Portable heat treating system reduces crack sensitivity in aluminum plate
December 13, 2016
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The Navy Metalworking Center, Johnstown, Pa., reports that it has designed and fabricated a heat treating system for aluminum plate that reduces sensitivity to cracking in the aluminum superstructure of the U.S. Navy's CG 47 class cruisers. Prior to this development, cracked aluminum superstructures required extensive repairs or replacement (i.e., removing and replacing the affected plate, as well as all of the outfitting obstructing the area).
The Navy Metalworking Center led a project to address the major contributor to the cracking – the sensitized microstructure in the 5456 aluminum-magnesium alloy used in the construction of the structure. An Integrated Project Team developed and demonstrated a portable heat treatment system that reverses the sensitization in the 5456 aluminum alloy, thereby restoring the affected material in the ship's superstructure to a stabilized condition, which greatly reduces the propensity for cracking.
NMC conducted laboratory tests and finite element simulations to derive the optimized parameters for the reverse sensitization process. Based on this data, NMC designed and fabricated a prototype reverse sensitization unit (RSU), which imparts the necessary heat treatment to the aluminum plate in the CG class cruiser superstructure. The RSU was tested on laboratory sensitized panels, and a mockup of a CG superstructure was designed by NMC. The RSU was then demonstrated onboard two cruisers (one decommissioned, one active duty).
The final RSU prototype system was transitioned to PMS 407 for additional evaluation and use during maintenance intervals. A procurement specification was also developed by NMC, so that additional units may be built after successful implementation. The new process and RSU were implemented in September 2016 with the transition of the equipment to Ingalls Shipbuilding, the planning yard for CG repairs.
Reverse sensitization will give the Navy a low-cost alternative to the current process of cutting out and replacing the sensitized plate. The reverse sensitization repair process can save as much as $2.4M per CG 47 ship availability, resulting in a cost avoidance of as much as $43.2M for 18 ships. The Littoral Combat Ship program will also benefit from this improved technology at a conservative estimate of $500K avoidance per hull, resulting in an additional $4M in cost avoidance for the LCS hulls in service over the next five years.
https://www.navalmetalworking.org/
The Navy Metalworking Center, Johnstown, Pa., reports that it has designed and fabricated a heat treating system for aluminum plate that reduces sensitivity to cracking in the aluminum superstructure of the U.S. Navy’s CG 47 class cruisers.
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Developers of Constellium Airware aluminum-lithium alloys receive award
December 7, 2016
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Constellium N.V., Amsterdam, announces that three of its researchers were awarded the Medal of the Academy by the Air and Space Academy for their achievement in developing groundbreaking Airware aluminum-lithium alloys: ASM member Timothy Warner, Knowledge Director and Metallurgy Group Manager; Alireza Arbab, Project Manager; and Bruno Chenal, Strategic Innovation Director. They received the medal at the annual Solemn Session held by the AAE on November 25 in Toulouse, France.
"We are particularly proud that Airware is now flying on the most prestigious aircraft and space programs, such as the Airbus A350 XWB, Bombardier's CSeries, the SpaceX Falcon Launcher, and Lockheed Martin's Orion Capsule," said Mr. Chenal.
Airware is a major component in the advanced materials portfolio of the A350 XWB manufactured by Airbus. At the same session, Fabrice Brégier, President and CEO of Airbus, received the Academy's Grand Award for his decisive role in the success of the A350 XWB program.
Constellium's Airware was launched in 2010 as a group of high-performance aluminum-lithium alloys suitable for applications in all parts of the primary aerostructure. Airware's lower density and improved properties allow optimization of structural designs, which leads to an overall weight reduction and a drop in CO2 emissions. Airware guarantees higher durability due to its greater resistance to fatigue and corrosion, which enables airlines to target extended intervals of heavy maintenance. Airware is endlessly recyclable without any loss of properties. The technology contributes to the development of a sustainable aerospace industry.
www.constellium.com
Constellium N.V., Amsterdam, announces that three of its researchers were awarded the Medal of the Academy by the Air and Space Academy for their achievement in developing groundbreaking Airware aluminum-lithium alloys: ASM member Timothy Warner, Knowledge Director and Metallurgy Group Manager; Alireza Arbab, Project Manager; and Bruno Chenal, Strategic Innovation Director.
