Seco Warwick reports record order portfolio and 10% sales increase over 2017
March 20, 2019
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The Seco Warwick Group, Meadville, Pa., reports a record order portfolio of over $106 million after three quarters of 2018, with an operating profit for this period of $5.3 million, and net profit of $3.5 million.
The Group's sales in the first three quarters of 2018 increased by 10% compared to the same period of 2017, reaching a record $106 million. The strong market position is built not only by factories and companies on three continents, but also by stable revenues and a record order portfolio for end-to-end solutions in five product categories.
One category of note is atmosphere heat treatment technology and equipment, the product segment that provided robust sales in 2018. The final results reflect great progress for this product segment, which has prompted continuing investment in this technology and expansion into new markets.
Another product segment that recorded excellent sales results was vacuum metallurgy. A significant increase in sales of vacuum induction melting systems (VIM) in 2018 has already become the success story of the segment. At Purdue University, the Group installed and commissioned a VIM type furnace with a unique oil cooling system - a furnace for infiltrating samples with a zirconium alloy. VIM also was delivered, among other vacuum metallurgy project, to an American company serving the aviation industry.
The aerospace industry built a strong order portfolio, 70% of sales, for the Group in 2018, because equipment from the three segments of the Group are devoted to this sector. Particularly noteworthy are furnaces for vacuum heat treatment. In 2018, 65% of the total volume were designed as customized projects.
www.secowarwick.com
The Seco Warwick Group, Meadville, Pa., reports a record order portfolio of over $106 million after three quarters of 2018, with an operating profit for this period of $5.3 million, and net profit of $3.5 million.
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European team produces 3D printed titanium pressure vessel for space exploration
March 11, 2019
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A European aerospace production team comprising Thales Alenia Space, Cranfield University, and Glenalmond Technologies announces the completion of the first full-scale prototype of an additively manufactured titanium pressure vessel to be used in future manned missions for space exploration.
The vessel is approximately 39 inches high and weighs about 19 pounds. Made of the titanium alloy Ti-6Al-4V, it was manufactured by the â€wire plus arc†additive manufacturing (WAAM) process, which Cranfield University has pioneered over the last decade. Thanks to being able to go straight from digital drawing to final structure, WAAM has integrated two individual pieces into a single part; eliminated the need for long-lead-time forgings; and substantially reduced the amount of waste material removed by machining.
If manufactured traditionally, the component would have required about 30 times more raw material than its final mass. By using the WAAM process, more than 440 pounds of Ti-6Al-4V has been saved for each component. There is room to improve this further, and Cranfield is working on innovative methods to deposit closer to the final thickness.
The WAAM shape was manufactured at Cranfield and then sent to Glenalmond Technologies, where it was stress-relieved, laser-scanned, machined, and inspected by an ultrasonic method. The final inspection was carried out by Agiometrix with a computer tomography scan for internal quality analysis and then an optical scanner, with Thales Alenia Space ensuring that the part met the mechanical requirements and specifications.
Following the checks, the project team was satisfied that the vessel fulfils the driving technical and quality requirements. The team is now proceeding to the building of a second prototype, to carry out a fine tuning of the whole manufacturing cycle, to demonstrate the repeatability and reliability of the process, and to push the implementation of the new approach into the flight hardware.
http://www.cranfield.ac.uk
A European aerospace production team comprising Thales Alenia Space, Cranfield University, and Glenalmond Technologies announces the completion of the first full-scale prototype of an additively manufactured titanium pressure vessel to be used in future manned missions for space exploration.
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Mineral and organic acids extract rare earth elements from phosphate rock waste
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Researchers from Rutgers University-New Brunswick, N.J., and members of the Critical Materials Institute in Ames, Iowa, announce that they have found a possible new source of rare earth elements in phosphate rock waste, and have developed an environmentally friendly way to extract the elements. Results of their study were published in the Journal of Chemical Thermodynamics.
The research team explored using mineral and organic acids, including a bio-acid mixture, to extract six rare earth elements (yttrium, cerium, neodymium, samarium, europium, and ytterbium) from synthetic phosphogypsum. Scientists led by David Reed at Idaho National Laboratory produced the bio-acid mixture - consisting primarily of gluconic acid, found naturally in fruits and honey - by growing the bacteria Gluconobacter oxydans on glucose.
The results suggest that the bio-acid did a better job extracting rare earth elements than pure gluconic acid at the same pH (2.1), or degree of acidity. The mineral acids (sulfuric and phosphoric) failed to extract any rare earth elements in that scenario. When the four acids were tested at the same concentration, only sulfuric acid was more effective than the bio-acid.
