Aluminium alloys, Ligatures on the basis of aluminium

  Switch to English Переключить на Русский 
The connection between quality and reputation
3.05.2010

We have many times drawn attention of aluminum alloys customers to the question of choosing ...

Kamalko is able to process raw materials
28.01.2010

Since March 2010 after the start up of a new workshop we can take raw materials for processing. ...

Our first secret
24.01.2010

One of our greatest secrets of alloy producing we promised to reveal in January 2010 (our news ...

Information of the production amount
18.12.2009

The amount of high quality alloys produced by our firm is about 1700 tons a month. The free amount ...

For business owners – Why it is recommended to use high quality casting alloys
11.12.2009

For business owners For business chiefs For chief engineer For chief metallurgist Why it is ...

Secrets of production and SMP
12.11.2009

We have decided to reveal one of our greatest secrets of alloy production at our site in January ...

High quality refining – myth or reality?
11.11.2009

Our company has many times said that we produce alloys that go through complicated multi-level ...

We are ready to produce the most complicated piston alloys for Volvo, Scania, Man, Mercedes, Renault, Ford
6.11.2009

The testing of our technology of manufacturing piston alloys at Kamsk Engine Plant has been a ...

Review Group GAZ- Ltd
6.11.2009

According to the review by the technical director of Group GAZ – Ltd «Ulyanovsk Engine ...



 

    



3-05-2010, 13:14

We have many times drawn attention of aluminum alloys customers to the question of choosing products of the highest quality and we hope we have proved their economic profitability.

Nevertheless there are some aspects of social importance. It turns out that use of faulty goods including aluminum alloys can greatly damage the image of a firm causing not only economic losses and quality reduction but its competitiveness also goes down as well as reputation of the firm.

There are a lot of examples of such situations. In Russian car industry cheaper materials are bought as a rule. It is done because of ISO and competitiveness when people try to decrease the cost of production as much as possible. Naturally it means quality reduction. Nobody calculates the losses caused by faulty goods (except maybe the ones while having to remelt faulty products for several times). And nobody calculates the losses to the business image in general. It may be one of the reasons why car produced in Russia are becoming less popular with customers though they are rather cheap.

Another example. The famous company RALPH LAUREN produces goods of rather high quality. They are used by numerous Olympic teams and are praised all over the world.

But we can give documentary proof that choosing improper supplier of components may do harm to the image of a company.

One of our colleagues bought an expensive child’s jacket made by this firm in the Central Department Store in Moscow. The next day the zipper of the jacket got broken. It was made of aluminum alloy. We dare say that they had used defective alloy for the zipper, the break-up happening in the oxide layer spot. The zipper was doomed to break. The jacket was replaced in the store, but how can one restore the firm reputation and its authority?

We guess it is possible to do only by providing the highest level of quality which we trying to achieve and which we advertise.

Also we are sure that not only a ready product must be of high quality, having a famous brand and image but its components as well.

We announce we are ready to provide such quality we are ready to be a famous brand




28-01-2010, 16:20

Since March 2010 after the start up of a new workshop we can take raw materials for processing. The charge for processing raw materials into the alloy AK5M2 is 140 $ per ton. The business takes utilization of slag upon itself and does not return it to the customer. For making the alloy AK5M2 it is necessary to have charge mixture in the following rate: 55% of moulding and 45% of pressed grade, the percentage of burn-off loss coming to 15%. If it is necessary to bring in even one ligation component for getting the needed chemical structure the charge for processing increases by 60$ for each ligation component. The charge for processing into alloys with refining to the premium class is 580$. The business also takes utilization of slag upon itself and does not return it to the customer. The burn-off loss depends on the materials used in each individual case.



24-01-2010, 16:19

One of our greatest secrets of alloy producing we promised to reveal in January 2010 (our news issue of 12.11.2009) is the new method of alloy quality diagnosis using gestation both the primary and the secondary aluminum smells. Thanks to the number of smells our degustators are able to define such metals and alloys which can make alloys defective if added. For example at some foundries at the process of casting there appear pellets with bad smell and the percentage of defects greatly increases. This is the result of critical accumulation of harmful, so called extrinsic admixtures. These admixtures should be got rid of at the stage of the first production of primary as well as secondary ingots. The matter is that admixture accumulation in the production cycles of a business within a certain time period will considerably increase the amount of defects. It is necessary to realize that extrinsic admixtures cannot be neutralized now; you just have to know where they are and cut the defected area like a surgeon.



