Wisconsin Oven ships heavy duty walk-in ovens to Chinese auto parts maker

October 11, 2017
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Wisconsin Oven Corp., East Troy, Wis., has shipped two natural-gas direct-fired heavy-duty walk-in series ovens to a manufacturer of automotive parts in China. The industrial ovens will be used to bake out phenolic resin from automotive brake components. These ovens are a duplicate of a previous order from this customer.

The work chambers are 6 x 13 x 8.5 feet, and the maximum temperature rating is 500°F. Both batch ovens have temperature uniformity of ±9°F at 450°F, which was proven by a fifteen point test.

The oven bodies are constructed with tongue and groove panel assemblies featuring patented high-efficiency panel seams, enabling 25% better insulating efficiency. The ovens feature combination airflow, which provides both horizontal and vertical upward airflow, thus maximizing heating rates and temperature uniformity.

"We ship equipment around the world, so we created a unique split-line design that allows us to break down fully assembled equipment into sections that are easily reassembled on site," says Jim Lucas, Senior Sales Engineer. "These ovens were being shipped in sea containers, so we utilized both vertical and horizontal split lines."-

The ovens were fully factory tested and adjusted prior to shipment. All safety interlocks were checked for proper operation and the equipment was operated at the normal and maximum operating temperatures. An extensive quality assurance check list was completed to ensure the equipment met all Wisconsin Oven quality standards.

www.wisoven.com

GKN develops case hardening steel powder for 3D printing high-strength parts

October 4, 2017
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GKN plc, Auburn Hills, Mich., has introduced 20MnCr5, a new case hardening steel powder optimized for metal additive manufacturing applications. According to the company, the new  powder offers high strength and ductility as well as excellent wear resistance.

Extensive testing and development has been carried out to optimize AM process parameters for maximum density and productivity with minimum surface roughness. Supported by microstructural analysis and mechanical testing, GKN's researchers state that they have achieved a density of 99.9% in finished parts made from 20MnCr5.

While high residual stress can be a challenge, the company says that this has been successfully reduced through process parameter optimization. The case hardening process for 20MnCr5 was developed with a focus on standard requirements for surface hardness and case-depth profile.

Thanks to its increased core strength and wear resistance, GKN believes that the availability of 20MnCr5 for additive manufacturing will benefit a range of components, including gears, camshafts, universal joints, and link applications. Following completion of the first small batch of one hundred gear wheels for a leading gear box supplier, the company reports that it has received a number of inquiries regarding the material's AM capabilities, and now has several collaborative projects in development.

A primary application for 20MnCr5 will be aftermarket parts for the automotive industry. The material is highly suitable for the manufacture of spare parts on demand, and GKN will also offer hybrid production, combining AM with different manufacturing techniques to achieve optimum results. A key advantage of 20MnCr5 is its ability to be combined with all weldable materials, making it possible to offer spare parts in low volumes at reduced costs.

GKN Sinter Metals will continue working with GKN Driveline on applications for aftermarket sales, while expanding its AM capabilities with this new material.

www.gkn.com

United States Steel, Kobe Steel to invest $400 million to galvanize high strength steels

October 1, 2017
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United States Steel Corp., Pittsburgh, and Kobe Steel Ltd., Japan, announce that they will begin construction of a new continuous galvanizing line at their subsidiaries' joint venture, Pro-Tec Coating Company in Leipsic, Ohio.

The new line, an investment of approximately $400 million, will utilize a proprietary process, and will have a yearly capacity of 500,000 tons. It will be capable of coating advanced high-strength steel that will help automakers manufacture economically lightweight vehicles while maintaining exceptionally high safety standards. Construction is expected to begin in the fourth quarter of 2017, and the line is expected to commence startup in 2019.

U.S. Steel is the exclusive manufacturer of its cold-rolled Generation 3 steels, which provide superior formability and high-strength properties because of their low-alloy chemistries, which also enable robust weldability. The new galvanizing line will allow Pro-Tec to produce these Generation 3 steels with a hot-dipped zinc coating. Automakers can utilize these steels with their existing stamping and assembly methods to produce safe, strong, and cost-effective structural components for vehicle bodies.

U. S. Steel President and CEO David B. Burritt said, "This line will be the first of its kind and utilizes proprietary technology capable of producing the high-quality, cutting-edge advanced high-strength steels that will meet our automotive customers' needs and solve some of their most pressing challenges."

Pro-Tec Coating Company was the 2007 Malcolm Baldrige National Quality Award winner. It is an innovative leader in technologically advanced steel, which it supplies in coil form, primarily to the automotive market. The product helps to improve vehicle crashworthiness as well as fuel economy through weight reduction.

