Alcoa awarded U.S. Army contract to reduce weight of combat vehicles
March 9, 2016
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Alcoa, Pittsburgh, announces that it has been awarded a five-year contract from the U.S. Army worth up to $50 million for R&D projects focused on developing innovative lightweighting solutions for ground combat vehicles such as tanks.
The U.S. Army Tank Automotive Research, Development, and Engineering Center (TARDEC) awarded Alcoa Defense a "Ground Vehicle Light-Weighting" contract to support efforts to accelerate technology research and development, and to provide engineering solutions for Department of Defense ground vehicles and intelligent ground systems.
"This agreement with TARDEC builds on Alcoa Defense's decades-long partnership with the U.S. Army to advance military ground vehicles," said Eric Roegner, President of Alcoa Defense. "Alcoa's lightweight solutions have improved troop protection while reducing vehicle weight and assembly time. We look forward to building on our successful track record to help develop the next generation combat vehicle."
Alcoa's first "work directive," or project funded under the contract, is an initiative to advance Alcoa-developed aluminum weld wire alloys. These alloys have already been proven to increase the strength of welded joints—typically the weakest point on a vehicle—as well as reduce corrosion of those welded joints on combat vehicles. Under potential future work directives, Alcoa will provide material research, development, engineering, testing, and evaluation efforts related to ground vehicle lightweighting. These research and development efforts will address aluminum forming technology, fastening and joining, modeling and simulation, armor development, material development, material fabrication, energy conservation, and coating and corrosion technology.
Alcoa has built a strong track record of partnering with the U.S. Army to develop solutions that advance the performance of ground combat vehicles. In 2013, Alcoa announced a joint Alcoa-U.S. Army Research Laboratory (ARL) initiative to manufacture the world's biggest single-piece forged aluminum hull for combat vehicles—the largest closed die forging ever made. This game-changing forging replaces the lower hull of a combat vehicle, significantly improving survivability over traditional welded hulls. In Army testing, the monohull has performed exceptionally well in mitigating the effects of blast events, such as those caused by improvised explosive devices.
www.alcoa.com/defense.
Alcoa, Pittsburgh, announces that it has been awarded a five-year contract from the U.S. Army worth up to $50 million for R&D projects focused on developing innovative lightweighting solutions for ground combat vehicles such as tanks.
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ALD Vacuum Technologies acquires ALD-Holcroft joint venture from AFC Holcroft
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AMG Advanced Metallurgical Group N.V., Amsterdam, announces that its subsidiary ALD Vacuum Technologies has acquired the remaining 50% share of its joint venture company ALD-Holcroft from AFC-Holcroft. Formed in 2005, the ALD-Holcroft joint venture acts as the exclusive sales agent for ALD's heat treatment product lines in the NAFTA region. The acquisition will enable AMG to streamline its heat treatment and metallurgy furnace marketing operations in the United States, Canada, and Mexico.
AMG produces highly engineered specialty metals and mineral products, and provides related vacuum furnace systems and services to the transportation, infrastructure, and energy idnustry, as well as specialty metals and chemicals markets.
AMG Critical Materials produces aluminum master alloys and powders, titanium alloys and coatings, ferrovanadium, natural graphite, chromium metal, antimony, tantalum, niobium, and silicon metal. AMG Engineering designs and produces vacuum furnace equipment and systems used to produce and upgrade specialty metals and alloys for the transportation, automotive, infrastructure, and energy markets.
With approximately 3000 employees, AMG operates globally with production facilities in Germany, the United Kingdom, France, Czech Republic, United States, China, Mexico, Brazil and Sri Lanka, and has sales and customer service offices in Russia and Japan (www.amg-nv.com).
www.amg-nv.com
AMG Advanced Metallurgical Group N.V., Amsterdam, announces that its subsidiary ALD Vacuum Technologies has acquired the remaining 50% share of its joint venture company ALD-Holcroft from AFC-Holcroft.
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Northrop Grumman selected to build B-21 stealth bomber
March 8, 2016
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Northrop Grumman, Falls Church, Va., has released this artist's rendering of its B-21 stealth bomber, selected last year by the United States Air Force as the Long Range Strike Bomber of the 21st century. It is expected to fly at high subsonic speeds and to be powered by four turbofan engines. The program recently entered the Engineering and Manufacturing Development phase, and the Air Force plans to field the initial capability of the aircraft in mid-2020s.
