Every car review that remarks on the exquisite handling of the new '04 BMW 5-Series makes executives at aluminum giant Alcan Inc. smile.

The 5-Series is the poster child for a new trend in aluminum use: a material hybrid where the front end of the car, from A-pillar forward, is lightweight aluminum and the back is steel.

The '04 Jaguar XJ showed it is possible to make an entire car body of sheet aluminum. Audi AG was an early adopter of the use of aluminum for the spaceframe of the A8 in 1997 and later the small A2.

"The jump to an all-aluminum platform is too big a risk for many," acknowledges Richard B. Evans, Alcan executive vice president. "That is why only Audi and Jaguar have done it to a large degree."

But Alcan sees real potential in the hybrid use BMW devised for the 5-Series.

It is not surprising BMW came up with this blend - it has built its "ultimate" brand on vehicles that strive for a 50:50 weight distribution between front and rear axles for better handling and maneuverability. This can better be achieved with the weight-savings properties of aluminum up front (structure, body panels, hood, fenders, suspension). Alcan provides aluminum sheet and developed a special alloy for the front structure with energy absorption qualities that helped BMW set new body-structure standards for crash performance.

The idea for this particular metal cocktail is BMW's - with the aluminum industry playing the role of enabler, says Rod Jones, Alcan vice president of technology and engineering-automotive.

The 5-Series may be the first high-volume hybrid in terms of an aluminum front end, but will not be the last.

"Virtually all OEMs are looking at that now," Evans says, especially in Europe.

Evans says Alcan has "three or four others coming," declining to give specifics. He does say Audi is looking at hybrids for the next-generation A6 (the '05 Audi A6 introduced in Europe in March has an aluminum-intensive front end) while Jaguar will continue to pursue its aluminum-body strategy with future models.

Jones says the Jaguar XJ and Audi A2 demonstrate aluminum can be used to do a whole car - in two different ways. Add to that piecemeal use of aluminum for parts, and now the BMW-model hybrid scenario.

"It shows the whole range is available and works," Jones says. "Car companies can use aluminum, and can work out their own model of how, where and how much," he says, recognizing individual auto makers are on different parts of the learning curve.

"I think aluminum finally has reached a critical mass in automotive," Evans says. "It has gone from a push mode in the last three years to one of pull mode."

European customers will pay a premium for performance. They also recognize the value in sophisticated bumper systems that aid in crash management, address new pedestrian safety regulations in Europe and have the ability to reduce insurance premiums.

It has allowed Alcan to migrate from awareness campaigns to responding to customer needs.

It is not happening as quickly in North America, where OEMs still put greater emphasis on cost, Evans says. But it is starting to change as more European auto makers manufacture and market in the U.S.

It is that growing demand that prompted Alcan to build two manufacturing facilities in North America. A new facility in Troy, MI, will begin bumper system production this summer and a sister plant in Saguenay, Que., Canada, will ramp up later this year. Japan also has not fully embraced the use of aluminum, but Alcan officials see signs of change there as well.

Alcan does not expect a huge breakthrough in which everything switches to aluminum from steel. But the supplier does forecast sustained growth of aluminum and displacement of steel, with automotive uses leading the charge. Automotive now is Alcan's highest consumer of aluminum.

The recent rising cost of steel has helped because aluminum prices have not increased at the same pace, narrowing the gap somewhat between the two metals.

The buzz: It’s Metal Gear Solid, only in lush outdoor environments and with promises that the guy you see in the screenshots really is the hero of the game. Oh, and it’s set in the past: “Since I was born in the ’60s, I still have memories of this time period from my early childhood,” says head MGS honcho Hideo Kojima. “However, we did our fair share of research during the development process, incorporating real historical events and information.” It also apparently wraps up the whole Metal Gear story line for the time being—according to Kojima, “The MGS series has always been planned to be a three-part story.”

What could go wrong? Though the camera is more adjustable than in past games, it might not go far enough for gamers who’ve been gorging themselves on Splinter Cell. “The MGS series has always combined first- and third-person view perspectives,” says Kojima. “There were benefits to both perspectives that enhanced the overall gameplay, but since 3D games give me motion sickness...I don’t think I will create a first-person shooter myself.” Apart from that, the only realistic obstacle is Kojima himself—not many took well to MGS2’s convoluted story, and if Snake Eater is similarly long winded, word of mouth could be bad.