18-12-2009, 15:28

The amount of high quality alloys produced by our firm is about 1700 tons a month. The free amount per month that may appear next year will be not more than 250-300 tons. So a set of orders for February-March 2010 gets planned in December 2009. We can make an exception for producers who need our goods of Premium and Super premium class.



11-12-2009, 16:19

For business owners
For business chiefs
For chief engineer
For chief metallurgist

Why it is recommended to use high quality casting alloys of aluminum silicon group.

For businesses producing complex important parts and items of aluminum alloys by casting into iron mold or under pressure it is typical to have a certain amount of all kinds of defects and defective moldings. They come to 2-3.5% with ordinary parts and 10% with complex ones (the majority of refined casting alloys of primary aluminum in Russia is made by 2 foundries – Novokuznetsk aluminum plant and Kamalko, not considering Bogoslovsky aluminum plant, and unrefined silumins e.g. silicon foundry alloys produced by Bratsk, Nadvoitsk plants of primary aluminum and others as well as KrAmZ. For secondary refined alloys (made by PZCM, SamZAS, RyazAZ and others) the number comes to 40-55% of defects, and to 90% for those producing of slag and chipping (like Vtormet) irrespectively of expensive and modern equipment that they may use for refining. There are undetected defects that reveal themselves during the guarantee period.

They cause economic harm to businesses that have to replace parts within the guarantee period or after it. They also cause moral damage which is hard to count and ruin the reputation of the product and the producer himself. Why do Japanese, Korean and other firms buy АК5М2, DIN226, ADC12 etc. produced of recycled materials of slag and chipping while we keep on saying that no expensive refining lines can raise the quality of such alloys? We mean the following figures (not more than 1 point of porosity, not more than 0.03% of aluminum oxide, trace contaminant not more than the standard rate, absence of extrinsic and harmful substances, average level of leaktightness and hydro resistance, average tightness for high-quality alloys and hydrodurability). So how is it possible to make high quality alloy (very similar to the primary one) out of an ingot produced of recycled materials? The answer can be found in a monograph by the famous Russian scientist V. I. Nikitin titled «Heredity in cast alloys».

This work obviously has been properly studied by Japanese, Korean and other specialists. It says it is needed to ERASE or ZERO alloy heredity. In our opinion aluminum melt should be heated to 2500 C and quickly cooled to about 750 C being let through copper funnel wintered with water, and also at a metal modulation in a mixer continuously to influence ultrasound,  during this process from 15 to 30% of the metal can be lost for good. Then in most cases it is recommended to refresh the alloy by primary aluminum adding not more than 20% to adjust other admixtures. And finally it is necessary to adjust so called «extrinsic» impurities (we promise to reveal the secret in January 2010, see the news issue of 12.11.2009) then slag impurities, oxygen and a part of oxide scabs must be got rid of by using well-known refining lines and foam-ceramic filters. Thus considering all above mentioned the price for alloys made of slag and shavings is like that of London Stock Exchange and is sure to increase by 150-180% so the customers interested in such products can get an alloy very similar to what is manufactured by Kamalko, Novokuznetsk and Bogoslovsky aluminum plants. It means that they sell their alloys at the price that is 2 times cheaper then the cost of the alloys made of secondary ones.

So what prevents foreign companies from buying refined primary alloys from NKAZ and Kamalko having no problems with defects? Why do they buy alloys in Russia made of slag and shavings getting their flaws as well or having to remake them into high quality ones as described above? It is strange but one of the reasons is the ISO system that leads to buying cheaper alloys. The second reason is the absence of exact criteria «price-quality» so alloys differ only by their chemical structure at Stock Exchange. So it is very easy to make businesses from the countries with economy based on raw materials sell alloys of various quality at low prices, e.g. at the price of London Metal Exchange. Other reasons can be political ones when governments wish to provide their people with jobs involving deep refinement of raw materials avoiding developing the whole industry in Russia. They don’t seem to want to use goods of their home producers in the military industry.

