Materials scientist Frank Mücklich, Professor of Functional Materials at Saarland University, Germany, has developed a laser surface texturing procedure that makes the surfaces of electrical contacts more stable and more efficient.
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Motion control is necessary to ensure operator safety and coating quality. Although handheld spraying has been carried out for nearly a century, it is not the preferred or safest means of spraying. The thermal spray environment is harsh and not suited for handheld operations.
Safety has become more of an issue as HVOF and plasma energies and velocities have continued to increase. Operator fatigue (typical surface speeds are 30 m/min, or 1200 in/min) and inconsistency also affect coating uniformity. Part- and gun-handling equipment is required to eliminate the operator from the process. Commercially available, off-the-shelf motion-control equipment usually takes the form of turntables, x–y manipulators, and six-axis robots.
Where the production volume of a specific part warrants the investment, specialized tooling is often used. The disadvantage of using manipulators is in spraying small numbers of complex parts. In limited production runs, programming the manipulation equipment can be more expensive and time-consuming than spraying the part. There are many applications where handheld spraying seems to be the only practical approach to the problem, for example, bridges, boilers, architecture, artwork, one-of-a-kind parts, and so forth.
High-volume production spraying dictates that ancillary processes such as surface cleaning, masking, and grit blasting also be automated. Coating process cells, which represent the highest level of automation, may include pick-and-place robots to handle part loading and unloading.
The figure shows an automated thermal spray cell for coating aircraft engine components. In this plasma spray cell, the operator loads and unloads parts, and the spray cell does all of the operations, including process control, statistical process control, quality inspection for thickness, and final processing. Although expensive, such equipment is justified for coating applications where consistency is critical.
Image – Advanced thermal spray cell. Courtesy of Sulzer Metco.
This information is from ASM Handbooks Online, Vol. 5A: Thermal Spray Technology, Coating Structures, Properties, and Materials. To find this information (subscription required), click on the link below and scroll down to Figure 11.
Florida International University, Miami, Fla., introduced its new Cold Spray and Rapid Deposition Laboratory, a facility that will advance techniques in the repair, design and durability of high-performance materials. The lab is supported by a five-year, $22.9 million grant from the U.S. Army Combat Capabilities Development Command Army Research Laboratory.
The lab will advance additive manufacturing techniques such as cold spray, a technique where particles are blasted onto a material surface at low temperatures. The techniques are highly relevant to 3D printing, the rapid repair of machinery, and the coating of materials to make them stronger. The research stands to benefit the manufacturing of next-generation vehicles and munitions while also boosting workforce development and activity across the economy.
“FIU’s commitment to innovation and impact is on full display today as we celebrate the opening of this lab,” said Kenneth A. Jessell, president of FIU. “We show the world today that we are a leader for Army Research Lab Cold Spray Technology and an influential partner, together with our congressional delegation, in building up Miami’s tech, innovation and manufacturing ecosystem.”
The lab will be led by Distinguished University Professor Arvind Agarwal, chair of FIU’s department of mechanical and materials engineering at the College of Engineering and Computing (CEC) and a renowned expert on advanced additive manufacturing techniques.
“From developing antibacterial coatings for biomedical use to assisting in environmental corrosion prevention in coastal communities, these technologies promise to deliver solutions to a myriad of real-world problems, while helping to train the next generation of researchers, technologists and STEM professionals in the fields of robotics, advanced manufacturing, aerospace technologies and machine learning,” Agarwal said.
The opening of the lab positions FIU as a key provider of research and talent for the Department of Defense and industry partners, particularly due to the increase demand for electronics and the expansion of both the aerospace and defense industries.
Image – Cold spay lab. Courtesy of: FIU.
For more information:
Florida International University
YouTube Video – First large scale cold spray facility in a Florida university
Researchers at the University of Illinois Urbana-Champaign have developed a coating for steam condensers used in fossil fuel steam-cycle generation that is made with fluorinated diamond-like carbon, or F-DLC.
Continue readingNitrex, Quebec, successfully commissioned two nitriding systems for Alumil S.A., Greece’s largest extrusion company and the leading producer of architectural systems, with an international sales network in over 60 countries worldwide.
With this collaboration, Nitrex further strengthens its global presence in extrusion profile manufacturing, demonstrating the industry’s confidence in Nitrex’s expertise to optimize die performance, increase the throughput of extruded profiles, and reduce overall tooling costs.