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Metalysis produces high-entropy metastable powder metals via solid state process
December 5, 2016
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Metalysis Ltd., England, has produced niobium-containing high entropy alloy (HEA) powders for high-temperature applications by means of its patented solid-state electrolysis process. HEAs are metastable materials in which five or more metals from the periodic table are combined. Niobium-containing HEAs, being refractory, are particularly suitable for high-temperature applications. These include future applications within the aerospace and gas turbine markets.
The Metalysis process is theoretically capable of producing the niobium-containing HEA, among others, at industrial scale. It is the latest achievement to utilize Metalysis' patented, scalable, solid state technology to produce new, high-demand metal powder products.
The company has raised substantial funds to increase productivity and carry out its Generation 4 ("Gen 4") expansion. Because it is modular, Gen 4 has the potential to be scaled up to provide hundreds of tons per annum of valuable specialty metal alloy powders. Efforts are ongoing to develop commercial applications across a range of producible HEAs and metal powders, as the Gen 4 project heads toward commissioning. These should prove the next step in the Metalysis roadmap for scalability of technology.
Metalysis Ltd. is committed to transforming the metals industry through the commercial exploitation of its patented process for producing titanium, tantalum, other metals, and innovative alloy powders.
www.metalysis.com
Metalysis Ltd., England, has produced niobium-containing high-entropy alloy powders for high-temperature applications by means of its patented solid-state electrolysis process.
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Aerobraze to overhaul USAF F-16 jet fighter heat exchangers via furnace brazing
December 1, 2016
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Wall Colmonoy's Aerobraze Engineered Technologies, Oklahoma City, announces that it has won a multi-year, multi-million dollar United States Air Force contract for the overhaul of the F-16 Fighting Falcon jet fighter primary and secondary heat exchangers. Wall Colmonoy developed high-temperature furnace brazing and pioneered the first heat exchanger overhaul procedures. The company continues to deliver significant cost savings and performance improvements to the United States Air Force. The F-16 has dominated the skies for over 30 years as a multirole and air superiority fighter in service in over 25 countries.
According to Brian Martin, General Manager for Aerobraze Oklahoma City, "As a major manufacturer and overhauler of heat exchangers for the USAF for over 33 years, it is with great pride that we continue to provide support to the United States Air Force. This new award demonstrates our ongoing commitment to increasing efficiency and cost savings for our customers, through extending the life of critical components for the aerospace industry."
The division meets aerospace quality standards in processes for brazing, surfacing, welding, thermal processing, fabricating, machining, and overhauling. Quality standards include ISO9100, AS9100 Revision C, EASA.145.6085, Nadcap approvals for brazing, heat treat, welding, coating, NDT, and chemical processing, along with FAA-Repair License. An FAA-DER is on staff to support customer engineering requirements.
www.wallcolmonoy.com/aerobraze.
Wall Colmonoy’s Aerobraze Engineered Technologies, Oklahoma City, announces that it has won a multi-year, multi-million dollar United States Air Force contract for the overhaul of the F-16 Fighting Falcon jet fighter primary and secondary heat exchangers.
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Electric pit furnace features two-stage gas nitriding system for high hardness
November 23, 2016
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Lindberg MPH, Riverside, Mich., has shipped an electrically heated gas nitriding pit furnace with an ammonia dissociator system for heat treating steel parts. It features a two-stage nitriding process to achieve high surface hardness. The ammonia dissociator provides dissociated ammonia during the nitriding cycle second stage. All of the equipment needed has been provided with the system, and is backed by the installation and start-up support of knowledgeable service personnel.
The cylindrical pit furnace has a maximum temperature rating of 1250°F and work chamber diameter of 28 inches and depth of 36 inches. A state of the art operator interface controls process parameters and is used to observe/archive historical data. The system monitors and controls the furnace temperature, fan speed, atmosphere flow, and cooling throughout the entire cycle. Accelerated cooling cuts down on overall cycle time. The advanced control system solves the problems of controlling furnace atmospheres, storing batch data, tracking alarm trending, and complying with AMS2750E specifications.
