How disorder makes materials tougher

Scientists at Penn Engineering, Penn Arts & Sciences, and Aarhus University found that adding just the right amount of disorder to the structure of certain materials can make them more than twice as resistant to cracking.

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Constellium and renault group complete r&d project advancing lightweight aluminium solutions

Constellium, Paris, announced the successful completion of the “ISA3” R&D project, an initiative launched in 2021 to advance lightweight aluminium solutions for automotive applications. Conducted in collaboration with Renault Group, ESI Group, the Institut de Soudure, and the University of Lorraine, the project was supported by a grant from the France Relance investment program. The research focused on developing cost-efficient, recyclable aluminium components to enhance vehicle performance and sustainability.

A key achievement of the project was the development of a lightweight aluminium door in partnership with Renault. Utilizing Constellium’s proprietary uni-alloy 6xxx rolled and extrusion-based solutions, the door design achieved a 14% weight reduction compared to existing aluminium doors used in compact battery electric vehicles. By employing a single alloy series, the project streamlined closed-loop recycling, reducing the door’s overall carbon footprint. This innovation resulted in a 33% reduction in Global Warming Potential (GWP), reinforcing the project’s emphasis on sustainability.

Beyond material advancements, the project also explored more efficient and flexible production processes to enhance performance while optimizing costs. Ludovic Piquier, senior vice president, manufacturing excellence and chief technical officer at Constellium, emphasized that the results highlight the company’s commitment to providing sustainable, high-performance aluminium solutions for the automotive sector.

Patrice Belliard, expert in flat products at Renault Group, noted that the project demonstrated how aluminium can support both weight reduction and cost efficiency in automotive manufacturing. Mathilde Chabin, manufacturing product director at ESI Group, added that the use of advanced pre-certification and validation technologies eliminated the need for physical prototypes, accelerating innovation while reducing costs and environmental impact.

The completion of Project ISA3 underscores the potential of aluminium to contribute to the automotive industry’s decarbonization efforts while delivering economic and environmental benefits.

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Automaker modernizes heat-treatment operations with Nitrex technology

Automaker modernizes heat-treatment operations with Nitrex technology

Nitrex, Quebec, announced that a major automotive manufacturer has selected its EndoFlex L generators to upgrade heat-treatment operations. This initiative supports the automaker’s commitment to improving production efficiency while advancing sustainability and cost management efforts.

The facility specializes in manufacturing engine components that require carburizing, a heat-treatment process that enhances surface durability by introducing carbon into the material. Previously, the site relied on aging, gas-heated generators to produce endothermic gas for this process. However, these generators had become inefficient, consuming excessive natural gas and increasing CO₂ emissions. To address these challenges, the manufacturer has chosen Nitrex’s electrically heated EndoFlex L endothermic gas generators to optimize efficiency and reduce environmental impact.

Designed specifically for carburizing applications, the EndoFlex L features a multi-retort design and precise temperature control, ensuring a consistent and stable supply of high-quality endothermic gas. The system operates on demand, significantly reducing gas consumption and emissions, making it a more sustainable and cost-effective solution.

Daniel Panny, head of sales Europe at Nitrex, emphasized the company’s long-standing relationship with the automaker, noting that previous projects included upgrading legacy generators with the EndoInjector gas injection system. He stated that this latest investment demonstrates how sustained partnerships can drive meaningful advancements in industrial manufacturing.

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Wisconsin Oven delivers two-zone belt conveyor oven for steel tempering

Wisconsin Oven Corporation, East Troy, WI, announced the shipment of a two-zone belt conveyor oven designed for tempering steel parts following induction hardening. The system is engineered for precise temperature control and enhanced energy efficiency, meeting industry specifications for uniform heating.

The oven has the capacity to heat 2,400 pounds of steel per hour from 70°F to 350°F, with a maximum temperature rating of 500°F. It features a top-down airflow recirculation system with a 32,000 CFM blower, evenly distributed between the two heating zones. Temperature control is managed by a Watlow F4T digital recorder/controller, which includes Ethernet communication capabilities and adaptive PID temperature control. A temperature uniformity survey verified uniformity within ±10°F at 350°F, ensuring compliance with AIAG specification CQI-9.

The conveyor system utilizes a continuous belt with a variable frequency drive for speed adjustments, and the work zone measures 4’0” W x 21’0” L x 14” H. To improve energy efficiency, the oven is equipped with the E-Pack™ Energy Efficiency Package, which includes additional insulation and variable frequency drives on the recirculation blowers. These features reduce energy consumption and operational costs, potentially providing substantial annual savings depending on utility rates and operating conditions.

The system’s design optimizes heat-up efficiency and uniformity, making it well-suited for high-volume steel tempering applications. The oven incorporates programmable temperature controls with auto-tuning functionality, ensuring consistent and repeatable performance for industrial heat treatment processes.

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Novel x-ray technique of functional materials maps their architecture

Researchers at the Swiss Light Source (SLS) recently developed a pioneering x-ray technique to probe the 3D orientation of a material’s building blocks at the nanoscale. Applied to a polycrystalline catalyst, the technique allows the visualization of crystal grains, grain boundaries and defects—key factors dictating catalyst performance. Beyond catalysis, the innovation unlocks previously inaccessible details about the structure of diverse functional materials in numerous applications.