Catering to various sectors, including construction, automotive, energy, and more, and serving as a key exporter to Europe, the Middle East, and the USA, Alumil has recently started up two pit-type nitriding systems installed at separate locations. The first system, an NX-1215 model with a 3-ton load capacity, is operational at Alumil’s facility in Greece. The second system, an NX-620 furnace model with a 1.2-ton load capacity, is located at the company’s operation in Serbia.
The turnkey solution provided by Nitrex includes the exclusive Nitreg® technology, ensuring consistent and superior nitriding results. In anticipation of Alumil’s plans to expand manufacturing capacities in Greece, the system installed at this location has been specially sized up to accommodate future growth.
Rutgers scientists have devised a highly accurate method for creating coatings of biologically active materials for a variety of medical products. Such a technique could pave the way for a new era of transdermal medication, including shot-free vaccinations, the researchers said.
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Sulzer, Switzerland, with expertise in rotating equipment retrofits and abrasive services, has helped a Philippines petrochemical plant solve a persistent reliability issue and prepare for a 64% increase in capacity by replacing critical pump components with new parts made from high-chromium C6 steel with an abrasion resistant coating applied using a high HVOF process.
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Johnson Matthey, Beijing, China, has signed an investment agreement with the Jiading District in Shanghai to help accelerate the hydrogen economy in China.
At a signing ceremony in Sonning, UK, JM and the Shanghai Jiading District announced plans to build a new catalyst coated membrane (CCM) production facility, providing CCM production capability for multiple proton exchange membrane (PEM) fuel cell applications and PEM electrolysers.
The facility, which will have an initial capacity of up to 5GW, will occupy 22,000m2 in the Jiading district of Shanghai, in a designated Hydrogen industrial zone and is due to be operational in 2025. It will have potential to expand further in line with customer demand.
The investment, which is backed by customer demand, is part of JM’s £1.1 billion global stated capital expernditure for the three years to 2024/25 and will include government support and incentives.
The new production facility will enable Johnson Matthey to supply existing Chinese and international customers with locally produced CCMs, and in addition there is a strong pipeline of further customer interest across both fuel cell and renewable (green) hydrogen technologies.
Cold-walled (double-walled water-cooled) systems were the first generation of plasma nitriding furnaces. This technology is also a vacuum-based process but employs the principle of glow discharge to provide energy for heating and nitriding at one time. Therefore, the independent control of the temperature stability and the nitriding intensity is not possible because both processes are using the same energy source—the plasma.
The hot-wall plasma nitriding furnaces, the next generation of cold-wall ion nitriding systems, are mainly used and built now. This system ensures optimal nitriding quality by fulfilling the highest demands on temperature and nitriding process control. The big advantage of this technology is the separation of the control of the heating and the plasma nitriding parameters. The heating and temperature control of hot-wall plasma nitriding furnaces is realized by several independent heating/cooling zones, which guarantees optimal temperature homogeneity
For more information, click on the link below (subscription required). Then scroll to Figure 26.
R Schneider; R. Mesquita; H. Altena; T. Müller; P. Seemann, Processes and Furnace Equipment for Heat Treating of Tool Steels, ASM International, 2014, https://doi.org/10.31399/asm.hb.v04d.a0005958
Raisoni College of Engineering, India, has published a critical review of significant performance and safety issues that arise from the deterioration of reinforced concrete (RC) structural components brought on by ageing processes and high stress occurrences.
Shape memory alloys (SMAs), one of the options for restoring such components, have special qualities including recovering inelastic strain when unloaded (super elasticity) or heated (shape memory effect, SME). To lessen permanent deformations into RC constructions, super elasticity and SME of SMA bars can be used. The stiffness and strength of RC structures can also be improved by the addition of SMAs, allowing them to withstand loads of high intensities with minimal damage.
Despite the wide range of studies done on the applications of SMAs in structures, a comprehensive analysis of the present state, key results, potential drawbacks, and future contemplation of SMA bars for the reinforcement of RC structures is lacking in the literature.
Lindberg/MPH, Mich., has announced the shipment of a rod overbend box furnace with powered load/unload table to the manufacturing industry. This heat-treating furnace has a maximum temperature rating of 2000°F and a load capacity of 900 lbs.
