The following is a discussion of considerations for substrate preparation, part configuration, and coating location.
Continue readingSpray Tips: Substrate preparation, part configuration, and coating location
TPS Solutions bolsters position for thermal spray systems in aerospace
Following a record-breaking year of thermal spray system deliveries in 2025, Switzerland-based TPS Solutions has strengthened its sales and engineering teams to expand its position in the European and North American aerospace sectors.
Continue readingSpray Tips: Disadvantage of thermal spraying – line of sight process
A disadvantage of thermal spraying is that it is a line-of-sight process.
Continue readingOerlikon Metco Coatings Ltd. strengthens aerospace offerings with Nadcap accreditation
Oerlikon Metco Coatings Ltd., U.K., has successfully completed the Nadcap accreditation process, marking an important milestone in the company’s continued expansion into the U.K. aerospace sector.
Continue readingSpray Tips: Disadvantages of thermal spraying
As with all coating technologies, thermal spray has some limitations; understanding them is important so that engineers can design effective solutions to the challenges of surface modification.
Continue readingSpray Tips: Advantages of thermal spraying
This introductory article reviews the key advantages of thermal spray processing and shows how sound practices help maximize coating performance.
Continue readingSpray Tips: Vaporization and precipitation during solution thermal spraying
Droplets entering the plasma undergo rapid vaporization, solute supersaturation, and precipitation, leading to different shell formation and breakup routes during thermal spray processing.
Continue readingSpray Tips: Phenomena occurring during suspension thermal spraying
The observation of splats obtained after a few passes of the torch over the substrate placed at different distances from the liquid injection enables visualization of those areas where droplets formed after a breakup of the liquid jet injected into the plasma jet, enabling description of the behavior of a slurry droplet within the plasma.
Continue readingSpray Tips: Historical studies of solution precursor plasma spray methods
Fauchais et al. and Gell et al. reveal how solution precursor plasma spray methods, including SPS and SPPS, achieve fine microstructures and unique thermal barrier coatings through precise control of injection parameters and thermal histories.
Continue readingAalberts acquires SGP thermal spray specialist in North America
Aalberts N.V., Netherlands, has reached an agreement to acquire 100% of the shares of Steel Goode Products LLC, Houston, Texas, operating two facilities in Texas and one in Ohio, generating an annual revenue of approximately $15 million with 75 FTE.
Continue readingIGS acquires thermal spray business from Liquidmetal Industrial Solutions
Integrated Global Services, Inc., Richmond, Va., has acquired the engineered coatings and materials business of Liquidmetal Industrial Solutions, Chattanooga, Tenn., strengthening its position as a global leader in asset integrity and environmental efficiency technologies.
Continue readingGKN Hoeganaes to support First Phosphate in LFP cathode active material development
GKN Hoeganaes, a division of GKN Powder Metallurgy, England, and one of the largest iron powder producers globally, announced a strategic collaboration with First Phosphate, Canada, marking a significant step toward establishing a North American supply chain for lithium iron phosphate batteries, a critical component for the electric vehicle and energy storage industries.
Continue readingSpray Tips: Historical studies of suspension plasma spray methods
This overview presents 20 historical studies on suspension plasma spray methods, including research by Podlesak et al. that examines the effects of spray distance and plasma power level on the microstructure of suspension plasma-sprayed hydroxyapatite (HA).
Continue readingSolar Manufacturing ships Mentor Pro furnaces for renewable energy applications
Solar Manufacturing, Sellersville, Pa., announced that it has shipped two Mentor Pro vacuum furnaces to a customer focused on developing advanced renewable energy technologies for large-scale industrial applications. The furnaces were selected after a collaborative process with the customer’s engineers, supported by the Research and Development team from Solar Manufacturing’s affiliate, Solar Atmospheres. The customer valued the furnace’s capabilities and compact design.
The Mentor Pro furnaces feature a molybdenum shielded hot zone, a maximum temperature capacity of 2500°F, and a workload capacity of up to 1000 pounds. They are equipped with SolarVac Essentials, a PLC-based control system, and include an internal gas quenching system with a 50 HP motor and variable frequency drive (VFD), offering flexibility in using nitrogen or argon gas for optimal metallurgical results. These features make the Mentor Pro well-suited for a variety of metallurgical applications in renewable energy development.
One Minute Mentor: Distortion of Ledeburitic Cold-Work Tool Steels
The different effects of steel composition on the dimensional change of plates made of ledeburitic cold-work tool steels and a working hardness of 61 HRC can be taken from the figure. Typical representatives of the new generation of improved toughness 8-9%Cr-steels show slightly higher growth in dimension than the classical 12%Cr-D2 steel.
