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
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.
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ATI to supply isothermal forgings and nickel-base powder alloys to Pratt & Whitney
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Allegheny Technologies Inc., Pittsburgh, announces that it has signed a new Long-Term Purchase Agreement (LTPA) with Pratt & Whitney, a United Technologies Corporation company, to supply isothermal forgings and nickel-base powder alloys for next-generation jet engines. The LTPA, which builds upon the Master Terms Agreement that ATI entered into with UTC last year, begins in 2017 and continues for the life of the engine programs. For the period 2017 to 2030, the LTPA is expected to generate revenues in excess of $1 billion.
"We are pleased to enter into this new agreement with Pratt & Whitney," says Rich Harshman, ATI's Chairman, President and Chief Executive Officer. "Demand for P&W's game-changing PurePower Geared Turbofan engine is scheduled to grow dramatically into the next decade and beyond in support of next-generation narrowbody aircraft build rates. Through this agreement, ATI significantly increases our content on the GTF engine as well as on the P&W F135 engine for the Joint Strike Fighter program."
"Our suppliers are a critical part of our production capacity. Agreements like this secure sources of parts and components for years to come and ensure the capacity investments to support our production ramp," says Sam Abdelmalek, Pratt & Whitney vice president, Global Supply Chain.
www.atimetals.com
Allegheny Technologies Inc., Pittsburgh, announces that it has signed a new Long-Term Purchase Agreement (LTPA) with Pratt & Whitney, a United Technologies company, to supply isothermal forgings and nickel-base powder alloys for next-generation jet engines.
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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
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.
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One Minute Mentor: Residual Stress Profiles as Determined by X-Ray Diffraction
August 18, 2017
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For nitrocarburizing or consecutive carburizing and nitriding, the typical stress profile is smoother than for nitriding only. The graph shows residual stress profiles determined with destructive X-ray diffraction methods in carburized/nitrided AISI 316. Carburizing/nitriding: 2 hours at 970°F in an atmosphere consisting of 30% CO-70% hydrogen, followed by nitriding (23 hours at 820°F, at KN = 1.14.
For comparison a profile for a carburized (2.5 hours at 970°F, in 90% CO/10% H2) sample and for a nitrided (22 hours at 830°F, in 100% ammonia) sample are given. Residual stress values were calculated assuming that the same elastic constants apply for expanded austenite and austenite. The presented values are therefore only an indication that very high compressive stresses are present.
Volume 4D, Heat Treating of Irons and Steels ⇒ Heat Treated High-Alloy Steels ⇒ Low-Temperature Surface Hardening of Stainless Steel ⇒ Gaseous Low-Temperature Surface Hardening of Austenitic Stainless Steel
For nitrocarburizing or consecutive carburizing and nitriding, the typical stress profile is smoother than for nitriding only.
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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.
Can-Eng Furnaces Int.l, Niagara Falls, Ontario, has received an order for a mesh belt furnace system for heat treating automotive thrust races, retainer/cages, and washers.
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Ipsen USA ships 15 atmosphere and vacuum heat treating furnaces around the world
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Ipsen USA, Cherry Valley, Ill., reports that it shipped 15 atmosphere and vacuum furnaces last quarter, all in support of the aerospace, commercial heat treating, and MIM industries around the world. This equipment was sent to China, Hong Kong, India, Japan, Saudi Arabia, and the United States.
The shipments included
♦ two large, vertical (bottom-loading) MetalMaster vacuum furnaces, each with a 120-inch diameter work zone and 10,000-pound load capacity;
♦ five standard Titan vacuum furnaces, complete with PdMetrics, Ipsen's cloud-based predictive maintenance platform that provides real-time diagnostics, text alerts, and peace of mind;
♦ debind and sinter vacuum furnaces for the MIM industry;
♦ an Atlas integral quench atmosphere furnace, which was delivered six weeks after order placement; and
♦ several sophisticated, custom-built vacuum furnaces that will process parts for the a•erospace industry.
Many customers also took advantage of the ICS (Ipsen Customer Service) Team's aftermarket support offerings, ordering spare parts kits to help keep the furnace running smoothly. Ipsen's global ICS Team provides comprehensive, ongoing support throughout the equipment's life span for any brand of furnace. This includes facilitating system installations, as well as providing startup assistance, expert training, spare parts, and maintenance programs.
www.IpsenUSA.com
Ipsen USA, Cherry Valley, Ill., reports that it shipped 15 atmosphere and vacuum furnaces last quarter, all in support of the aerospace, commercial heat treating, and MIM industries around the world.
