Are you looking for additional mill processing capacity on either a short- or long-term basis? Do you need a reliable source that will not only provide conversion services for your alloys, but has the expertise and capabilities that many other mills lack?

Special Metals Corporation, the world's largest and most-diversified producer of high-performance nickel-based alloys, is now offering its resources, expertise, and excess capacity to other metals producers for toll work. This service is available through our manufacturing facilities in Huntington, West Virginia; Dunkirk, New York; New Hartford, New York; Burnaugh, Kentucky; Elkhart, Indiana and Hereford, England.

Special Metals produces nickel alloys in all significant mill forms from large ingots and billets to flat stock, seamless tubing, bar and wire, the latter of which includes core and filler wires for welding products. Its specialty metals are used in some of the world's most technically demanding industries and applications, including: aerospace, power generation, chemical processing, and oil exploration.

While Special Metals production facilities are ideally suited for nickel-based alloys, we are capable of processing a wide range of ferrous and non-ferrous alloys through the same facilities. Operations of the Company's production facilities include the melting, remelting, forging, hot rolling and finishing of rod, sheet/strip, plate, tubular products, extrusion, large diameter tube reduction, mechanically-alloyed powder manufacture, and by cold strip finishing.

Manufacturing Capabilities by Location

HUNTINGTON, WEST VIRGINIA CAPABILITIES
Manufacturing capabilities at the Huntington, WV facility include:

Vacuum Induction Melting (VIM)
Single furnace: 24-ton/15 ton box sizes

EAF/AOD
35-ton electric arc furnace (2)
38-ton argon-oxygen-decarburization vessel

Vacuum Arc Remelting (VAR)
5 furnaces; crucible sizes ranging from 18" to 36" in diameter

Primary Mill Rolling Equipment
110" Mill capable of rolling plate, rounds and slabs.

Steckel Mill
Capable of rolling Hotbands up to 52" wide.

Press Forge
5,000-ton capacity forging press; diameter: 4" min./45" max.; 50,000 lbs. maximum weight; upset opening: 99", die width: 60"

Plate Finishing
Key equipment includes: plate annealing furnaces, roller leveler, stretcher leveler, shot blaster, shear, abrasive saws, and plasma cutting equipment

Bar & Wire
Wire mill: product size ranging from .217" to 1.031" in diameter in coil form
Rod mill: product size ranging from .50" to 5.250" in diameter in straight lengths.

Cold Draw Finishing
Key equipment includes: Cold Pilger mills, tubing draw benches, roller hearth annealing furnaces, pickle tanks, straighteners, cutters, centerless grinders, and batch wire annealer
Tubing: product size ranging from ½" to 9 ½" in diameter, up to 86' in length

Machine Shop
Key equipment includes: Rod turners, peelers, saws and milling machines

Sheet & Strip
Key equipment: Coil Build-up, Continuous Anneal and Pickle; Bright Anneal, cold reduction mills, coil grinder, slit/cut-to-length line and slitters
Max coil weight: 30,000 lbs
Max coil width: 52.000"
Max coil starting ga.: 0.4"
Min coil gauge: .006"

For more information, contact:
Roger Chapman
Conversion Services Representative
Special Metals Corporation
3200 Riverside Drive
Huntington, WV 25705
Phone: +1.304.526.5280
Fax: +1.304.526.5196
rchapman@specialmetals.com

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BURNAUGH, KENTUCKY CAPABILITIES
Manufacturing capabilities at the Burnaugh, Kentucky plant include:

Air Induction Melting (AIM)
Single furnace: 31,500 lbs. capacity

Electroslag Remelting
Eight furnaces

Tube Extrusion
6,000-ton Extrusion Press, Wean Tube Reducer, Trepanning equipment, pickling facility

For more information, contact:
Roger Chapman
Conversion Services Representative
Special Metals Corporation
3200 Riverside Drive
Huntington, WV 25705
Phone: +1.304.526.5280
Fax: +1.304.526.5196
rchapman@specialmetals.com

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ELKHART, INDIANA CAPABILITIES
Manufacturing capabilities at the Elkhart, Indiana plant include:

Sheet & Strip
Key equipment: Sendzimir mill; Bright Anneal line; slitting line
Product sizes: Z-mill 50" wide; BA 38" wide;

For more information, contact:
Roger Chapman
Conversion Services Representative
Special Metals Corporation
3200 Riverside Drive
Huntington, WV 25705
Phone: +1.304.526.5280
Fax: +1.304.526.5196
rchapman@specialmetals.com

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DUNKIRK, NEW YORK CAPABILITIES
Manufacturing capabilities at the Dunkirk, New York plant include:

Saw cutting
17" diameter ingot to 6"diameter billet

Homogenization

General condition "A" type heat treatment w/ water quench capability

Press forge ( two open die hydraulic presses, 4.5K ton and 2K ton)
-Large press (4500 ton)
12.5 ton capacity
daylight for upsetting =120"
ingot/billet diameter = 6" min/48"max
max slab width = 44"
max billet length =29.5 ft (finish) ; 19 ft (reheat)

- Small press (2000 ton)
: 6.0 ton capacity
: daylight for upsetting =120"
: ingot/billet diameter = 6" min/48"max
: max slab width = 72"
: max billet length =19 ft
Forge practices can be followed to customer specifications.

