Magnesium syntactic foam metal matrix composite floats on water
May 20, 2015
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Researchers from Deep Springs Technology, Toledo, Ohio, and New York University Polytechnic School of Engineering have reportedly demonstrated a magnesium syntactic foam metal matrix composite with density so low that it can float on water. The magnesium matrix is reinforced with small silicon carbide hollow spheres and has a density of only 0.92 g/cc vs. 1.0 g/cc for water. In addition to its low density, it is strong enough to withstand the harsh conditions in the marine environment.
The syntactic foam made by DST and NYU captures the lightness of foams, but adds substantial strength. The secret of this syntactic foam starts with a matrix made of a magnesium alloy, which is then turned into foam by adding strong, lightweight silicon carbide hollow spheres developed and manufactured by DST. A single sphere's shell can withstand pressure of over 25,000 psi before it ruptures—one hundred times the maximum pressure in a fire hose.
The hollow particles also offer impact protection to the syntactic foam because each shell acts like an energy absorber during its fracture. The composite can be customized for density and other properties by adding more or fewer shells into the metal matrix to fit the requirements of the application. This concept can also be used with other magnesium alloys that are non-flammable.
The new composite has potential applications in boat flooring, automobile parts, and buoyancy modules, as well as vehicle armor.
The authors recently published their findings in the International Journal of Impact Engineering. "Dynamic Properties of Silicon Carbide Hollow Particle Filled Magnesium Alloy (AZ91D) Matrix Syntactic Foams." (http://www.sciencedirect.com/science/article/pii/S0734743X15000767).
The technology for the new composite is very close to maturation and could be put into prototypes for testing within three years. Amphibious vehicles such as the Ultra Heavy-lift Amphibious Connector (UHAC) being developed by the U.S. Marine Corps can especially benefit from the light weight and high buoyancy offered by the new syntactic foams, the researchers explained.
"This new development of very light metal matrix composites can swing the pendulum back in favor of metallic materials," forecasts Nikhil Gupta, an NYU School of Engineering professor in the Department of Mechanical and Aerospace Engineering and the study's co-author. "The ability of metals to withstand higher temperatures can be a huge advantage for these composites in engine and exhaust components, quite apart from structural parts." This research is conducted in collaboration with the U.S. Army Research Laboratory.
http://engineering.nyu.edu
Researchers from Deep Springs Technology, Toledo, Ohio, and New York University Polytechnic School of Engineering have reportedly demonstrated a magnesium syntactic foam metal matrix composite with density so low that it can float on water.
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Laser shock peening improves fatigue and durability of aircraft structures
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The University of Cincinnati reports that its researchers and Airbus engineers have developed a laser shock peening technology in which several lasers simultaneously focus beams of infrared light on sections of aluminum, titanium, or nickel-base superalloy components. The laser beams deeply compress and change the structure, altering the physical and mechanical properties and increasing strength, durability, and corrosion resistance.
When the metal is processed, a ridged, geometric grid patterns its surface; that's the section of the sample that is enhanced for fatigue and corrosion resistance. Each sample goes through a rigorous series of manipulations and tests for stress, heat, and environmental effects. Structural and chemical properties are assessed right down to its nanostructure.
UC is said to be the only university in the United States to offer LSP for use in research and development and prototyping efforts through the Ohio Center for Laser Shock Processing for Advanced Materials and Devices. The center was recently established with a $3 million grant from the State of Ohio Third Frontier Program. General Electric, which developed and patented the process, gifted its original equipment and know-how to the university in 2005.
"Critical aircraft components are subjected in service to high stresses, fatigue, and corrosion. We hypothesize that the LSP processes impart deep, compressive, residual stresses to these components, strengthening the metal in a very deliberate way, which makes it less likely to fail," explains S.R. ‘Manny' Mannava, professor in the department of mechanical and materials engineering in the College of Engineering and Applied Science.