Unique features include low iron brick insulation to prevent reactivity with furnace atmosphere; heater coils designed with low surface watt density for extended service life; and a thermocartridge fan for increased heat and atmosphere recirculation. A nitriding gas flow control system has full automatic recipe control for each stage of the two-stage nitriding process.
Lindberg MPH is owned by Thermal Product Solutions, a leading American manufacturer of custom industrial ovens for heat treating, finishing, drying, curing, manufacturing automation and process control. TPS is a global leader in thermal processing products and test solutions with brands including Baker Furnace, BlueM, Gruenberg, Tenney, Lindberg MPH, and Wisconsin Oven.
www.lindbergmph.com
Lindberg MPH, Riverside, Mich., has shipped an electrically heated gas nitriding pit furnace with an ammonia dissociator system for heat treating steel parts.
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All-Metal Planes for Coast-to-Coast Transport
November 22, 2016
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Classic article from July 1933 Metal Progress
Classic article from July 1933 Metal Progress
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Computationally Optimized Heat Treatment Process wins R&D 100 Award
November 18, 2016
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The National Energy Technology Laboratory (NETL), Pittsburgh, announces that its Computationally Optimized Homogenization Heat Treatment Process has been named a winner of the 2016 R&D 100 Awards. NETL's technology provides an easy method to optimize heat treatment to achieve the required degree of homogenization with a minimum of furnace time.
Conventional processes for homogenizing metal alloys are trial-and-error in their approach, resulting in increased process cost and limits to the possible paths that may be explored. The primary application for this technology is for alloys that are exposed to extreme environments, including heat-resistant alloys or those needing corrosion/oxidation resistance. A properly homogenized alloy will not only function better, but also will have an extended life cycle.
During solidification of any alloy, the elements segregate unevenly. This chemical segregation is unavoidable and results in non-uniform regions that negatively impact mechanical and physical properties. Even distribution of the alloying elements is necessary to achieve optimal performance for the specified application.
The computational approach to homogenization is based on kinetics of the chemical diffusion coefficient of each element to determine the homogenization cycle necessary to evenly distribute the elements that are susceptible to segregation. Conventional homogenization processes rely on a trial-and-error approach that results in the need for more experimentation and analysis. If the selected times and temperatures do not achieve the correct degree of homogenization, additional experimentation become necessary.
The Computationally Optimized Homogenization Heat Treatment Process is designed especially for alloys exposed to extreme environments, including heat-resistant alloys and those that require corrosion/oxidation resistance. Such alloys are typically in industries that service the aerospace, military, petrochemical, power generation, nuclear, structural, automotive. and instrumentation sectors.
www.netl.doe.gov
The National Energy Technology Laboratory (NETL), Pittsburgh, announces that its Computationally Optimized Homogenization Heat Treatment Process has been named a winner of a 2016 R&D 100 Award.
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Customized MetalMaster heat treating furnaces process a range of materials
November 17, 2016
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Ipsen, Cherry Valley, Ill., announces that in the past few weeks it has shipped five customized MetalMaster vacuum furnaces to companies in locations around the world: Washington, South Carolina, Mexico, and China. Comprised of both horizontal- and vertical-loading systems, these shipments will be used to process parts for the commercial heat treating and aerospace industries .
The customized furnaces also vary in size, ranging from 36 x 48 x 30 inches with all-graphite hot zones and a 2000-pound load capacity, all the way up to a 72 x 156 x 92-inch all-metal hot zone with moly heating elements and a 20,000-pound load capacity. These heat-treating systems are also capable of providing tight temperature tolerances with DigiTrim controls settings, while meeting applicable AMS 2750E requirements.
The MetalMaster furnace design has demonstrated ultimate performance and reliability for more than 45 years, with 500+ installations worldwide. It delivers the cleanliness and uniform cooling that customers request, while also providing a cost-effective, versatile, and adaptable vacuum furnace system.
MetalMaster furnaces may also be ordered with several high-productivity options such as Specialized instrumentation; Increased pumping capability; and Material handling systems.
www.IpsenUSA.com/MetalMaster
Ipsen, Cherry Valley, Ill., announces that in the past few weeks it has shipped five customized MetalMaster vacuum furnaces to companies in locations around the world: Washington, South Carolina, Mexico, and China.
