The trading division of Chinese copper giant CMOC Group Ltd. is expanding into the iron ore market. IXM SA, a subsidiary of CMOC, has signed a prepayment agreement with Brazilian mining company Itaminas Comércio de Minérios SA in exchange for guaranteed long-term supplies of raw materials. This arrangement involves paying in advance for future deliveries, with interest payable on the funds used. This was reported by Bloomberg.

This agreement marks IXM’s first foray into the iron ore sector. It is in line with a general trend among leading global traders, such as the Vitol Group and the Trafigura Group, which are actively expanding their portfolios of metallurgical raw materials through prepayment arrangements.

Iron ore producers are increasingly turning to private investors and trading houses for financing as global commodity prices fall below the $100 per tonne mark.

IXM, a company headquartered in [location], which was previously a subsidiary of the agribusiness giant Louis Dreyfus Co., was acquired by CMOC in 2019. In recent years, the trader has scaled back its third-party operations in lead and zinc, focusing instead on marketing its parent company’s products — notably copper and cobalt. CMOC owns the Tenke Fungurume deposit in the Congo – the world’s second-largest copper mine.

IXM is currently headed by Branko Buhavac (a former trader at Mitsubishi and Trafigura), who succeeded Kenny Ives as the company’s CEO and CMOC’s commercial director. The Chinese group is also steadily expanding its presence in Brazil: in addition to mining niobium and phosphates, last year CMOC agreed a deal to purchase local gold-bearing assets worth $1 billion.

As reported by GMK Center, iron ore production in China for the first six months of 2026 fell by 7% compared with the same period in 2025, to 466.9 million tonnes. The decline accelerated significantly in June, when production volumes fell by 19.8% year-on-year to 70.4 million tonnes, marking the lowest monthly level on record.

Vale, one of the world's largest iron-ore producers, reported iron-ore output of 84.3-million tons for the April to June quarter, above a Visible Alpha consensus of 82.2-million tons.

The miner said iron-ore production in the period was supported by a record second-quarter performance in its S11D complex and additional volumes from Capanema and VGR1 projects, all of them located in Brazil.

Vale maintained its projection of producing between 335-million and 345-million tons of iron ore this year, while also keeping its other yearly output estimates unchanged.

Iron-ore sales, which include fines, pellets and run-of-mine, stood at 79.7-million tons in the quarter, a 3.1% rise reflecting the sale of stocks and higher output, Vale said. Analysts expected 78.2-million tons, according to estimates compiled by Visible Alpha.

Vale said its Oman pellet plants, which it had halted earlier this year due to the conflict in the Middle East and associated logistics constraints, partially resumed production in late June.

The average realized price for iron-ore fines rose 11.6% year-on-year to $95 a ton, but fell 0.8% from the first quarter on "negative impact of pricing mechanisms", according to Vale's output and sales report.

Jefferies' analysts wrote Vale's report was "good enough," citing better-than-expected iron-ore production. The main uncertainty, they added, is regarding unit costs.

Citi expects market estimates for Vale's second-quarter earnings before interest, taxes, depreciation and amortisation to move up between 1% and 2% after the report, analyst Alexander Hacking wrote. "These results represent a continued strong start to the year – especially for copper and nickel," he added.

On copper, Vale's production rose 6.3% to some 98 400 tons, with output at the Salobo project in Brazil reaching a record for a second quarter, while the Sossego plant in Brazil, and Voisey's Bay in Canada, also showed improved performance.

Nickel output reached around 42 000 tons, up 4.2%, as higher production at the Brazilian Onca Puma project and a record at Canada's Long Harbour refinery outweighed the impact of a biennial planned maintenance at Canada's Sudbury downstream facilities.

Vale is set to release second-quarter earnings on July 30 and will vote to appoint a new chairperson this week.

However, evolving vehicle architectures, shorter development cycles and growing demand for design flexibility are pushing manufacturers to explore alternatives that can overcome the limitations of conventional casting.

A recent collaboration between Nikon SLM Solutions and Bosch Industry Consulting demonstrates how metal additive manufacturing is beginning to address these challenges. The partners successfully produced a fully functional one-piece aluminium V8 engine block using laser powder bed fusion (LPBF), eliminating the need for conventional tooling and multi-part assembly.

While the project is not intended to replace casting for mass production, it highlights how additive manufacturing can complement traditional processes for high-value, complex applications. More importantly, it signals a shift in how aluminium components may be designed, manufactured and supplied in the years ahead.

Why traditional casting faces new challenges

Aluminium casting remains the most economical solution for producing millions of identical components. Its maturity, scalability and established supply chains continue to make it indispensable for automotive manufacturing.

Yet several industry trends are exposing its limitations.

Modern vehicles increasingly demand components with intricate internal geometries, integrated cooling channels and optimised weight distribution. At the same time, OEMs are under pressure to shorten product development cycles and introduce new models more rapidly.

Conventional casting often requires dedicated tooling, mould design and multiple manufacturing stages before production begins. Any design modification typically involves additional tooling costs and longer lead times, making rapid iteration both expensive and time-consuming.

