix” winners at the Paris World Exhibition. Move forward to 2009 and FAKOP is once again in the spotlight with the world’s largest fluidized bed

boiler. Success with boilers and high-tech leadership require quality - and when it came to the weld cladding of the 12-meterhigh finned walls used in waste incineration plants, they chose a solution from Fronius. More specifically, a tower-high CMT cladding system operated with

two elevator platforms. The large water-tube boilers used in commercial and industrial power generation use heating surfaces called finned walls made from tubes and flat iron. Due to the changing trends in fuels and the burning of increasingly difficult and

CMT cladding tower: finned walls are fixed, platform view

aggressive fuels, it is necessary to develop additional anticorrosion protection for the finned walls. Hardfacing is the most efficient way to protect the

finned wall surfaces.

“To surface the finned tubes, we use a cladding tower from Fronius Welding Automation that is approximately 15 meters high,” explains Arkadiusz Osuch, managing director of FAKOP. “It can accommodate two 12-meterhigh and 1.6-meter-wide finned walls and is operated by two elevator platforms, each equipped with innovative CMT welding technology.”

Iron in the weld metal diluted to less than 3% Many challenges are associated with the process of overlay welding. The ratio of base material to applied alloy is crucial for the effectiveness of the corrosion protection. The aim is to keep the ratio as low as possible while ensuring good fusion between the base material and the protective layer. A lower base material content ratio means longer equipment service life.

Jaroslaw Olej, senior welding expert, confirms that “The mixing ratio is now regularly below 3%.”

Before the management of FAKOP decided to purchase a mechanical CMT welding system, the finned walls were surfaced using other techniques.

In order to satisfy the high quality demands of their customers, FAKOP’s welding technology production engineers pay attention to every detail during the pretreatment of finned walls. Once the surface

pretreatment is complete, the finned walls move on to overlay welding, which takes place in dust- and rust-free conditions.

The welding process is crucial

When opting for the Fronius welding tower, a key factor was the use of CMT technology. Its advantage lies in the digital process control, which independently detects short circuits and supports droplet detachment by retracting the welding wire. This creates a back-and-forth motion that keeps the arc phase short and reduces heat input. The result is a material transfer that enables spatter-free cladding results with a particularly smooth surface, soft seam overlaps, and a consistent layer thickness.

“Nowadays, we find the majority of our customers require the CMT process,” says Olej, adding “You can safely say it’s established itself as the standard, and those who know how to use it properly enjoy good opportunities in the market.”

Expertise comes up trumps

Welding expertise and experience are vital. For example, arc stability and the susceptibility to porosity largely depend on an equally optimal and constant wire speed.

“From the inner liner to the welding torch, we are dealing with an enormous wire length

of around 15 meters. That’s why it’s difficult to keep the speed completely stable - you need a reliable wirefeeder, a series of tests, and sufficient expertise,” says Piotr Ogórek, technology and development expert, explaining the importance of specialist knowledge in laying membrane walls. “A further criterion is the ideal position of the welding torch, because spatter will occur if the torch angle is set incorrectly,” Ogórek adds.

The stick-out and associated arc length are other significant quality-determining factors which–together with constant wire speed–contribute to reducing porosity. With the help of Fronius, the specialists at FAKOP adapted the properties of their TPS/i CMT power sources to achieve optimum application results without pore formation by adjusting the stickout accordingly.

High-tech welding tower with outstanding ease of use

Welding is performed with horizontal oscillation from top to bottom in the vertical-down position (PG). Both elevator platforms are equipped with CMT welding technology and have intuitive HMI system controls with touchscreen, an ArcView camera and monitor, two CMT welding torches, and a joystick for fine adjustment.

Since welding torch temperature has a major

Arkadiusz Osuch, Managing Director of FAKOP

Jaroslaw Olej, Senior Welding Expert

Piotr Ogórek, Technology and Development Expert

influence on the dilution rate, all welding torches are watercooled. To further ensure that the dilution limit of 3% is never

exceeded, precise regulation by the plant’s cooling system is required.