The workspace dimensions of the furnace are 24” W x 36” D x 18” H and it is designed for air atmosphere applications. The box furnace features an automated actuator to flip the push/pull mechanism on the load table to eliminate the operators need to manually flip it into push position. This option allows the push/pull head to retract from the furnace once the work grid is in the furnace chamber and increase operator safety by removing the need to reach into the hot furnace with a hook to flip the push/pull head and.
The furnace chamber is heated with a radiant heating system the utilizes heavy gauge alloy rod over-bend heating elements mounted along the side-walls and the floor. The furnace temperature is controlled by an Allen Bradley ControlLogix Programmable Logic Controller that includes digital setpoint and display. A Honeywell DC2500 high limit controller disconnects the power to the heating elements and sounds an audible alarm if the temperature exceeds desired set-point.
Seco/Warwick, Meadville, Pa., has been chosen by a recognized manufacturer of wind power plants to deliver a vertical vacuum furnace designed to perform low-pressure carburizing for the large structural elements (gearboxes) used in wind power plants.
The solution on order combines the advantages of two technologies: atmospheric and vacuum processing. The furnace is designed for low-pressure carburizing oversized parts, made possible due to a very large, vertical heating chamber, while the furnace pit structure saves space in the production facility. The Pit-LPC technology is a modern alternative to atmosphere carburizing. Its main advantage is the ability to carry out efficient and effective carburizing in a much shorter time than in atmospheric furnaces. The vacuum processing solution provides more than twice the productivity, and consequently lower process costs and a quick investment return.
The main advantage of this furnace is the ability to open the furnace at process temperature at the end of the cycle. This is the advantage of atmospheric furnace technology implemented within a vacuum furnace. This type of solution combines the advantages of an atmospheric furnace with the advantages of a vacuum furnace, which include: elimination of the oxidation effect at the grain boundary, process purity, and heating uniformity. The product solves the problem of high energy and process gas consumption by the partner’s old furnaces, and shortens the carburizing process, which significantly improves efficiency and production costs.
Castolin Eutectic, Belgium, introduced XupersoniClad in the European market, a new thermal spraying service leveraging supersonic spraying technology with significant advantages in the protection of components, vessels, and structures from abrasion, erosion, and wear.
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Lindberg/MPH, Mich., has announced the shipment of an electrically heated, full muffle, mesh belt conveyor furnace. This furnace is designed for treating pressed powdered material.
The furnace is designed for applications with a maximum process temperature of 1000° C (1832° F) that utilize a nitrogen or clean dry filtered air process atmosphere. The unit is configured with 9 temperature control zones and includes a water-cooling section. The conveyor system features a 14 inch wide mesh belt with belt stop alarm to provide an audible and visual indication in case of a conveyor stoppage.
There are purge chambers at the entrance and exit of this conveyor furnace. In these chambers purge gas flows from perforated plenum chambers above and below the belt and exhaust stacks with adjustable butterfly valves are located at the inner ends of each chamber. Load and unload tables at the entrance and exit of the conveyor provide ease of product transfer for the operator.
The furnace zone temperatures are controlled by Eurotherm controllers. These controllers have advanced PID control with variable overshoot inhibition. A hi-limit Eurotherm controller guards against over temperature conditions in each zone of temperature control. A visual and audible alert and removal of power to the heating element occur in the event the monitor temperature exceeds a desired set point.
Inspired by the wings of dragonflies and cicadas, researchers have developed a new coating for orthopedic implants. It not only shreds harmful bacteria, but also monitors stress on the system, meaning it could warn of impending implant failure.
Continue readingAn international research group with researchers from China, Japan, and the Los Alamos National Laboratory, Los Alamos, NM, developed a new surface coating technology that is capable of significantly increasing electron emission in materials.
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Can-Eng Furnaces International Ltd., Niagara, Ontario, was recently contracted to engineer and commission a continuous quench and temper furnace system for a North American producer of mining, construction, and materials handling products. The purchase of this equipment is part of a larger plant expansion and initiative to bring foreign outsourced manufacturing in house.
This move is not only to improve part quality but also to help eliminate overall shipping costs and reduce supply chain issues which have been plaguing many industries over the past couple of years. This equipment will be part of an automated manufacturing cell and fed automatically from upstream handling equipment. Special considerations have been made to precisely control the quench temperature to reduce hardness variations and improve overall part quality.
