Preparation and high-temperature oxidation resistance of zirconium alloys

June 11, 2024
Source: ASM International

Preparation and high-temperature oxidation resistance of zirconium alloys

Researchers from the National Engineering Research Center for Instrument Functional Materials and Chongqing University, both in Chongqing, China, have highlighted the pivotal role of zirconium alloys in nuclear power systems. Their latest paper reviews the significant advancements in coating technologies for zirconium alloy fuel cladding, a crucial component in nuclear reactors. The study discusses various preparation methods, types of coatings, and their efficacy in resisting high-temperature oxidation—a key challenge for fuel cladding materials. This comprehensive review aims to serve as a critical reference in advancing the surface coating technology of fuel cladding zirconium alloys, promising enhanced performance and safety in nuclear power applications.

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Can-Eng announces expansion with subsidiary Evergreen Kiln Technologies


Source: ASM International

Can-Eng announces expansion with subsidiary Evergreen Kiln Technologies

EvergreenKilnTechnologies, LLC, based in Niagara Falls, USA, together with Suzhou Kilnpartner Mechanical Technology Co., Ltd., based in China, have announced a strategic partnership aimed at addressing the burgeoning needs of the North American Lithium-ion battery market. This alliance is poised to offer battery material producers advanced Kiln System solutions tailored for the production of cathode (LFP, NMC) and anode active materials.

As part of the arrangement, EvergreenKilnTechnologies LLC will function as a subsidiary under Can-Eng Furnaces International LTD., leveraging Can-Eng’s extensive 60-year expertise in designing and developing bespoke thermal processing systems.

The partnership extends across various domains, including marketing, brand collaboration, technology development, production, engineering, and after-sales services. The primary objective is to innovate thermal processing methods for battery powders, ensuring that the collaborative venture can deliver superior kiln solutions to clients across North America.

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Seco/Vacuum awarded nine-furnace contract


Source: ASM International

Seco/Vacuum awarded nine-furnace contract

Seco/Vacuum, Meadville, Pa., announced it has secured a record-breaking contract for nine furnaces in June. The order includes three Vector vacuum Furnaces and six tempering furnaces, along with necessary auxiliary systems, marking a significant expansion for a returning heat-treat partner that already operates twelve Seco/Vacuum furnaces across North America.

The new furnaces are part of the heat-treater’s strategic shift from atmospheric heat treatment to vacuum processes. This transition aims to modernize their facilities, offering cleaner, safer, and more cost-effective operations. Vacuum processes also allow for finer control and reduce the carbon footprint, aligning with contemporary environmental standards.

The Vector® furnaces, known for their versatility in heat-treating processes like hardening, tempering, and brazing, will primarily be used for hardening due to their high-pressure gas quench capabilities. These furnaces ensure high uniformity and consistency in heat-treated parts, with enhanced batch processing speed and reduced energy and gas usage.

The accompanying Tempering Furnaces, designed for efficient atmospheric tempering, feature convection heating for faster process temperatures and smoother workflow integration, crucial during the often-congested tempering stage.

To support the intensive hardening cycles of the Vectors, six tempering furnaces were chosen to maximize throughput and efficiency. Each furnace, both vectors and temperers, are front-loading with a capacity of 3,300 lbs and dimensions of 36 x 36 x 48 inches.

The full modernization will require a temporary shutdown of existing operations. Seco/Vacuum will mitigate downtime by also acting as the general contractor, overseeing the installation of furnaces, systems, and necessary infrastructure, ensuring a swift resumption of operations with new capabilities.

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One Minute Mentor: Gas Nitriding Equipment

May 22, 2024
Source: ASM International

One Minute Mentor: Gas Nitriding Equipment

Gas nitriding and nitrocarburizing can be processed in horizontal or vertical chamber furnaces with refractory insulation. However, to allow a quick change of the atmosphere and to avoid influences resulting from previous processes in the same furnace, retort furnaces are preferred.