Each year, an estimated 250 million tons of phosphate rock are mined to produce phosphoric acid for fertilizers. In the United States, approximately 28 million metric tons were mined in 2017. Rare earth elements generally amount to less than 0.1 percent in phosphate rock. But worldwide, about 100,000 tons of these elements per year end up in phosphogypsum waste. That's almost as much as the approximately 126,000 tons of rare earth oxides produced worldwide each year.
www.newbrunswick.rutgers.edu
https://cmi.ameslab.gov/
Researchers from Rutgers University-New Brunswick, N.J., and members of the Critical Materials Institute in Ames, Iowa, announce that they have found a possible new source of rare earth elements in phosphate rock waste, and have developed an environmentally friendly way to extract the elements.
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Harper develops on-line cleaning system for hot carbon-fiber production furnaces
March 3, 2019
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Harper International, Buffalo, N.Y., has developed an on-line furnace cleaning system that is located in the entrance section, which enables cleaning while the furnace is hot. Left untended, debris and filament buildup impedes and disrupts smooth gas flow in a carbon fiber high-temperature furnace, resulting in non-uniform properties across the tow band. The debris needs to be removed periodically during the operation of a fiber production line. However, traditional cleaning techniques require reduction of furnace temperatures in order to gain access for cleaning, resulting in reduced furnace run times.
To prevent exposure of the furnace to an air atmosphere, the on-line cleaning feature is self-contained and sealed with an incorporated nitrogen purge. Additionally, Harper’s on-line cleaning system includes sight-ports that permit the operator to see into the process chamber to assess the level and location of the debris. Utilizing the on-line cleaning feature enables improved fiber thermal uniformity and increased furnace utilization.
“Continuous uniformity across the tow band throughout the entire campaign has never been more achievable than with Harper’s innovative online cleaning system,†says Rebecca Stephenson, Applications Engineer. “Increased fiber quality throughout the whole production campaign is now possible with this solution for removing debris that negatively impacts the velocity uniformity within the HT furnace throat.â€
www.harperintl.com
Harper International, Buffalo, N.Y., has developed an on-line furnace cleaning system that is located in the entrance section, which enables cleaning while the furnace is hot.
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Norsk Titanium, SAE International develop first directed energy deposition specifications
February 24, 2019
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Norsk Titanium, Plattsburgh, N.Y., and SAE International announce the release of the first specifications for direct energy deposition additive manufacturing. The specifications utilize Norsk’s Rapid Plasma Deposition (RPD) process and material requirements, which are currently used by many original equipment manufacturers. With the release of the SAE Aerospace Materials Specifications (AMS) documents, the process will be available to a broader base of users across the world.
Developed within the SAE Additive Manufacturing Committee (SAE AMS-AM), these specifications establish the minimum basis required for the procurement of RPD Preforms from Norsk by an aerospace or non-aerospace customer. In addition, these specifications support the regulatory certification process by ensuring consistent process and quality control.
The release of “AMS7004 Titanium Alloy Preforms from Plasma Arc Directed Energy Deposition Additive Manufacturing on Substrate Ti-6Al-4V Stress Relieved and AMS7005 Wire Fed Plasma Arc Directed Energy Deposition Additive Manufacturing Process†is a milestone achievement for the metal additive manufacturing industry.
“These new material and process specifications help address the regulatory authorities’ request for guidance material for this critical emerging technology,†said David Alexander, Director, Aerospace Standards at SAE International.
Established by aerospace industry leaders in 2015 and supported by a Federal Aviation Administration tasking request, SAE’s AMS-AM Committee continues to develop aerospace material specifications (SAE AMS) for metal and polymer AM to support the needs of the aerospace industry. Over 500 global participants from more than 20 countries representing aircraft, spacecraft, and engine OEMs, material suppliers, operators, equipment/system suppliers, service providers, regulatory authorities, and defense agencies are involved in the committee.
www.norsktitanium.com.
Norsk Titanium, Plattsburgh, N.Y., and SAE International announce the release of the first specifications for direct energy deposition additive manufacturing.
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Wisconsin Oven ships solution treat system to a supplier of the aerospace industry
February 22, 2019
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Wisconsin Oven Corp., East Troy, has shipped an electrically heated horizontal quench solution treat system to a supplier of the aerospace industry for treating a mixture of aluminum and steel.
The horizontal quench solution treat system has a maximum oven operating temperature of 1200°F and work zone dimensions of 5 ft. 4 in. wide x 5 ft. 6 in. long x 5 ft 4 in. high (above the rollers).
Guaranteed temperature uniformity of ±5°F at set points of 250°F and 550°F and ±10°F at set points of 980°F and 1100°F was documented with a nine point temperature uniformity survey in an empty oven chamber under static operating conditions in accordance with AMS 2750E.