For prototype development, performance vehicles and specialised applications, these constraints are becoming increasingly significant.

Metal additive manufacturing changes the design equation

Unlike conventional casting, metal additive manufacturing builds components layer by layer directly from a digital model. This removes the dependency on moulds while allowing engineers to create geometries that would be difficult or impossible to manufacture using traditional processes.

In the Bosch-Nikon project, the complete aluminium V8 engine block was produced as a single integrated component using AlSi10Mg alloy on Nikon’s NXG XII 600 LPBF system.

By consolidating multiple parts into one structure, the approach reduces assembly complexity while enabling greater design freedom. Engineers can optimise material placement, incorporate internal cooling passages and develop lightweight structures without being constrained by conventional manufacturing requirements.

For industries where performance, speed and engineering flexibility outweigh production volume, these capabilities represent a significant competitive advantage.

Why aluminium remains central to the transition

The success of metal additive manufacturing depends not only on the printing technology but also on material performance.

Aluminium continues to offer several advantages that make it particularly well suited for advanced manufacturing applications.

Its lightweight properties support ongoing vehicle lightweighting initiatives, helping improve fuel efficiency and extend electric vehicle range.

Excellent thermal conductivity makes aluminium suitable for engine components requiring efficient heat management, while its strength-to-weight ratio supports structural performance without unnecessary mass.

When combined with additive manufacturing, these material characteristics enable engineers to optimise both component performance and manufacturing efficiency simultaneously.

Business implications across the aluminium value chain

The significance of this development extends far beyond automotive OEMs. For aluminium producers, additive manufacturing presents an opportunity to expand into specialised aluminium powder markets alongside traditional cast alloys.

Foundries may increasingly position themselves as providers of hybrid manufacturing solutions, combining casting expertise with additive manufacturing capabilities for prototype development and low-volume production.

Automotive suppliers can accelerate product development, reduce tooling investment and respond more quickly to changing customer requirements, particularly in premium, motorsport and emerging mobility segments.

Equipment manufacturers and technology providers also stand to benefit as demand grows for metal powder production, process optimisation, simulation software and post-processing solutions.

Rather than disrupting the existing value chain, additive manufacturing is creating new opportunities across it.

Where casting and 3D printing can coexist

Despite growing interest in additive manufacturing, aluminium casting is unlikely to lose its dominant position in high-volume automotive production.

The economics remain firmly in favour of casting for large production runs, where tooling costs can be distributed across millions of components.

Instead, additive manufacturing is expected to strengthen applications where complexity, customisation and rapid development are more valuable than production scale.

Potential use cases include:

• Performance and motorsport components
• Premium and luxury vehicle platforms
• Prototype and validation programmes
• Low-volume speciality vehicles
• Complex structural and thermal management components
• Emerging hydrogen and electric vehicle applications

This complementary relationship allows manufacturers to select the most appropriate production method based on performance, volume and commercial requirements rather than relying on a single manufacturing approach.

Looking ahead

The Bosch-Nikon collaboration demonstrates that metal additive manufacturing is progressing from experimental projects towards practical industrial applications.

As automotive manufacturers continue to prioritise lightweighting, shorter product development cycles and greater design flexibility, additive manufacturing is likely to become an increasingly valuable complement to traditional aluminium processing technologies.

For companies operating across the aluminium value chain, the question is no longer whether additive manufacturing will influence the industry. The more important consideration is identifying where it creates the greatest value and how existing capabilities can evolve to support this transition.

The future of aluminium manufacturing is unlikely to be defined by one process replacing another. Instead, it will be shaped by the ability to combine established manufacturing expertise with emerging technologies to deliver stronger performance, faster innovation and greater competitiveness.

Source: 3D printing to replace casting? Nikon SLM, Bosch unveil one-piece aluminium V8 engine block

Leonardo Turini has taken over the role of Secretary General at AMAFOND, the Italian Association of Foundry Suppliers, succeeding Fabrizio Carmagnini. In an exclusive interview, Turini reflects on his professional journey, shares his perspective on today’s market conditions, and explains his vision for the further development of the Italian and European foundry sectors.

  Leonardo Turini, Secretary General at AMAFOND

With broad international experience and a strong strategic mindset, Turini brings a comprehensive understanding of both the opportunities and challenges currently shaping the industry. His deep appreciation for Italy’s manufacturing heritage is paired with a pragmatic assessment of the obstacles companies are facing. Increasing geopolitical uncertainty, fluctuating energy costs, and vulnerable supply chains are creating significant challenges for manufacturers worldwide. Nevertheless, Turini believes these circumstances can serve as a catalyst for transformation. He highlights the Italian foundry sector’s proven resilience and its ability to remain competitive through high quality standards, specialized expertise, and ongoing technological progress.

Turini also points out that Europe’s established industrial strengths are undergoing a period of change. With global manufacturing landscapes shifting and developments such as the slowdown of Germany’s industrial sector influencing traditional market structures, companies must adapt to a new competitive environment. However, he views this transformation as a source of opportunity for businesses prepared to innovate and adjust their approaches. His goal is to position AMAFOND as a trusted guide for Italy’s foundry supply industry, an organization that does not merely respond to change but actively supports its members by fostering international connections, encouraging cooperation, and creating stronger partnerships in global markets.

