Foundry alloys and wrought alloysBig enough to dare, small enough to care.

Aluminium alloys for demanding markets

AMAG casting GmbH is part of the AMAG Group, which is under the majority ownership of Constantia Packaging AG. The company is one of Europe’s larg-est aluminium recyclers at one location. In addition to slabs, the company also produces high-quality alumin-ium foundry alloys, which are used in the automotive, mechanical engineering and electrical engineering in-dustries. Sales are focused on Central Europe. The two AMAG casthouses produce foundry alloys and wrought alloys using the very latest scrap processing, melting and casting technology, which combines high energy and environmental efficiency for all types of aluminium materials on the market. Moreover, in order to meet the steady increase in demands regarding quality, costs and logistics, at the beginning of 2006 liquid metal deliveries for the automotive industry were added to the standard bi-part and horizontal cast ingots and then successfully expanded.

Indeed, AMAG’s enormous innovation potential is based on the integrated location in Ranshofen with its multifaceted product competence, which has been sub-ject to ongoing development in close co-operation with the company’s in-house rolling mill and customers. In addition, the company culture and the exceptional com-mitment of the workforce to the CIP process contribute to the creation of high-quality products, solutions, services and innovations, as well as the optimum use of company know-how and systems, whereby equal attention is allocated to work safety.

Employee motivation is characterised by quality aware-ness, productivity and inventiveness. Their suggestions constitute a major factor in AMAG’s success and the interplay between these various factors provides a high degree of flexibility and the ability to deal with customer needs through individual consulting and targeted solu-tions, which extend from the choice of material up to final processing steps.

AMAG casting possesses ISO/TS 16949:2002 and ISO 14001:1996 accreditation and company standards are oriented towards the stringent requirements of the automotive industry. The officially accredited AMAG testing laboratories fulfil the high international EN ISO/IEC 17025 standard, which is recognised by the aero-space industry.

Innovative expertise for recycling and aluminium alloys

COMPANY

AMAG Ranshofen – the integrated location for specialised, inventive solutions

The basis for high-quality castings and rolled products is the availability of customised foundry alloys and slabs. The current AMAG production programme includes over 600 different alloys.

Top quality requirements

All AMAG casting customers benefit from strict quality requirements, which in particular relate to the casthouse for wrought alloys. In every case, the quality thus obtained flows directly into the finished products, which extend to technically sophisticated applications in the aerospace and automotive industries. For this reason technical experts from the customers and the casthouse work very closely to optimize alloy compositions for the development of new products.

High quality slabs are defined mainly by the following parameters:• Chemical analysis (alloying elements, impurities)• Casting microstructures (e.g. grain and cell sizes)• Hydrogen content• Non-metallic inclusion content

To secure analytical quality, in the metal analysis area modern optical emission spectrometers are available, which can analyse 32 differing chemical elements in fully automatic operation. A homogenous and stable casting grain size has been ensured since 2003 through the use of the Opticast process (one of the first applications in a casthouse worldwide).

State-of-the-art measurement of melt cleanliness, impurity and hydrogen levels takes place by means of Alscan, Podfa and Limca measurement devices. Since 2006, a fully automated ultrasonic testing system with two phased array heads has been in use for the control of complete slabs with regard to non-metallic inclusions.

Leadership through the teamwork be-tween the casthouse and the rolling mill

The casthouse for wrought alloys enables the rolling mill to react with flexibility to customer requirements. As a result of highly developed technology, the casthouse can use electromagnetic casting (EMC), low head composite casting (LHC©Wagstaff) and conventional moulds. This also creates the metallurgical basis for the further technological develop-ment of the rolling mill.

Technology and logistics for customised foundry alloys

AMAG casting, which today is one of Europe’s leading aluminium recycling companies, systematically pursues the objective of creating closed material cycles. All scrap processing, melting and casting systems correspond with the international state-of-the-art and guarantee the environment-friendly recycling of every type of standard aluminium scrap. The required alloys and alloy variations, which are developed jointly with the customer for specific applications and subsequent production, are already taken into account during scrap sourcing.

Thorough scrap pre-treatment provides the basis for computer-aided planning and scheduling. All produc-tion parameters are designed to achieve maximum final product quality. Indeed, the quality of the melting process starts with scrap sampling and continues through every complex production phase up to the recycled aluminium in original quality. In this connection, special attention is paid to cost-efficient processing and melting technolo-gies with low environmental impact.