This horizontal quench system was designed to heat a 565-pound gross load, consisting of a mixture of aluminum and steel, to 1000°F operating temperature, provide a soak at temperature, and then quickly move the load into a quench tank. A powered pusher/extractor is used to load and unload the oven.
A pneumatically operated lift system lowers and raises the load for quenching. This system achieved a quench time from the time the oven door starts to open until the load is fully submerged of less than nine seconds.
“The Horizontal Quench System is a cost-saving alternative to drop bottom systems and results in a quicker ROI,†says Gary Hanson, Senior Application Engineer. “It may actually take up less total floorspace than some drop bottom systems of the same chamber volume.â€
www.wisoven.com
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Wisconsin Oven Corp., East Troy, has shipped an electrically heated horizontal quench solution treat system to a supplier of the aerospace industry for treating a mixture of aluminum and steel.
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Seco Warwick vacuum heat treating/brazing system includes high-pressure gas quench
February 5, 2019
Source: ASM International
Seco Warwick, Meadville, Pa., announces that is has provided a vacuum heat treatment and brazing system equipped with high-pressure gas quench to Grupo TTT for its facility in Bergara, Spain.
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Titanium carbide nanoparticles infused into aluminum alloy 7075 enable strong welds
January 27, 2019
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Engineers at the UCLA Samueli School of Engineering announce that they have developed a way to weld aluminum alloy AA 7075 by infusing titanium carbide nanoparticles into welding wires, which results in welded joints with a tensile strength up to 392 MPa. (By comparison, AA 6061 has a tensile strength of 186 MPa in welded joints.) According to the study, post-welding heat treatments could further increase the strength of AA 7075 joints up to 551 MPa, which is comparable to steel.
"The new technique is just a simple twist, but it could allow widespread use of this high-strength aluminum alloy in mass-produced products such as cars or bicycles, where parts are often assembled together," said Xiaochun Li, UCLA's Raytheon Professor of Manufacturing and the study's principal investigator. "Companies could use the same processes and equipment they already have to incorporate this super-strong aluminum alloy into their manufacturing processes, and their products could be lighter and more energy efficient, while still retaining their strength."
The researchers already are working with a bicycle manufacturer on prototype bike frames that would use the alloy; and the new study suggests that nanoparticle-infused filler wires could also make it easier to join other hard-to-weld metals and metal alloys.
“Nanoparticle-enabled phase control for arc welding of unweldable aluminum alloy 7075,†was published in the January 9 issue of Nature Communications.
Engineers at the UCLA Samueli School of Engineering announce that they have developed a way to weld aluminum alloy AA 7075 by infusing titanium carbide nanoparticles into welding wires, which results in welded joints with a tensile strength up to 392 MPa.
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Stack Metallurgical installs Quintus Mega HIP for heat treating aerospace, medical products
January 23, 2019
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Stack Metallurgical Group, Albany, Ore., announces that it has installed a Quintus Mega-HIP hot isostatic press for heat treating and processing of aerospace, power generation, medical implant, and other products. The model QIH 286 M URC is equipped with proprietary uniform rapid cooling and features a work zone of 63 in. dia. by 102 in. tall, allowing densification of large batches at 29,000 psi and a maximum operating temperature of 2280°F.
The URC design enables all casting areas to cool uniformly, minimizing thermal distortion and non-uniform grain growth. Heating and cooling the workload only once, in a single cycle, enhances efficiency and dramatically reduces per-unit processing costs. In addition, the press offers significant savings in space, energy, and infrastructure investment.
With its new HIP facility coming on-line in 2019, Stack will offer four Nadcap-accredited locations with a focus on the aerospace, power generation, medical implant, and high-end knife and cutlery markets. The company’s modern and extensive equipment line-up offers a comprehensive portfolio of services for demanding clients throughout North America. With a range of aerospace OEM approvals for heat treatment, Stack has built trusted relationships with aerospace titans Boeing, General Electric, Sikorsky, and PCC Aerostructures.
“As a new entrant into the HIP market, it was critical that we continue to have the ability to offer a premium combination of quality and delivery to our clients,†says Doug Puerta, CEO, Stack Metallurgical Group.
http://www.stackmet.com
Stack Metallurgical Group, Albany, Ore., announces that it has installed a Quintus Mega-HIP hot isostatic press for heat treating and processing of aerospace, power generation, medical implant, and other products.
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Optomec partners with Phillips Federal to bring 3D printing to US government agencies
January 17, 2019
Source: ASM International
Optomec, Albuquerque, N.M., has signed a partnership agreement with Phillips Federal that will enable Phillips to resell the Optomec Laser Engineered Net Shaping (LENS) systems to U.S. government facilities.
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