Outokumpu now categorizes its stainless steels by properties instead of chemistry
June 4, 2015
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Outokumpu Oy, Finland, has developed a new way to categorize its wide range of stainless steel products by arranging them according to strength, hardness, machinability, heat resistance, and corrosion resistance. The new approach will help customers to identify and compare different product options and so find the best product for their specific performance and cost needs.
The new portfolio structure features nine product ranges, which highlight the key properties of their respective products. In the Classic product family, the three ranges – Core, Moda, and Supra – represent the basic, all-round grades.
The Pro product family includes six ranges: Forta for Duplex and other high-strength needs, Ultra for extremely corrosive environments, Dura for high hardness, Therma for high heat-resistance, Prodec for improved machinability, and Deco for special surfaces.
To further facilitate exploration of the portfolio, Outokumpu has introduced a new interactive on-line tool.
Outokumpu has also launched three new alloys: Supra 316plus, which has better strength, corrosion resistance, and formability than austenitic Supra 316L/4404; Core 4622, a ferritic containing no nickel; and high-strength lightweight Forta H-series, for the automotive industry.
www.outokumpu.com
Outokumpu Oy, Finland, has developed a way to categorize its wide range of stainless steel products by arranging them according to strength, hardness, machinability, heat resistance, and corrosion resistance.
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EFD Induction rotary table system hardens sun gears for auto supplier
May 27, 2015
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EFD Induction USA, Madison Heights, Mich., reports that a major U.S. tier-one automotive supplier recently ordered an EFD Induction Rotary Table (HardLine RT 550) hardening system for treating sun gears, and a vertical scanner system (HardLine VM 1000) for hardening output shafts. The Sinac power source delivers a constant power factor of 0.95 at all power levels.
HardLine is EFD Induction's family of systems for surface and through-hardening, with equipment available to handle everything from small gears with complex geometries, up to the giant slewing rings used in modern wind turbines. The vertical scanners support a range of optional subsystems, including automated loading/unloading solutions, indexing tables with unlimited position control, double tailstocks and centers for the simultaneous hardening of two workpieces, and a HF/MF chuck connection for quick changeovers between high and medium frequencies. The hardening system can also be paired with an integrated or separate tempering station.
www.efd-induction.com
EFD Induction USA, Madison Heights, Mich., reports that a major U.S. tier-one automotive supplier recently ordered an EFD Induction Rotary Table (HardLine RT 550) hardening system for treating sun gears, and a vertical scanner system (HardLine VM 1000) for hardening output shafts.
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Outokumpu stainless steel fuel tank weighs 3 kg less than plastic
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Outokumpu Oy, Finland, announces that the stainless steel fuel tank developed by its engineers and TechROi Fuel Systems has received the New Applications Award presented by the International Stainless Steel Forum in the "Best New Development" category at the ISSF Annual Conference in Hong Kong. Outokumpu HyTens steel grade allowed extremely thin walls and tailored strength, making the tank about three kilograms lighter than the conventional fuel tank made of plastic.
According to the ISSF, the winning concept provides a combination of good design, appropriate material selection, engineering expertise, and sufficient delivery reliability. The stainless steel fuel tank is superior in terms of crashworthiness and does not need surface treatment or maintenance.
Said Outokumpu CEO Mika Seitovirta: "We are very pleased with the ISSF's recognition of this innovation, which showcases the potential that stainless steel and customer focused innovation have in meeting the demands of car industry. As a versatile, long-lasting and 100% recyclable material, stainless steel offers great opportunities for a number of industries to create a more sustainable future."
The International Stainless Steel Forum (ISSF) is a non-profit research and development organization which was founded in 1996 and serves as the world forum for the international stainless steel industry.
www.outokumpu.com
Outokumpu Oy, Finland, announces that the stainless steel fuel tank developed by its engineers and TechROi Fuel Systems received the New Applications Award presented by the International Stainless Steel Forum in the “Best New Development” category at the ISSF Annual Conference in Hong Kong.
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New method for friction stir welding aluminum is ten times faster
May 20, 2015
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Researchers at Pacific Northwest National Laboratory, Richland, Wash., in partnership with General Motors, Alcoa, and the Tailor Welded Blank (TWB) Co., have developed a friction stir welding technique that is said to be ten times faster than current FSW techniques. This represents production speeds that meet high-volume assembly requirements for rapidly joining aluminum sheets of varying thicknesses. The process is also said to be capable of delivering a car door that is 62% lighter and 25% cheaper than possible with today's manufacturing methods.