A Global Perspective Built Through International Experience

Turini’s international perspective has been shaped by a career that has taken him across different markets and cultures. After completing a Master’s degree in Political Science as well as an Executive Master’s program in Export Management, he spent eight years working in the United States. During this period, he was active for the Italian Trade Agency (ICE) in Miami and Chicago, two important hubs of American business and industry. In addition, his professional development included specialized training with the Los Angeles Customs Brokers Association, allowing him to gain valuable expertise in international commerce, customs procedures, and the complexities of global supply networks.

Following his time in the United States, Turini continued to build experience in a wide range of international markets, with a particular focus on Europe, India, the United States, and Mexico. However, he views these countries not simply as commercial regions, but as places that have significantly influenced his personal and professional understanding of global business. His extended stays in India, including his time in New Delhi, where he received the news that he would become a father, as well as his family life in the United States, where he became a U.S. citizen, have provided him with unique insights into different economic systems and business approaches. Today, Turini sees the combination of international trade knowledge, technical expertise, and a broad global network as a key strength in his role as AMAFOND Secretary General. For him, leading the association is not limited to advocating for the interests of the industry; it is about creating connections between Italian engineering excellence and new opportunities in international markets.

Building on Heritage to Shape the Future – 80 Years of AMAFOND

Under Leonardo Turini’s leadership, AMAFOND will continue to build on the principles that have defined the association throughout its history. Since its establishment in 1946, technical expertise and a strong sense of cooperation among members have formed the foundation of AMAFOND’s identity. These values will remain central as the organization moves forward. One of the key events of the year will be the association’s 80th anniversary celebration, which will take place in Venice this November. The milestone will honor eight decades of commitment to the foundry supply industry while also highlighting AMAFOND’s ambitions for the years ahead.

Alongside preserving its established strengths, Turini aims to expand AMAFOND’s international presence and role as a partner for its members. Developing access to new markets is among his most important strategic objectives for the future. Through enhanced market insights, broader international connections, and increased visibility beyond Italy, AMAFOND seeks to support its member companies in expanding their global reach, diversifying their activities, and identifying new opportunities for sustainable growth.

Working Together to Enhance Competitiveness

According to Turini, addressing the current challenges facing the industrial sector requires commitment and coordinated efforts from both governments and companies. He emphasizes the need for competitive energy costs, less administrative complexity, and more efficient political processes. In addition, Europe requires a unified industrial strategy that acknowledges the importance of strong industrial value chains while promoting investments in innovation, digital transformation, and technical expertise. At the same time, companies must take responsibility for their own future by continuously refining their business models and increasing their flexibility to successfully navigate changing market conditions.

In this context, Turini views AMAFOND as an important partner and source of stability for the foundry supply sector. The association should serve as a connection point between its members and international markets, while also representing the interests and perspectives of Italy’s foundry industry in discussions with key decision-makers and institutions. A central element in advancing this mission will be the International Foundry Forum in Venice. Turini considers the event an important international meeting place for exchanging knowledge, fostering dialogue, and building stronger cooperation across borders. At the same time, the forum will help translate AMAFOND’s eight decades of experience and tradition into practical measures that support the long-term competitiveness and global positioning of Italy’s foundry supply industry.

About AMAFOND

AMAFOND (Associazione Italiana Fornitori Fonderie) serves as the representative body for Italy’s foundry suppliers. Established in 1946, the association brings together leading companies involved in the development and production of foundry machinery, equipment, melting and thermal treatment systems, die casting solutions, raw materials, as well as a wide range of products and services for ferrous and non-ferrous foundries. Today, with almost 100 member companies, AMAFOND represents a significant share of Italy’s manufacturing capacity in this field. The association supports its members in strengthening their international competitiveness by providing technical, economic, and regulatory expertise, while actively encouraging innovation and the expansion of export activities. In 2026, AMAFOND celebrates 80 years of commitment to the foundry industry.

  Sharon Grossman

At present, the industry is at a pivotal moment. It provides essential components for sectors such as aerospace, medical technology, defense, mobility, mechanical engineering, and energy. Without precision cast parts, many advanced applications, from turbine systems and medical implants to safety-critical technologies, would not be feasible. Despite this importance, the industry remains largely unknown to the general public, and this lack of visibility is becoming an issue.

During the 34th EICF in Seville, psychologist and executive coach Dr. Sharon Grossman from Florida delivered a keynote speech to international representatives of the investment casting industry, offering a direct and engaging perspective on these challenges.

Future Challenges in the Foundry Industry: Talent, Visibility and Skills Development

The foundry industry is facing a decisive transformation phase. Its long-term success will depend less on technology alone and more on people, specifically talent attraction, skills development, and knowledge preservation.