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Nucor acquires St. Louis Cold Drawn for its cold finished bar products
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Nucor Corp., Charlotte, N.C., has agreed to acquire St. Louis Cold Drawn Inc., a manufacturer of cold-drawn rounds, hexagons, squares, and special sections that mainly serves the United States and Mexico automotive and industrial markets.
"This acquisition fits with our planned growth strategy by expanding Nucor's position as the market leader in cold finished bar products. It also creates synergies with our bar mills by providing an additional channel to market for the special bar quality (SBQ) products we produce," said John Ferriola, Nucor Chairman, CEO ,and President. "The acquisition of St. Louis Cold Drawn complements our long-term strategy to profitably grow our value-added product portfolio."
St. Louis Cold Drawn employs 125 people and has two manufacturing locations, one in St. Louis, Missouri, and the other in Monterrey, Mexico, that have a combined annual capacity of 200,000 tons. The addition of these facilities will increase the total capacity of Nucor's cold finished bar and wire facilities to more than 1.1 million tons annually and also will help advance its goal of growing sales to automotive customers.
Nucor and its affiliates are manufacturers of steel products, with operating facilities primarily in the United States and Canada. Products include carbon and alloy steel -- in bars, beams, sheet and plate; hollow structural section tubing; electrical conduit; steel piling; steel joists and joist girders; steel deck; fabricated concrete reinforcing steel; cold finished steel; steel fasteners; metal building systems; steel grating; and wire and wire mesh.
Through the David J. Joseph Company, Nucor also brokers ferrous and nonferrous metals, pig iron and HBI/DRI; supplies ferro-alloys; and processes ferrous and nonferrous scrap. Nucor is North America's largest recycler.
http://www.nucor.com
Nucor Corp., Charlotte, N.C., has agreed to acquire St. Louis Cold Drawn Inc., a manufacturer of cold drawn rounds, hexagons, squares, and special sections that mainly serves the United States and Mexico automotive and industrial markets.
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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
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.
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Magnesium extracted from ore in continuous process by carbothermic technology
August 7, 2017
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The University of Colorado at Boulder announces that its researchers have developed a technology to extract magnesium from ore in a continuous process that requires less energy and generates less waste. University researchers have launched a spinoff company called Big Blue Technologies, where they are working to translate the laboratory innovations into a viable commercial-scale enterprise.
"I'm doing it in the lab; I'm seeing the product and seeing the results," says Boris Chubukov, a graduate researcher in CU Boulder's Department of Chemical and Biological Engineering, and one of Big Blue Technologies' co-founders. "I know the potential is really there."
The U.S. Advanced Research Projects Agency provided the $3.6 million grant that funded the preliminary research. The following description of the process is from the abstract submitted to win the grant: "Continuous Production and Collection of Magnesium via Carbothermal Reduction."
Production of magnesium based on carbothermic chemistry can be realized at temperatures below 2282°F using a combination of three operational parameters:
1) reduced pressure atmosphere,
2) addition of a catalytic material,
3) extensive size reduction of the reactant materials.
In conjunction with a continuous condensation and collection system, magnesium produced from this process entails at least a 50% reduction in energy consumption and greenhouse gas emissions compared to the predominant Pidgeon process.
The project will employ a variety of high-temperature experimental systems and methods to investigate performance of pelletized reactant materials and obtain recovered metal yields above 85%.
An optimized composition will be statistically determined and used in a low-temperature prototype reactor system for continuous production of crude magnesium.
The goal of the project is to produce a cast magnesium product and prove the reduction of energy intensity and economic feasibility with a techno-economic analysis.
The Big Blue Technologies founders believe this new process could reduce costs enough to enable production in the United States. They have secured almost a half-million dollars so far from backers who agree, including a $225,000 seed grant from the National Science Foundation's Small Business Technology Transfer program. Early this year, the fledgling company formed a partnership with Nevada Clean Magnesium, a publicly traded company, to further develop, test, and improve the production method.
www.bigbluetec.com
http://www.colorado.edu/today/2017/08/04/thoroughly-modern-magnesium-process
The University of Colorado at Boulder announces that its researchers have developed a technology to extract magnesium from ore in a continuous process that requires less energy and generates less waste.
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Get the latest on titanium brazing
August 4, 2017
Source: ASM International
An article by one of the leading authorities on titanium brazing – vetted and accepted for publication in the peer-reviewed ASM Handbook, Volume 6, Welding, Brazing, and Soldering – is now available online in digital form. “Brazing of Conventional Titanium Alloys,” a comprehensive, fact-filled survey by industry expert Alexander E. Shapiro, Ph.D., Titanium Brazing Inc., offers in-depth analysis and practical advice on how to braze commercially pure and alloyed titanium with itself as well as with other materials such as copper, stainless steel, carbon steel, ceramics, graphite, and titanium aluminide.
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