"When we have confirmed that the metal itself won't fail due to fatigue, cracking, or corrosion, we will fortify huge pieces of metal for use in prototypes and, eventually, mass production," says Vijay K. Vasudevan, professor in the department of mechanical and materials engineering in the College of Engineering and Applied Science. "We will also conduct basic research to understand the effects of the process on material behavior, in order to optimize the process for specific future applications."
http://www.uc.edu
http://www.ucri.org
The University of Cincinnati reports that its researchers and Airbus engineers have developed a laser shock peening technology in which several lasers simultaneously focus beams of infrared light on sections of aluminum, titanium, or nickel-base superalloy components.
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Ipsen TurboTreater heat treats castings for aerospace applications
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Ipsen, Cherry Valley, Ill., recently shipped a horizontal TurboTreater vacuum furnace with two-bar gas quenching to a metal-casting company in Texas. This specific TurboTreater features a 36 x 36 x 48-inch graphite hot zone with a carbon steel gas distribution plenum and a 3000-pound load capacity. It operates at temperatures of 1000 to 2400°F, with ±10°F temperature uniformity. The furnace is also equipped with a 20-inch Varian diffusion pump and Ipsen's CompuVac control system.
The Texas company will use the furnace to process parts for the aerospace industry, as it is capable of meeting the strict requirements of applicable AMS 2750E standards. In addition, this TurboTreater is equipped with a motion sensor on the mechanical pump with software that isolates the diffusion pump if it should fail or if the maximum allowable foreline pressure were exceeded.
A variable-frequency drive on the gas fan cooling motor provides controlled cooling. Other additions include a barcode scanner/reader, a paperless recorder with a channel for recording the dew point, and a spare parts starter kit – which helps users prevent unnecessary downtime by supplying them with essential parts and consumables.
Other possible modifications include variations on the hot zone insulation package, heating elements, pumping systems, and control system. Overall, the Ipsen TurboTreater line allows customers to order heat treatment furnace systems specified to their unique needs.
In addition, this multi-purpose vacuum furnace offers patented mechanical features such as Ipsen's unique quarter-twist graphite heating element support hanger, which provides metallic support for ceramics; the flare locking rim for molybdenum cooling gas nozzles, which secures them in place into a rounded extrusion in the plenum wall; and the cooling system design, which generates the highest heat transfer coefficient of any vacuum furnace on the market.
www.IpsenUSA.com/Products
Ipsen, Cherry Valley, Ill., recently shipped a horizontal TurboTreater vacuum furnace with two-bar gas quenching to a metal-casting company in Texas.
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Ametek acquires Global Tubes for its high-precision small-diameter tubing
May 15, 2015
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Ametek Inc., Berwyn, Pa., has acquired Global Tubes, a leading manufacturer of high-precision, small-diameter metal tubing, for approximately $200 million. Global Tubes manufactures highly customized metal tubing from a wide variety of metals and alloys, including stainless steel, nickel, zirconium, and titanium. Its products are used in highly engineered applications in the aerospace, energy, power generation, and medical markets.
The business has annual sales of approximately $120 million. Global Tubes is comprised of two businesses: Fine Tubes, based in Plymouth, U.K.; and Superior Tube, based in Collegeville, Pa.
"Global Tubes metallurgical capabilities, processing capabilities, and alloy ranges are complementary to our existing Specialty Metals businesses and give us the opportunity to expand our offerings both internationally and in attractive growth markets," says Frank S. Hermance, Ametek Chairman and Chief Executive Officer.
Global Tubes joins Ametek as part of its Electromechanical Group (EMG) -- a differentiated supplier of electrical interconnects, precision motion control solutions, medical components, specialty metals, thermal management systems, and specialty motors.
www.ametek.com
Ametek Inc., Berwyn, Pa., has acquired Global Tubes, a leading manufacturer of high precision, small diameter metal tubing, for approximately $200 million.
