A state-of-the-art production line realizes both high quality and cost competitiveness
The First Phase Line dealing with the processes from cold rolling to finishing was completed in January 2014, and the Second Phase Line responsible for the processes from casting to hot rolling was completed in summer 2015. This system enables annual production of 192,000 tons of aluminum sheet.
UACJ (Thailand) has established an optimal manufacturing process to meet the needs of a variety of aluminum products, including automotive heat exchanger materials and beverage can end materials.
Aluminum metalAluminum products are produced from lumps of aluminum called ‘ingots’ created by electrolytic refining.
Melting furnaceAluminum metal and other metallic materials are mixed and melted at a high temperature to form the required ratio of components.
Holding furnaceThe furnace keeps the molten aluminum from the melting furnace hot to prevent it solidifying before casting.
Degassing treatmentTo avoid defective surfaces, a purge gas absorbs the hydrogen gas dissolved in the molten aluminum and lets it float to the surface.
Removing inclusionsA ceramic filter is used to remove minute oxides and inclusions dissolved in the molten aluminum.
CastingMolten aluminum is poured into molds of sizes that vary depending on the product to produce aluminum alloy slabs.
SlabIt is possible to produce the world’s largest slabs, including ones with a gross weight of over 32 tons, a width of over 2 meters, and a thickness of over 600 millimeters.
CuttingThe base of slabs, which may have been bent or cracked during hot rolling, are cut. The top of some types is also cut.
ScalpingThis facing equipment fettles and removes metallically any uneven parts of the slab surface.
SoakingTo homogenize the internal structure of slabs, annealing (heating) is conducted.
HeatingSlabs are reheated to a high temperature in a heating furnace to prepare for hot rough rolling.
Hot rough rolling millOne unit of a four-stage rolling mill produces the target thickness from a 500mm-thick slab. For beverage can materials, rolling is repeated 20 times in both directions.
Hot rolling finishing millThe four serial units of a four-stage rolling mill produce the target thickness and roll the sheet into a coil. Our original technique produces coils with superior thickness precision, sheet crown (across-the-width cross-sectional shape), and mechanical properties.
Cold rollingA non-reversible six-stage single-stand rolling mill produces products with high thickness precision and the required strength, surface roughness, and polish.
TemperingFinal tempering and annealing are carried out to meet the processing requirements of customers.
LevelingThe flatness of rolled aluminum sheets is normalized to a high level of precision.
Surface treatment & coatingChemical surface treatment is carried out to remove surface grease, add an undercoating, provide corrosion resistance, etc. Next, a dedicated aluminum sheet paint line provides an optimal surface treatment.
SlittingThe coils are continuously cut and wound into products with the required widths.
Inspection & packagingA final inspection is carried out to ensure that the completed products satisfy the specifications ordered. They are then packed in an optimal manner for transport and storage.