One system optimization

worth mentioning is the new fine adjustment joystick for the welding torch position. Originally it was necessary to

manually move the torch into position using a slide rail. This made fine adjustment almost impossible and always required extreme dexterity. With the ArcView camera and joystick, fine adjustment can now be carried out quickly, easily, and with millimeter precision.

User safety is ensured by fume extractors on each welding torch and a dark-red tinted protective curtain that seals off both elevator platforms, and extends the full height of the system protecting welding operators from UV radiation.

“Another important feature of the Fronius system is the WeldCube welding data management software,” concludes Osuch. “WeldCube records all process data during the overlay welding process and the information captured assists us with process management.

We are highly satisfied with the

CMT cladding tower: finned walls are raised

CMT cladding tower: view of the cladding process

Added bonus for the environment

FAKOP not only produces high-quality finned walls and water tube boilers, it also makes an important contribution to sustainable waste management with its products for waste incineration plants. According to the ISWA (International Solid Waste Association), around 7-10 billion tons of municipal waste are produced worldwide yearly. A large proportion of this waste ends up in landfill sites where it produces methane, which is 20 times more harmful than carbon dioxide as a greenhouse gas. Waste-to-energy plants are an effective alternative to landfill and help reduce greenhouse gas emissions while generating electricity and system heat, which assists in promoting the circular economy.

Fronius overlay welding device and have decided to purchase another one.”

CMT cladding tower: welding torches with fume extraction

Slash maintenance, downtime and ownership costs

In the current commodities space the control of costs is front and centre for all industries. Input costs, especially when it comes to heavy-use equipment, can either erode the bottom line through capital expenditure or enhance profits and add value by extending the life of existing machinery through maintenance. And Welding Alloys’ unique wear plate called Hardplate™ is proven to extend by up to 400% the service life of equipment, confirmed Mining, Quarries and Earthmoving Industry Expert, Andre Bouwer.

For one large South African iron ore mine, its bucket wheel reclaimers operate daily under extreme wear conditions, subject to moderate impact and intense mineral abrasion. These buckets are vital to keeping downstream operations running through a constant supply of material. Replacement is not a viable option considering pressures on operating and Capex costs and constant refurbishment were proving expensive on the maintenance and downtime fronts.

“When we were called in by the mine it was soon clear a longer term solution was needed,” said Welding Alloys Andre Bouwer. “The issue was to reduce the very high cost of maintaining the bucket wheel reclaimers and to extend the service life of buckets that were simply not meeting expectations due to the inevitable effects of excessive wear.”

Mine records revealed the buckets underwent costly

maintenance and significant downtime every few months to repair damage caused by mineral abrasion.

“Our technical team conducted a detailed investigation of the buckets, the surrounding areas, and the general working environment and spent significant time onsite for purposes of observation and data gathering,” said Pieter du Plessis, Mining, Quarries and Earthmoving Services Expert at Welding Alloys.

“In these instances, there is no off-the-shelf one-solution-fitsall. That understanding comes from decades of experience and is why Welding Alloys’ technical wear specialists treat each new project as unique, and work hand-in-glove with customers through every phase to identify and deliver optimal solutions.

Once analysis of the data and findings had been completed at this mine, our local Integra™ wear services team reviewed details of similar successful solutions undertaken elsewhere in the world.”

This time the solution was to reinforce the buckets with Hardplate™ – one of Welding Alloys’ market leading composite wear plates formulated to improve resistance to wear and increase service lifetime. The chromium carbide-based product offers a hardness of between 60 – 64 HRC and is designed to withstand moderate impact, intense abrasion, and fair corrosion resistance.

“Our Integra™ Services team took full advantage of the versatility offered by Hardplate™ by cutting and welding it to fabricate bespoke liners for the buckets.” confirmed Welding Alloys Andre Bouwer.

Welding Alloys has a global network of Integra™ engineering workshops offering a wide range of services to identify, solve, and improve a multitude of equipment adversely affected by wear. Flexibility is key and Welding Alloys Integra™ teams enable hardfacing solutions in situ, on-site, and in wellequipped workshops delivering increased wear life and lowering

total ownership costs, confirmed Pieter du Plessis.

