Natural-gas conveyor oven system designed to heat treat auto engine components
June 17, 2014
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Davron Technologies Inc., Chattanooga, Tenn., has designed and manufactured the DTI-1140, a natural gas-heated indexing conveyor oven system that heat treats engine components for a Tier 1 automotive supplier. The system includes an indexing conveyor oven, a quench tank, and a rinse tank. It also includes an automated pick-and-place system, which had to be precisely calibrated to streamline the heat treating process and meet demanding production requirements.
The heated chamber in the system includes four index positions that process 840 parts (530 pounds) in an eight-hour cycle. In the first zone, product ramps to temperature, and then soaks in the next three positions. For the heat-treat process to be successful, the product must never dip below the temperature reached in the first zone. Upon exiting the heated chamber, the product must be submersed in the quench tank within seconds. The DTI-1140's sophisticated heating and air distribution system, along with its pick-and-place system, ensure that both of these critical requirements are met.
The system features two zones of temperature control in the heated chamber. Each zone is individually controlled to enable flexibility in the temperature profile, and utilizes its own natural gas burner and circulation fan. It also includes one exhaust fan to meet NFPA standards for gas-fired equipment. The maximum operating temperature is 1000°F. The indexing conveyor oven features PLC control, and all motion functions are controlled by servo for accuracy and speed. Both the quench and rinse tanks include electric heaters to ensure that the solutions are the required temperatures prior to the start of production. The quench tank also features a chiller to cool the solution after each cycle.
The furnace is 4 feet wide by 2 1/2 feet high and 29 2/3 feet long. The interior of the oven is made of 16-gauge aluminized steel, backed by 10 inches of eight-pound density mineral wool insulation. The exterior is constructed of 16-gauge carbon steel backed by a structural steel frame and finished with high-temperature paint. The oven features four access doors for explosion relief and access to the heated chamber. Pneumatically operated vertical doors cover both the entrance and exit of the oven chamber.
www.davrontech.com
Davron Technologies Inc., Chattanooga, Tenn., has designed and manufactured the DTI-1140, a natural gas-heated indexing conveyor oven system that heat treats engine components for a Tier 1 automotive supplier.
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Temperature-sensing friction stir welding tool enables complex joints
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Researchers at University West in Trollhättan, Sweden, have invented a friction-stir-welding tool that also functions as a temperature sensor. The temperature is measured continuously and, if it becomes too hot, the heat is reduced by controlling the force and tool rotation. With the aid of an industrial robot and the temperature sensor, the researchers have been able to weld advanced three-dimensional joints. This enables the welding of small and more complex components with curved surfaces.
The robot welds with higher precision, and with the temperature controller, it takes only a few hours to program 3D joints. Manual programming of a similar component took up to a week.
The research project at University West was initiated through a collaboration between Volvo Aero, SAAB Automobile, and the welding equipment company ESAB.
In FSW, a rotating non-consumable cylinder is pressed into the material. The combination of frictional heat and the mechanical "stirring" creates a high-quality welding joint, without melting the material. However, one of the problems with this method has been that if the temperature becomes excessively high, the metals can reach the melting point and the welding tool can sink through the sheets. To achieve good welds with a FSW robot, both the process forces and the temperature must be properly controlled.
http://www.hv.se/en/research
Researchers at University West in Trollhättan, Sweden, have invented a friction-stir-welding tool that also functions as a temperature sensor.
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Ford’s Lightweight Concept vehicle includes aluminum, high-strength steel, magnesium
June 10, 2014
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Ford Motor Company, Dearborn, Mich., has developed a Lightweight Concept vehicle in which advanced materials are applied to explore weight-reduction solutions that could improve performance and fuel efficiency while reducing carbon dioxide emissions. This Lightweight Concept vehicle represents a comprehensive blend of advanced materials, including strategic application of aluminum, ultra-high-strength steels, magnesium, and carbon fiber.
