Seco Warwick to display vacuum furnace, present three papers at Heat Treat 2015
October 16, 2015
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Seco Warwick, Meadville, Pa., will be presenting three technical papers and exhibiting a full-size, production-scale vacuum furnace at the upcoming ASM International Heat Treating Conference & Exposition in Detroit. The furnace will be available for inspection by potential customers during show hours or by special appointment, and will be shipped directly to the new owner's site immediately following the show. The owner, Exco Tooling Solutions, Exco USA, is North America's largest supplier of extrusion dies, and is a major force in the global extrusion die-making industry. The vacuum furnace, proudly manufactured entirely in Meadville, will be shipped to Exco USA's plant in Wylie, Texas.
Dr. M. Korecki, PhD, will present a paper on the development of the world's first single-piece, high-volume, production-scale gear case hardening furnace, UniCase Master. Designed to produce up to one million gears annually, this new in-line vacuum furnace system is intended to be integrated directly into gear production lines, taking the place of one or more finish machining cells which can be eliminated due to the minimization of distortion. A proprietary "4D Quenching" process essentially eliminates distortion and the need for finish machining. Dr. Korecki's paper is being presented as part of the American Gear Manufacturing Association's Fall Meeting, which is held concurrently with the Heat Treat Show and is scheduled for Sunday, 18 October, at 2:50 p.m., in the downtown Detroit Marriott.
Prof. L. Maldzinski and Mr. M. Hemsath will present new technology on how to reduce the consumption of ammonia and carrier gasses during nitriding. The proprietary process, known as Zero Flow, will be discussed. With the growth of nitriding, this new technology has the potential to significantly decrease the operating costs of nearly all nitriding operations. Prof. Maldzinski's paper will be presented on Tuesday, 20 October, 8:00 a.m., Cobo Center Room 251B
Mr. T. Lord will present seco Warwick's final technical paper. He will describe a carburizing technology that can reduce production times to one-fifth under ideal circumstances. Known as PreNit, it is a proprietary pre-nitriding process that helps prevent grain growth while processing nitrided parts at higher than normal temperatures and shorter than normal cycle times. This discussion will be of significant value to high-volume carburizers. Mr. Lord's presentation is scheduled for Tuesday, 20 October, 2:00 p.m., Cobo Center Room 251C
Seco Warwick, Meadville, Pa., will be presenting three technical papers and exhibiting a full-size, production-scale vacuum furnace at the upcoming ASM International Heat Treating Conference & Exposition in Detroit.
Austenitizing is the heat treatment in which the final alloy element partitioning between the austenitic matrix (which will transform to martensite) and the retained carbides occurs. This partitioning fixes the chemistry, volume fraction, and dispersion of the retained carbides. The retained alloy carbides not only contribute to wear resistance but also control austenitic grain size. The finer the carbides and the larger the volume fraction of carbides, the more effectively austenitic grain growth is controlled. Thus, if the tool steel is austenitized at too high a temperature, undesirable grain growth may occur as the alloy carbides increasingly coarsen or dissolve into the austenite.
The graph shows that tempering by a combination of retained austenite transformation and secondary hardening, will eventually raise the hardness of as-quenched structures with large amounts of retained austenite. Not shown is the deleterious increase in austenite grain size that develops as more and more carbides dissolve at the higher austenitizing temperatures.
Volume 4D, Heat Treating of Irons and Steels -> Heat Treating of Carbon and Low-Alloy Steels -> Introduction to Heat Treating of Tool Steels -> Heat Treatment Applied to Tool Steels
Austenitizing is the heat treatment in which the final alloy element partitioning between the austenitic matrix (which will transform to martensite) and the retained carbides occurs.