A central topic of Dr. Sharon Grossman’s presentation was the growing challenge of attracting new talent into the foundry industry. As experienced professionals retire, younger generations are increasingly drawn to more visible sectors such as IT, consulting, or modern skilled trades.

The core issue is not relevance, but perception. The foundry industry plays a critical role in aerospace, medical technology, energy systems, mobility, and defense. However, this contribution is often not visible to potential entrants.

To address this, companies must strengthen their presence early in the education journey, through schools, universities, vocational training programs, digital platforms, and structured career guidance initiatives. Greater visibility is essential to ensure long-term workforce sustainability.

Another key message was the need for stronger communication about the industry’s real-world impact. Young professionals are increasingly motivated by purpose and meaning in their work.

Rather than focusing only on production processes and materials, the industry must highlight its role in enabling technologies such as robotics, sustainable mobility, aerospace innovation, medical implants, and energy transition systems.

By reframing casting as a high-tech enabler rather than a traditional manufacturing field, the sector can significantly improve its attractiveness as an employer.

The widening skills gap remains a major structural challenge. Many specialized foundry competencies are not fully covered in standard engineering or technical education programs. As a result, even highly qualified graduates often require extensive onboarding to understand industry-specific requirements.

To close this gap, structured training systems are becoming increasingly important. These include internal academies, mentoring programs, partnerships with educational institutions, hands-on learning opportunities, cross-training initiatives, and continuous professional development.

Such approaches are essential not only for skills transfer but also for preserving decades of accumulated industry expertise.

Building Culture to Secure the Future of the Foundry Industry

Leadership emerged as a key success factor. Highly skilled technical specialists are frequently promoted into management positions without sufficient preparation. However, leadership in today’s foundry environment can no longer depend primarily on instruction and control; it increasingly requires clear communication, constructive feedback, employee development, trust, and the active involvement of teams.

Equally important is the transfer of knowledge. In many organizations, critical process expertise remains largely with experienced employees. Without systematic documentation and sharing, this knowledge is lost when staff retire. To prevent this, companies need structured methods for preserving expertise, such as video documentation, process manuals, mentoring programs, job shadowing, digital knowledge systems, and the targeted use of AI-supported tools.

A central message of the keynote was that securing the future is also a cultural task. Organizations must foster working environments in which people want to stay, develop, and take responsibility. As a practical example, Dr. Grossman presented the use of short daily team meetings, often referred to as “huddles.” These brief sessions support recognition of employees, help gauge team morale, encourage continuous improvement, address operational challenges early, and increase transparency around performance.

The recommendation for the industry was deliberately pragmatic: avoid attempting large-scale change all at once. Instead, start with one team, test new approaches over a 90-day period, evaluate the outcomes, and scale what proves effective.

Overall, the message was clear: the foundry industry must communicate its value more effectively both externally to attract talent and customers, and internally to strengthen engagement among employees and leadership alike. Companies that succeed in attracting people, preserving knowledge, and deliberately shaping their culture will not only secure their own future, but also enhance the long-term resilience of the industry as a whole.

China Mineral Resources Group intends to become an exclusive sales agent for some of CSN’s iron ore cargoes sold in China, one of the sources said, emulating similar deals struck with Roy Hill, now part of Australia’s Hancock Prospecting.

This approach differs from the deals CMRG has struck with other miners such as BHP, where it instead negotiated better terms for sales between miners and steelmakers.

CSN and CMRG did not immediately respond to Reuters requests for comment.

CMRG was set up in 2022 to centralize China’s iron ore procurement and win better terms from upstream mining giants.

At 45.5 million metric tons of iron ore produced last year, CSN is a large producer in Brazil, although its output is less than the 250 million tons plus produced by majors like Australian BHP.

The sources asked not to be named as the talks are private and they are not authorized to speak to the media.

Produced by The Engineer publication, in partnership with the Engineering Council, the annual salary survey was published in May.
Professional registration is an important career choice for engineers and technicians, with over forty per cent of respondents choosing to pursue it. Registration is particularly strong in the energy sector, including renewables and nuclear (seventy per cent) and the in rail, civil and structural engineering sector (65 per cent). The academia and manufacturing sectors present significant potential for increased engagement.

Results from this year’s survey show that, although registered professionals earn nine thousand pounds more on average than those who are not, only 23 per cent of respondents associate registration with higher pay. This is an opportunity for the profession to highlight the value of registration.

Commenting on the findings, Engineering Council CEO, Paul Bailey, said: “I was pleased to note that 43 per cent of respondents were professionally registered, an indication perhaps of the way that registered engineers and technicians tend to be highly engaged and committed to advancing the profession.

“Encouragingly, the data shows that those respondents who are professionally registered, i.e. those who have demonstrated a commitment to responsible engineering, ethical behaviour, and professional standards, earn, on average, nine thousand pounds more than their non registered peers. However, it is interesting that less than a third of respondents believe that professional registration increases earning potential. This is a perception that the Engineering Council and the wider profession need to address, as ethical, competent and trustworthy engineers remain essential to the long term wellbeing of both people and the planet.”