The growth in thickness (in the rolling direction) is always significantly higher than in width, confirming again the generally known behavior. Salt-bath heat treatment results in higher distortion than various vacuum heat treatments with high-pressure gas quenching, but the results indicate that there is also a significant scatter for gas quenching depending on the detailed quenching conditions.
For more information, click on the link below (subscription required). Then scroll to Figure 12. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014 https://doi.org/10.31399/asm.hb.v04d.a0005980
Nitrex celebrates 40 Years of innovation in heat treatment solutions
Nitrex, Quebec, announced that it is celebrating its 40th anniversary this year, marking four decades of growth and innovation in the heat treatment industry. Founded in 1984, Nitrex has evolved from a pioneer in controlled nitriding to a global leader offering end-to-end heat treatment solutions. The company’s technological advancements have expanded its capabilities to encompass metallurgy, engineering, process optimization, and automation.
Since 2019, under the current leadership, Nitrex has broadened its portfolio to include advanced vacuum furnaces and introduced technology for improved brake rotor performance. The company has also launched digital platforms such as QMULUS, aimed at optimizing customer processes and boosting operational efficiency.
In addition to its own milestone, Nitrex is celebrating the 50th anniversary of its UPC-Marathon office in Germany, recognizing the long-standing contributions and achievements of its global team. These anniversaries reflect Nitrex’s ongoing commitment to innovation and excellence.
Bodycote presented aerospace materials solutions at Farnborough International Airshow
Bodycote, Macclesfield, U.K., participated in the 2024 Farnborough International Airshow, held this summer.
Bodycote showcased its advanced thermal processing solutions specifically designed for the aerospace industry. The airshow, a key event for aerospace innovation, emphasizes themes like sustainability, future flight, and workforce development, providing Bodycote with a platform to highlight its role in enhancing the performance and reliability of aerospace components.
At the event, visitors could explore Bodycote’s range of services, including heat treatment, metal joining, and specialized thermal processes such as hot isostatic pressing and thermal spray coatings. These processes are essential for improving the properties of metals and alloys in aerospace applications, helping them withstand the stringent requirements of the industry.
Bodycote’s presence at the Farnborough Airshow underscores its expertise and ongoing commitment to fostering collaborations that drive progress in the aerospace, aviation, and defense sectors.
One Minute Mentor: Distortion of High-Speed Steels
High-speed steels show a typical distortion behavior depending on the heat treatment parameters. The figure shows the change in length of cylindrical bars (diameter = 20 mm, or 0.8 in.) and length = 140 mm, or5.5 in.), with rolling direction longitudinal to the sample) for various heat treatment conditions with austenitizing, salt bath quenching, and double tempering.
Quenching and tempering up to 500 °C (930 °F) results only in very small changes in length (either growth or shrinking). Higher tempering temperatures lead to a transformation of the retained austenite into martensite and a corresponding growth in length. For typical tempering temperature of 560 °C (1040 °F) changes in length of about 0.2% take place. Additional alloying with Co (5%) leads to slightly higher changes in length. The effect of an additional third tempering shifts the curve slightly to the left, whereas oil quenching leads to a slight reduction of the change in length.
For more information, click on the link below (subscription required). Then scroll to Figure 9. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014 https://doi.org/10.31399/asm.hb.v04d.a0005980
Constellium celebrates the grand opening of its new recycling center in France
Constellium, Paris, announced the grand opening of its new advanced recycling center in Neuf-Brisach, France. The €130 million investment, supported by a grant from the France Relance investment program, is aimed at boosting Constellium’s presence in the automotive and packaging industries while fostering a circular, sustainable economy. The new facility will increase the plant’s recycling capacity for automotive and packaging products by up to 75%, adding 130,000 metric tons of capacity.
With the expanded capabilities, the Neuf-Brisach plant expects to raise the recycled content of its products, meeting the growing demand for sustainable materials. This investment brings Constellium’s global recycling capacity to approximately 735,000 metric tons and will help reduce greenhouse gas emissions by 400,000 metric tons, aligning with the company’s goal of a 30% emissions intensity reduction by 2030 and increasing recycled input to at least 50% by the same year.
The facility incorporates energy-efficient technologies designed to minimize environmental impact, including reduced water consumption and air emissions, and biodiversity studies were conducted to protect the local ecosystem during construction.
High-quality, high-performance fuel cells powered by Openair-Plasma
Plasmatreat Gmbh, Germany, presents plasma as a pretreatment method in the manufacture of fuel cells.
