H.C. Starck joins WPI Center for Heat Treating Excellence
April 13, 2016
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H.C. Starck, Newton, Mass., announces that it has joined the team at the Worcester Polytechnic Institute's Center for Heat Treating Excellence, an alliance between the industrial sector and university researchers that addresses short- and long-term needs in the heat treating and thermal processing industry. Membership in CHTE is unique because members have a voice in selecting quality research projects that help them solve today's business challenges globally.
With close to 100 years of metallurgy experience in the technology metals molybdenum, tantalum, niobium, and tungsten, H.C. Starck has a wealth of research, technical knowledge, and experience to share.
"With our commitment to quality and technological expertise, we work side by side with our customers to ensure they have the highest quality product," says Dmitry Shashkov, Member of H.C. Starck's Executive Board and Head of the Fabricated Products Division. "We are also rapidly growing our business to match the demands of the global marketplace, working with OEM and aftermarket furnace manufacturers on their new designs. To match this growth, H.C. Starck has made significant investments in our fabrication capabilities, and we are leading the development of new materials for high-temperature applications to improve cost and performance for our customers."
H.C. Starck supplies fabricated products to OEMs, end-users, and aftermarket furnace manufacturers for heat treating medical, aerospace, defense, automotive, energy, nuclear fuel, crystal growth, and waste treatment products.
www.hcstarck.com
H.C. Starck, Newton, Mass., announces that it has joined the team at the Worcester Polytechnic Institute’s Center for Heat Treating Excellence, an alliance between the industrial sector and university researchers that addresses short- and long-term needs in the heat treating and thermal processing industry.
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Selective separation sintering enables 3D printed parts to be made of Martian materials
April 8, 2016
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The University of Southern California, Los Angeles, announces that a novel 3D-printing process called selective separation sintering has won the NASA competition for a technology that could enable space travelers to build structures of crushed basalt rock and regolith found on Mars.
Selective separation sintering (SSS) is a powder layer-based additive manufacturing approach. In the printing process, a dry powder of higher sintering temperature (S powder) is deposited into the base powder (B powder) of lower sintering temperature, outlining the shape of the part. When printing of all layers is completed, the material is sintered at the lower temperature, making a solid part that is easy to remove from the S powder. SSS can reportedly fabricate high-temperature ceramic and metallic parts at comparatively lower cost with high quality.
According to Prof. Behrokh Khoshnevis and his team, who won the NASA competition, the technology is suitable for building structures such as blast walls, hangars, radiation shields, and landing pads on the Moon and Mars. Preliminary results have proven the capability of SSS in successfully printing ceramic and metallic parts. Future experiments are planned for improving the process resolution.
The printing time in SSS, which is linearly proportional to the size of the part, becomes relatively shorter for larger parts. The S-powder in SSS is removed completely, hence no contamination remains on the part or on the sintering furnace. In addition, the cost of the SSS hardware is said to be a fraction of all other machines for additive manufacturing.
Details of the SSS process including diagrams are here: http://sffsymposium.engr.utexas.edu/sites/default/files/2015/2015-6-Zhang.pdf
www.usc.edu
The University of Southern California, Los Angeles, announces that a novel 3D-printing process called selective separation sintering has won the NASA competition for a technology that could enable space travelers to build structures of crushed basalt rock and regolith found on Mars.
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3D-printed metal aircraft parts
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Alcoa, Pittsburgh, entered into an agreement with Airbus, France, to supply 3D-printed metal parts for commercial aircraft. The parts will be produced using comprehensive capabilities—from multimaterial alloy development to additive manufacturing and aerospace parts qualification. The first additive manufactured parts are expected to be delivered midyear.
The agreement draws on Alcoa's aerospace experience and new technologies gained through its recent acquisition of RTI. The company also recently invested in 3D-printing and metallic powder production capabilities at its technical center outside of Pittsburgh.
Last year, Alcoa acquired RTI International Metals (RTI)—now known as Alcoa Titanium & Engineered Products (ATEP)—which grew its additive manufacturing capabilities to include 3D-printed titanium and specialty metals parts produced at ATEP's Austin, Texas facility. The Airbus agreement draws on these capabilities as well as ATEP's titanium ingot melting and billetizing, machining, finishing, and inspection technologies.