The multizone belt style temper furnace employs high efficiency natural gas fired heating and recirculation systems which have been proven to provide the ultimate in temperature uniformity in even the most demanding of applications.
Ipsen, Tainan City, Taiwan, has announced the installation of a TurboTreater vacuum furnace for a customer in Southeast Asia. Established in 2002, Taiwan Hodaka Technology Co., Ltd. is an aluminum extrusion supplier, specializing in high-end aerospace aluminum alloys.
They also produce products used in the sporting goods, consumer electronics and automotive industries. The TurboTreater boasts a work zone size of 36” (914 mm) x 36” (914 mm) x 48” (1219mm) with a weight capacity of 3000 lb (1360 kg) and normal operating temperature up to 2400 °F (1315 °C). The furnace was designed with convection heating, allowing for more uniform processing of large cross-section parts and dense loads. It is also capable of quenching at up to 12 bar positive pressure in nitrogen.
Hodaka chose Ipsen for their positive brand reputation, technical capabilities and process know-how.
Kanthal and Rath, Amherst, NY, have announced a strategic partnership aimed at expanding their combined offering in industrial heating technology. This collaboration is set to benefit industries such as steel and petrochemical as they strive to transition to greener practices.
By joining forces, Kanthal and Rath will create the most extensive range of sustainable industrial heating solutions available in the market. Kanthal’s expertise in heating elements and systems, combined with Rath’s premium insulation and refractory products, will provide customers with a unique and comprehensive offering to meet their industrial heating needs.
Robert Stål, president of Kanthal, expressed enthusiasm about the partnership, stating, “We are thrilled to partner with Rath to further expand our offerings in industrial heating technology, enabling societies and industries to make the green shift. In this era of electrification, this partnership will provide our customers with a broader range of innovative solutions that will enable them to optimize their operations and achieve their sustainability goals. Together, we can leverage our collective expertise to deliver greater value to our customers and help them thrive in a rapidly evolving market.”
Andreas Pfneiszl, CFO/CSO of Rath, emphasized their focus on sustainability, particularly in developing energy-saving refractory products and materials for electrically heated furnaces. He stated, “With our strategic partner Kanthal, we will enable customers’ shift towards fossil-fuel-free production.” This partnership aligns with Rath’s commitment to environmentally friendly practices.
Through closer collaboration in developing new technologies and solutions, Kanthal and Rath will leverage their expertise to drive the technology shift that industries like steel and petrochemical are currently undergoing. The joint go-to-market model will provide customers with a comprehensive portfolio of products and services, offering enhanced value and convenience.
Constellium, Paris, announced today its agreement with Renault Group to establish a closed-loop recycling process for the all-new Megane E-TECH Electric.
Aluminum, lightweight and fully recyclable, is the material of choice for the electrification of the automotive fleet, and Constellium is well-positioned to support this transition with advanced products and solutions.
Renault Group has developed a closed-loop recycling process to bring manufacturing scrap from the stamping process directly back to Constellium, resulting in a reduced CO2 footprint. Based on best practices to avoid mixing 5xxx and 6xxx alloys and to compact scrap for optimal logistics at Renault Group, the closed-loop process will recycle these alloys, so that they can be reused in Renault Group’s production without any loss of properties, and overall with no downcycling.
Constellium, a full-service supplier of rolled and extruded aluminum solutions for the global automotive market, supplies aluminum for 1 in 4 vehicles produced in Europe and the U.S. We help automakers produce lighter, safer and more fuel-efficient vehicles, as well as electric vehicles with greater range. Renault Group is supplied by Constellium’s ASI-certified facility in Neuf Brisach, France.
UPC-Marathon, Quebec,, a Nitrex company, has commissioned a 100 M3H EndoFlex endothermic gas generator for a South American manufacturer of industrial fasteners.
This is a repeat customer that has UPC-Marathon‘s gas panels, flowmeters, oxygen probes, and Protherm plant automation software installed in their heat treatment operations. With the addition of the EndoFlex generator, they will now be able to supply gas to a new continuous mesh belt neutral hardening furnace for the treatment of metal fasteners used in automotive applications.