Producing 60,000 initial lumens, Uni-Form MP 575 metal halide lamp utilizes tipless, formed-body arc tube technology. Arc tube follows shape of arc stream, improving thermal characteristics and eliminating cold spots on lamp, enabling uniform light output. Lamp and ballast system ensures improved warm-ups and restrikes, light control, and precise cut-off angles. Rated for 20,000+ hr, system offers reduced light pollution.

New Product Introduction: Uni-Form[R] MP 575 - energy-saving pulse-start metal halide lamp and ballast lighting system.

Design: Venture Lighting Engineering and Product Development Team

Manufacturer: Venture Lighting International, an Advanced Lighting Technologies (ADLT) company.

Product Applications: Uni-Form MP 575 is designed to save energy, yet outperform, probe-start metal halide lamps across a wide range of commercial, industrial or institutional site lighting environments; installations where higher wattage MH or HPS lamps would typically be employed.

Uni-Form MP 575 installations encompass a broad range of site lighting and high-bay applications, and replacements for 1000-watt MH lamps.

Product Description: Uni-Form MP 575 is part of the Venture Lighting Super Site Lighting System; state-of-the-art metal halide lamps and companion ballasts, designed to provide more light output, longer, using less energy. MP 575 is the brightest pulse-start metal halide lamp in its class, producing 60,000 initial lumens and twice the mean lumens of a standard lower output 400-watt metal halide lamp.

Uni-Form MP 575 lamps embody Venture Lighting's unique, tipless, formed-body arc tube technology. The arc tube follows the shape itself of the arc stream, for improved thermal characteristics of the arc tube, resulting in greater light output. This tipless design further eliminates cold spots on the lamp, for more uniform light output and longer lamp life.

The Uni-Form MP 575 system ensures faster initial warm-ups and faster restrikes, greater light control, more precise cut-off angles, and less light pollution, than probe-start metal halide or high-pressure sodium lamps in similar uses.

Construction: Uni-Form MP 575 pulse-start metal halide lamps use patented weldless technology for reliable, consistent optical precision. Each lamp is rated for 20,000+ hours, meets NEC and ANSI requirements.

When MP 575 pulse-start metal halide lamps are used in conjunction with Venture Opti-Wave[R] magnetic ballasts, the result is superior lamp regulation. Venture ballasts maximize lumen consistency, lifespan and color uniformity.

Ordering Information: For literature, specifications and pricing information about Uni-Form[R] MP 575 pulse-start metal halide lamp and ballast lighting systems, contact Venture Lighting International, 10295 Philipp Parkway, Streetsboro, Ohio 44241. Telephone toll-free: (800) 451-2606. Fax toll-free: (800) 451-2605. E-mail: venture@adlt.com. Learn more about Venture lighting by visiting: www.venturelighting.com.

There's more to scrap metal than meets the eye. Even the most practiced scrap dealers can't always differentiate between the chemical variations that determine particular grades of metal without a little help.

When it comes to determining the chemical makeup of the scrap metal that comes into their facilities, many recyclers have turned to metal analyzers. Like any piece of technology, metal analyzers can be great tools in helping scrap dealers ply their trade--but only if used correctly.

Businesspeople in all walks of life turn to technology to help them do business better and they employ an increasing number of gadgets, from cell phones to digital cameras to Global Positioning Systems in personal vehicles. But how many people undergo the proper training or take the time to really learn how to use these gadgets to their utmost potential?

Like any piece of technology, metal analyzers can be extremely useful and offer recyclers a return on their investment--if they, in turn, invest in learning to use them.

HEAD OF THE CLASS. To make sure they get the most out of their metal analyzers, recyclers should first take advantage of the initial operator training provided by the manufacturer immediately after a purchase. Most analyzer companies offer some kind of initial training with additional on-site training at an additional cost, according to Stuart Freilich of Universal Metal Corp., an international processor of scrap titanium, high-temperature nickel, nickel/cobalt and refractory metals and alloys located in Worcester, Mass.

Analyzer manufacturer and distributor Thermo Electron Corp., Waltham, Mass., has an initial training program and schedules free training classes for customers on an ongoing basis at locations across the country, says Tom Anderson, director of marketing for the Niton Analyzers Group, a division of Thermo Electron.

Formal classroom training is a common first step following an analyzer purchase, Anderson says. Much of the classroom training focuses on teaching operators how to use the equipment safely. This is especially important for X-ray fluorescence (XRF) analyzers, which use radiation.