Alcoa will use advanced CT scan and hot isostatic pressing (HIP) capabilities at its advanced aerospace facility in Whitehall, Mich. HIP strengthens the metallic structures of traditional and additive manufactured parts made of titanium and nickel based superalloys. Through a $22 million investment in the technology, Alcoa today owns and operates one of the largest aerospace HIP technology complexes in the world.
Additionally, Alcoa is bolstering its additive manufacturing capabilities through a $60 million expansion in advanced 3D-printing materials and processes, including metallic powders. The expansion is located at the Alcoa Technical Center near Pittsburgh.
Alcoa, Pittsburgh, entered into an agreement with Airbus, France, to supply 3D-printed metal parts for commercial aircraft.
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Solar Manufacturing partners with Refrac Systems for GFQVHP system
March 30, 2016
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Refrac Systems, Chandler, Ariz., has contracted with Solar Manufacturing, Souderton, Pa., and Beckwood Press & Machinery/Triform, Saint Louis, to help design and build a large 100-ton-load gas fan quench vacuum hot press (GFQVHP) system for its aerospace diffusion bonding operation. Solar Manufacturing was selected due to its world class experience in the design and use of vacuum furnaces with gas fan quench cooling capabilities. The furnace chamber for this unit was built by Amity Industries, Douglassville, Pa. Beckwood Press & Machinery/Triform was selected to build the large 100 ton "Four Post" hydraulic press frame for the system. The control console unit was built by Optima Stantron, Lawrenceville, Ga.
Refrac Systems, working with Solar's engineering team, selected a derivative of the Solar Manufacturing standard HLF-5748-2IQ internally quenched 2-bar vacuum furnace as the base design of the system. The new system contains many new engineered designs as needed to be both an automated vacuum hot press, and to be extra versatile for making super plastically formed and diffusion bonded (SPFDB) aerospace structures.
Norm Hubele, President of Refrac Systems, states "Solar Manufacturing and Beckwood Press & Machinery are both industry leaders with robust engineering experience. We have worked closely together to design and build this one of a kind GFQVHP."
William Jones, CEO of the Solar Atmospheres family of companies, notes "Norm put together a team of engineers to design and build this furnace back in 2013. This state-of-the-art GFQVHP contains many innovations that will be discussed at a later time. Throughout the entire process, Norm has personally reviewed all aspects of the design and added considerable insight to the development of this unique vacuum furnace system."
Solar Manufacturing expects to ship the GFQVHP unit in July, and final assembly, testing and startup is projected for the 4th quarter 2016 in Chandler.
www.solarmfg.com
www.refrac.com
Refrac Systems, Chandler, Ariz., has contracted with Solar Manufacturing, Souderton, Pa., and Beckwood Press & Machinery/Triform, Saint Louis, to help design and build a large 100-ton-load gas fan quench vacuum hot press (GFQVHP) system for its aerospace diffusion bonding operation.
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Composite foams of steel spheres embedded in aluminum insulate against heat
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North Carolina State University, Raleigh, reports that novel lightweight composite metal foams made of materials such as steel spheres embedded in aluminum are more effective at insulating against heat than solid conventional metals such as steel. The composite metal foam consists of metallic hollow spheres — made of materials such as carbon steel, stainless steel or titanium — embedded in a metallic matrix made of steel, aluminum, or other metallic alloy. These foams are especially promising for storing and transporting nuclear material, hazardous materials, explosives, and other heat-sensitive materials, as well as for space exploration.
"We have developed two technologies for manufacturing composite metal foams (CMF)," says Afsaneh Rabiei, a professor of mechanical and aerospace engineering at NC State and corresponding author of a paper on the work. "One is based on casting a low melting point matrix material, such as aluminum, around hollow spheres made of a material with a higher melting point, such as steel. This creates aluminum-steel CMFs, for example. The other technique is based on sintering the matrix powder around prefabricated hollow spheres. This creates CMFs such as steel-steel, which consist of steel hollow spheres in a steel matrix."
In one test, researchers exposed samples of 2.5 by 2.5-inch steel-steel CMF that were 0.75 inches thick to a fire with an average flame temperature of 800°C for a period of 30 minutes on one side, and monitored the material to see how long it would take for the heat to reach the opposite side of the sample.
For a piece of bulk stainless steel with the same dimensions as the CMF sample, it took only four minutes to reach 800°C, but it took eight minutes for the steel-steel CMF to reach the same temperature.
"We already knew the CMFs have outstanding high-velocity impact resistance, and effective radiation shielding. Now we know that it can withstand high heat," Prof. Rabiei says.
