Iowa State wins $2.8 million DOE grant to make ductile 6.5% Si electrical steel
October 31, 2016
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Iowa State University and its Ames Laboratory report that researchers have received a three-year, $2.8 million grant to develop a ductile electrical steel containing 6.5% silicon, twice the amount in electric motor steel today. The extra silicon increases the electrical resistivity of the material by about 50%, helping to make the motors smaller, lighter, more powerful, and more cost effective. Associate Professor of Materials Science and Engineering Jun Cui says he thinks these motors could run at much higher frequencies – jumping from today's 60 hertz all the way to 400 hertz — but the alloy is currently too brittle and too expensive to make.
Therefore, the U.S. Department of Energy is supporting the work with a three-year, $3.8 million grant from the DOE's Vehicle Technologies Program. Of that, $2.8 million will support research at Iowa State. The project also includes research partners from the United Technologies Research Center in East Hartford, Connecticut; and the University of Delaware in Newark.
The Iowa State-Ames Laboratory researchers will study and characterize different processes for making the new electrical steel to increase ductility and reduce manufacturing costs. Prof. Cui says that the researchers are also committed to developing materials and motors that do not depend on magnets made with rare-earth materials, which are rising in cost.
"The fundamental drive for this project is that we want more cost-effective and efficient electric motors," Prof. Cui says. "In about ten years, if we're lucky, we should see a real impact of this work. We should see these motors on the road." (Image courtesy Nucor)
http://www.news.iastate.edu/news/2016/09/27/electricalsteel
Iowa State University and its Ames Laboratory report that researchers have received a three-year, $2.8 million grant to develop a ductile electrical steel containing 6.5% silicon, twice the amount in electric motor steel today.
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Thermo-Calc and QuesTek partner for advanced modeling and materials design
October 28, 2016
Source: ASM International
Thermo-Calc Software AB, Stockholm, and QuesTek International LLC, Evanston, Ill., have partnered to establish a joint company, QuesTek Europe AB, which will offer Integrated Computational Materials Engineering modeling services and novel materials design and development to the European market.
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Harper teams with Oak Ridge to improve carbon fiber production
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Harper International, Buffalo, N.Y., announces that in partnership with Oak Ridge National Laboratory, it has been awarded funding for a project through the U.S. Department of Energy Advanced Manufacturing Office's HPC4Mfg Program. The program was designed to spur the use of high-performance supercomputers to advance U.S. manufacturing via public-private partnerships.
Specifically, the Harper International/ORNL project, titled "Development and Validation of Simulation Capability for the High Capacity Production of Carbon Fiber," will focus on analysis of critical processing factors, such as temperature, gas flow, and chemical reaction, in carbon fiber production equipment. The purpose is to ensure that designs provide the necessary uniformity to produce fiber of a certain quality, output, and cost ideal for automotive applications. Results will then be validated at the pilot scale equipment designed and installed by Harper at ORNL's Carbon Fiber Technology Facility, followed by testing in a commercial production facility.
"This project allows Harper to continue its work as a champion of innovative carbon fiber processing technologies to meet the needs of future markets, such as mass automotive applications, now with access to world-class supercomputers and deeper scientific expertise," commented Dr. Prasad Apte, Director of Technology at Harper International. "We are proud to be collaborating with the pioneering thought leaders at ORNL in continuation of our strong relationship."
www.harperintl.com
Harper International, Buffalo, N.Y., announces that in partnership with Oak Ridge National Laboratory, it has been awarded funding for a project through the U.S. Department of Energy Advanced Manufacturing Office’s HPC4Mfg Program.
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Constellium invests $200 million in aluminum sheet finishing line in France
October 19, 2016
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Constellium N.V., Amsterdam, has invested $200 million in a new state-of-the-art finishing line at its plant in Neuf-Brisach, France, to meet growing demand for aluminum automotive body sheet. With a production capacity of 100,000 tons, the new 240-meter long finishing line features high-speed thermal treatment, precise temperature control, a highly efficient quenching process, and greater flexibility on the thickness of processed alloys.
This diverse range of innovative technologies will enable Constellium to manufacture high-quality aluminum products for automotive closure inners, outers, and body-in-white. The new finishing line is in the final stage of the qualification phase, and has already started commercial production.