Linde highlights advanced technologies at Heat Treat 2015
October 15, 2015
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Linde LLC, Murray Hill, N.J., will showcase advanced gas control technologies and engineering services for heat treatment furnaces at Heat Treat 2015 next week in Detroit, booth 248. These include Carbojet gas-injection technology for improving production up to 20%; Hydroflex atmosphere control system for more reliable oxide-free annealing; world-class heat treatment engineering and laboratory services; and safety solutions for flammable atmosphere furnaces (re: NFPA 86)
These heat treatment services and proven technologies are in demand for improving process efficiency, productivity, and quality in manufacturing metal parts for automotive, aerospace, and military components; construction and industrial equipment; and electrical systems, to name a few. More consistent process quality can mean less rework and fewer rejects, and lead to higher profits, process reliability and longer service life.
Linde offers decades of experience in heat treatment across all common furnace types from continuous to batch type furnaces, including roller hearth, pusher, pit or rotary-retort. Expertise spans all typical protective atmospheres—from pure nitrogen, pure hydrogen, nitrogen/hydrogen, nitrogen/hydrocarbon type atmospheres to endothermic gas, exothermic gas and monogas atmospheres.
Improve gas flows and atmosphere homogeneity without fans
The patented CARBOJET gas-injection technology can improve efficiency and the productivity of heat treatment furnaces including roller hearth, pusher, pit, or rotary-retort. Ultrahigh-speed injection of a gas or gas mixture through special CARBOJET lances improves gas flows and atmosphere homogeneity without the use of circulation fans. This includes both the better mixing of the injected gases with the furnace atmosphere, and better movement of the gas flows within the furnace.
Oxide-free parts annealing
The HYDROFLEX atmosphere control system offers a universal solution for clean and bright oxide-free annealing of steel, stainless steel, copper, bronze or brass, with high reliability and repeatability. One or more carrier gases (nitrogen or argon) maintain the furnace pressure while a controlled ratio of hydrogen helps prevent oxidation. With the HYDROFLEX® technology, many annealing tasks can be completed with non-flammable gas mixtures containing less than 5 percent hydrogen.
Engineering and lab services
Engineering is key to optimizing heat treatment solutions. Linde engineers can perform process audits to investigate areas for improvement. This may include analyzing furnace atmospheres, gas supply and control systems, as well as upstream and downstream processes. Linde can also perform customer tests and demonstrations in furnaces at its Technology Center to support feasibility studies, and provide safety and process training.
In addition, engineers at Linde Application Centers can develop new gas supply systems for heat treatment processes and improve the control systems of existing processes. Our metallography laboratory services include material analyses, scanning electron micrography (SEM) and a variety of hardness tests.
Meeting new NFPA safety standards
The National Fire Protection Association (NFPA) is the industry accepted authority of industrial gases and furnaces. All heat treating facilities should familiarize themselves with NFPA 86 "Standard for Ovens and Furnaces". Within NFPA 86 there are specific requirements for Nitrogen Supply Systems used to purge flammable atmosphere furnaces. Linde developed the system to satisfy the NFPA 86 "Standard for Ovens and Furnaces." It includes a nitrogen supply system with an integral alarm panel for safety purge of flammable atmosphere furnaces.
Heat Treat 2015 is the premier heat treating event in North America and presented by the ASM Heat Treating Society. The conference and exposition run in conjunction with Gear Expo, presented by the American Gear Manufacturers Association.
Linde LLC, Murray Hill, N.J., will showcase advanced gas control technologies and engineering services for heat treatment furnaces at Heat Treat 2015 next week in Detroit, booth 248.
NMSU's UAS FTC provides direct access to more than 15,000 m2 of airspace, and was the first civil UAS test facility that provided direct, available access to restricted airspace—a must for testing developmental aircraft or multi-aircraft scenarios. Henry Cathey, interim deputy director of NMSU's Physical Science Laboratory, was honored at NMSU's Scholarly Excellence Rally Friday, Oct. 9.
"The Flight Test Center in Las Cruces has been operating for a number of years, and it's not only a unique resource for the state of New Mexico, but it is a unique resource for the entire country," Cathey says. "It's state-of-the-art, cutting-edge, and it's very exciting that New Mexico is leading the way in this area."
