MMM

Sr. No.
1 2 3 4 5 6

Names
AJANI KAJAL P. SWAMIKUTTY ANISH RAJ DHAS AMIT J. JADHAV SAMIR S. KAMATH VINAYAK R. RAI ANIKET B.

Roll No.
MM-10-01 MM-10-02 MM-10-08 MM-10-14 MM-10-15 MM-10-23

Overview of Hindalco

Capacity - Aluminium:

Hindalco : 531 kt Novelis : 2,943 kt

Capacity Copper : 500 kt Turnover FY10:

Hindalco- Novelis $ 13.7 bn.

Employees: 36,000

Hindalco : Footprint in India

Renukoot
DAHEJ Muri
Integrated Plant Foil FRP Alumina Extrusions Copper Smelter Sales offices:
Mumbai, Delhi, Bangalore, Kolkata

Silvass a Kalwa Taloja

Mouda Hiraku d Kollur

Belur

Belgaum

Alupuram

Hindalco - Marketing Structure

MHO (Primary Metal, Rolled & Extrusions)

CMO

Central Market Development

Training & Development Marketing Services

IT

SBU Head Primary

SBU Head Extrusions

SBU Head Rolled - Domestic

SBU Head Rolled - Exports

FRP & Extrusions has Independent Market Development Cell

5

Hindalco - Marketing Structure

A typical Product Structure

SBU Head- Flat Rolled Products

Market Development Cell

Product Executive RM North RM East

Business Finance

R M - West

R M South

Primary Aluminium

Ingots

Billets

Wire Rods

Major Usage : Auto Industry / Construction/ Electrical Industry

Primary Metal -Castings

STEERING KNUCKLE

WHEEL

SUSPENSION ARM

SPACE FRAME NODE

GS BRACKET

Control Arm

High purity aluminium required to ensure grain structure

Extrusions

Major Usage : Building Industry, Industrial Machinery, Defence

Flat Rolled Products

COOK WARE

FAN BLADE & VENETIAN BLINDS

Semi rigid containers

Al - Containers

Pharma Foils- Printed

PP Cap & Vial seals

Vial seals

HVAC

HVAC

Flooring Sheets

ALUMINIUM COMPOSITE PANELS

Building Sheets

Curvomatic Roofings

Cabinets

Reflectors & diffusers

Lamp caps

Metal Bridges

Electrical bus bars

Lithographic sheets

Melting and Casting (Direct Chill Method)

Process Flow
Al. Ingot Rolling Ingot Scalping Melting and Continuous Casting

Continuous Cast Coil

Soaking/Pre-Heating Hot Rolling Annealing Cold Rolling Finishing Profiling Roll Forming

Circle Blanking
Packing

Shearing

Sheeting

Coiling

Aluminium Ingots

Continuous Casting Process

Direct Clill Slab Casting

A process/facility of production of slabs of various desired dimensions from molten metal by extracting heat through direct cooling by water, keeping both metal flow & thermodynamics in equilibrium.

Why Scalping ?
1. The outer surfaces of the ingots (both the flat surface and the edges) contain more of impurities, oxides and have greater alloy segregation.
2. For any critical application like those requiring for subsequent rolling to thin or ultra thin gauges it is necessary to get rid of these surface impurities and segregation. 3. The depth of the unsound casting zone could be anything from about less than a millimeter to as high as 10 12 mm depending on the casting technology, process controls and alloy of the cast.

Preheating, Homogenizing and soaking:

1. Casting leads to some extent of alloy heterogeneity in the entire mass of the ingots.
2. This heterogeneity needs to be taken care so that the final product shows uniform physical and chemical properties much needed for uniform and smooth behaviors in further processing. 3. In order this to happen, the ingots are heated as close to the solidifying temperature as possible. This process is called HOMOGENIZATION. It is best carried out at temperature as close to the solidifying (solidus) temperature as possible.

Soaking Pit

Soaking Pit
HEATER HEATER FAN COVER

INGOT

INGOT

TOP VIEW

FRONT VIEW

What do u mean by Rolling??

1.Rolling is defined as the reduction of the cross-sectional area of the metal stock, or the general shaping of the metal products, through the use of the rotating rolls . 2.It allows a high degree of closed-loop automation and very high speeds, and is thus capable of providing high-quality, close tolerance starting material for various secondary sheet metal working processes at a low cost .

Schematic Drawing of Rolling Process

Hot Rolling Mill converts preheated cast Aluminium slabs of thickness approx. 305 /330 mm into a sheet/coil of thickness 6 to 9 mm by passing the slab between work rolls for an integral number of times

Annealing:
is a particular process of Heat treatment used to relieve the metal from internal stresses by loosing stored energy.
Metal

losses its stored energy in the following three

stages:
Recovery Recrystallisation Grain

growth

Recovery:
Remove internal stresses by heating to a relatively low temperature.

Dislocations start reducing and rearrange themselves. It does not affect grain structure.
It does not affect hardness & strength

Recrystallisation:
Strain free new grains are formed. Hardness and Strength decreases sharply.

Grain growth:
Grains grow in size due to combination of individual grains. Boundary area reduces, so total energy decreases and grains become stable.

Annealing Furnace

GECA Annealing Furnace

51

Annealing Furnace

Sunbeam

Otto Junker
52

What is Cold Rolling ?

Cold rolling is the process of getting desired
thickness of material by passing it through work rolls at normal temperature (Below Re-crystallization

temperature)
Angle of Bite

53

Cold Mill
Bridle Deflector

X-Ray Gauge control

Vidimon Shape control

6.50 MM

4.00 MM
Uncoiler

Coiler Pass Line Roll

54

Pinch Roll 4 Hi Mill

Bliss Cold Mill

55

Davy Cold Mill

56

Spinning & Flanging

Stretching

Bending & embossing

Blanking & shearing

Sheet Forming:

a combination of Processes

Equipment - Roll Former

Consists of 2 rafts (for CR & ICR); 4 sub-rafts; 5 forming rolls in each raft Forming - from centre to side; last 3 rolls for width adjustment

Gauge : 0.28-1.63 mm Width : 800/950 for CR 795/920 for ICR Length: 545 - 10000 mm (1875-7000 preferred range)