He added: “In a follow-up visit two months later, the mine was extremely satisfied with the liners’ performance. Not only had they already outstripped the lifespan of the previous buckets but in full operation, showed very little evidence of wear.”

“Only after 10 months of daily use did the bucket liners require replacement as opposed to the previous every few months. This was an increase in the lifetime of 400% and, in turn, drastically reduced the maintenance, downtime, and total cost of ownership,” said Mining, Quarries and Earthmoving Industry Expert, Andre Bouwer.

“Based on the performance of the initial bespoke liners, and to reduce lead times, the mine decided to order and hold stock of Welding Alloys’ bespoke bucket liners fabricated from Hardplate™. This project was tackled with the highest level of expertise ensuring the best outcome possible for the mine owners.”

Welding Alloys has been active in the global mining industry for more than 30 years. Expert experience ranges from small soft rock mining operations to some of the world’s largest, deepest, and most remote hard rock mines. “Today, our products and innovative engineering solutions provide wear protection in the most extreme conditions imaginable,” concluded Welding Alloys Industry Expert Pieter du Plessis.

www.welding-alloys.com/

Unison launches advanced tube bending app

Unison Ltd, the UK’s premier manufacturer of tube and pipe bending machines, has launched an all-new version of its industry leading, free-touse Tube Bending Application app. With intuitive new features, it is believed to be the most advanced app of its kind for users of tube bending machinery.

The app makes it simple and straightforward for tube bending machinery operators to establish the required tooling type, mandrel style, size and material, as well as bend torque and machine size. As an additional benefit, a clear, simple indication of ‘application difficulty’ - the difficulty of bending virtually any metal, wall thickness and diameter - is also provided. Where customers are looking to bend new components or start new projects, but do not have the correct tooling or machinery, the app provides a valuable feasibility/viability check, detailing essential data regarding the equipment they will need to use.

New user-friendly features

In creating their all-new Tube Bending Application app, Unison’s in-house software design team introduced a whole range of user-friendly, intelligent new features. These include a new project-specific filing system and a new dashboard for instant access to tube data, project notes, tooling setup, mandrel setup and machine power. There is an updated conversion tool for transforming XYZ coordinates into YBC bending data. As in previous versions of the app, units of measurement can be displayed as either metric or

imperial, while reports can be downloaded in PDF format for desktop filing, sharing, review and consideration.

First introduced in 2012 for iPhone, and regularly updated, Unison’s Tube Bending Application app quickly became an essential tool for application engineers and tooling designers. As the app grew in popularity, and requests for android and desktop operating systems were received, in 2018 it became fully web-based, with a mobilefriendly look and feel.

Revolutionising the way bend data is calculated

“Since it was first launched some ten years ago, our free Tube Bending Application app has revolutionised the way customers calculate bending criteria, providing them with a rapid insight into the necessary

tooling setup, machine type and torque required to successfully complete even the most complex of bends,” comments Unison Ltd’s joint managing director, Alan Pickering. “Never content to rest on our laurels, in our latest app, we have made significant improvements to useability and navigation, as well as enabling users to organise files into a folder structure that can be accessed across all their devices. We will soon also be linking the data created by the app to our comprehensive bend tool quoting and manufacturing offer. This will provide users with a seamless, rapid means of costing and ordering any tooling they require.

“Before creating our all-new app,” he continues, “we took the time to consult with a number of customers – all to ensure that it

would bring even greater value to their tube and pipe bending processes. The new app does precisely that and is a further reflection of our commitment to not only build world-leading tube bending machines, but also provide the finest software and support systems to maximise their usage. We are incredibly proud that around the world, Unison software is considered to be the most user-friendly for tube manipulation tasks.”

How to access Unison’s new Tube Bending Application app:

• Companies wishing to register to use Unison’s new app simply need visit https://app.unisonltd. com

• Existing users will be able to enjoy all the new features of the app when they next log in. www.unisonltd.com

Xiris releases new digital Sub-Arc Welding Camera

Xiris Automation is pleased to announce that it has released the XVC-S100 Weld Camera, its new all-digital welding camera for Submerged Arc applications.