To enable an acceptable production capacity, large vertical retort furnaces are used. Figure 23 shows a schematic sketch of a vertical retort furnace with a compensator for sealing against atmosphere. Nowadays large horizontal retort furnaces are also used. Horizontal retort furnaces of different size and execution are preferred for nitrocarburizing processes. Figure 24 shows a schematic of a typical horizontal retort furnace. Similar to the vertical execution, a good circulation of the process gas is needed to get uniform results, which can be reached by the use of a muffle and a high circulation rate. Indirect cooling is performed with an external cooling fan, blowing cold air along the retort. Other designs allow direct cooling of the process gas with an external heat exchanger.

For more information, click on the link below (subscription required). Then scroll to Figure 23. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014  https://doi.org/10.31399/asm.hb.v04d.a0005958

Nitrex announces second endoflex generator order from South American automotive company


Source: ASM International

Nitrex announces second endoflex generator order from South American automotive company

Nitrex, Quebec, announced that an automotive company in South America has placed a follow-up order for a second EndoFlex generator from UPC-Marathon, a Nitrex company. Following the successful installation of a 200 m³/h EndoFlex unit last year, the new generator, with a similar capacity, aims to enhance stability, ensure consistent composition and gas flows, and prioritize top-tier quality in automotive gear boxes while achieving efficiencies in heat treatment operations.

Before adopting the EndoFlex solution, the manufacturer relied on four outdated generator units, each with a capacity of 70 m³/h and consuming 80 kW of power. Remarkably, with the same 80 kW of power consumption, the EndoFlex generator delivers an impressive 200 m³/h capacity. This transition represents not only a remarkable 75% reduction in power consumption but also a significant boost in efficiency and cost-effectiveness for the customer.

The shift to EndoFlex also signifies a substantial contribution to operational efficiency and sustainability efforts. The new generator streamlines maintenance procedures, adheres to stringent quality standards, and reduces CO2 emissions. EndoFlex’s precision control over gas quality and production for the neutral hardening furnace enhances product quality, reduces operating costs, and optimizes energy consumption. By automatically adjusting gas production to match real-time furnace demand, EndoFlex effectively eliminates overproduction and waste.

This order underscores the automotive company’s commitment to leveraging advanced technologies for enhanced productivity and sustainability in their operations.

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SECO/WARWICK finds the way to complete successful projects in Brazil


Source: ASM International

SECO/WARWICK finds the way to complete successful projects in Brazil

Seco/Warwick, Meadville, Pa., announced a significant milestone in its operations in Brazil. The company has successfully implemented a solution for Nitrion do Brasil, a leading commercial heat treater in South America, in their new production hall to manage the increasing order volume. This achievement underscores the strong synergy between SECO/WARWICK and its strategic partner in the region, Combustol.

SECO/WARWICK’s presence in Brazil has seen dynamic sales growth and promising market forecasts, driven by their popular Vector single-chamber vacuum furnaces. These furnaces are highly favored by commercial heat treaters in the region for their ability to enhance the hardening process and improve economic efficiency. The successful collaboration with Combustol has been instrumental, providing not only sales support but also service activities and the supply of spare parts, which has given SECO/WARWICK a competitive edge.

The Vector vacuum furnace ordered by Nitrion do Brasil is designed to address the challenge of hardening larger elements, thanks to its spacious working area. This feature enhances process economics through energy savings and increased efficiency of the graphite chamber, while also ensuring process cleanliness and speed. The furnace’s convection heating system improves heat transfer efficiency at lower temperatures, and its directional cooling system allows for effective cooling of parts with complex shapes.

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Constellium has announced new initiative to boost circularity of beverage cans


Source: ASM International

Constellium has announced new initiative to boost circularity of beverage cans

Constellium, Paris, has announced an initiative to enhance the circularity of beverage cans. In collaboration with three leading flat-rolled aluminium manufacturers and members of the European Aluminium Packaging Group (EAPG) – Elval, Novelis, and Speira – Constellium has signed an agreement to embark on a standardization project aimed at maximizing the recycled content in beverage cans. This initiative is a significant step towards substantially lowering carbon emissions by focusing on the increased recyclability of the can end.