At London Metal Exchange the price for secondary aluminum alloys is so low that it leads to the miserable price for aluminum items in foreign made automobile spare parts (5%) and is no sufficient reason for reducing their cost.

At the same time their price in Russian automobile spare parts (important ones) can come to 50% and even more. In our opinion nowadays there is a wrong economical approach to using aluminum raw material both in Russia and Europe. Aluminum alloys of doubtful quality are purchased by commercial departments of businesses at low price for increasing economical statistics that leads to great problems for manufacturers while spoilage and defects make these alloys more expensive than analogous primary alloys. Spoilage goes to a second, a third, a fourth, a fifth remelt and so on, THE REAL PERCENTAGE OF SPOILAGE IS KEPT BACK FROM A BUSINESS OWNER, as well as from the shareholders. It is very hard or even impossible to check the balances especially if «interested» hired managers are against it. Thus casters either languish in poverty or go bankrupt like most Russian casters. European businesses do not have such a situation as they have almost tenfold safety factor because of miser prices for aluminum alloys at London Metal Exchange in comparison with ready products.

Nevertheless specialists realize that quality results from raw materials that are 30-40% more, as the cost of producing quality alloy are higher than just refining wastes or slag and shavings. But corruption schemes of kickback are much more pleasant and cheap alloys of slag and shavings are more likely to bring profits.

No doubt that economical figures are different for different businesses and it is not hard for experts to calculate that it is real to reduce defects as much as possible by choosing the proper quality of raw materials. So even high prices for quality raw materials as they may seem at first will be indemnified, profits will increase, defects, their reprocessing, consuming electricity, gas and additional materials will decrease. That means that IT IS RECOMMENDED TO PURCHASE ONLY EXPENSIVE PRIMARY REFINED ALLOYS OF HIGH QUALITY FOR PRODUCING SPARE PARTS FOR AUTOMOBILES AND RESPONSIBLE PARTS, and it will be cheaper than the cheapest alloys of slag and shavings.

For alloys of slag and shavings there is a huge export market which is impossible to fill, they are needed for cheap unimportant components.

We are ready to support our point of view at the talks with our customers and prove not to managers (who are often not interested in it) but OWNERS of some Russian and foreign foundry and other profile businesses that our position is correct.




12-11-2009, 16:17

We have decided to reveal one of our greatest secrets of alloy production at our site in January 2010. Specialists may be shocked at absolutely new method of alloy quality diagnosis. The new method allows not only sort out the alloys having harmful trace contaminants at their first production in the form of ingots but even to prevent their critical accumulation in recyclable wastes at different phases of components production by various casting methods



11-11-2009, 15:59

Our company has many times said that we produce alloys that go through complicated multi-level refining and have no analogs in Russia. While draining alloy we use foam-ceramic filters PPI 50 and PPI 60. For nonspecialists we can explain that it is similar to draining an alloy through a brick. According to the information of PolytegMet ltd. the official dealer of the firm «Drachi»(Germany) that produces the best foam-ceramic filters only our company buys such filters. Other firms buy as a rule PPI 20 and sometimes PPI 30. So we dare say statements of most companies claiming they provide high level of refining and consequently high quality of alloys do not correspond to the facts



6-11-2009, 16:16

The testing of our technology of manufacturing piston alloys at Kamsk Engine Plant has been a success. We have managed to produce one of the most difficult piston alloys АК13М5МгН2,5. Now we are waiting for orders from western automobile plants and are ready to launch the process



6-11-2009, 15:09

According to the review by the technical director of Group GAZ – Ltd «Ulyanovsk Engine Plant» V.N. Nikolenko and chief metallurgist A.V. Usov (issue 119 of 04.06.2009) «Kamalko» ltd has been a provider of aluminum alloys and addition alloys for «Ulyanovsk Engine Plant». The total amount of the supplied alloys is 300-500 tons a month according to the needs of production.

During the period of supply the experts of «Kamalko» ltd have been working non-stop to increase the quality of the alloys provided that allows making products with minimal defects.


Aluminium LME:

top