Pro-Tec is a 50/50 joint venture partnership of subsidiaries of United States Steel and Kobe Steel Ltd. The company is privately held.

www.proteccoating.com

www.ussteel.com

Auto parts manufacturer orders Lucifer ceramic-fiber-lined box furnace

August 30, 2017
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Lucifer Furnaces Inc., Warrington, Pa., has received an order for an electric, ceramic-fiber-lined box furnace from a leading U.S. manufacturer of stamped automotive products.  Model LI7-M18, with a chamber size of 12x18x18 inches, quickly heats to a uniform temperature of 2200°F. A hotface of two-inch-thick ceramic fiber insulation with three inches of coldface mineral wool block insulation around the entire chamber, maximizes heating efficiency with low power input. 

Ceramic Fiber insulation, with low heat storage and low thermal conductivity, combined with high thermal shock resistance, allows faster heat-up/cool-down cycles, reducing wait times between loads and resulting in higher production. 

Heavy gauge coil wound Kanthal A1 iron-chromium-aluminum wire heating elements are supported on ceramic rods, providing rapid heat-up.  Elements mounted on both side walls can be easily replaced individually, reducing cost.  A one-inch-thick hearth plate protects the floor insulation and supports up to 40 pounds per square foot of hearth area. 

Temperature is monitored by a rear-mounted Type K thermocouple, and is regulated by a Honeywell DC2500 microprocessor-based digital time proportioning temperature controller.  An insulated horizontal swing door with a tight seal comes standard with safety switch.

Ceramic fiber lined furnaces are general purpose box furnaces for batch heat treating in an air atmosphere.

www.luciferfurnaces.com

Spinning magnesium billets during extrusion enables higher ductility and lower cost

August 23, 2017
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Pacific Northwest National Laboratory (PNNL), Richland, Wash., announces that its researchers have developed a method of extruding magnesium alloys that greatly improves their energy absorption by creating novel microstructures that are not possible with traditional extrusion methods. The process involves spinning the metal as it is forced through a tool to create a certain shape. It reportedly has the potential to reduce cost by eliminating the need for rare-earth elements, while simultaneously improving structural properties.

Researchers theorized that spinning the magnesium alloy during the extrusion process would create just enough heat to soften the material so it could be easily pressed through a die to fabricate tubes, rods, and channels. Heat generated from mechanical friction provides all of the heat necessary for the process, eliminating the need for power-hungry resistance heaters.

The PNNL team designed and commissioned an industrial version of their idea and received a one-of-a-kind, custom built Shear Assisted Processing and Extrusion machine — coining the acronym for ShAPE.

The billets of bulk magnesium alloys flow through the die in a very soft state, thanks to the simultaneous linear and rotational forces of the ShAPE machine. This means only one tenth of the force is needed to push the material through a die compared to conventional extrusion.

Engineers have successfully extruded very thin-walled round tubing, up to two inches in diameter, from magnesium-aluminum-zinc alloys AZ91 and ZK60A, improving their mechanical properties in the process. For example, room temperature ductility above 25% has been independently measured, which is a large improvement compared to typical extrusions.

This significant reduction in force would enable substantially smaller production machinery, thus lowering capital expenditures and operations costs for industry adopting this patent pending process.

"In the ShAPE process, we get highly refined microstructures within the metal and, in some cases, are even able to form nanostructured features," says principal investigator and mechanical engineer Scott Whalen. "The higher the rotations per minute, the smaller the grains become, which makes the tubing stronger and more ductile. Additionally, we can control the orientation of the crystalline structures in the metal to improve the energy absorption of magnesium so it's equal to that of aluminum."

www.pnnl.gov

https://www.youtube.com/watch?v=rsjkZZv-irg

Constellium high-strength machinable aluminum alloys for autos resist corrosion

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Constellium N.V., New York, introduces HSA6, a new generation of high-strength 6000-series alloys for extrusion-based automobile crash management systems, body-in-white structural components, and battery enclosures.

The alloy enables designers to optimize extrusion shapes and reduce wall thickness to achieve weight savings of 15 to 30% over conventional aluminum alloys. With UTS higher than 400 MPa, HSA6 also provides enhanced recyclability, machinability, and corrosion resistance.

Alternately, it can provide 15 to 30% additional strength to reduce intrusion in the event of a crash, thereby enhancing protection of batteries, cooling systems, and other critical vehicle systems. Aluminum is the ideal material for absorbing energy in a collision to protect occupants, pedestrians, and vehicle integrity.

"With Constellium HSA6, we are able to offer automakers a family of the highest strength 6000-series aluminum alloys available on the market for extruded automotive components," says Martin Jarrett, Operational Excellence and Technology Director for Constellium's Automotive Structures and Industry business unit.

According to a new study by Ducker Worldwide, aluminum extrusions are expected to increase 65% for crash management systems and 100% for body-in-white components between 2015 and 2020, with continued growth through 2028. The alloy is in production for several 2017 and 2018 model year vehicles, including the Mini Countryman.

Constellium HSA6 was recognized by the Altair Enlighten Awards for innovation in vehicle lightweighting, receiving the award for Runner Up in the Enabling Technology category.