The 2026 survey, conducted between January and mid March this year, received 652 responses from engineering professionals working across twelve sectors. The responses indicate steady pay growth, stable job satisfaction and a rising appetite for career change and international mobility.

It reveals that more than half of respondents are happy in their current role. It also highlights growing interest in new career paths, with 71 per cent saying they would consider moving into a different sector, and 48 per cent of respondents are open to working overseas.

Professional registration is a benchmark for trust and confidence, and it demonstrates that industry relevant and internationally recognised standards of competence and commitment have been met. 

The Engineering Council holds the national register of almost 215,000 engineers and technicians professionally registered as:

• Chartered Engineer (CEng).
• Incorporated Engineer (IEng).
• Engineering Technician (EngTech).
• Information and Communication Technology Technician (ICTTech).
• Chartered Engineer HRB.
• Incorporated Engineer HRB.
• Engineering Technician HRB. 

To become professionally registered, individuals must first join a professional engineering institution licensed by the Engineering Council, such as the Institute of Cast Metals Engineers (ICME).

Further information on professional registration and its benefits is available on the Engineering Council website (www.engc.org.uk) and directly from ICME, email: info@icme.org.uk

Following the first article, which outlined the basic operating principles of the technique, this second contribution focuses on key applications that have been successfully implemented in highly competitive foundries. It is written by Iker Asenjo, researcher and project manager for iron foundry technologies, AZTERLAN Metallurgy Research Centre. A third and final article will provide a more advanced perspective on in-line quality control, combining thermal analysis with simulation of filling and feeding systems. 

In today’s highly demanding industrial environment, where quality excellence and cost reduction are essential to remain competitive in global markets, process control tools have become critical.

Thermal analysis has established itself as a reliable and widely adopted tool for metallurgical control in the production of graphite cast irons.

In the previous article (published in the April/May 2026 issue of Foundry Trade Journal), the theoretical foundations of thermal analysis systems were presented, highlighting their potential for process optimisation.

This article focuses on practical applications of thermal analysis, presenting case studies where implementation has led to measurable improvements in both process stability and final product quality. 

All thermal analysis systems are based on recording and analysing the cooling curve of molten metal during solidification and subsequent cooling.

In practice, molten metal is poured into a standard pre-coated sand cup equipped with a thermocouple. The signal is transferred to a data acquisition unit, providing temperature readings over time. This enables the evolution of temperature [°C] versus time [s] to be tracked, capturing key transformations such as liquid-to-solid, eutectic and solid-state (eutectoid) transformations. 

A typical example of such curves is shown in fig.1.

Different types of commercial cups are used depending on the application.

The recorded data are automatically processed, and key parameters are displayed according to the selected configuration. The use of numerical outputs removes subjectivity from result interpretation.

IMPLEMENTATION OF THERMAL ANALYSIS IN PRODUCION FACILITIES: LAY-OUTS

Thermal analysis is commonly used on melting platforms, mainly to determine carbon and silicon levels in molten metal, as discussed later. It also plays an important role in the pouring area, where it is used to assess the metallurgical quality of the metal prior to casting.

As a result, a wide range of equipment layouts can be found in industrial environments (fig.4), from simple configurations to more advanced setups where a single unit controls multiple moulding lines, including wireless data transfer and remote result visualisation in decisión making areas (fig.5).

MAIN APPLICATIONS

Chemical composition estimation (GJL – GJS – GJV)

Transformation temperatures are directly related to chemical composition, allowing carbon and silicon contents to be calculated from the cooling curve based on the metastable model. For this purpose, cups with Te addition are used for grey iron (GJL), and cups with Te and Mg neutraliser are used for ductile and compacted graphite irons (GJS and GJV).

The uncertainty in carbon measurement using Thermolan®, for example, is below 0.05 per cent (k=2), comparable to combustion techniques. In addition, results are available within seconds, offering a clear advantage in production environments.

Recent developments have focused on extending the controllable range of carbon and silicon, as shown in fig.6.

Active magnesium control (GJS)

Total magnesium content does not guarantee adequate nodularity. Part of the magnesium can react with sulphur, oxygen or other elements, leading to a fading (or loss) of magnesium activity.

For this reason, foundries are primarily interested in active magnesium, defined as the fraction effectively available in the molten metal after treatment.

Thermal analysis systems can determine whether the metal meets the minimum active Mg threshold required to ensure proper nodularisation.

This application is based on proprietary control cups capable of identifying not only threshold limits but also active Mg ranges.

Metallurgical quality control (GJL – GJS)

Metallurgical quality control ensures that melting and treatment processes are sufficient to achieve the required mechanical and functional properties. Monitoring the metal prior to pouring provides valuable information for process control.

The recording of the solidification curve makes it possible to parameterise the nucleation potential of the metal, as well as to predict the tendency for carbide formation and microshrinkage. Some thermal analysis systems are capable of predicting the nodule count and the self-feeding capacity of the metal in GJS. In GJL, it is also possible to predict the percentage of A-type graphite or various numerical factors related to metallurgical quality.