The AMAG casting product portfolio is supplemented by logistical precision and on time deliveries. In particular, deliveries of liquid aluminium for the automotive indus-try on a just-in-time basis, not only demands advanced technology, but also perfect co-ordination. In turn, such deliveries offer customers tangible cost advantages and due to its successful mastery of these challenges, AMAG casting has already established partnerships with leading automotive companies in both Austria and Germany.

High-quality casting technology and customer-oriented flexibility

TECHNOLOGY

Product dimensionsSows, bi-part ingots, horizontal cast ingots and liquid metal are all produced. AMAG casting only makes deliveries to order.

SowS

Unit weight 250 - 2000 kg (special sizes on request)

BI-PART INGoTS

Dimensions Length approx. 610 mm

Width approx. 110 mm

Height approx. 55 mm

Unit weight approx. 7 kg

Bundle weight 11 or 13 layers Single bundle (450 - 550 kg)

Double bundle (900 - 1,100 kg)

HoRIZoNTAL CAST INGoTS

Dimensions Length 594 mm (special sizes on request)

Width 54 mm

Height 74 mm

Unit weight 6 kg

Bundle weight 7 or 9 layers Single bundle (500 - 650 kg)

LIQUID METAL

Pot weight Liquid metal is supplied in isolated containers with capacities of 5 - 6 tons, which allows the supply of deliveries to the customers of 15 - 18 tons of liquid metal.

PRODUCTS AND SOLUTIONS

PRoDUCTIoN PRoGRAMME – ALLoY DESIGNATIoNS

Numerical Chemical Chemical composition of the ingots in % Other additions

Si Fe Cu Mn Mg Ni Zn Pb Sn Cr Ti Individual Total

226 D/die castEN AB-46000

EN AB-AlSi9Cu3(Fe) 8.0 - 11.0

0.6 - 1.1

2.0 - 4.0

-0.55 0.15 - 0.55

-0.55 -1.2 -0.35 -0.25 -0.15 -0.20 -0.05 -0.25

231 D/die castEN AC-47100

EN AB-AlSi12Cu1(Fe) 10.5 - 13.5

0.6 - 1.1

0.7 - 1.2

-0.55 -0.35 -0.30 -0.55 -0.20 -0.10 -0.10 -0.15 -0.05 -0.25

230 D/die castEN AB-44300

EN AB-AlSi12(Fe) 10.5 - 13.5

0.45 - 0.9

-0.08 -0.55 -0.15 -0.15 -0.05 -0.25

239 D/die cast EN AB-43400

EN AB-AlSi10Mg(Fe) 9.0 - 11.0

0.45 - 0.9

-0.08 -0.55 0.25 - 0.50

-0.15 -0.15 -0.15 -0.05 -0.15 -0.05 -0.15

260 D/die castEN AC-48000

EN AC-AlSi12CuNiMg 10.5 - 13.5

-0.6 0.8 - 1.5

-0.35 0.9 - 1.5

0.7 - 1.3

-0.35 -0.20 -0.05 -0.15

226/sand mouldEN AC-46200

EN AB-AlSi8Cu3 7.5 - 9.5

-0.7 2.0 - 3.5

0.15 - 0.65

0.15 - 0.55

-0.35 -1.2 -0.25 -0.15 -0.20 -0.05 -0.25

231/sand mouldEN AC-47000

EN AB-AlSi12(Cu) 10.5 - 13.5

-0.7 -0.9 0.05 - 0.55

-0.35 -0.30 -0.55 -0.20 -0.10 -0.10 -0.15 -0.05 -0.25

233/sand mouldEN AC-43200

EN AB-AlSi10Mg(Cu) 9.0 - 11.0

-0.55 -0.30 -0.55 0.25 - 0.45

-0.15 -0.35 -0.10 -0.15 -0.05 -0.15

AlSi7MgEN AB-42000

EN AB-AlSi7Mg 6.5 - 7.5

-0.45 -0.15 -0.35 0.25 - 0.65

-0.15 -0.15 -0.15 -0.05 0.05 - 0.20

-0.05 -0.15

Sows

Bi-part ingots

Horizontal cast ingots

Special alloys on request

Reduced process costs through liquid aluminium In 2005, AMAG casting started to make intensive preparations with regard to top precision analysis, melt quality and logistics in line with requirement defined by the customers for the delivery of liquid metal.

The use of liquid aluminium enables customers to further increase their competitiveness and to concentrate fully on their core casting and processing competences.