The technology is reported in the May issue of JOM, the member journal of the Minerals, Metals & Materials Society. "We looked at the barriers preventing the use of more lightweight alloys in cars, picked what we felt was a top challenge, and then formulated a team that represented the entire supply chain to tackle it," said Yuri Hovanski, the program manager at PNNL and lead author. "The result is a proven process that overcomes the speed, scale, and quality limitations of FSW that previously were showstoppers for the auto industry."
The two-phase, six-year project is funded by the Department of Energy's Office of Energy Efficiency and Renewable Energy with in-kind partner contributions from each of the participating companies.
http://www.twbcompany.com
http://www.pnnl.gov/news/release.aspx?id=4200#.VVECQt-HGZY.email
Researchers at Pacific Northwest National Laboratory, Richland, Wash., in partnership with General Motors, Alcoa, and the Tailor Welded Blank (TWB) Co., have developed a friction stir welding technique that is said to be ten times faster than current FSW techniques.
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Magnesium syntactic foam metal matrix composite floats on water
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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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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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British universities form consortium to optimize steel for railroad track
April 28, 2015
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The University of Huddersfield, England, announces that its researchers will take part in a new $3 million railway steel development project backed by major funding groups. The Rail Safety and Standards Board (RSSB) and the Engineering and Physical Sciences Research Council (EPSRC) have combined to provide funds for three linked programs of research into new materials that will reduce heavy maintenance and renewal costs for rail tracks.
The university is home to the Institute of Railway Research (IRR), which has a multi-national team of experts based in specially equipped labs. It formed a consortium that was joined by three other universities, including Cambridge, Leeds and Cranfield, to bid for a share of the RSSB and EPSRC funding.
A panel of leading industrial and academic figures appraised the IRR-led consortium's proposal and then gave the go-ahead to a two-year investigation into developing a fundamental understanding of how different characteristics of steel microstructures respond to rail-wheel contact conditions. This understanding will establish the design rules for the optimum rail steel microstructure that is best at resisting degradation resulting from the contact between wheel and rail.
The Principal Investigator for the project is Dr. Adam Bevan, the IRR's Head of Enterprise. Technical leadership will also be provided by Dr. Jay Jaiswal, a Visiting Professor at the IRR and a leading metallurgist specializing in rail materials. He has held important research posts with British Steel, Corus, and Tata Steel.
Professor Jaiswal previously contributed to the development two patented high-performance steels currently produced by Tata Steel for railway tracks. He is convinced that further improvements are possible and that they are vital to the economics of the railway.
The study will also provide much needed data on the economic impact of the increased rail life to facilitate wider and more rapid deployment of more degradation-resistant steels.
www.hud.ac.uk
The University of Huddersfield, England, announces that its researchers will take part in a new $3 million railway steel development project backed by major funding groups.
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Cerium-cobalt alloy added to NdFeB magnets raises Curie temperature, cuts cost
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The U.S. Department of Energy's Ames Laboratory, Ames, Iowa, reports that ASM Fellow Karl A. Gschneidner and a team of researchers have developed a low-cost cerium-cobalt alloy that can be added to neodymium-iron-boron to improve magnetic properties in rare-earth magnets. The new alloy eliminates the need for dysprosium, one of the scarcest and most costly rare earth elements.
The result, an alloy of neodymium, iron, and boron co-doped with cerium and cobalt, is a less expensive material with properties that are competitive with traditional sintered magnets containing dysprosium. The materials are at least 20 to 40% cheaper than the dysprosium-containing magnets.
Experiments demonstrate that the cerium-containing alloy's intrinsic coercivity — the ability of a magnetic material to resist demagnetization — far exceeds that of dysprosium-containing magnets at high temperatures.
"We found that this material works better than anything out there at temperatures above 150°C," says Dr. Gschneidner. "It's an important consideration for high-temperature applications."
Previous attempts to use cerium in rare-earth magnets failed because it reduced the Curie temperature, above which an alloy loses its permanent magnet properties. The research team discovered that co-doping with cobalt allowed cerium to substitute for dysprosium without losing magnetic properties.
Finding a comparable substitute material is key to reducing manufacturing reliance on dysprosium, because current demand far outpaces mining and recycling sources.
The research was supported by the U.S. Department of Energy's ARPA-E REACT program (Advanced Research Projects Agency-Energy-Rare Earth Alternatives in Critical Technologies) which develops cost-effective alternatives to rare earths.
www.ameslab.gov
The U.S. Department of Energy’s Ames Laboratory, Ames, Iowa, reports that ASM Fellow Karl A. Gschneidner and a team of researchers have developed a low-cost cerium-cobalt alloy that can be added to neodymium-iron-boron to improve magnetic properties in rare-earth magnets.
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