Results obtained from thermal analysis cups can be extrapolated to different areas of castings, enabling earlier decision making and cost optimisation through adjustment of ladle additions based on dynamic pre-inoculation concepts.

The results of a complete test for GJS, including composition control, active Mg threshold and metallurgical quality assessment of the metal, are shown in fig.7.

Nodularity Index (NI) control in GJV

Some systems also provide solutions for controlling compacted graphite iron production using a single cup. The cooling curve is used to determine whether the metal falls within the required window for CGI production, reducing the risk of flake graphite formation.

As with other applications, results can be extrapolated to different sections of castings with complex geoemtries.

PRACTICAL APPLICATION CASES OF THERMAL ANALYSIS

The integration of thermal analysis into process management enables intelligent, precise and optimised control of molten metal treatment, both in the spheroidisation stage and in conditioning and inoculation processes. It also ensures control of nodularity and overall metallurgical quality.

Case 1: Minimum active Mg control in GJS

Plant overview:

• Production: 14,000 t/year (75 per cent ductile iron, 25 per cent grey iron).
• Two horizontal high pressure moulding lines.
• Two medium frequency induction furnaces (8t).
• Wire feeding nodularisation in 1,000kg ladles.

Initial situation:

Due to the inability to ensure Mg content prior to pouring, the plant applied an average over treatment of 25.3m/t to guarantee a minimum Mg level.

Proposal:

Implementation of a thermal analysis system for early detection of minimum active Mg threshold.

Results:

• 100 per cent detection of insufficiently treated ladles.
• 22 per cent reduction in wire consumption.
• Estimated annual savings: US$78,000.00 (€66,000.00).

Case 2: GJV production control

Plant overview:

• Production: 36,000 t/year (45 per cent ductile iron, 55 per cent compacted graphite iron).
• Three vertical moulding lines with pressurised pouring.
• Six medium frequency induction furnaces (10t).
• Sandwich nodularisation in 1,800kg ladles.

Initial situation:

No predictive control system was available. Validation relied on chemical analysis with a delay of three treatments, resulting in rejection of four treatments. Average defect rate: 0.1 per cent.

Proposal:

Implementation of a thermal analysis system providing early warning of defective treatments.

Results:

• 100 per cent early detection of defective ladles.
• Elimination of in-process rejection.
• Estimated annual savings: US$48,000.00 (€41,000.00).

Case 3: Metallurgical quality control in GJS

Plant overview:

• Production: 24,000t/year (100 per cent ductile iron).
• Two vertical moulding lines with pressurised pouring and in-stream inoculation.
• Four medium frequency induction furnaces (12t).
• Sandwich nodularisation in 1,500kg ladles.

Initial situation:

A 0.30 per cent pre-inoculant addition was applied without metallurgical quality control, making its effectiveness unknown.

Proposal:

Implementation of thermal analysis to assess metallurgical quality under different pre-inoculation conditions.

Results:

• Definition of a systematic metallurgical quality control approach.
• 33 per cent reduction in pre-inoculant addition.
• Estimated annual savings: US$140,000.00 (€120,000.00).

Process control through thermal analysis tools has become a key requirement for foundries aiming to enhance their competitiveness. These technologies not only enable real-time monitoring of metal behaviour, but also allow deviations to be anticipated and decision making to be optimised at critical stages of the production process.

In this context, the evolution of control systems and the growing relevance of generated data have driven the integration of additional tools capable of complementing traditional thermal analysis. The combination of multiple sources of information – from metallurgical quality to process variables – provides a higher level of context, significantly improving predictive capabilities and moving foundries closer to zero defect manufacturing strategies.

Furthermore, integrating information related to in-plant metal quality with the geometric characteristics of components and the specific conditions of feeding systems enables a deeper understanding of the root causes of defects. This holistic approach facilitates the correlation between process parameters and final results, allowing for more precise adjustment of manufacturing conditions and advancing towards more robust, efficient and sustainable production models.

A forthcoming article will further explore how predictive models, applied to real component designs and feeding systems and supported by representative data on metal quality in production, can be used to optimise mould and tooling design. In addition, the use of these models in combination with real-time data will enable the anticipation of deviations and contribute effectively to defect prevention in manufacturing.

For copies of the figures supporitn the article, refer to the printed version of the June/July 2026 issue of Foundry Trade Journal. Email: info@foundrytradejournal.com

Imports currently account for around 80% of China’s total iron ore consumption.

China’s share of global steel output will fall to 46% by 2030 from 52% last year, as lower consumption reduces the country’s production, Yilin Wang, general manager of the department of market research and external cooperation at the CMRG Institute, told delegates at an industrial conference in Singapore.

“I have been very fortunate to spend my entire career focussed on one thing: Compacted Graphite Iron. The journey has brought challenge, learning and achievement in equal measure, and above all, many good friends throughout the foundry and automotive industries, for whom I am thankful. Together, we’ve put more than 15 million fuel-efficient vehicles on the road with SinterCast-Inside. I look forward to watching the roll-out of the next 15 million” said Dr Steve Dawson. “As I step down as CEO, I am happy to pass the torch to Vítor. He has the expertise, the energy, the demeanour – and the team – to carry SinterCast forward. He also has my full respect and support!”

