Wuxi Wondery Industry Equipment Co., Ltd

1. Market Background In Russia, the automotive, construction and cable industries generate steady and growing demand for aluminum ingots. Ingot quality—hydrogen content, inclusions and chemical homogeneity—directly affects the stability of downstream casting and rolling processes. Many plants operate relatively simple ingot casting lines with limited investment in degassing and filtration, making it difficult to systematically address hydrogen and inclusion issues in molten aluminum and leading to higher defect rates downstream. 2. Customer & Application Scenario The customer is an ingot producer supplying multiple industries. Its existing ingot line had limited length, with degassing and filtration units scattered and loosely integrated. As end users tightened their quality specifications, the existing setup struggled with melt cleanliness, ingot dimensional consistency and line throughput. The customer sought a full-line upgrade, combining melt purification and ingot casting in a single, integrated solution. 3. Our Solution (Product & Specifications) The new system centers on a 9 m ingot casting machine, a mobile in-line degassing unit and a filtration box, forming a complete ingot casting solution: The 9 m ingot caster provides stable ingot forming and cooling rhythm, supporting continuous casting; The mobile in-line degasser is positioned upstream of the ingot caster, using argon or nitrogen purging to reduce hydrogen content in the molten aluminum; The filtration box houses ceramic filter media to remove non-metallic inclusions and improve melt cleanliness. With carefully designed elevation and flow paths, molten aluminum flows through filtration and degassing before entering the ingot caster, effectively integrating “purification + casting” into a single line. Rather than optimizing each unit in isolation, the solution focuses on the coordination and layout of all three modules to ensure a coherent upgrade of the entire process. 4. Customer Feedback After start-up, the customer reported more consistent ingot surface and internal quality. Downstream users observed fewer gas porosity and inclusion-related defects during remelting and secondary casting. The 9 m ingot caster delivered smoother cycle control, and ingot size and weight consistency improved, simplifying packaging and inventory management. The combination of in-line degassing and filtration allows melt purification settings to be adjusted according to alloy grade and production schedule, and maintenance or filter changes are relatively straightforward. The customer believes this integrated upgrade provides a strong foundation for entering higher-end markets with stricter quality demands. 5. Conclusion For Russia and other regions with concentrated aluminum processing industries, a complete ingot casting line combining a 9 m ingot caster, in-line degassing and filtration can improve ingot quality at the source and reduce defect rates in downstream operations. This case demonstrates that planning melt purification and ingot casting as a single integrated system yields a better balance between quality and efficiency than upgrading individual pieces of equipment in isolation.

1. Market Background In South Africa’s recycled aluminum and casting industry, collecting, cooling and stacking ingots after casting has long relied on manual work or simple mechanisms. As output grows, manual handling in hot areas becomes physically demanding, stacking rhythm is unstable, and pile height and neatness are difficult to standardize. This not only reduces yard utilization but also raises safety risks. Automated ingot stacking systems are therefore attracting increasing interest. 2. Customer & Application Scenario The customer is an aluminum ingot producer serving local metallurgy and casting markets, operating multiple casting lines. Previously, ingot collection and stacking depended mainly on workers and basic conveyors. At high throughput, operators had to work close to hot zones and handle ingots frequently, making it difficult to guarantee both efficiency and safety. The customer wanted to implement gantry-type ingot stacking systems on two lines to automate piling, reduce manual workload and improve stack quality. 3. Our Solution (Product & Specifications) The solution consists of two gantry manipulator ingot stacking machines, each assigned to one ingot production line, featuring: Gantry beams with manipulators that move in two or three axes; Automated pickup from the casting line, with gripping, rotating and placing according to predefined patterns; Flexible stacking patterns defined by pallet size and target stack height, building neat and consistent ingot piles. The ingot stacking systems are integrated with existing conveyors and line signals, adjusting manipulator cycle times to match line speed and prevent both blockages and missing ingots. 4. Customer Feedback After commissioning, the customer reported that ingot stacking on both lines became essentially unmanned, with fewer operators required and reduced physical workload and heat exposure. Because the gantry ingot stacking machines follow consistent stacking programs, pile heights are uniform and edges are neat, improving yard utilization and making forklift handling smoother. In terms of system stability, the manipulator cycle times match the casting line throughput well. Alarms and interlocks work as intended to prevent cascade failures, giving the customer confidence to push further with automation upgrades. 5. Conclusion For South African ingot producers, deploying gantry manipulator ingot stacking systems is an effective way to cut labor and safety risks while improving yard management and loading efficiency. This project shows that integrating stacking into the overall production line automation strategy is an important step toward enhancing overall competitiveness.

1. Market Background In aluminum extrusion, dies are expensive and need frequent changes. Once the working surface is worn or fatigued, profile dimensional accuracy and surface quality are directly affected. Many extrusion plants in Iraq previously relied on simple quenching and tempering, which provided limited surface hardness and fatigue strength. As a result, die life was short, changeover frequency was high, and overall production costs remained elevated. 2. Customer & Application Scenario The customer in this case is an extrusion plant serving the building profile market. While its line throughput is moderate, it uses many die sizes and faces rapidly changing orders. With only basic heat treatment, the die working zone suffered fast wear and unstable nitrided case depth and hardness distribution, which led to dimensional variations and fluctuating extrusion force on certain profile batches. The customer needed a dedicated nitriding furnace to carry out stable gas nitriding for extrusion dies, extending die life and reducing total die cost. 3. Our Solution (Product & Specifications) The proposed system is a 60 kW nitriding furnace with an effective size of Φ700×900 mm, designed for multiple medium-sized dies per batch. It provides: 60 kW power for balanced heating rate and energy usage; An effective diameter and height of Φ700×900 mm to fit common extrusion die dimensions; Multi-segment programmable cycles for heating, soaking and cooling; Atmosphere control for tuning nitriding potential and matching surface hardness with case depth. This allows the customer to tailor nitriding recipes to different die steels, giving the working zone a hard, wear-resistant surface while retaining sufficient toughness in the core to avoid brittle failures. 4. Customer Feedback After a period of operation, the customer reported a significant increase in die life, with some critical dies staying in service for more than one additional maintenance cycle compared with the old process. Wear on the die surface became more uniform, cracking was delayed, and extrusion pressure fluctuations decreased, improving profile dimensional stability. With the Φ700×900 mm furnace volume, multiple dies can be treated in a single batch. Nitriding cycles are easier to align with die maintenance schedules, reducing the need to dedicate full cycles to just one die and improving overall efficiency. 5. Conclusion For aluminum extrusion plants in Iraq that are expanding capacity, adding a properly sized 60 kW nitriding furnace with adjustable process recipes is a practical way to cut total die costs and stabilize profile quality. This case shows that a nitriding system optimized for extrusion dies can deliver tangible improvements in die life and process stability without overcomplicating day-to-day operation.