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Linde launches compact hydrogen generators with high natural-gas conversion rate
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The Linde Group, Holly Springs, Ga., launches its Hydroprime plant line of innovative, cost-effective compact hydrogen generators based on proven steam methane-reforming technology. Hydro-Chem, a division of Linde Engineering North America, has tested and proven the reliability and suitability of these units in various applications. The company is now launching the mass-production release of Hydroprime as a competitive and reliable local production alternative to trucked-in bulk gases.
Hydroprime plants have a capacity of 0.15 - 0.9 MMSCFD (165 - 1000 Nm3/h) and produce ultrahigh-purity hydrogen (99.999+ %) at 200 psi (13.8 bar), reducing the need for product compression in most uses. The new product line has a very high natural-gas conversion rate and is highly heat integrated, which translates into low operating cost.
The plants are ideally suited for customers who expect high reliability and superior environmental and safety performance. The plants are fully automatic with fail-safe controls, allowing unattended operation, remote start-up, and monitoring. In addition, they feature a modular open skid design and a small footprint. This facilitates easy installation while providing good access for routine maintenance.
Recognizing the diverse needs of a global market place, Linde offers Hydroprime as a build-own-operate solution to simplify ownership and maintenance for the end user and eliminate customer-owned capital investment. Alternatively, plants can be owned and operated by the end user with various support models by Linde, if desired. Linde is able to offer even more flexible solutions for hydrogen supply to an extensive range of industries, including glass, chemicals, foods, metals, electronics, photovoltaics, and energy.
www.linde.com
The Linde Group, Holly Springs, Ga., launches its Hydroprime plant line of innovative, cost effective compact hydrogen generators based on proven steam methane reforming technology.
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Ipsen shaft-sealing mechanism enables placing motor outside the vacuum chamber
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Ipsen, Cherry Valley, Ill., was recently awarded a U.S. patent for the development of a new shaft-sealing mechanism. This invention enables motors to be located outside of the vacuum chamber, thus placing it in a cooler and more stable environment. Relocation of the motor has numerous advantages, including extended motor life and a longer interval between rebuilds.
In addition, placing the motor outside in ambient air means that a step-down transformer for argon cooling gas is no longer needed. Maintenance has also been simplified, with users able to easily grease bearings, monitor vibration, and perform routine maintenance checks. Combined with Ipsen's unique, innovative production and assembly process that integrates premium components, this lowers the cost of ownership.
Chief Engineer Craig Moller, Chief Operating Officer Jake Hamid, and Dr. W. Hendrik Grobler, the named inventors on the patent, began formulating this design seven years ago for Ipsen's Titan vacuum furnace lines. Today, this innovative shaft seal is present in every Titan furnace in the field – almost 200 total to date. Since the installation of this shaft seal on the first Titan unit in 2009, the furnaces have experienced thousands of hours of trouble-free operation.
With more than 120 approved and 50 pending patents worldwide, Ipsen's shaft seal is just one invention among many that helps improve day-to-day operations.
www.IpsenUSA.com/titan
Ipsen, Cherry Valley, Ill., was recently awarded a U.S. patent for the development of a new shaft-sealing mechanism.
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NASA Langley recognized for advancing helicopter research
May 7, 2015
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NASA Administrator Charles Bolden was at NASA's Langley Research Center, Hampton, Va., on May 8 to participate in a ceremony recognizing Langley's decades of contributions to improving helicopters and other vertical flight aircraft.
During the ceremony, the (AHS) International formally named Langley a Vertical Flight Heritage Site. Bolden and Jaiwon Shin, associate administrator for NASA's Aeronautics Research Mission Directorate in Washington, accepted the designation on behalf of the agency. Hampton Mayor George Wallace and AHS International executive director Mike Hirschberg also attended.
AHS International presented Langley with a plaque that states: "Since its establishment in 1917 as the Langley Memorial Aeronautical Laboratory, the Langley Research Center has performed groundbreaking research to advance the state of the art in vertical flight."