For more information, contact:
Debbie Bartkowski
Conversion Coordinator
Special Metals Corporation
100 Willowbrook Ave.
Dunkirk, New York 14048
Phone: +1.716.366.5663 ext.226
Fax: +1.716.366.7436
dbartkow@specialmetals.com

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NEW HARTFORD, NEW YORK CAPABILITIES
Manufacturing capabilities at the New Hartford, New York plant include:

VIM Melting
40,000 lb and 12,000 lb furnaces
Mold diameters 14, 17, 21, 27, 30, 34

VAR Melting
Ingot sizes 17, 20, 24, 30

ESR Melting
Ingot sizes 17, 20, 24, 30, 36

Rolling
22-inch hand mill can roll 2.25-inch round up to 5-inch round
16-inch hand mill can roll 0.406-inch round up to 2-inch round

For more information, contact:
Debbie Bartkowski
Conversion Coordinator
Special Metals Corporation
100 Willowbrook Ave.
Dunkirk, New York 14048
Phone: +1.716.366.5663 ext.226
Fax: +1.716.366.7436
dbartkow@specialmetals.com

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HEREFORD, ENGLAND CAPABILITIES
Manufacturing capabilities at the Hereford, England plant include:

Melting and Forging

Vacuum Induction Melting (VIM)
Computer controlled processing available.
High-frequency melting, refining, and casting with a nominal capacity of 8 tonnes.
Typical ingot sizes, 320, 345, 420, 440, and 540 mm diameter.

Electroslag Remelting (ESR)
Computer controlled processing.
Nominal capacity up to 5.8 tonnes depending on the product diameter.
Mould sizes, 460 mm, 540 mm, and 665 mm diameter.

Vacuum Arc Remelting (VAR)
Computer controlled processing available.
Nominal capacity up to 5.8 tonnes depending on the product diameter.
Mould sizes, 380, 520, and 610 mm diameter.

Forging
A computer controlled hydraulically operated 1750 tonne press.
Maximum billet size, 700 mm diameter. Smallest size typically 100 mm diameter, round or square with rectangles down to 50 X 140 mm.
Mobile manipulator has 360° jaw rotation and a capacity of 17 tonnes at 2.5 m.
Maximum workpiece size, 1400 mm diameter.
Railbound manipulator has 360° jaw rotation and a capacity of 18 tonnes at 6 m.
Maximum workpiece size, 1300 mm diameter.

Homogenized Heat Treatment
A natural gas fired furnace with an oxidizing atmosphere operating in the range of 550 - 1250°C. Controlled to a +10°C/-20°C at 750°C.
Bar length, 3.5 m max. Load weight, 20 tonnes max. Maximum piece weight, 7 tonnes X 2.5 m X 1400 mm diameter.

Hot and Cold rolling - Plate and Sheet

Hot Rolling (General Guidelines) - Plate
Maximum length, 3500 mm. Maximum width, 1250 mm. Thickness, 90 mm max. - 3 mm min. Weight, 300 kg max.

Cold Rolling (General Guidelines) - Sheet
Maximum length, 3200 mm. Maximum width, 1220 mm. Minimum gauge, 0.50 mm.

Heat Treatment (Temperatures up to 750°C)
Maximum length, 3900 mm. Maximum width, 1020 mm.

Shears
Maximum length, 3000 mm. Maximum width, 2000 mm. Maximum gauge, 20 mm.

Extrusion

The extrusion press at SMW (Hereford) is available for hirework activity subject to inquiry to Production Management. The press is rated at 5650 tons maximum press force and can accommodate billet parameters of 175 mm, 225 mm, 275 mm, 300 mm , 343 mm up to a maximum of 750 mm. Product forms available are solid bar (round or profile) and tube ( not 175 mm billet). Preheating is via gas fired batch furnaces and temperature range available is 400°C to 1250°C (+ or - 15°C at 400°C to 600°C; + or - 10°C at above 800°C to 1250°C).

Rod Rolling

10 Stand Rod / Bar and Wire Coil Mill incorporating:
2 Roughing / Cogging Stands
4 Intermediate Stands
4 Finishing Stands
5 Gas Fired Oxidizing / Reducing Furnaces
2 Wire Coilers
Air Cooling and Water Quench Facilities

Feedstock
Straight Lengths:
Maximum - 6" round / square bar. 6'6" length. 205 kgs weight on Roughing Mill.
Minimum - 2'6" length on Roughing Mill. 1'6" on Intermediate.
Maximum piece weight / length on Intermediate dependent on requirement.
Wire Coil:
Maximum coil weight currently 45 kgs.
Maximum piece weight / length dependent on requirement.

Finished Sizes
Straight Lengths - 12 mm to 115 mm. 35 sizes currently available.
Wire Coil - 3/8" and 1/2". 2 sizes currently available.

Preheating Temperature Range
750°C to 1250°C.
Oxidizing and reducing.

Products
Bar, Rod, and Wire Coil for direct sale or further processing.

Heat Treatment

All types of heat treatments are conducted in air atmospheres.

Temperatures are controlled on multi-point recorders within tolerances of:
+/- 5°C for treatments up to 750°C.
+/- 10°C for treatments above 750°C.

Furnace Limitations

For more information contact:

Primary (Hot Working) Operations
Mark Docker
Phone: +44 (0)1432 382562
Fax: +44 (0)1432 351965
mark.docker@specialmetalswiggin.co.uk

Finishing (Cold Working) Operations
Phil Buckman
Phone: + 44 (0) 1432 382215
Fax: +44 (0)1432 352005
phil.buckman@specialmetalswiggin.co.uk

Wire Products
Tony Jude
Phone: +44 (0)1432 382518
Fax: +44 (0)1432 353995
tony.jude@specialmetalswiggin.co.uk

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