“As I step into my new role at SinterCast, I would first like to recognise the pivotal role that Steve has played in establishing CGI technology within the automotive industry and in guiding the company to profitability and long-term success. I am grateful for the trust and support he has shown me over the past two years working together. I look forward to continuing to benefit from his experience and guidance in his ongoing roles as Board Member, consultant, advisor, and friend”, said Dr Vítor Anjos, President & CEO of SinterCast. “Looking ahead, I am excited to build on our strong foundation by continuing the growth of our CGI production, further strengthening the support we provide to our customers, and expanding the company beyond our core business to create even greater long-term value for our shareholders.”

For more information:

Dr Vítor Anjos
President & CEO
SinterCast AB
Mobile: +46 764 924 633
E-mail: vitor.anjos@sintercast.com

Today, however, the industry is undergoing a fundamental transformation. Increasingly, competitiveness is no longer defined solely by engineering perfection — but by the ability to innovate faster. The rapid rise of Chinese manufacturers is accelerating this shift and forcing European industry to rethink established business models.

China’s Rapid Expansion in Global Mechanical Engineering

China has evolved from a low-cost manufacturing hub into a technologically competitive industrial powerhouse. Recent market data shows how dramatically global market shares are changing.

With machinery exports reaching approximately €735 billion in 2024, China surpassed Germany for the first time as the world’s largest machinery exporter. Growth has been particularly strong in Europe: Chinese machinery deliveries to European markets increased by nearly 87 percent between 2020 and 2024.

Chinese suppliers are gaining ground not only through pricing advantages but also through advances in key future technologies, including:

• industrial robotics
• laser processing systems
• CNC machine tools
• automation and smart manufacturing solutions

This development marks a structural shift rather than a temporary market cycle.

Understanding “China Speed”: Faster Innovation Cycles as a Competitive Advantage

A central driver behind China’s industrial success is what many analysts describe as “China Speed.”

Unlike traditional European development models, which often follow sequential stages from research to production, many Chinese companies operate with parallel processes. Product development, manufacturing preparation and customer testing frequently occur simultaneously. This agile approach delivers several advantages:

• significantly shorter product development timelines
• faster market launches
• rapid integration of customer feedback
• continuous product iteration

In markets shaped by digitalisation and automation, speed has become a decisive differentiator.

From Engineering Perfection to “Good Enough” Solutions

Global customer expectations are also changing. In many industrial applications, buyers increasingly prioritize availability, flexibility and cost efficiency over maximum technological sophistication.

Chinese machinery often follows a “fit-for-purpose” philosophy: machines deliver sufficient performance for specific applications at highly competitive prices. In some segments, equipment from China is 30 to 70 percent cheaper than comparable European solutions while meeting operational requirements in practice.

For European manufacturers, this represents a major strategic challenge. Traditional strengths, complex engineering processes, extensive customization and perfection-driven development, can slow response times in fast-moving markets.

Declining order volumes and restructuring measures across parts of the European mechanical engineering sector suggest that the industry is facing a long-term transformation rather than a short-term downturn.

How European Mechanical Engineering Companies Are Responding

European companies are already adapting to the new competitive environment through several strategic initiatives:

1. Localization of Development and Production

Manufacturers increasingly establish regional engineering and production capacities in major growth markets such as China and Southeast Asia to shorten decision cycles and improve customer proximity.

2. Modular Product Platforms

Standardized machine platforms allow faster configuration, reduced costs and shorter delivery times while maintaining quality standards.

3. Digitalization and Software Integration

Software, artificial intelligence and data-driven services are becoming central competitive elements. Digital solutions enable faster upgrades and continuous performance optimization without complete hardware redesigns.

4. Balancing Speed and Quality

Companies are reassessing the balance between engineering perfection and market responsiveness, developing differentiated product strategies for premium and high-speed market segments.

Europe’s Strengths Remain but Adaptation Is Essential

Despite intensifying competition, Europe continues to benefit from deep industrial expertise, advanced research capabilities and strong engineering traditions. These advantages remain valuable foundations for future growth.

However, success will depend on combining technological leadership with faster innovation cycles, leaner processes and greater strategic flexibility.

The Future of Mechanical Engineering: Quality Alone Is No Longer Enough

Global mechanical engineering has entered a new competitive era. The decisive question for European industry is no longer whether it can produce the best machines but whether it can deliver innovation at the pace demanded by global markets.

In the emerging industrial landscape, speed, adaptability and technological intelligence will determine who leads the next generation of manufacturing.

This market recovery is primarily driven by a 30% increase (compared to March) in shipments to China, where 25.3 million tons of raw material were shipped in April. In March, exports were held back by holidays and the scheduled shutdown of blast furnaces in China for maintenance during the first quarter of the year.

Asia remains the main market for Brazilian ore—28.7 million tons of raw material were shipped there in April. Next are:

• Europe – 1.3 million tons;
• South America – 822,000 tons;
• Africa – 516,000 tons.