The researchers also found that the composite metal foam made entirely of stainless steel expands 80% less than bulk stainless steel at 200°C — and the differential increases at higher temperatures. Another noteworthy advantage is that the composite metal foam expands at a fairly constant rate when exposed to high heat — whereas conventional bulk metals and alloys such as stainless steel expand more rapidly as temperature increases.
www.ncsu.edu
North Carolina State University, Raleigh, reports that novel lightweight composite metal foams made of materials such as steel spheres embedded in aluminum are more effective at insulating against heat than solid conventional metals such as steel.
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Ipsen ships heat treating furnaces for aerospace, automotive, and power applications
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Ipsen, Cherry Valley, Ill., recently shipped seven furnaces around the globe for applications in aerospace, automotive, and power-generation. Shipments included both custom-built furnaces and standard Titan furnaces, and they were sent to customers in Alabama, California, Missouri, and Texas, as well as China and Japan.
The equipment ranged from a vertical bottom-loading MetalMaster with an 84 x 84-inch molybdenum hot zone sent to California, to a Titan H2 vacuum furnace sent to Japan. Other furnaces included horizontal MetalMaster furnaces, H2- and H4-size furnaces from Ipsen's Titan line, and a Global Vertical furnace from the TurboTreater line. Overall, these shipments represent sophisticated and intuitive heat-treating solutions through an all-inclusive product line that supports a wide range of applications and processes.
To best support such diverse industries and needs around the world, Ipsen's Global Support Team facilitates furnace installations, and provides expert training, startup assistance, and 360-degree support throughout the entire lifespan of the equipment.
www.IpsenUSA.com/Products
Ipsen, Cherry Valley, Ill., recently shipped seven furnaces around the globe for applications in aerospace, automotive, and power-generation.
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IBC to supply Beralcast components to semiconductor manufacturer
March 20, 2016
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IBC Advanced Alloys Corp., Vancouver, has signed an agreement with a leading global manufacturer of semiconductor and electronics assembly equipment to be its exclusive supplier of Beralcast beryllium-aluminum cast components. IBC will supply Beralcast 363 cast components for a four-year period, with the agreement expected to generate baseline sales of approximately $4,800,000 over the term of the contract.
Beralcast 363 is a metal matrix composite that consists of 65% Be (by weight) and 35% Al. It provides an ideal solution for weight, stiffness, and thermal-critical applications in aerospace, defense, and commercial markets. BeAl-363 is used primarily for high-strength/high-elastic modulus precision cast structural applications. This alloy is 22% less dense than Al-356 and is 3.5 times as stiff.
"IBC's Beralcast components are ultra-lightweight, with high modulus and excellent thermal characteristics, and are ideally suited to applications requiring high precision and performance," says IBC Engineered Materials President Chris Huskam.
"While IBC will continue to focus on near term growth opportunities in its core aerospace and defense business, we are pleased to be strengthening our relationship with a recognized global leader, and look forward to supporting them for many years to come," says General David Heinz, IBC's Chief Operating Officer. "Recent changes to our IBC Engineered Materials operations have resulted in improved production rates and operating efficiencies, and we are well positioned to continue and grow our sales in the precision manufacturing sector while we broaden our aerospace product offerings and customer base."
www.ibcadvancedalloys.com
IBC Advanced Alloys Corp., Vancouver, has signed an agreement with a leading global manufacturer of semiconductor and electronics assembly equipment to be its exclusive supplier of Beralcast beryllium-aluminum cast components.
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Paulo Products Kansas City Division becomes AS9100 certified
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Paulo Products Co., St. Louis, Mo., announces that its Kansas City Division is now AS9100 certified, and joins the Cleveland Division in being both AS9100 certified and Nadcap accredited. The AS9100 certification will reinforce the Kansas City Division's position as a leading aerospace heat treating facility.
"I am proud of the accomplishments of our Kansas City Division. AS9100 certification will further assure our aerospace customers that Paulo has the systems in place to provide the quality heat treating services required for the integrity and safety of parts used in aerospace applications," says Ben Rassieur, President.
Led by David Mailes, Director of Quality, the Paulo quality team worked hard through 2015 to secure the AS9100 certification. Kansas City Division Quality Assurance Manager Mark Affolter had a very busy 2015. In addition to working towards AS9100, Mark was faced with several audits, as the Kansas City Division maintained ISO9001 and ISO14001 while also securing Boeing approval.