The services relating to the supply of liquid aluminium pri-marily relate mainly to the technical and logistical advice of the customers. Their main decision-making criteria consist

of quantifiable economic benefits. These derive from a massive reduction in the metal losses, which normally de-rive from the re-melting of the ingots, as well as decisive savings with regard to energy and logistics costs and cur-rent assets. In addition, short-term adjustments in the cus-tomers’ liquid aluminium requirements can be dealt with in a targeted manner, which results in productivity increases in combination with simultaneous cost reductions.

It is the aim of the AMAG Group to realise a high degree of problem-solving competence on the basis of partner-ship through the linkage of production and logistics.

PRoCESS wITH LIQUID ALUMINIUM

Goods acceptance check Unloading These process steps, metal losses and energy needs do not occur when

liquid metal is usedMaterial ready for use

The advantages of liquid metal over ingots

PRoCESS wITH INGoTS

Goods Melting acceptance (including metal check loss and energy)

Material ready for use

Melt treatment

Stock withdrawalUnloadingMetal to stock

ENVIRONMENT

Active environmental management is part of AMAG’s corpo-rate strategy. The integrated management system includes environmental protection, quality, job safety and productivity to an equal extent.

Recycling of aluminium in a global contextThe recycling of aluminium only requires approximately 5% of the energy needed for the production of primary aluminium from aluminium oxide. Accordingly, aluminium scrap con-stitutes a valuable raw material and in the Western world is largely recycled. As the quality properties of the metal remain constant during re-melting, it can be used repeatedly and therefore aluminium is an ideal material for recycling. Indeed, global recycling rates are as high as 90% in the transport and construction industries and over 60% in the cans segment.

The objectives of AMAG environmental policyThe fundamental aim of AMAG Group environmental policy is the protection of natural resources and a reduction in waste, wastewater and emissions within the framework of the pro-duction process. These endeavours in the field of sustainable environmental protection and the progress achieved in this area are confirmed by re-accreditation in 2008 in line with ISO 14001:2004.

Company environmental policy involves the interplay of bind-ing guidelines. These not only include compliance to all the statutory regulations and official stipulations, but above all continuous improvements with regard to operational environ-mental protection using the most cost-efficient technology available. All measures are aimed at eco-efficiency and the prevention of environmental impact and this range of activities is further supplemented by periodic checks on ongoing proc-esses and plants and the assessment of planned processes and plants in respect of their effects on the environment. Finally, regular audits of the entire management system, em-ployee training and the subsequent assumption of individual responsibility by the entire workforce assist target achieve-ment. The public is also informed periodically concerning matters of environmental significance.

Progress for the environment

Multifaceted accreditations

Melting furnace Filter system

Scrap

Environment-friendly melting at AMAG castingA major factor in connection with the melting of scrap is the selection of the correct furnace technology for the var-ious materials involved. In addition, upon delivery the scrap must already have been precisely inspected and classified. The storage of clearly sorted scrap under roof and charge planning on the basis of guidelines facilitate the production of high-quality alloys and formats using cost-efficient raw materials. Standardised guidelines ensure the employment of the ideal melting technology. The control of the gas-air ratio regulated by the residual oxygen content in the waste gas, the energy content of the organic impurities in the scrap can be used for the process, which prevents harmful waste gases. The regula-tion of afterburning in dependence on the carbon dioxide content in the waste gas also further optimises energy consumption and prevents dioxin emissions.

Environmental measures and concrete results in the casthouse

In addition to the melting furnaces, the filter systems in the AMAG casthouse has also been upgraded to the state-of-the-art in the course of an extensive modernisation programme. The use of environment-friendly technologies allows low-impact operation with emissions far below the mandatory limits.

In the past five years, an amount running into double-digit millions has been invested in the measures described above. Specific energy use has been cut by 30% and melt losses have been decisively reduced. All in all, salt purchases have fallen by 50% and 35% less salt slag has required disposal. CO2 emissions have been slashed by over 3,000 t/y, although the tonnage has increased. Moreover, dust emissions are lower than 10% of the mandatory limit, in spite of the fact that this has been lowered by 20 mg/Nm3 to 10 mg/Nm3 within the scope of the adjustment to the state-of-the-art in line with the IPPC directive. All in all, this comprehensive environmental programme has resulted in a major improve-ment in both the cost efficiency and the environment-friendli-ness of the aluminium melting furnaces.

AMAG casting GmbH P.O. Box 355282 Ranshofen AUSTRIA

T +43 7722 801 0F +43 7722 809 415casting@amag.atwww.amag.at

GROUP COMPANIES & LOCATIONS