The XVC-S100 has been designed to meet fabricators’ requirements to remotely view and monitor Sub-Arc Welding processes, enabling improved operator safety and efficiency. The camera provides an excellent view of features such

as seam-to-wire alignment, wire feed, and flux coverage during welding with on screen guides to allow operators to monitor and fine tune the process. After welding, the weld bead and slag removal could also be inspected with an optional second XVC-S100 camera.

The XVC-S100 Weld Camera incorporates cooling and integrated light sources all in a ruggedized housing and is compatible with Xiris’ WeldStudio™ 3 software that provides full camera control,

multiple cross-hair overlays, video recording and playback via a user-friendly interface. The XVC-S100 works with all Xiris software and can be

used with any of Xiris’ other open arc cameras, allowing for monitoring of both open arc and sub-arc processes through one integrated camera system.

Seco Hydraulic Chucks and Reduction Sleeves take the hassle out of tool holding

Manufacturers must overcome specific machining challenges cost effectively. With this goal in mind, Seco offers its comprehensive range of Hydraulic Chucks and accompanying Reduction Sleeves in three versions, each able to accommodate several tool shank size variations for reduced tooling inventory. With 360° tool-shank holding strength and precise centering, the Hydraulic Chucks and Expansion Sleeves ensure reliability, along with exceptional machining performance and maximized tool life.

Easy to use and versatile

For simple, easy-to-use, versatile tool holding, the three versions of Seco Hydraulic Chucks include the HC Conventional, HCR Reinforced and the HCS Slim.

The HC Conventional version delivers precision holding for drilling, reaming and light milling. As a universal solution,

the HCR Reinforced version provides effective holding for all applications from HSM to HPM and for all kinds of tool shank types like Cylindrical, Weldon and Whistle Notch. The HCS Slim holder version is ideal for accessing deep, narrow part cavities during 5-axis machining at high speeds.

Complicated tool holding systems not only require special care and training to avoid operator injury, they add extra time and costs,said Seco Product Manager Yves Heitz. Seco Hydraulic Chucks and Reduction

Sleeves eliminate the risk as well as any extra maintenance to allow users to get in the cut faster while gaining tool holding versatility with less required tooling.

For added flexibility to accommodate a wide range of cutting tool sizes, 05FHC slotted Reduction Sleeves for the Hydraulic Chucks allow one holder to handle various shank diameters. They provide through-tool or peripheral cooling capabilities and work with either metric or inch-size tools.

Low runout and high precision

According to Heitz, at high spindle speeds, controlling tool holder runout is imperative. When machining at speeds up to 25,000 rpm for example, Seco Hydraulic Chucks and Expansion Sleeves minimize runout and the vibration it causes. Users gain worry-free tool holding without the added cost of specialty

holders.

To keep vibration under control, Seco Hydraulic Chucks incorporate internal reservoirs in which oil generates strong 360° tool clamping forces and acts as a natural vibration dampening system - engaged with the simple turn of a hex screw. Additionally, reduction sleeves compress uniformly and completely around tool shanks for precise centering and holding strength.

The slotted reduction sleeves come in sealed and peripherical coolant versions, and the Hydraulic Chucks support all Seco round tools. The holders are compatible with all common machine tool spindle interfaces, including HSK, DIN, BT, BT Taper/ face, CAT, CAT

Taper/face and cylindrical straight shanks. Metric shank tools clamp directly in chuck IDs, while inch shanks are held through use of the reduction sleeves.

Messe Düsseldorf expands metal trade fair portfolio to include Egypt

Messe Düsseldorf extends its metal trade fair portfolio with an investment deal in Cairo (Egypt) in 2023.

As a special area of METAL & STEEL EGYPT from 2 to 4 September 2023, the four trade fairs GIFA Middle East Africa, METEC Middle East Africa, wire Middle East Africa and Tube Middle East Africa will be held at the Egypt International Exhibition Center for the first time.