"On the heels of the launch of our new manufacturing plant with our joint venture partner UACJ Corporation in Bowling Green, Kentucky, opening of the new finishing line in Neuf-Brisach is another critical step in the execution of our worldwide automotive growth strategy," said Jean-Marc Germain, Chief Executive Officer of Constellium.
According to Arnaud Jouron, President of Constellium's Packaging and Automotive Rolled Products business unit, "With top-notch technologies, a long-standing automotive expertise among our staff on both sides of the ocean, and an additional line located in the heart of Europe, we are well positioned to capture the growth for automotive body sheet in Europe and across the globe."
Built in 1967, the Neuf-Brisach plant is an integrated aluminum rolling, finishing, and recycling facility. In Neuf-Brisach, Constellium designs and produces a wide portfolio of coil and sheet products for automotive OEMs as well as food and beverage can customers. Adding to the production capacity of aluminum automotive body sheet in Neuf-Brisach, the opening of this additional finishing line is expected to significantly boost Constellium's sheet production capacity in Europe to meet anticipated automotive market growth.
www.constellium.com
Constellium N.V., Amsterdam, has invested $200 million in a new state-of-the-art finishing line at its plant in Neuf-Brisach, France, to meet the growing demand for aluminum automotive body sheet.
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Bright annealing furnace heat treats stainless steel under inert gas
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Ajax Tocco Magnethermic, Warren, Ohio, recently shipped a bright annealing induction furnace to a major stainless steel tube manufacturer in the Northeast United States. This bright annealing system progressively heats the stainless steel tube to high temperatures in an atmosphere of inert gases, and then anneals the tube in a cooling chamber, reducing the hardness to achieve ductility for further processing. Special features include the ability to produce a high-quality product with a ready-to-ship surface finish.
The equipment supplied consists of a hydrogen atmosphere heating and cooling system, utilizing an Ajax Tocco 75 kW Pacer T IGBT induction power supply. The system is capable of processing tubing from 0.25 - 0.625 inch outside diameter.
Ajax Tocco is a leader in providing induction heating and processing solutions for bar and tube applications, including bright annealing. Its experience in providing this type of system was a key factor in the tube manufacturer's decision to choose Ajax Tocco Magnethemic as the supplier.
www.ajaxtocco.com
Ajax Tocco Magnethermic, Warren, Ohio, recently shipped a bright annealing induction furnace to a major stainless steel tube manufacturer in the Northeast United States.
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Powder metallurgy systems combine reactive metals with inert gas atomization
October 13, 2016
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Seco Warwick, Meadville, Pa., announces that its subsidiary Retech Systems LLC, Ukiah, Calif., has developed metal gas atomization systems that combine melting of reactive metals and alloys with inert gas atomization to meet a variety of powder specifications. Designed in a range of capacities, from laboratory and pilot to large-scale production, Retech's systems are tailored to achieve specific customer demands .
Products include powder metallurgy technologies that utilize gas atomization to produce powders that meet specific quality requirements. For example, vacuum induction melting (VIM) and casting systems are designed to easily handle a wide range of materials for automotive and consumer products, as well as critical, high-value equiax, directionally solidified, or single-crystal aerospace parts.
Cold wall induction (CWI) melting systems enable casting of titanium parts for demanding applications. Vacuum arc remelt (VAR) and consumable casting (skull melting) systems are designed for the manufacture of aerospace, consumer, and commercial products. Plasma arc melting (PAM) and electron beam (EB) melting systems are engineered for production of ingots and electrodes.
www.secowarwick.com
Seco Warwick, Meadville, Pa., announces that its subsidiary Retech Systems LLC, Ukiah, Calif., has developed metal gas atomization systems that combine melting of reactive metals and alloys with inert gas atomization to meet a variety of powder specifications.
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Voestalpine expands capabilities to additive manufacturing of steel
October 5, 2016
Source: ASM International
The Voestalpine Group, Dusseldorf, announces that it is expanding from traditional steel manufacturing to 3D printing with the opening of an additive manufacturing research and development facility.