In May 2015, the FAA announced that the Alliance for System Safety of UAS through Research Excellence (ASSURE) would operate a new National Center of Excellence for UAS. NMSU is a core member-university on a team, which is comprised of 15 universities and six affiliates.
As a core university of ASSURE, NMSU is helping lead the partnership of academic and industry members that will begin a new era of commercial unmanned aircraft research, development and integration into the nation's airspace. Dallas Brooks, NMSU UAS research and development strategic manager, is the principle investigator on the ASSURE project and co-chairs the Federal UAS Science and Research Panel, which oversees and coordinates UAS research conducted by the FAA, NASA, the Department of Defense, and the Department of Homeland Security.
The center of excellence will supply research to the FAA and UAS industry to increase the potential uses of unmanned systems with minimal changes to the current system regulating manned aircraft. The center of excellence research areas include detect and avoid technology; low-altitude operations safety; control and communications; spectrum management; human factors; compatibility with air traffic control operations; and training and certification of UAS pilots and other crewmembers.
"We are supporting and trying to make the skies safer for using things like UAS or unmanned aircraft systems in the national airspace," Cathey says. "We have been tasked to look at detect and avoid technology on how we can integrate things from small UAS up to things with a 15- to 20-foot wingspan into national airspace safely.
"The detect and avoid research area focuses on issues related to the detection of potential threats to remain well clear and avoid collisions. It explores sensors, the data produced from sensors, the management and use of that data, and the operational outcome that is considered safe and acceptable," he said.
In this research area, NMSU is evaluating the requirements for an airborne or ground-based Detect and Avoid system compatible with small UAS (55 pounds and less) operating in limited portions of the National Air Space to comply with the regulations and not increase the risk to other aircraft or people on the ground, beyond what is currently in effect. Additionally, NMSU is accessing the requirements for software along with what are the most feasible airborne or ground-based sensors.
ASSURE will form teams between its member universities, government agencies and industry partners to address both government and commercial UAS challenges. "Each of those universities has specific skills and abilities, and the idea is to marry all of the technical expertise to provide real research answers for flight safety in the National Air Space," Cathey said.
Established in 2007, the New Mexico State University Physical Science Laboratory’s Unmanned Aircraft Systems Flight Test Center is the first of its kind.
The Boeing Co., Seattle, released a video showcasing the lightest metal structure ever, called Microlattice—"the world's lightest material."
Sophia Yang, a research scientist at HRL Laboratories, Malibu, Calif., who worked with Boeing on the creation of the material, says the metal is 99.99% air. She compares the material to bone, which has a rigid outside and mostly hollow inside, creating an open-cellular structure, which means it's remarkably strong and light. The structure is composed of a network of super thin, hollow struts. The struts are around 100 μm in diameter and have walls just 100 nm thick. It's this design that makes Microlattice 10 times lighter than Styrofoam. However, despite it being extremely light, it is also tremendously strong.
Yang also highlights the material's ability to absorb high levels of impact. Using the "egg challenge" as an example, she says: "You need to drop an egg from 25 stories and protect that egg ... What we can do is design the microlattice to absorb the force that the egg feels. So instead of having an egg that's wrapped in three feet of bubble wrap, now you have a much smaller package that your egg can sit in."
The material has been made primarily for use in in aerospace engineering. Engineers intend to use the microlattice for plane interiors in places such as side panels, overhead cabins, or walkway areas. This would dramatically reduce the weight of the aircraft, making it more fuel-efficient and cheaper to run.
Microlattice was first announced in 2011 when a nickel-phosphorous alloy prototype was developed in collaboration between University of California, Caltech, and HRL Laboratories—the Boeing-owned lab that built the first laser in 1960. As the video explains, this development has many possibilities, ranging from use in aerospace, high-performance vehicles, as well as shock absorption and vibration insulation.