Continue readingOMM: Material aspects of Distortion
Size distortion in ledeburitic cold-work tool steels is always higher in longitudinal direction (the direction of main deformation, which is the direction of the elongated carbide stringers). The figure shows the effect in three different cases.
If plates for cutting tools made from ledeburitic cold-work tool steels are taken from small bar materials in the longitudinal direction, the main direction of distortion will also be in the longitudinal direction of the plate (case I). If the same plate is taken in the transverse direction from a wide bar material, the main direction of distortion will be in the transverse direction of the plate (case II). Finally, if the plate is taken as a slice from a large-cross-section thick bar, the carbide orientation and the main direction of distortion will be in the direction of the plate thickness (case III).
For more information, click on the link below (subscription required). Then scroll to Figure 7. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014 https://doi.org/10.31399/asm.hb.v04d.a0005980
One Minute Mentor: Distortion in Tool Steels
Some of the main interactions that occur during the heat treatment of steel alloys including temperature, microstructure, and stress/strain. Especially for tool steels these interactions are mainly influenced by the carbon content in the steel matrix, the types and relative amounts of the alloying elements, and the carbide formation/transformation/precipitation characteristics of the alloy system.
Heat treatment involves changes of temperature with time, which determine changes in microstructure. The rate of temperature change results in a change of microstructure which is described by phase transformation kinetics, as in e.g. TTT (time-temperature-transformation) diagrams; every phase transformation releases/absorbs latent heat, which influences the temperature field. An inhomogeneous temperature distribution, i.e. temperature gradients, within the tool during heat treatment can generate thermal stresses that lead to plastic deformation, if the yield strength of the material at that temperature is exceeded. Every mechanical deformation generates heat which, in turn, influences the temperature field. Furthermore, there is an interaction between the stress state and the microstructure. Phase transformations can result in micro-plastic deformation, which can be globally described using transformation plasticity models.
For more information, click on the link below (subscription required). Then scroll to Figure 2. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014 https://doi.org/10.31399/asm.hb.v04d.a0005980
Confluent announces significant investment in ATI nitinol melt expansion
Confluent, Scottsdale, AZ, announced a partnership with ATI to invest over $50 million in expanding ATI’s Nitinol melt and materials conversion infrastructure. This investment will more than triple ATI’s melt capacity for medical Nitinol, with Confluent becoming ATI’s fulfillment partner. Confluent will provide value-added services and order fulfillment for ATI’s medical Nitinol mill products.
Dean Schauer, CEO and president of Confluent, highlighted the demand growth in the Neurovascular, Electrophysiology, Structural Heart, Peripheral Vascular, and Orthopedic device markets, which is driving an 18% growth rate (CAGR) in Nitinol demand. Schauer emphasized that the industry has struggled to support this growth due to the substantial equipment and infrastructural costs needed to increase supply chain capacity. Confluent’s investment aims to provide the necessary mid-term and long-term melt and conversion capacity to meet this demand, ensuring a reliable supply chain for OEM customers.
Rob Foster, president of ATI’s Specialty Alloys & Components business, expressed appreciation for Confluent’s investment and trust in ATI’s expertise. Foster noted that this partnership would ensure a stable supply of Nitinol, crucial for the industry’s growth. The expansion at ATI’s Millersburg, Oregon facility is expected to be operational by 2027.
With these expanded capabilities, Confluent will continue to offer a reliable supply chain, delivering a comprehensive range of medical Nitinol services, including mill products, hollows, tubes, wires, and components.
One Minute Mentor: Plasma Nitriding Equipment
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; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014 https://doi.org/10.31399/asm.hb.v04d.a0005958
The aviation industry chooses Seco/Warwick vacuum furnaces
Seco/Warwick, Meadville, PA announced that their previous furnace with an aviation industry client will be retired and replaced by a new, economical, and versatile furnace for brazing jet engine parts.
Seco/Warwick has been a recognized metal heat treatment equipment manufacturer for decades. In fact in many plants, units were manufactured in the 1980s and 1990s. The partners are gradually replacing these units with modern solutions, continuing to be loyal to the SECO/WARWICK brand.
“The aviation industry is a very important partner that has been cooperating with Seco/Warwick for decades. This is proof of satisfaction with the products we create, but also an expression of trust. Long-term, strategic, good relationships are key. Our furnaces are designed to operate without failure for many, many years, as evidenced by the replacement of this furnace after so many years,” said Maciej Korecki, vice president of the Vacuum Furnaces Segment at Seco/Warwick Group.