Northrop Grumman built the flying wing B-2 Spirit bomber fleet (which consists of only 21 aircraft) 25 years ago, and has maintained and upgraded the aircraft ever since. The company also recently built the X-47B flying-wing naval unmanned combat aircraft demonstrators.
The Long Range Strike Bomber (LRS-B) is intended to be a heavy-payload stealth aircraft capable of carrying thermonuclear weapons, with the first aircraft planned for the mid-2020s. The Air Force plans to purchase 80 to 100 aircraft at a cost of $550 million each.
At the 2016 Air Warfare Symposium last month in Orlando, the LRS-B was formally designated as the B-21, the 21st century's first bomber. It is a fifth-generation global precision attack platform that will give the United States networked sensor-shoot capability for faster response and greater accuracy than ever possible before. The head of the U.S. Air Force Global Strike Command expects that 100 B-21 bombers would be the minimum ordered, and he envisions some 175 to 200 bombers in service. Initial operating capability is expected to be reached in the mid-2020s.
The U.S. Air Force current bomber fleet of B-1Bs, B-52s, and B-2s average 34 years old, and the new B-21 is expected to replace all but the Northrop B-2A through the mid-2030s. It will supplement the B-2 fleet and could allow the Air Force to retire its fleet of B-52s. These bombers first flew in 1952, and the B-52 is on track to become the first aircraft to operate for more than 100 years. The Air Force goal is 175 to 200 bombers, of which at least 100 will be the B-21 plus the 21 B-2 aircraft.
www.northropgrumman.com
Northrop Grumman, Falls Church, Va., has released this artist’s rendering of its B-21 stealth bomber, selected last year by the United States Air Force as the Long Range Strike Bomber of the 21st century.
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One Minute Mentor: Hardness Gradients in Nitrided High-Speed Tool Steel
March 4, 2016
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The graph shows the effect of bath conditions and immersion time on hardness gradients in Type T1 high-speed tool steel.
It compares the hardness gradients obtained on specimens of T1 high-speed steel nitrided at 565°C (1050°C) for 90 minutes in a new bath and for various lengths of time in an aged bath. Nitriding of decarburized high-speed steel tools should be avoided because it results in a brittle surface condition. For those surfaces that have been softened from grinding, nitriding is frequently employed as an offsetting corrective measure.
Volume 4D, Heat Treating of Irons and Steels ⇒ Tool Steels ⇒ Heat Treating of High-Speed Tool Steels ⇒ Recommended Heat-Treating Procedures
The graph shows the effect of bath conditions and immersion time on hardness gradients in Type T1 high-speed tool steel.
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NIST ultrasound method detects cracks in capacitors
March 3, 2016
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The National Institute of Standards and Technology, Gaithersburg, Md., and collaborators have demonstrated a nondestructive acoustic method for detecting cracks in ceramic capacitors before they go bad. The method relies on acoustic measurements at frequencies much higher than humans can hear. Researchers briefly apply an electric field across the electrodes of a capacitor, causing a vibration at a specific frequency. They then measure the decay over time (called ringdown) of the signal. These data are analyzed to determine slight shifts in frequency versus the magnitude of the vibration. These shifts are greater when cracks are present. This nonlinear approach — focusing on frequency shifts relative to signal strength, rather than the frequency shifts alone — is especially useful because it is not affected by slight variations in size of the capacitors.
NIST researchers invented the technique, and the study of crack detection levels was carried out with collaborators from the University of Maryland, NASA Goddard Space Flight Center, and Colorado State University. In the study, the prototype method led to the rejection of more than 90% of sample capacitors with visible cracks. Once further studies quantify and confirm detection levels, the new technique may help prevent failures in medical devices such as cardiac pacemakers and defibrillators, and also avert electronics failures in satellites and other spacecraft. The new method may also detect structural flaws in other types of materials.
The ceramics in the NIST study are highly nonlinear, meaning the capacitors get less stiff and their resonant frequency drops when they vibrate more strongly. The new NIST method measures patterns in how this tone changes over time in relation to the strength of the vibrations.