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Constellium to supply aluminum for the Peugeot 3008 compact SUV
September 28, 2016
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Constellium N.V., Amsterdam, announces that it will supply aluminum crash management systems and automotive body sheet for the new Peugeot 3008 compact SUV, which will be presented to the public at the 2016 Paris Motor Show. The front crash management system includes a lower beam for enhanced pedestrian safety. Constellium will also provide aluminum coils and sheet for the inner and outer hood panels, as well as for the fenders.
Aluminum is the ideal material for crash management, as it provides superior energy absorption. This crash behavior also minimizes damage to the vehicle, which helps reduce repair costs. The bumper beam and crash boxes are extruded components, allowing Constellium to design a product that is not only lightweight, but also engineered to customer specifications in terms of size, shape, package space, and strength.
For the hood outer panel and fenders, Constellium provides material with high surface quality and specific hemming and roping properties, allowing designs with sharp lines. For the hood inner, the good formability and mechanical resistance of its alloys enable efficient processing of complex shapes.
"PSA Group has been a long-standing customer of Constellium. Our commitment to innovation enables us to develop new alloys and solutions from the new model design phase to the start of production," said Dieter Höll, Sales and Marketing Director, Constellium's Packaging and Automotive Rolled Products Business unit.
www.constellium.com
Constellium N.V., Amsterdam, announces that it will supply aluminum crash management systems and automotive body sheet for the new Peugeot 3008 compact SUV, which will be presented to the public at the 2016 Paris Motor Show.
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Ipsen ships heat treating systems for aerospace, tooling, other industries
September 27, 2016
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Ipsen, Cherry Valley, Ill., recently shipped ten heat-treating systems to process parts for the aerospace, commercial heat treating, defense, metal injection molding and tooling industries. Among the shipments were a six-bar Global Vertical vacuum furnace and a vacuum aluminum brazing furnace with a 35-inch diffusion pump.
Also shipped were four Titan H2 furnaces – two of which were shipped with Ipsen's PdMetrics software platform for predictive maintenance. This exclusive platform helps optimize equipment performance and production efficiency. Ipsen also shipped horizontal MetalMaster and TurboTreater heat-treating systems, Titan DS (debinding and sintering) vacuum furnaces, and a custom furnace upgrade that will be used in the aerospace industry. This upgrade will help enhance furnace performance and ensure continued high-quality results.
To best support such diverse industries and needs around the world, Ipsen's Global Support Team facilitates system 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 ten heat-treating systems to process parts for the aerospace, commercial heat treating, defense, metal injection molding and tooling industries.
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Nucor to build $230 million cold mill complex at its Arkansas sheet mill
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Nucor Corp., Charlotte, N.C., announces that its Nucor Steel Arkansas division is building an additional cold mill that will expand its ability to produce advanced high-strength, high-strength low-alloy, and motor lamination steel products. The mill will cost an estimated $230 million to build, and is expected to be operational in approximately two years.
"This specialty cold mill complex supports our strategy of moving up the value chain and growing sales to the automotive market," says John Ferriola, Chairman, Chief Executive Officer, and President of Nucor. "It will bring value to all of Nucor's sheet mills by expanding our capability to produce advanced high-strength steels and broadening the automotive capability of our galvanized lines at Nucor Steel Decatur and Nucor Steel Berkeley."
Ducker Worldwide estimates that four million tons of advanced high-strength and ultra-advanced high-strength steels will be used for the automotive market by 2025. The specialty cold mill complex will give Nucor the capability to produce products the company currently does not make, adding to Nucor's comprehensive product portfolio and further differentiating Nucor from its competitors. Locating the cold mill at Nucor's sheet mill in Arkansas will give the company a transportation advantage over competitors outside the region currently supplying the local market and the growing Mexican market.
Nucor Steel Arkansas employs 650 teammates. The addition of the specialty cold mill complex is expected to add approximately 100 jobs at an estimated average annual salary of $80,000.
www.nucor.com
Nucor Corp., Charlotte, N.C., announces that its Nucor Steel Arkansas division is building an additional cold mill that will expand its ability to produce advanced high-strength, high-strength low-alloy, and motor lamination steel products.
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