This collaborative effort underscores the aluminium industry’s commitment to sustainability. By increasing the recycled content in beverage cans, the project aims to significantly reduce the carbon footprint associated with aluminium production. The focus on recyclability and circularity not only benefits the environment but also sets a new standard for sustainability within the industry.

By prioritizing these eco-friendly practices, Constellium and its partners are paving the way for a more sustainable future in aluminium production, highlighting the importance of innovation and collaboration in achieving environmental goals.

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Ipsen wins German Innovation Award 2024


Source: ASM International

Ipsen wins German Innovation Award 2024

Ipsen, Kleve, Germany, has been honored with the prestigious German Innovation Award 2024 by the German Design Council for its Ipsen ATLAS Green furnace. In a competitive field of 520 submissions from 23 countries, Ipsen’s innovative approach stood out, earning accolades from an interdisciplinary jury of experts for its user-centric design and significant added value.

The Ipsen ATLAS Green furnace represents a new standard in quality and innovation, addressing the dual challenge of high-quality heat treatments and low CO2 emissions. The furnace’s unique ability to operate using both hydrogen and green electricity ensures a 100% CO2-neutral process, offering an environmentally friendly and cost-effective solution for customers.

This award highlights Ipsen’s commitment to intelligent innovations that meet the evolving needs of its customers while promoting sustainability. The recognition of the Ipsen ATLAS Green furnace underscores the company’s dedication to delivering advanced, user-focused technologies that contribute to a greener future.

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One Minute Mentor: Salt Bath Nitrocarburizing Equipment

May 6, 2024
Source: ASM International

One Minute Mentor: Salt Bath Nitrocarburizing Equipment

Modern salt bath nitrocarburizing units can be arranged as fully automated and contained lines and usually consist of an air-preheating furnace, one or several salt bath nitrocarburizing furnaces, which can either be heated electrically or by gas combustion, and a cooling unit that can be an oxidizing salt bath. Such oxidizing posttreatment builds up a thin and dense oxide layer on top of the compound layer that significantly increases the corrosion resistance. 

Online monitoring of the chemical composition is not required due to the high stability of the melt and the automatic supply of refill salt and regenerators. The nitrocarburizing line usually ends with three- to four-step washing cascades that also act as a regeneration system for the salt.

Gas nitriding and nitrocarburizing is the most sensitive process regarding passivation effects typical for medium- to high-alloy tool steels. Therefore special attention must be paid to cleaning and pretreatment processes such as preoxidation, controlled oxinitriding, or the use of chemicals such as hydrazine. On the other hand, gas processes have the best accessibility for boreholes and thin gaps.

For more information, click on the link below (subscription required). Then scroll to Figure 21. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014  https://doi.org/10.31399/asm.hb.v04d.a0005958

 

Researchers overcome manufacturing challenges in aluminum alloys with nano-treatment


Source: ASM International

Researchers overcome manufacturing challenges in aluminum alloys with nano-treatment

Researchers at the University of California, Los Angeles, have achieved a significant breakthrough in the field of metal additive manufacturing (AM), specifically with Al–Cu alloys like AA2024, which are prevalent in the aerospace and automotive industries. 

These alloys are known for their high strength and good fatigue resistance but have been notoriously difficult to work with in additive manufacturing due to issues like hot cracking and other solidification defects.

The UCLA team has successfully developed a nano-treated AA2024 deposition that incorporates TiC nanoparticles, leading to a groundbreaking enhancement in the manufacturing process. This new method allows for the additive manufacturing of AA2024 without the occurrence of cracks, a common issue that has hindered broader adoption of these materials in high-precision sectors.

Microstructural analysis conducted by the researchers reveals that the TiC nanoparticles not only reduce the susceptibility to hot cracking but also refine and homogenize the grain structure of the alloy. The grains were significantly refined to an average size of 23.2 ± 0.4 μm. This refinement contributes to the material’s enhanced properties, including its mechanical performance.

These findings highlight the potential of nano-treatment techniques in overcoming the longstanding challenges associated with high-strength aluminum in additive manufacturing. This advancement not only paves the way for more reliable production of critical components in aerospace and automotive applications but also promises to expand the capabilities and applications of metal additive manufacturing technology.

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