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Investing in technology to improve molten metal quality

JW Aluminum identified the need to quantify inclusion loads in its molten metal in order to deliver higher quality products to our customers. The inclusion detection system had to be able to identify and quantify potential sources of inclusion related defects as well as the benefits from process improvements.A paper JW Aluminum submitted to The Minerals, Metals and Materials Society describes the validation of principle and measurements made before the final decision to invest in a MetalVision MV20/20 ultrasonic inclusion analyzer. Written by JW Aluminum's Ph.D. Metallurgist Dawid Smith and Melting Process Engineer Brett Hixon in conjuntion with Hugh Mountford and Ian Sommerville from MetalVision, the paper also discusses the initial practical experience after purchasing the system. Click here to request the complete paper.

Basic Components of MetalVision MV20/20 Inclusion Analyzer

Lean initiatives uncover raw material & process opportunities

One of JW Aluminum's key goals is to continuously improve molten metal quality to provide better end products for our customers. As part of the Six Sigma DMAIC process, we designed experiments using critical variables and controlled Key Process Inputs. The MetalVision MV20/20 captured the principle outputs and analysis determined final product quality evaluations. The analysis showed that raw materials have a statistically significant effect on molten metal quality. We then performed Lean Rapid Improvement events and significantly altered the way JW Aluminum melts and processes raw materials, resulting in improved products for customers. Written by JW Aluminum's Melting Process Engineer, Brett Hixson,
Director of Chemical Transformation, Claude Dube and Ph.D. Metallurgist Dawid Smith and submitted to The Minerals, Metals and Materials Society, request the complete paper here.

Molten metal treatment improve overall metal quality

Through Rapid Improvement Events and other Six Sigma techniques,
JW Aluminum introduced and monitored systemic changes, made significant improvements in melting, degassing and filtration resulting in the ability to adapt the production process to varying raw material types. In this paper written by JW Aluminum's Director of Chemical Transformation Claude Dube, Ph.D. Metallurgist Dawid Smith and Melting Process Engineer Brett Hixon, we discuss the changes made as well as their effects on the molten metal quality measurements. Implementation challenges and follow up controls ensuring uniform and consistent sustainable benefits are also discussed. We also present data proving that final product quality has improved as measured by in plant non-conformances and the goal of zero customer returns and complaints. Click here to request a copy of the paper.


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