At the same time, pellet exports in April rose by 32% compared to March, reaching 2.9 million tons. The bulk of shipments went to Asia (1 million tons). Meanwhile, deliveries to Europe totaled 686,000 tons, to Africa – 446,000 tons, and to the U.S. – 390,000 tons.

It is worth noting that, according to the country’s Ministry of Development, Industry, Trade, and Services, iron ore exports from Brazil reached a record high of 416.4 million tons last year, a 7.1% increase year-on-year. This was the first time the annual figure exceeded 400 million tons, breaking the previous record of 390 million tons set in 2018. Overseas shipments were substantial in the final months of the year, exceeding 40 million tons per month in October and December.

The aluminium industry is undergoing a quiet but profound bifurcation. On one side sits undifferentiated commodity-grade metal, increasingly exposed to carbon pricing pressure, regulatory scrutiny, and procurement de-prioritisation. On the other stands a rapidly growing premium tier of certified low-carbon, recycled-content aluminium that European manufacturers are actively seeking to lock into long-term supply agreements. Understanding which producers are positioning themselves on which side of that divide is becoming one of the more consequential questions in European industrial strategy.

Norway's hydropower-rich industrial corridor has emerged as a natural home for the premium tier. The physics are straightforward: aluminium smelting is extraordinarily energy-intensive, and the carbon credentials of the finished metal are largely determined by the electricity source powering the reduction process. Norwegian smelters, operating on a grid dominated by renewable hydropower, begin with a structural carbon advantage that coal or gas-fired competitors simply cannot replicate through incremental efficiency improvements alone.

When post-consumer recycled aluminium is layered into that equation, the carbon intensity gap between Norwegian production and the global primary average widens further still. Norway climate-efficient metals have increasingly attracted capital precisely because of this structural advantage, reinforcing the country's position as a destination of choice for low-carbon industrial investment.

It is within this context that Alcoa's latest capital commitment at its Mosjøen facility in Northern Norway deserves careful analysis, not merely as a project announcement, but as a signal of where the competitive centre of gravity in European aluminium supply is heading.

Breaking Down the Alcoa Mosjøen $65 Million Investment in Recycled Aluminium

Alcoa low-carbon aluminium has been a consistent strategic priority across multiple facilities, and the Mosjøen commitment represents one of the most concentrated expressions of that ambition. Alcoa Corporation confirmed on 11 May 2026 that it will commit USD $65 million to expand and upgrade the casthouse at its Mosjøen aluminium smelter. The Alcoa Mosjøen $65 million investment in recycled aluminium represents the single largest tranche in a capital programme that has now reached approximately USD $180 million in cumulative spend at the site since 2020, making Mosjøen one of the most consistently funded smelter assets in Alcoa's global portfolio over the past six years.

The practical outputs of this commitment are both infrastructural and operational:

• A new open mold foundry casting line will be installed, enabling greater flexibility in ingot geometry and format
• New melting furnaces will be deployed, configured to handle the variable alloy chemistry that comes with processing post-consumer scrap feedstock
• The facility will introduce post-consumer recycled aluminium integration for the first time in Mosjøen's operational history
• The expanded foundry alloy portfolio will accommodate a wider range of alloy specifications, multiple ingot sizes, and certified recycled-content products

The phased commissioning timeline extending through 2028 reflects the genuine engineering complexity involved. Integrating post-consumer scrap into a primary smelter casthouse is not simply a feedstock substitution exercise. Post-consumer aluminium arrives with variable alloy chemistry, contamination profiles, and traceability characteristics that differ substantially from primary metal or clean industrial offcuts.

New furnace configurations must reliably homogenise these inputs to produce certified alloy specifications that automotive and packaging customers will stake their own compliance records on. According to Alcoa's official announcement, the investment is designed to meet rising demand for low-carbon, recycled-content aluminium across European markets.

"The ability to certifiably blend primary and post-consumer recycled aluminium within a single casthouse, while maintaining documented alloy specifications for tier-one customers, is a technically demanding undertaking that should not be underestimated as a differentiator."

See more at: https://discoveryalert.com.au/alcoa-mosjoen-recycled-aluminium-investment-norway-2026/

The reasons for the termination of the production process were reported by the press service of the metallurgical concern, referring to the statement of CEO Mauro Longobardo.

He explained that Ukrzaliznytsya (Ukrainian Railways) cannot cope with the necessary volume of transportation of products and raw materials, which makes the production process impossible.

"They simply do not deliver to us the key component of the iron foundry, without which we are not able to produce pig iron," said the head.

In addition, the company has been operating without profit for the fourth year in a row, which eventually led to the inability to maintain operating activities.

The plant in Krivoy Rog is the largest steel producer in the country. Its products are critically important for defense needs: steel is used for the production of fortifications and repair of armored vehicles.

As EADaily reported, earlier the European Commission refused to make an exception for Ukraine as part of the introduction of a carbon duty in the EU in 2026. This hit Ukrainian metallurgists, who lost orders by 1.1 million tons in the first quarter alone.