METAL & STEEL EGYPT, organised by AGEX (Arabian German Exhibitions & Publishing Ltd), has presented a wide range of machinery,

equipment and products from the steel and metal industries for the Near and Middle East since 2010.

“We are very much looking forward to the partnership with AGEX and are confident that our metal trade fair quartet offers profitable synergies for all parties involved,” Daniel Ryfisch and Malte Seifert, Directors of the wire, Tube, GIFA and METEC trade fairs at the Düsseldorf, Germany location, are pleased to say.

The leading Egyptian organiser AGEX has been successfully staging trade fairs and conferences in the region since 2004 and is renowned for its special expertise in the

industrial sector. With this cooperation, this organiser and Messe Düsseldorf are combining their expertise.

Registrations for wire MEA and Tube MEA are accepted by Cem Bagci and Patrick Hayek at bagcic@messe-duesseldorf. de and HayekP@messeduesseldorf.de and for GIFA MEA and METEC MEA by Sarah Möller at moellers@messeduesseldorf.de.

More information as well as the registration documents will be available starting in January 2023 at: www.wire-mea.com www.tube-mea.com www.gifa-mea.com www.metec-mea.com

Industry to meet at Expo Centre Sharjah from January 9 to 12, 2023

Innovative solutions in welding technology are in demand internationally. This is why the world’s leading trade fair SCHWEISSEN & SCHNEIDEN is involved in other strong trade fairs and opens up promising market and sales opportunities for companies there.

There is also a close partnership with SteelFab, which will be held in the United Arab Emirates from January 9 to 12, 2023. For example, SteelFab offers exhibitors of SCHWEISSEN & SCHNEIDEN the opportunity to present their products and services at the Middle

East’s most important trade fair for metalworking, metal production and steel processing, together with around 150 other exhibitors.

SteelFab makes it possible to establish contacts in this economically important region.

The majority of trade visitors come from the Gulf region, followed by other countries from the Middle East and North Africa.

Exhibitors from more than 30 countries use SteelFab as a platform for their presentation. Germany, the UK, India, Italy and Turkey make up the largest

international participations. In total, more than 400 brands will be represented, providing a comprehensive overview of

industry innovations on more than 12,000 square meters.

SCHWEISSEN & SCHNEIDEN international

SCHWEISSEN & SCHNEIDEN has already been working with SteelFab for several years. With BEIJING ESSEN WELDING & CUTTING and INDIA ESSEN WELDING & CUTTING, SCHWEISSEN & SCHNEIDEN is also present in the important markets of China and India. Preparations are already in full swing for the next edition of SCHWEISSEN & SCHNEIDEN, which will be held at Messe Essen/ Germany from Sept 11 to 15, 2023.

World’s leading trade fair for joining, cutting and surfacing

The best omens for SCHWEISSEN & SCHNEIDEN 2023: All industry giants have already firmly booked their stands for the world’s leading trade fair for joining, cutting and surfacing.

In addition to Lincoln, ESAB, Microstep, ABICOR BINZEL, EWM, Fronius, Messer Cutting, voestalpine and many other companies will also be presenting their products and services to the international trade audience at Messe Essen from September 11 to 15, 2023.

Furthermore, numerous niche players, hidden champions, start-ups, associations and research institutions have confirmed their participation in the fair. Overall, around 90 percent of the stand space has already been allocated. Christina Kleinpaß, project

manager of SCHWEISSEN & SCHNEIDEN, sees this as a strong signal: “We feel the catch-up demand in the industry, everyone can hardly wait to finally meet again. In this respect SCHWEISSEN & SCHNEIDEN, as the number one event, is the platform for innovations and networking.”

This is also confirmed by Prof. Dr. Emil Schubert, CTO of ABICOR BINZEL: “SCHWEISSEN & SCHNEIDEN is the industry highlight and offers the great opportunity to present innovations of one’s own company and also to observe what the market competitors exhibit in terms of new products. Ultimately, however, the most important thing for us is the direct and personal exchange with welders in order to be able to recognize and meet their needs.