Ford engineers took a holistic approach to weight reduction by incorporating advanced materials into the entire design of the vehicle, including powertrain, chassis, body, battery and interior features such as seats. The research vehicle was developed with the U.S. Department of Energy's Vehicle Technologies Program, together with Cosma International – a subsidiary of Magna International – to illustrate long-term potential light-weighting solutions. Magna's design and development of the multi-material body-in-white, closures, and chassis components are a significant contribution in light-weighting the concept vehicle.
"Our goal was to investigate how to design and build a mixed-materials, lightweight vehicle that could potentially be produced in high volume, while providing the same level of safety, durability and toughness as our vehicles on the road today," said Matt Zaluzec, Ford technical leader, Global Materials and Manufacturing Research. "There's not a one-size-fits-all approach to light-weighting. The Lightweight Concept gives us the platform to continue to explore the right mix of materials and applications for future vehicles."
www.ford.com
Ford Motor Co., Dearborn, Mich., has developed a Lightweight Concept vehicle in which advanced materials are applied to explore weight-reduction solutions that could improve performance and fuel efficiency while reducing carbon dioxide emissions.
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Wayne State develops technology for high-strength bainitic steels and austempered ductile irons
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Wayne State University, Detroit, has finalized a license agreement with a new start-up company, Detroit Materials Inc., for a Wayne State-patented portfolio of high-strength low-alloy steels and cast irons for demanding applications. The portfolio includes bainitic steels and austempered ductile irons exhibiting a combination of excellent mechanical properties currently available only in costly exotic steels.
A team of researchers led by Susil Putatunda, Ph.D., professor of chemical engineering in Wayne State University's College of Engineering, have been working to create advanced materials with high yield strength, fracture toughness, and ductility. Dr. Putatunda's research was initially funded by a grant from the National Science Foundation (award number 0854962), and more recently received funding from the New Economy Initiative's (NEI) Technology Development Incubator Program. This program is aimed at accelerating feasibility studies necessary for licensing, industry partnerships, and start-up opportunities.
The company was founded by Pedro Guillen in his role as entrepreneur-in-residence for the Detroit Technology Exchange, with direct financial and administrative support from Detroit Innovate, a new venture fund based in southeast Michigan.
Mr. Guillen, Chief Executive Officer of Detroit Materials, specializes in corporate innovation strategy and new technology commercialization. He has over 15 years of product development and innovation experience in automotive, defense, off-highway, and clean energy markets. He has led engineering teams developing proof-of-concept technologies and demonstrator vehicles for the Department of Defense, and founded two successful start-ups.
www.wayne.edu
Wayne State University, Detroit, has finalized a license agreement with a new start-up company, Detroit Materials Inc., for a Wayne State-patented portfolio of high-strength low-alloy steels and cast irons for demanding applications.
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Ipsen ships 15 vacuum furnaces for aerospace, automotive, and energy industries
May 28, 2014
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Ipsen, Cherry Valley, Ill., recently shipped more than 15 vacuum furnaces to customers around the world for a diverse range of applications and industries. Of these recent shipments, several were sent to international customers in Singapore, Japan, China, Hungary, Vietnam and Russia; the remaining furnaces were delivered to sites within the United States. These vacuum furnaces were for the aerospace, automotive, energy, commercial heat treating, and surface engineering industries, to name a few.
This continues Ipsen's long-standing tradition of supporting global growth by engineering thermal processing systems that sustain complex recipes and produce components from simple tools to giant wind turbine gears. The equipment models shipped out included horizontal MetalMaster furnaces, Titan furnaces, horizontal and vertical TurboTreater furnaces, and Titan DS furnaces.
Ipsen delivers custom-built solutions that allow customers to tailor features to their exact specifications. These features include: horizontal or vertical configurations, manual or automatic loading systems, custom load size/configurations, high pressure gas quenching and/or control systems to support any applicable industry requirements. Customers can also take advantage of Ipsen's Global Support Team; they facilitate on-site installation, expert training and start-up assistance from the moment of delivery through the entire life span of your equipment.
In addition, Ipsen also offers customers the opportunity to either send employees to an Ipsen U training or schedule one at their facility, during which they can ask questions about specific equipment and processes, as well as receive hands-on instruction.
www.IpsenUSA.com/map.