Oxford Instruments of Boston also offers formal classroom training in the form of monthly sessions held at four different locations in the United States, business development manager Mark Lessard says.

In addition to its formal classroom courses, Oxford Instruments' includes on-site installation training, which is typically a half-day for the company's XRF units and two days for its trickier OES equipment.

Anderson says that while some operators may catch on faster than others, it is important that scrap processors make sure everyone on their staff who is going to be using the analyzers devotes enough time to training. "People need to understand when they buy an instrument, it's not like buying something you're automatically going to know how to use," Anderson says. "You need to devote some time to learning how to use it."

AVOIDING MISTAKES. While analyzers can be a big help, if operators are not trained to use them properly, mistakes are easily made.

Operators must have a basic understanding of the equipment, how it works and what it can do, says Anderson. For example, optical-emission systems (OES) are considered trickier to use and require a more technically adept user than XRF analyzers. Understanding the difference is critical, because the two types of analyzers respond differently to particular alloys. XRF analyzers are marketed as performing better on high-temperature alloys, while OES analyzers fare better on aluminum alloys and carbon steel.

With the XRF analyzers Thermo manufactures, Anderson says the most common mistake is trying to get the equipment to go above and beyond its call of duty, like calling on it to measure carbon. "We get people trying to measure various grades of carbon steel, which [the XRF analyzer] is not going to do," he says.

Peter Nagusky of red metals ingot manufacturer The Federal Metal Co. in Bedford, Ohio, says improperly trained employees are likely to overestimate the accuracy of an XRF analyzer and misunderstand its limitations. "Many analyzers cannot read silicon or aluminum or other critical elements, and users tend to jump to conclusions about the metal based on the programmed categorization, as opposed to using the information from the spectrometer to infer and draw independent and more reasonable conclusions," he says.

Simply holding the analyzer too far away from the sample is another common mistake novices often make, says Lessard. "They might think they can be a foot away and shoot the sample, but they have to be right up there," Lassard says.

Learning the equipments' limitations and how to prepare a sample properly are two of the most important things operators should know to ensure that they get the right results from metal analyzers.

With increased focus on quality and the avoidance of contamination, the metal detector has become a critical inspection tool. A metal detector is a sophisticated piece of equipment used to detect metal contamination in product. When properly installed and operated, it will help improve product quality.

Proper training and education on metal detectors is a key to proper installation. A topic that creates countless hours of training and numerous service calls is product rejection. False rejects, false positives, constant rejecting and kickouts are all terms used in describing metal detectors reacting to a change.

There are two types of reactions: the first causes product to be ejected from the production line. The most common reason for this type of reaction is because there is metal contamination found in the product. Companies that are new to metal detection are often amazed when a detector finds metal in their product. In fact, some don't even believe it is possible that they have a contamination issue. The second type of reaction occurs when the detector reacts without anything going through it. Often referred to as a false reject, this can create a loss of confidence in the metal detector.

Prior to purchasing a metal detection system, proper research and product testing is the first way to reduce false rejects. When creating a metal detection system for a company, typically the vendor requests that product is sent to be to be tested. Product factors like product temperature, line speed, core temperature for frozen food and product alignment on the conveyor, must be considered in a proper test. This test provides a solution for the customer; creating detection sensitivities, metal specifications and a specific metal detection system.

The vendor should offer a test lab specifically for this purpose operated by a product test specialists using multiple detectors of various sizes and frequencies.

It is always advisable for customers that request product testing, to review the results from all vendors and look for consistency in the sensitivities. Detectors can be set to meet a particular specification, however if they run for long periods of time in a production environment they might cause false rejects or erratic operation. A reputable vendor will always provide the customer with a detailed "Sensitivity Statement" that guarantees the sensitivity of the detector. In some cases, the statement will clearly state that their specifications are beyond the limits of the metal detector.

Long periods without false rejects are the key distinguishing factor of a top quality metal detector. Improper installations can cause false rejects. In some cases, a quality metal detector can be mounted on a conveyor that is not designed for metal detection. This will create false rejects as a common problem. An incorrectly designed conveyor structure, reject device or even an improperly installed unit can cause interference signals from ground loops. A modification, like the addition of a belt scraper, if it is not properly isolated, can cause false rejects. These problems typically result in service visits and eventually the problem is resolved, but not after service costs and lost production time. Education and training will eliminate these service costs and lost production time.