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Siemens to acquire Mentor Graphics for its electronics IC and systems design
November 14, 2016
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Siemens AG, Munich, and Mentor Graphics, Wilsonville, Ore., announce that they have entered into a merger agreement under which Siemens will acquire Mentor for $37.25 per share in cash, which represents an enterprise value of $4.5 billion. The offer price represents a 21% premium to Mentor's closing price on November 11, 2016, the last trading day prior to the announcement.
This acquisition decisively extends Siemens' leading Digital Enterprise Software portfolio with Mentor's well established electronics IC and systems design, simulation, and manufacturing solutions. These capabilities are essential for today's smart connected products such as autonomous vehicles. The combination provides mechanical, thermal, electronic and embedded software tools which will allow Siemens' customers to further accelerate their innovation, drive production efficiencies, and optimize the operation of their products in the field. Now, for the first time, quality, efficiency, flexibility, safety and speed can be optimized across technical domains, throughout the entire lifecycle and for the entire extended enterprise.
"Siemens is acquiring Mentor as part of its Vision 2020 concept to be the Benchmark for the New Industrial Age. It's a perfect portfolio fit to further expand our digital leadership and set the pace in the industry," said Joe Kaeser, President and CEO of Siemens AG.
"With Mentor, we're acquiring an established technology leader with a talented employee base that will allow us to supplement our world-class industrial software portfolio. It will complement our strong offering in mechanics and software with design, test and simulation of electrical and electronic systems," said Klaus Helmrich, member of the Managing Board of Siemens.
"Combining Mentor's technology leadership and deep customer relationships with Siemens' global scale and resources will better enable us to serve the growing needs of our customers, and unlock additional significant opportunities for our employees," said Walden C. Rhines, chairman and CEO of Mentor. "Siemens is an ideal partner with financial depth and stability, and their resources and additional investment will allow us to innovate even faster and accelerate our vision of creating top-to-bottom automated design solutions for electronic systems.
www.mentor.com
www.siemens.com
Siemens AG, Munich, and Mentor Graphics, Wilsonville, Ore., announce that they have entered into a merger agreement under which Siemens will acquire Mentor for its electronics IC and systems design, simulation, and manufacturing solutions.
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Ampco Pittsburgh acquires ASW Steel for its specialty steel products
November 8, 2016
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Ampco-Pittsburgh Corp., Carnegie, Pa., has acquired ASW Steel Inc., Welland, Ontario, a specialty steel producer with customers in the oil and gas, power generation, aerospace, transportation, and construction industries. ASW offers a unique combination of carbon, stainless, and other specialty steelmaking capabilities, as well as flexible steel refining methods such as argon oxygen decarburization, vacuum oxygen decarburization, vacuum degassing, and a ladle metallurgical station.
According to John Stanik, Ampco-Pittsburgh's Chief Executive Officer, "This acquisition is a very important element in Ampco-Pittsburgh's strategic diversification plan. ASW's proven broad expertise in flexible steel refining methods will provide us with the capabilities to manufacture the additional chemistries needed to expand our reach in the open-die forging market. The transaction also enhances our ability to grow in markets in which we currently participate and to add new markets."
"Our combined capabilities will offer forgers, ring rollers, and rolling mills, a high-quality supplier with the broadest range of specialized steel products in the marketplace," says Tim Clutterbuck, President of ASW Steel, Inc.
The total purchase price was approximately $13.1 million, including $3.5 million in cash and assumption of approximately $9.6 million of outstanding indebtedness.
ASW, whose annual revenues are approximately $48 million, will be an indirect subsidiary of Union Electric Steel Corporation, a wholly owned operating subsidiary of Ampco-Pittsburgh. Union Electric Steel is a leading producer of forged and cast engineered products for the global steel and aluminum industries.
www.ampcopgh.com
Ampco-Pittsburgh Corp., Carnegie, Pa., has acquired ASW Steel Inc., Welland, Ontario, a specialty steel producer with customers in the oil and gas, power generation, aerospace, transportation, and construction industries.
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