The customer had the option to choose between a nitrogen-methanol system or an endothermic gas generator for their neutral hardening furnace. After careful consideration, they selected UPC-Marathon’s EndoFlex generator in order to achieve better control and consistency of the process atmosphere. The result is an improved hardening process and higher-quality hardened fasteners, along with reduced operating costs. The EndoFlex mixes ratios more accurately and efficiently, ensuring a constant furnace atmosphere and consistent gas quality, leading to immediate cost savings through reduced electricity and gas consumption and zero waste.
The system was started in March 2023, and its consistent performance has exceeded the customer’s expectations.
An innovative polymer coating pioneered by researchers at Lawrence Berkeley National Laboratory, Calif., has been demonstrated to boost electric car battery life by up to 15 years.
Continue readingFurukawa Electric, Tokyo, has received the top rating for its climate change initiatives across the entire supply chain and related information disclosure from CDP, an international environmental NGO.
This is the fourth year in a row that Furukawa Electric has been recognized with this high rating, having been selected by CDP for its Leader of “A” rated companies. The Supplier Engagement Rating (SER) is an index that rates companies’ engagement with their supply chains concerning climate change issues and promotes coordination among companies in the value chain. Furukawa Electric has been acknowledged for its outstanding climate change initiatives, which are in line with the company’s goal of eliminating greenhouse gas emissions from its business activities (carbon neutral).
To achieve the sustainable development goals (SDGs) and realize Furukawa Electric Group Vision 2030, the company has been working on strengthening its ESG (Environment, Social, Governance) management. Furukawa Electric Group Environmental Vision 2050 was established in March 2021, declaring the company’s goal of achieving carbon neutrality. The company has also identified “Creating environmentally-friendly businesses” as a key management issue to be addressed to achieve Vision 2030 and is taking steps to enhance its responses to these materiality issues. Furukawa Electric’s commitment to environmental sustainability and its consistent recognition by CDP highlight the company’s ongoing efforts to lead the way in climate change initiatives and make a positive impact on the world.
Wisconsin Oven Corp., East Troy, has shipped one electrically heated conveyor oven to an automotive manufacturer, which will be used for tempering automotive parts. The conveyor oven features a chain style conveyor system with vertical pins, ensuring the uniform transfer of parts through the heating and cooldown zones of the oven. The maximum temperature rating of the conveyor oven is 260° C, with interior chamber dimensions of 3’6” W x 20’10” L x 9” H.
The conveyor oven also features a top-down bottom-up airflow configuration designed with a 55,000 CFM @ 50 HP blower, ensuring optimal temperature uniformity of ±2.5° C at 163°C, documented with a temperature uniformity test. The oven is equipped with a continuous chain conveyor with vertical pins, programmable temperature controller, and recorder with Ethernet capabilities.
The unique features of this tempering oven include the ability to automatically scan the parts while being loaded onto the conveyor and validate that the correct part is being loaded, providing a pass/fail regarding heating time and temperature. The conveyor oven also includes an ambient cooldown zone and supervised installation with start-up and training.
Mike Grande, vice president of sales,said that, “Our continuous designs provide customers with innovative solutions to meet their load and process requirements. This conveyor oven was designed with high-velocity impingement air nozzles for rapid, uniform heating and optimal part results.” The equipment was fully factory tested and adjusted prior to shipment from the facility, ensuring it met all Wisconsin Oven quality standards. The equipment comes with a 2-year warranty, providing peace of mind for the automotive manufacturer.
Ipsen, Pecatonica, Ill., formerly known as Ipsen Ceramics, is expanding its vacuum furnace hot zone assembly. The refurbishments include new lighting, HVAC, roofing, and other interior and exterior upgrades. Located at 325 John Street, less than 30 miles from Ipsen’s Vacuum Technology Excellence Center in Cherry Valley, the factory will initially employ up to eight material assemblers.
Incorporating the Pecatonica location into Ipsen’s vacuum furnace production and aftermarket process will provide added benefits to customers. Jake Hamid, Ipsen’s director and chief Operating Officer, stated that “Our goal is to reduce delivery times and better control the critical phase of assembly.” In the future, Ipsen is considering other manufacturing activities in Pecatonica to supplement the needs of the Vacuum Technology Excellence Center.
The move to repurpose the Pecatonica plant aligns with Ipsen’s commitment to providing high-quality vacuum furnace equipment and services to customers. The company’s dedication to meeting customer needs and reducing delivery times will be further enhanced by this strategic move, ensuring that Ipsen remains a leader in the vacuum furnace industry.