The new solution is based on a standard Vector vacuum furnace with a working space of 900x900x1200 mm, equipped with screen insulation and metal heating elements. It has been specifically adapted to meet the unique needs of the aviation industry, capable of heat treating complex jet engine components such as gears and main shafts.
This latest advancement underscores Seco/Warwick’s dedication to innovation and excellence, ensuring their continued partnership with the aviation industry for years to come.
Tencarva Machinery Company, backed by Bessemer Investors, acquires Tri-State Coating & Machine
Tencarva Machinery Company, Greensboro, N.C., the Southeast’s premier value-added distributor of, and service provider to, flow control and process equipment solutions to industrial and municipal end-markets, has acquired Tri-State Coating & Machine, Salt Rock, W. Va., a leading provider of specialized thermal coating services and related parts to the industrial market.
Continue readingSECO/WARWICK finds the way to complete successful projects in Brazil
Seco/Warwick, Meadville, Pa., announced a significant milestone in its operations in Brazil. The company has successfully implemented a solution for Nitrion do Brasil, a leading commercial heat treater in South America, in their new production hall to manage the increasing order volume. This achievement underscores the strong synergy between SECO/WARWICK and its strategic partner in the region, Combustol.
SECO/WARWICK’s presence in Brazil has seen dynamic sales growth and promising market forecasts, driven by their popular Vector single-chamber vacuum furnaces. These furnaces are highly favored by commercial heat treaters in the region for their ability to enhance the hardening process and improve economic efficiency. The successful collaboration with Combustol has been instrumental, providing not only sales support but also service activities and the supply of spare parts, which has given SECO/WARWICK a competitive edge.
The Vector vacuum furnace ordered by Nitrion do Brasil is designed to address the challenge of hardening larger elements, thanks to its spacious working area. This feature enhances process economics through energy savings and increased efficiency of the graphite chamber, while also ensuring process cleanliness and speed. The furnace’s convection heating system improves heat transfer efficiency at lower temperatures, and its directional cooling system allows for effective cooling of parts with complex shapes.
28th Maintenance Group’s Additive Manufacturing Flight accelerates mission readiness with mobile cold spray system
The Additive Manufacturing Flight of the U.S. Air Force’s 28th Maintenance Group became the first field-level unit to utilize the new Mobile Cold Spray System at Ellsworth Air Base, South Dakota.
Continue readingConstellium Ravenswood to receive $75 million for zero carbon technology
Constellium, Ravenswood, WV, announced that it has been selected by the U.S. Department of Energy (DOE) Office of Clean Energy Demonstrations to begin award negotiations for up to $75 million in Bipartisan Infrastructure Law and Inflation Reduction Act funding as part of the Industrial Demonstrations Program (IDP). This investment will help fund the implementation of breakthrough low-to-no emissions technologies in Constellium’s Ravenswood facility, supporting the decarbonization of the casthouses, the plant’s most energy intensive operation.
This investment will support the installation of low-emissions SmartMelt furnaces that can operate using a range of fuels, including clean hydrogen, paving the way towards a zero carbon casthouse. In addition to reducing carbon emissions, the project is expected to help maximize recycled scrap intake, and to improve worker safety with the introduction of a hands-free casting process.
The project will also contribute to the local communities around Ravenswood with a dedicated budget to build a new training and wellness center for all employees and an onsite childcare, and to provide financial and technical resources for local schools and universities.
Constellium Ravenswood will now enter negotiations on the specific terms of the investment, including operational milestones, and timing of access to funds throughout the life of the project, estimated to be approximately five years. The final details of the project investment are subject to these negotiations.
https://www.constellium.com/news/constellium-ravenswood-selected-by-us-doe-to-receive-usd75million-investment
ALD develops a new powder recycling process for a sustainable circular economy
ALD Vacuum Technology, Germany, has developed an additive manufacturing solution, the EBuild 850 that can process powder with a wide distribution, enabling it to be used not only in industrial-scale part production, but also in powder recycling efforts.
Using selective electron beam melting to create powder-filled ingots, ALD achieves an unprecedented build rate of over 1000 cm³ per hour. These ingots can be seamlessly converted into new powder, for example in ALD’s EIGA Premium systems, promoting a sustainable circular economy.
ALD’s approach not only reduces waste, but also offers versatile options for downstream processes. The powder-filled solid cased ingots are much safer to handle and process than loose powder. This flexibility increases the overall efficiency of the recycling process and enables integration into established processing routes.
By adopting ALD’s innovative approach, industries can now achieve economical production while contributing to a circular economy. ALD remains committed to driving sustainable practices within the industrial sector, paving the way for a greener future.