False rejects can also be caused by influences beyond the metal detection system. Hand held radios and cell phones are typical sources of interference. Other interference sources are variable frequency drives, however they will make the detector act erratic vs. a random false reject. Quality equipment will address these interference issues with specialized frequency tilters. A common source of false detection is static discharge, found in gravity feed systems, pipe lines and conveyors. Static discharge is not typically random but more of a timed trigger. By integrating a conductive plastic to dissipate the static, manufacturers of metal detection equipment can eliminate this problem.

The last area that can cause false rejects is conveyor belt contamination. The conveyor belt can be contaminated from weld slag, small pieces of wire, or even used grease. Precautions should be taken when working around metal detection systems to prevent belt contamination.

It is important to remember that simply having a metal detector on a production line, while providing a measure of protection, will never replace an all-inclusive contamination detection plan. Proper procedures and training must be integrated into the everyday production cycle to insure a contaminant free workplace.

Rolf Hildenbeutel is Service Manager at Safeline Metal Detection. A world leader in metal detection, providing food industry applications, Safeline is located in Tampa, Fla. For more information call 800/447-4439 or visit www.metaldetection.com.

A French packager of high-end salads is using metal bowls with peelable aluminum lids to ensure portability and product protection.

William Saurin's line of "salades gourmandes," available with chicken, ham, sausage and other meats, are on sale in supermarkets throughout France and Belgium. The 230-gram (8-ounce) packages use metal bowls with Peel Seam technology from Crown Holdings Inc.

The Peel Seam opening system consists of a 99-millimeter aluminum ring, sealed with a peelable flexible aluminum lid and seamed to the 314-milliliter steel bowl, also provided by Crown. The peelable lid has a tab that allows it to be easily and safely removed from the top of the bowl.

"The Crown solution enables consumers to enjoy a tasty meal with a new level of ease," says Laurence Masce, product manager at William Saurin. "The lightweight, durable package can easily be carried in a handbag, briefcase or lunch box without spilling. Consumers can enjoy the salad straight from the bowl."

Automation CNC version 6.0 software from Hypertherm, Inc. is now available for metal fabricators seeking greater productivity from mechanized HyPerformance plasma systems and FastLaser processes.

The performance upgrade will be standard on all future shipments of the company's CNC controllers, including Edge, MicroEdge, Voyager and Mariner models.

The HyPerformance interface features full-screen diagnostics, configurable HPR watch windows and the ability to create customized cut chart databases. The HPR130 auto gas console features allow users to set up plasma supply operations by selecting material type, material thickness, and process current and gases.

Also included in the release are FastLaser-enhanced tools. Using the company's customized process monitoring, these tools provide an automatic adjustment feature for determining focal position. The automated focal position calibration tontine can simplify the process of locating the spot where the laser focal position meets the material surface. It can be used when a shift in focal position occurs, as with lens installation or resonator maintenance.

Other laser enhancements include Dynamic Pierce Control (DPC), auto process control and laser marking.

The end of summer and beginning of fall are the traditional times for counties and states to hold fairs. Children and adults alike compete to win "Grand Champion steer" or the blue ribbon apple pie. Here in the manufacturing arena, there's a different kind of fair going on, but it still invites you to submit items for competition. The 14th Annual Precision Sheet Metal Technology Fair is sponsored by Amada America, Inc. (Buena Park, California). The company invites its U.S. customers to enter their finest fabricated parts. The company sees the competition as a stimulus for innovation, workmanship and sophisticated processing technologies. Submissions should represent unique or hard-to-make parts and will be judged in five categories (fiat shapes, welding fabrication, assembling technology, forming fabrication and high precision intricate parts) by n team of industry experts and academics in Japan. Maximum parts dimensions should not exceed 23.6" x 11.8". For rules and entry forms, visit www.amada.co m. The deadline is October 5, 2001. Maybe this year it will be your turn to win the prize!

Fortress' highly reliable Phantom[c] Pipeline Metal Detector has a faster, high-performance DPS system. User friendly and simple to operate, this rugged system provides plants with the accurate, on-line detection of tramp metals in dairy operations. The Phantom Pipeline Metal Detector features automatic set-up and operation, multiple product changeover, self-test to meet demanding HACCP procedures, self diagnostics, compensation for product effect, and modular electronics. The unit is ideal for liquid and semi-viscous dairy products.