Researchers measured 41 multilayer barium-titanate ceramic capacitors, each roughly 2 by 3 millimeters in size, before and after heating to high temperatures (189°C) and quenching in ice water. This thermal treatment generated surface-breaking cracks in 27 samples. The nonlinear acoustic results were strongly correlated with the presence of visible cracks: Measurements on 25 of the 27 visibly cracked capacitors yielded results that were outside the range of those for capacitors without cracks.
The study concluded that nonlinear acoustic measurements offer a promising approach for nondestructive detection of cracks in capacitors before electrical failure occurs, and that further work should be pursued to quantify the level of detection. NIST staff are continuing this research in collaboration with a capacitor manufacturer.
www.nist.gov
The National Institute of Standards and Technology, Gaithersburg, Md., and collaborators have demonstrated a nondestructive acoustic method for detecting cracks in ceramic capacitors before they go bad.
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3D-printed titanium hip implant features fully porous acetabular cup
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Smith & Nephew, Andover, Mass., introduces its first 3D-printed titanium hip implant, the new Redapt revision acetabular fully porous cup with Conceloc technology. To support bone growth, the 3D manufacturing process will be used to produce an entirely porous implant, one that mimics the structure of cancellous bone.
The company noted that the Conceloc advanced porous titanium technology is an alternative to external porous coatings, such as sintered beads or fiber mesh, used in other uncemented implants. The new Redapt cup has been developed for use in revision cases where compromised bone makes implant fixation and stability more difficult.
"Bringing to market a 3D-printed titanium acetabular cup for difficult revision procedures is just one example of the potential of this remarkable technology," says Smith & Nephew global reconstruction vice-president Mike Donoghue.
Redapt variable-angle locking screws, as well as traditional non-locking screws, work within the implant's geometry to provide both compression and a rigid construct to the acetabular shell. The 3D-printed titanium hip implants are available at selected sites in the United States.
www.smith-nephew.com
Smith & Nephew, Andover, Mass., introduces its first 3D-printed titanium hip implant, the new Redapt revision acetabular fully porous cup with Conceloc technology.
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Bonnell Aluminum to invest $18 million in extrusion line for auto structures
March 2, 2016
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Bonnell Aluminum, Newnan, Ga., announces it will invest approximately $18 million over the next year to fund an expansion project that will include the purchase of a new state-of-the-art aluminum extrusion line at its Aacoa facility in Niles, Mich. The new line will include a state-of-the-art 3600-ton extrusion press, housing a nine-inch container, handling systems, and ancillary equipment. Capacity is estimated at approximately 16 million pounds. The project also includes additional floor space to accommodate future value-added fabrication capacity. Planned startup is the second quarter 2017.
Aacoa reportedly has a solid market reputation as a manufacturer, fabricator, and anodizer of aluminum extrusions with operations in Niles, Mich., and Elkhart, Ind. It is said to be highly regarded as a leader in the markets it serves, primarily consumer durables and machinery and equipment. The Niles facility also serves the automotive market due to its regional location.
"With continued growing demand from our customers, it is exciting to invest in this additional capacity, knowing that we will satisfy these opportunities with the high quality products and services that Aacoa is known for in the industry," commented Brook Hamilton, President and General Manager for Bonnell Aluminum.
Bonnell Aluminum is a subsidiary of Tredegar Corp., Richmond, Virginia. The company produces soft and medium-strength alloy aluminum extrusions for building and construction, automotive, machinery and equipment, consumer durables, transportation, electrical and distribution markets. On October 1, 2012, Bonnell Aluminum acquired Aacoa, a world-
www.bonlalum.com
www.aacoa.com
Bonnell Aluminum, Newnan, Ga., announces it will invest approximately $18 million over the next year to fund an expansion project that will include the purchase of a new state-of-the-art aluminum extrusion line at its Aacoa facility in Niles, Michigan.
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Solar Atmospheres partners with Pressure Technology for aircraft parts
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Solar Atmospheres, Hermitage, Pa., announces that it now partners with Pressure Technology Inc. (PTI), Concord, Ohio, to provide heat treating of aircraft parts after they have been hot isostatically pressed to high density at the PTI facility. With the escalation of additively manufactured components being printed, and the increased production of engine blade manufacturing to support newer more efficient aircraft, hot isostatic pressing (HIPing) is in more demand for the densification of many materials.