An optimized hall layout will offer exhibitors and visitors numerous synergies for their participation in the trade fair. Thus, exhibition halls 1 to 5 are reserved for companies from the welding sector. In Halls 6 to 8, companies will be presenting their cutting products and services. The appropriate equipment, filler materials, surface technology, services and digitization offerings are available directly in the respective exhibition areas. “This guarantees short distances and a perfect fit,” explains Christina Kleinpaß. “Our visitors will find products and the matching

solutions in the direct vicinity. In this way, we offer exhibitors great potential for

The world’s leading trade fair offers special added value through thematic exhibition areas. For example, underwater technology will be the focus of attention in exhibition hall 7. A dedicated diving container gives companies the opportunity to demonstrate their products live to trade visitors. The demand is great. After all, underwater technology has long been of crucial importance for energy generation or even raw materials extraction in coastal regions and in the open sea. www.schweissen-schneiden.com

I am convinced that the entire industry is looking forward to SCHWEISSEN & SCHNEIDEN 2023 in Essen.”

Optimized hall layout guarantees short distances

their presentation and minimize spreading loss.”

Underwater technology is a highlight at SCHWEISSEN & SCHNEIDEN 2023

Unison Tube enjoys a fabulous FABTECH 2022 Exhibition

FABTECH

Unison machines on show at FABTECH included an allelectric Unison Breeze Twin Head tube bender and one of the company’s all-new ‘Synergy’ hybrid multi-stack models. The Synergy machine on display - a 2” (50 mm) collet, multi-stack model - was quickly snapped up by full-service precision tube bending specialists, Accurate Tube Bending Inc. of Newark, California. The Breeze Twin Head bender, a machine developed for the high-speed manufacture of symmetrical tubular shapes, such as those typically found in automotive, agricultural and furniture applications, was purchased by a leading street furniture specialist.

In addition to showcasing several of its CNC machine tool technologies at FABTECH, Unison also used the event to launch Opt2Sim Tube, the latest addition to its industry leading Opt2Sim tube simulation software suite, with delegates being invited to enter a draw to win one of several Opt2Sim Tube software licenses. With the opportunity to benefit from speed enhancements of up to 25 percent, depending on the component being bent, Unison’s recently upgraded Unibend CNC also caught the attention of delegates.

“FABTECH 2022 was a great event for us,” comments Unison Tube LLC’s Vice President, Stuart Singleton. “Quite apart from selling two of our display machines on the first day of the

show, we gained an exceptional number of high-quality leads from manufacturers and subcontractors – industry professionals, who clearly know their tube and were looking for first-class tube manipulation technologies.

“Our newly-released Opt2Sim Tube simulation software attracted considerable interest thanks to its ability to make it easier than ever to create virtual parts, ready for precise bending data to be uploaded to the bending machine,” he continued. “We met friends, customers and colleagues old and new; we sold our display machines – and we came away with some excellent

leads. All in all, it was fantastic to be back at FABTECH for the first time since the Covid pandemic. In fact, it’ll be no surprise to hear that, after such a great exhibition, we’re already thinking about what we’ll show at FABTECH 2023 in Chicago.”

New Opt2Sim tube simulation software – a complete end-to-end solution

Continuous innovation has ensured that Unison’s Opt2Sim suite of 3D simulation software programs remains a firm favorite among users of Unison and other brands of tube bending machinery. Perfected

for ‘Design to Manufacture’ production strategies, Opt2Sim tube bending simulation software uses machine and component data to provide a precise, virtual insight into the tube bending process before a single part is bent. In new Opt2Sim Tube, Unison gives users the ability to drag and drop STEP files into the software program and extract tube data instantly. Parts can also be drawn by simply entering XYZ or YBC coordinates and viewed in 3D. Bend data is quickly converted into printable reports and individual tube data can be extracted.

www.unisonltd.com

2022 Atlanta was a resounding success for Unison Tube LLC, the North American arm of UKbased Unison Ltd – the inventors of all-electric tube manipulation.

(From left) Unison Tube’s Vice President Stuart Singleton, with Tim Morrow, owner of Accurate Tube Bending Inc.