Leveraging prior experience from the Cleveland Division certification, benchmarks were established that proved helpful for the Kansas City certification. Additional support came from the Kansas City Division sales team of Jeb Clement and Curt Heineck, as well as Plant Manager Tee Rassieur. The Kansas City Division is committed to growing with customers and meeting the stringent requirements of the aerospace industry.
www.paulo.com
Paulo Products Co., St. Louis, Mo., announces that its Kansas City Division is now AS9100 certified, and joins the Cleveland Division in being both AS9100 certified and Nadcap accredited.
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Solar partners with Refrac to build system for superplastic forming/diffusion bonding
Source:
Solar Manufacturing, Souderton, Pa., announces that it has contracted with Refrac Systems, Chandler, Ariz., to help design and build a large 100-ton-load gas fan quench vacuum hot press (GFQVHP) system for its aerospace structures diffusion bonding operation. Refrac engineers, working with Solar's engineering team, selected a derivative of the Solar Manufacturing standard HLF-5748-2IQ internally quenched two-bar vacuum furnace as the base design. The new system contains many new engineered designs that are needed to build a versatile and robust system that can process aerospace structures by both automated vacuum hot pressing and by superplastic forming/diffusion bonding.
Amity Industries, Douglassville, Pa., built the furnace chamber for the unit. Beckwood Press & Machinery/Triform, Saint Louis, Mo., was selected to build the large 100-ton "Four Post" hydraulic press frame. Optima Stantron, Lawrenceville, Ga., built the control console unit.
According to Norm Hubele, President of Refrac Systems, "Solar Manufacturing and Beckwood Press & Machinery are both industry leaders with robust engineering experience. We have worked closely together to design and build this one-of-a-kind GFQVHP."
"Norm put together a team of engineers to design and build this furnace back in 2013," says William Jones, CEO of the Solar Atmospheres family of companies. "This state-of-the-art GFQVHP contains many innovations that will be discussed at a later time. Throughout the entire process, Norm has personally reviewed all aspects of the design and added considerable insight to the development of this unique vacuum furnace system."
Solar Manufacturing expects to ship the GFQVHP unit in July, and final assembly, testing, and startup are projected for the 4th quarter 2016 in Chandler.
www.solarmfg.com
www.refrac.com
Solar Manufacturing, Souderton, Pa., announces that it has contracted with Refrac Systems, Chandler, Ariz., to help design and build a large 100-ton-load gas fan quench vacuum hot press (GFQVHP) system for its aerospace structures diffusion bonding operation.
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Alcoa chooses the name Arconic for its future value-add company
March 16, 2016
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Alcoa, Pittsburgh, announces that the name for its future company dedicated to value-added products will be Arconic, in which "A" represents Alcoa, "arc" represents the arc of progress, and "-conic" speaks to the company's history of creating iconic products. The logo also includes a tagline, "Innovation, Engineered" to communicate the company's goal to invent, develop, and deliver products and solutions through precision engineering and advanced manufacturing.
The future upstream company will operate under the Alcoa name. The company's separation into two independent publicly-traded companies in the second half of 2016 remains on track.
"The ‘Arconic' brand fuses our extraordinary heritage with our highly promising future," said Alcoa Chairman and Chief Executive Officer Klaus Kleinfeld. "It echoes our 127-year history of invention – and reinvention. Our logo depicts the realm of possibility brought to life. It reflects our vision of limitless innovation solving complex engineering challenges, to transform the way we fly, drive, build, package and power. And it represents the ingenuity of our people, who are dedicated to inventing, developing, and delivering high-quality, innovative products and solutions that contribute to our customers' success and create shareholder value."
Both Arconic and Alcoa will be based in the United States and listed on the New York Stock Exchange: Arconic as ARNC, and Alcoa as AA. The upstream company (Alcoa) will comprise the five business units that today make up Global Primary Products: Bauxite, Alumina, Aluminum, Cast Products, and Energy.
Arconic will include the three business segments that today comprise Alcoa's Value Add portfolio: Global Rolled Products, Engineered Products and Solutions, and Transportation and Construction Solutions.
www.alcoa.com/arconic
www.alcoa.com/alcoabrand
Alcoa, Pittsburgh, announces that the name for its future company dedicated to value-added products will be Arconic, in which “A” represents Alcoa, “arc” represents the arc of progress, and “-conic” speaks to the company’s history of creating iconic products.
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