Ipsen, Cherry Valley, Ill., has recently shipped more than 15 vacuum furnaces to customers around the world for a diverse range of applications and industries.
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Ford heat treatment nearly doubles strength of aluminum parts in Ford F-150
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Ford Motor Co., Dearborn, Mich., says that the aluminum door panels and box panels in its new Ford F-150 pickup truck are more resistant to dents than the previous steel panels. The reason is said to be the high-strength 6000-series aluminum alloys in the panels, which are heat treated using proprietary technology "that nearly doubles the strength." Starting with the signature fully boxed frame, Ford engineers increased the use of high-strength 70,000-psi steel from 23% to 77% of the frame. This improves stiffness and durability while reducing weight. The new frame is up to 60 pounds lighter than the previous frame.
Thanks to its high-strength military-grade aluminum-alloy body, coupled with the high-strength steel frame, the all-new F-150 is nearly 700 pounds lighter, resulting in increased towing and hauling capability and better efficiency.
"Our objective was to find materials that allowed us to design the truck to be as tough – or tougher – than the current model, yet could help it be hundreds of pounds lighter for better capability and fuel economy," said Pete Friedman, manager, Ford manufacturing research. "Out of all the materials we tested, we carefully selected only certain grades of aluminum that met our high performance standards in all of our tests, while allowing us to trim hundreds of pounds from the truck."
Ford engineers have also filed patent applications for spot welding methods, adhesives, and hydroforming.
www.media.ford.com.
Ford Motor Co., Dearborn, Mich., says that the aluminum door panels and box panels in its new Ford F-150 pickup truck are more resistant to dents than the previous steel panels.
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Advanced High-Strength Steels Application Guidelines Version 5.0 published by World Auto Steel
May 19, 2014
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WorldAutoSteel, Brussels, Belgium, has launched the Advanced High-Strength Steels Application Guidelines (AHSS Guidelines) Version 5.0, the largest and most comprehensive update since its first publication in 2004. Previous versions covered metallurgy, forming, and joining. Version 5.0 includes new content highlighting the broader materials portfolio, advanced fabrication technologies, and optimized joining processes.
The AHSS Guidelines are available free of charge at worldautosteel.org to aid automakers and manufacturers in applying the latest in lightweighting with steel.
"These guidelines are the leading AHSS information resource for engineers and press shop personnel," said Ronald Krupitzer, vice president, automotive market for the Steel Market Development Institute, a business unit of the American Iron and Steel Institute. "It represents the steel industry's strong commitment not only to produce new generation steels, but to assist automakers in actively applying them."
Applications of the latest steels will proliferate during the next 10 years as auto manufacturers seek to achieve improved safety and fuel economy requirements for their customers. Current vehicles have not nearly exhausted the breadth of AHSS grades available that can achieve lightweighting targets at less cost and five to 20 times less production emissions than alternative materials.
This rapid increase in demand requires users of AHSS to quickly learn the basics about AHSS and acquire specific application knowledge. AHSS Guidelines Version 5.0 gathers that knowledge and experience in two volumes. Volume I includes metallurgy, forming and joining. Volume II includes over 200 pages of case studies, which demonstrate actual manufacturing practices.
www.worldautosteel.org
WorldAutoSteel, Brussels, Belgium, has launched the Advanced High-Strength Steels Application Guidelines (AHSS Guidelines) Version 5.0, the largest and most comprehensive update since its first publication in 2004.
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Constellium and UACJ form joint venture for aluminum automotive sheet
May 13, 2014
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Constellium N.V., Paris, and UACJ Corp., Japan, have signed a Joint Venture Agreement to supply Body-in-White aluminum sheet to the North American automotive industry, following their January 2014 announcement of plans to collaborate.
The JV will have an initial target capacity of 100,000 metric tons supplied by cold rolled coils from both partners' rolling mills. The facility, which will be located in Bowling Green, Kentucky, will be designed to allow for expansion beyond 100,000 tons. The total joint investment is expected to be approximately $150 million. Production is scheduled to start in the first half of 2016, with full capacity reached by 2018.