Image caption — NASA's Langley Research Center has done research on helicopters and other vertical flight aircraft almost since the laboratory was founded in 1917, including this Sikorsky HNS-1 that was tested in the Langley Full-Scale Tunnel in 1944.
NASA Administrator Charles Bolden was at NASA’s Langley Research Center, Hampton, Va., on May 8 to participate in a ceremony recognizing Langley’s decades of contributions to improving helicopters and other vertical flight aircraft.
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Solar Atmospheres adds large advanced vacuum furnace to California facility
May 6, 2015
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Solar Atmospheres of California (SCA), Fontana, has added a large furnace to its facility equipment. Uniquely designed for SCA, Solar's new furnace offers new features and characteristics that will enhance its ability to add a multitude of diverse processing parameters that currently exist in the vacuum heat treating industry. The furnace will also enable planning for future material advances and specification modifications that require strict adherence to process controls. The furnace has the ability to control heating/cooling rates, process vacuum levels, and temperature uniformity.
Key performance characteristics include an 84-in. diameter by 144-in. long hot zone; Maximum operating temperature of 2650°F; Hearth that can support in excess of 30,000 lb.; Energy-efficient all-graphite hot zone; and Solar Manufacturing's state-of-the-art furnace control package, SolarVac 5000.
"SCA has worked very closely with our sister company Solar Manufacturing to design this furnace," says President Derek Dennis. "It will add a competitive advantage by allowing us to expand our vacuum processing capabilities in the large-parts market."
http://solaratm.com/news
Solar Atmospheres of California (SCA), Fontana, has added a large furnace to its facility equipment.
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Lake City Heat Treating acquires VFS vacuum furnace
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Lake City Heat Treating Corp., Warsaw, Ind., has acquired a VFS Model HIQ3836-6 furnace that can achieve vacuums of 10-6 torr and process temperatures up to 2400°F with a workload size up to 24 x 24 x 36 in. It features "6 bar" capabilities with a variable-speed 200-hp cooling blower. With this new furnace, the company now offers nitrogen as well as argon quench. It also allows processing customer requirements to exact specifications.
Lake City provides heat treating services for the aerospace, medical, and other quality-critical industries. It specializes in bright aging, hardening, annealing, and stress-relieving of many different alloys, including; nickel, cobalt and titanium.
The new furnace brings the company's vacuum heat treating line to seven.
www.lakecityheattreating.com
Lake City Heat Treating Corp., Warsaw, Ind., has acquired a VFS Model HIQ3836-6 furnace that can achieve vacuums of 10-6 torr and process temperatures up to 2400°F with a workload size up to 24 x 24 x 36 in.
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Composite curing oven to support aerospace research at University of South Carolina
April 28, 2015
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Wisconsin Oven Corp., East Troy., Wis., has shipped a composite curing batch oven to the McNair Center for Aerospace Innovation and Research at the University of South Carolina. The composite curing oven will be used by university faculty, students, and industry partners to support education and research efforts as part of the McNair Center's Advanced Composite Manufacturing Laboratory, an industrial-scale applied R&D facility. With a maximum operating temperature of 800°F, the oven will allow students to process and develop new higher-temperature materials as they hit the market.
The electrically heated walk-in oven has a maximum temperature rating of 800°F and a work chamber 6 ft. wide, 10 ft. long, and 6 ft. high. The batch oven features guaranteed temperature uniformity (+/-10°F at 600°F) which was verified through a nine-point profile test prior to shipment.
The recirculation system utilizes a 10,800 CFM @ 10 HP plug-mounted blower and combination airflow to maximize heating rates and temperature uniformity. Unique features include a reinforced insulated 4-in. thick floor, a vacuum manifold with four interior stubs and transducers, a Eurotherm 3504 programmable controller, a Eurotherm Versadac to record part temperatures and vacuum pressure, and a 12-position thermocouple jack panel.
www.wisoven.com
Wisconsin Oven Corp., East Troy., Wis., has shipped a composite curing batch oven to the McNair Center for Aerospace Innovation and Research at the University of South Carolina.
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