"It is an honor for Constellium to be celebrated as a leader in technology that helps reduce vehicle weight," said Paul Warton, President of Constellium's Automotive Structures and Industry business unit.

In addition to its existing extrusion plants in Europe, Constellium has created a new joint venture, Astrex, in Ontario, Canada, to produce its proprietary alloy for components supplied from Constellium's Automotive Structures plants in North America

www.constellium.com

Can-Eng mesh-belt furnace system enables both neutral hardening and carburizing

August 16, 2017
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Can-Eng Furnaces International, Niagara Falls, Ontario, has received an order for a mesh belt furnace system for heat treating automotive thrust races, retainer/cages, and washers. The new, CQI-9 compliant production line features built-in flexibility that allows for both neutral hardening and carburizing.

Included with the system are an atmosphere-controlled hardening furnace, salt quench, two-stage post-quench washing system, salt reclamation unit, temper furnace salt holding tank, and Can-Eng's Level 2 SCADA-PET system.  The electrically heated system utilizes unique loading combinations on its belt to meet production requirements while achieving the customer's required low residence times for the system's hardener and quench.

Additionally, through the integration of the PET System, the automotive supplier gains access to vital tracking of product status, detailed process data for continuous process improvements, comprehensive equipment diagnostics, cost analysis, and inventory management.

The continuous mesh belt heat treatment systems were chosen for this project not only for their proven track record, but also for the custom engineering and flexibility for meeting the customer's needs. The systems are capable of treating three separate part types, multiple heat treating processes, unique temperature operating ranges, and diverse residence times for each piece of equipment.

Seco Warwick controlled atmosphere brazing system treats variety of aluminum alloys

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Seco Warwick, Meadville, Pa., announces that one of its controlled atmosphere aluminum brazing (CAB) systems has been installed by Mainstream Engineering for brazing a wide assortment of very large cold plates and heat exchangers made of a variety of aluminum alloys. This system will process advanced heat exchangers and cold plates for military, government, and commercial applications.

On a selective basis, Mainstream will also be offering tours of their CAB facility to those with an active interest in aluminum brazing. According to Dr. Josh Sole, Mainstream's Technology Leader for Thermal Control, ʺWe're pleased to expand our research and production capabilities with the addition of a new system that enables us to process a wide variety of products quickly and efficiently." 

Seco Warwick Managing Director Jonathan Markley remarked, "Seco Warwick is committed to delivering brazing technology that provides our customers with the flexibility they need to meet the ongoing challenge of adapting to new alloys and customer requirements."

Based in Rockledge, Fla., Mainstream Engineering is a solution-oriented business specializing in manufacturing, and research and development. They have been manufacturing equipment and doing R&D for most U.S. government agencies as well as many government prime contractors for over 30 years. The company is new to the CAB industry and just purchased the first CAB furnace to produce heat exchangers and electronic cold plates that will integrate with high-heat-flux active thermal control systems. Bringing the CAB system in-house improves quality by providing process control of all variables, ensures confidentiality with sensitive military solutions, and lowers costs and lead times.

Seco Warwick's Universal Batch CAB line is a standard CAB product offering. This line offers versatility through its ability to braze products in both horizontal and vertical orientations. It provides tight temperature uniformity, atmosphere integrity, and can be used as a batch R&D line for periodic production or as a production line working 24/7. It also has faster heat-up rate abilities, which will allow braze temperatures for trials to be prepared within hours instead of full shifts.

www.secowarwick.com

Can-Eng Furnaces awarded contract for austenitizing and molten salt quenching system

August 1, 2017
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Can-Eng Furnaces International Ltd., Niagara Falls, Ontario, has been awarded a contract to design and build a 1500 lb/hr mesh belt furnace system for the austenitizing and molten salt quenching of unique components for drivetrain systems.  This contract was awarded by a repeat Mexico-based client who has purchased several Can-Eng multi-facility heat treatment lines.

The system incorporates several technological advancements for continuous atmosphere processing of products requiring carbon diffusion and quenching by a molten salt system. The new austempering system includes automated bin-dumping loading, mesh belt atmosphere hardening furnace, salt quench, post quench wash and rinse system, mesh belt temper oven, and endothermic gas generator.

This new project is a result of Can-Eng's commitment to its customer's success, years of teamwork, and mutual cooperation, yielding a custom engineering project integrating the customer's focused needs with Can-Eng's robust Continuous Mesh Belt Heat Treatment System technology.

The project is scheduled to be commissioned early 2018 in Mexico's centralized automotive manufacturing corridor.  Can-Eng's mesh belt heat treatment design team continues to focus globally on the design and development of mesh belt heat treatment technology, servicing the increasingly stringent and demanding global automotive industry. These systems continue to lead the industry in up-time reliability, energy efficiency, and soft handling features.

www.can-eng.com