Over the years, Solar Atmospheres and PTI have understood the complementary synergies between the two companies. As an added value service, parts that require heat treat processing after HIP will be picked up by Solar from the PTI facility at no charge.
According to Michael Johnson, Sales Manager for Solar's Hermitage facility, "As both vacuum heat treating and HIPing are gaining popularity, by providing the customer with both state-of-the-art services as one, we can offer quicker turnaround time and savings on shipping costs."
www.solaratm.com
www.pressuretechnology.com
Solar Atmospheres, Hermitage, Pa., announces that it now partners with Pressure Technology Inc. (PTI), Concord, Ohio, to provide heat treating of aircraft parts after they have been hot isostatically pressed to high density at the PTI facility.
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Single-flow precision case hardening enables low-distortion gears
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Seco Warwick, Meadville, Pa., introduces the UniCase Master, which is said to provide a single flow, precision case hardening system for low-pressure vacuum carburizing; and 4D high-pressure gas quenching with low distortion for high-volume gear manufacturing.
The UniCase Master system is very flexible, as it can be resized depending on part shape and size, and is not limited to case hardening. It can be adapted for through hardening, brazing, annealing, and other heat treatment processes for in-line production. The system is dedicated to high-volume manufacturing for continuous, automated, single-piece flow, and can be operated with no human intervention. With a part exiting the system at a rate as short as 30 seconds each, customers can experience throughput as high as one million parts per year. This process is ideal for the automotive, transmission, and bearing industry and related industries.
The company also introduces ZeroFlow, a new method of controlled gas nitriding and nitrocarburizing based on nitriding with a single-component atmosphere – raw ammonia (NH3). The nitriding potential Kn is controlled by temporary stop and reactivation of the NH3 feeding into the furnace. Industrial applications to date have shown that the ZeroFlow gas nitriding technology is characterized by much lower consumption and emission of post process gases. The system requires a simpler control system and allows for forming the layer phase structure, while at the same time it delivers even better precision as processes with double-component atmospheres.
www.secowarwick.com
Seco Warwick, Meadville, Pa., introduces the UniCase Master, which is said to provide a single flow, precision case hardening system for low-pressure vacuum carburizing; and 4D high-pressure gas quenching with low distortion for high-volume gear manufacturing.
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UTC Aerospace Systems opens $8 million advanced materials laboratory in Connecticut
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UTC Aerospace Systems, Windsor Locks, Conn., has opened an $8 million, 20,000 ft2 state-of-the-art Materials and Process Engineering laboratory to support research, engineering, and production of advanced materials for aerospace applications. Lab capabilities include additive manufacturing to build metal and plastic parts. The lab will develop high-temperature materials such as carbon-carbon and silicon carbide-based composites for applications such as aircraft brakes. The lab will also focus on nanomaterials to develop light-weight metal-matrix and polymer-matrix composites for a variety of applications across UTC Aerospace Systems.
UTC Aerospace Systems also announces establishment of the Materials Engineering Center of Excellence at the University of Connecticut (UCONN). The agreement includes a five-year, million-dollar commitment to work with UCONN in the areas of additive manufacturing, high-temperature composites, thermoplastics, and other advanced materials. UTC Aerospace Systems will provide opportunities to rising UCONN sophomores and juniors to work in the new MPE lab and learn alongside UTC Aerospace Systems engineers and scientists in the areas of materials and manufacturing technologies for future aircraft.
"We are very excited about the new MPE lab, which will transform the way engineers and scientists collaborate to produce innovative solutions using a spectrum of material and manufacturing combinatorial techniques," said Mun Choi, Provost at the University of Connecticut. "The Center of Excellence we've established will provide our students with a unique learning experience by working in the lab with talented engineers."
UTC Aerospace Systems designs, manufactures and services integrated systems and components for the aerospace and defense industries. UTC Aerospace Systems supports a global customer base, with significant worldwide manufacturing and customer service facilities.
www.utc.com
www.utcaerospacesystems.com
UTC Aerospace Systems, Windsor Locks, Conn., has opened an $8 million, 20,000 ft2 state-of-the-art Materials and Process Engineering laboratory to support research, engineering, and production of advanced materials for aerospace applications.
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