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Integer completes sale of Electrochem business, focusing on medical technology

Integer Holdings Corp., Plano, Texas, announced that it has finalized the divestiture of its Electrochem business to Ultralife Corp. for $50 million in cash. The sale marks Integer’s transition to a pure-play medical technology company, allowing it to focus exclusively on the development and manufacturing of medical devices.

The proceeds from the transaction will be used to reduce the company’s outstanding debt. Joseph Dziedzic, president and chief executive officer at Integer, emphasized that this move positions the company to allocate resources toward high-growth opportunities within the medical technology sector. He also expressed gratitude to the Electrochem team for their contributions over the years and confidence in their future under Ultralife’s ownership.

The divestiture aligns with Integer’s strategic goal to concentrate on advancing its role as a leading contract development and manufacturing organization for the medical device industry.

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Fort Wayne metals introduces customizable tube for medical applications

Fort Wayne Metals, Ind., announced that it has developed HHS tube, an innovative product with a highly customizable structure designed to meet the specific functional requirements of various medical applications. This advancement is intended to address the increasing demand for versatile and reliable metal tubing in devices such as endovascular tools, minimally invasive instruments, neurological components, and urological devices.

HHS tube stands out from conventional tubing due to its ability to be tailored to precise specifications. The product can be manufactured in single, two, or three-layer stranded configurations, with customization options that include inner and outer diameters, wire count and size, pitch direction, and overall length. Inner diameters range from 80 µm to 2.2 mm, while outer diameters span 0.13 mm to 4 mm, allowing it to meet a wide variety of customer requirements.

The versatility of HHS tube makes it suitable for a broad range of applications. For example, neurological stimulation devices require thin, flexible filaments to navigate small and complex areas, while vascular tools demand elongation and compressive strength to deliver instruments to targeted sites. Endoscopy devices benefit from the tube’s ability to provide rotational control in navigating the body. Each configuration of the HHS tube is engineered to meet the specific functional demands of the application.

Fort Wayne Metals also offers custom finishing options to streamline the supply chain for its customers. These include custom fittings, terminations, Nitinol coatings, and specialized parts to support seamless integration into final medical device assemblies. This capability underscores the company’s commitment to meeting the evolving needs of the medical sector.

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Furukuwa opens new laser processing laboratory in Aichi prefecture to advance industrial solutions

Furukawa Electric Co. Ltd., Tokyo, Japan, and Nichia Corp., Tokushima, Japan, announced that they have jointly opened the Cutting-Edge Laser Processing Solution Laboratory (CELL) in Kariya City, Aichi Prefecture. Located in a key hub of the automotive industry, the new facility is designed to accelerate the development of laser processing technologies and provide innovative solutions to industrial challenges.

The laboratory is equipped with Furukawa Electric’s advanced industrial lasers, including the newly developed 5kW blue laser (BR5000), which delivers world-leading brightness through optical fiber. Plans are in place to install the full range of Furukawa Electric’s industrial lasers, including the BRACE Series of Blue-IR hybrid lasers, enabling the lab to meet diverse customer requirements and expedite process testing and evaluations.

CELL is a collaborative effort between Furukawa Electric and Nichia, facilitating activities that span laser processing and light source development. This partnership will enable the two companies to propose next-generation laser solutions tailored to specific customer needs, with a particular focus on addressing the demands of copper processing for the electrification of mobility.

Both companies are committed to advancing laser technology and supporting the development of innovative production methods, contributing to the evolution of the automotive and related industries.

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GTP elastomer sockets for high-speed applications

Ironwood Electronics, Eagan, Minn., is now producing elastomer sockets which include a protective “P” layer that allows for more insertions by protecting the elastomer from erosion and debris build up, extending the life of the elastomers to 200,000 plus insertions.

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TESCAN Group acquires EXpressLO LLC

TESCAN Group, a.s, Czech Republic, a leading global manufacturer of electron microscopes and advanced scientific instruments, has acquired EXpressLO LLC, Lehigh Acres, Fla., a provider of innovative FIB lift-out solutions for specimen preparation in STEM and other analytical techniques.

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Airbus and Plastometrex partner on standardization of PIP

In a significant move to streamline mechanical testing and enhance material insights, Airbus, France, the global aerospace leader, is collaborating with Plastometrex, England, to support the standardization of profilometry-based indentation plastometry (PIP) – the innovative mechanical testing technique developed and commercialized by the Cambridge-based technology provider.

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Nanoscale transistors could enable more efficient electronics

In order to overcome a fundamental limit of silicon semiconductor technology that prevents transistors from operating below a certain voltage, Massachusetts Institute of Technology researchers fabricated a different type of three-dimensional transistor using a unique set of ultrathin semiconductor materials.

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Hours needed to mill forming tools? A thing of the past!

The Fraunhofer Institute for Laser Technology ILT, Germany, is pioneering a new approach in fuel cell production by using extreme high-speed laser material deposition to create wear-resistant functional metal layers on low-cost structural steel, replacing traditional milling methods and significantly reducing costs, construction time, and tool wear.

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