"Bowling Green is the right place for this plant, particularly because its central location will allow us to serve automotive OEMs across the United States with our advanced and innovative range of products," commented Laurent Musy, President of Constellium's Packaging and Automotive Rolled Products business unit. "The availability of a highly skilled local labor force and the entrepreneurial spirit of the area were the decisive factors in choosing the city of Bowling Green and the state of Kentucky, which has been very supportive during the decision process".
"This project is very significant for UACJ in terms of our Body-in-White market strategy. We look forward to supplying automotive OEMs throughout the Unted States with advanced products utilizing the technologies each party has separately developed in the EU and Japan. We welcome this Joint Venture with Constellium to tackle the strategic automotive market in the U.S.," said Mitsuru Okada, CEO of UACJ. "Both companies have been working hard together in the spirit of equal partnership, allowing us to finalize the agreement in a timely and efficient manner."
www.constellium.com
Constellium N.V., Paris, and UACJ Corp., Japan, have signed a Joint Venture Agreement to supply Body-in-White aluminum sheet to the North American automotive industry, following their January 2014 announcement of plans to collaborate.
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AK Steel engineer and ASM member Grant Thomas wins award for steel-quenching research paper
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AK Steel, West Chester, Ohio, announces that Research Engineer and ASM International member Grant Thomas, Ph.D., has received the AISI "Finalist Medal" for the technical paper titled, "Tensile Properties Obtained by Quench & Partition Processing of Mn-Ni Steels at Room Temperature Quench Temperatures." These products, which feature enhanced formability, are expected to help automakers further reduce vehicle weight and increase fuel efficiency without sacrificing occupant safety.
Written in collaboration with two research colleagues from the Colorado School of Mines, the paper highlights research by AK Steel and the Colorado School of Mines in regard to the development of third-generation advanced high-strength steels.
"We applaud Grant and his co-authors for receiving the Finalist Medal from AISI," said James L. Wainscott, Chairman, President and CEO of AK Steel. "Grant's contributions to the award-winning paper reflect his technical expertise, as well as AK Steel's commitment to meeting the needs of automotive customers now and in the future."
According to AISI, the Finalist Medals are awarded for technical papers having special merit and importance in connection with the activities and interests of the iron and steel industry. Papers are judged based on their potential value to the future prosperity of the industry, technical excellence and originality, effective communication and breadth of interest to AISI members.
Dr. Thomas joined AK Steel in 2012 as an Engineer at the company's Research Center in Middletown, Ohio. He was promoted to Research Engineer in 2014. Dr. Thomas holds a Bachelor's degree in Materials Science and Engineering from Iowa State University, as well as a Master's degree and a Doctor of Philosophy, both in Metallurgy and Materials Engineering, from the Colorado School of Mines.
www.aksteel.com
AK Steel, West Chester, Ohio, announces that Research Engineer and ASM International member Grant Thomas, Ph.D., has received the AISI “Finalist Medal” for the technical paper titled, “Tensile Properties Obtained by Quench & Partition Processing of Mn-Ni Steels at Room Temperature Quench Temperatures.”
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ASM Fellow Dr. Pradeep Rohatgi elected Fellow of Wisconsin Academy of Sciences
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Pradeep Rohatgi, Fellow of ASM International and Distinguished Professor of Materials Engineering at the University of Wisconsin- Milwaukee, has been elected Fellow of the Wisconsin Academy of Sciences Arts and Letters.
Prof. Rohatgi is internationally recognized as a world leader on solidification synthesis of metal matrix composites. He has made fundamental contributions on the interaction between solidifying interfaces and particles, nucleation and growth, and micro-segregation in solidifying alloys in the presence of reinforcements. He also established the mechanisms of solid lubrication by incorporating solid lubricant particles, leading to self-lubricating metal matrix composites.
He followed this basic research with synthesis of several new metal matrix composites, conducting technology and product development that resulted in widespread use of these composites in the transportation sector, electromechanical machinery, and thermal management applications.
www.wisconsinacademy.org
Pradeep Rohatgi, Fellow of ASM International and Distinguished Professor of Materials Engineering at the University of Wisconsin- Milwaukee, has been elected Fellow of the Wisconsin Academy of Sciences Arts and Letters.
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