Air Products to highlight latest gas technologies at Heat Treat 2015
October 14, 2015
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Air Products, Lehigh Valley, Pa., will highlight the company's latest gas technologies for the metals processing industry at the Heat Treat 2015 Conference and Exhibition in Detroit, October 20-22. The company will also share its latest developments in furnace atmospheres — including plasma-activated case hardening of steels at atmospheric-pressure.
Zbigniew Zurecki, FASM and senior research associate at Air Products, will share new developments in atmosphere treatments as part of the "New Directions and Opportunities in Heat Treating" panel session on Wednesday morning, October 21. In addition, Air Products' Dr. Liang He, principal application engineer, will present the results of original research titled "Optimization of Protective Atmospheres for Annealing and Hardening Operations in Continuous Furnaces" during the Atmosphere Technology Session on Wednesday afternoon.
Metals processors are invited to stop by Air Products booth 508 to speak with a knowledgeable representative about their particular heat treating challenges. With over 50 years of heat treating experience, Air Products' applications engineers can work with customers to learn their specific annealing, brazing, hardening, or sintering process and make recommendations to help improve their overall operation.
Air Products' industrial gases are available in a variety of supply modes to match each customer's requirements efficiently and cost-effectively. The company also offers gas handling equipment and technology, as well as process audits and troubleshooting, to help metals processors optimize gas use, lower operating costs, maximize uptime, increase throughput, and improve product quality.
Air Products, Lehigh Valley, Pa., will highlight the company’s latest gas technologies for the metals processing industry at the Heat Treat 2015 Conference and Exhibition in Detroit, October 20-22.
Lockheed Martin awards Alcoa titanium supply contract for Joint Strike Fighter
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Alcoa, Pittsburgh, announces that Lockheed Martin has awarded it a contract to supply titanium plate and billet for the F-35 Lightning II aircraft program, also known as the Joint Strike Fighter. Under the contract, Alcoa becomes the titanium supplier for airframe structures for all three variants of the F-35 over nine years, from 2016 to 2024. At current projected build rates, the contract has an estimated value of approximately $1.1 billion.
"Through our expansion in titanium, Alcoa is sharpening its leadership edge on state-of-the-art aircraft, including the most advanced fighter jet in the world—the F-35," said Alcoa Chairman and Chief Executive Officer Klaus Kleinfeld. "We are expanding Alcoa's range of multi-material offerings for this program while helping Lockheed Martin meet aggressive weight, range, and fuel efficiency targets."
The titanium will be used to manufacture airframe structures for all three F-35 JSF variants: The F-35A Conventional Takeoff and Landing (CTOL) aircraft, the F-35B Short Takeoff/Vertical Landing (STOVL) aircraft, and the F-35C Carrier Variant (CV). Under a different existing contract, Alcoa will use the metal to forge all of the largest titanium bulkheads—the "backbone" of the aircraft structure—for the CTOL variant at its Cleveland, Ohio operations. Approximately 75 percent of all F-35s produced are CTOLs.
"This contract with Alcoa is a key element in securing our supply chain with a strong U.S. partner for a critical, strategic raw material," said Dan Pleshko, vice president of Lockheed Martin Aeronautics' Enterprise Supply Chain Management.
The F-35 Lightning II is an advanced fighter aircraft combining stealth, speed and agility, designed for many kinds of missions. Lockheed Martin's full-rate production goal is 13 aircraft a month by the mid-2020s, up from an average of three aircraft delivered per month in 2014.
Alcoa has been growing its multi-material aerospace business to capture growth in the global aerospace market in support of its broader transformation. Alcoa recently acquired global titanium leader RTI International Metals, aerospace components manufacturer Tital, and global jet engine parts leader Firth Rixson.
Alcoa, Pittsburgh, announces that Lockheed Martin has awarded it a contract to supply titanium plate and billet for the F-35 Lightning II aircraft program, also known as the Joint Strike Fighter.
Ipsen introduces Quick Ship program for heat treating furnace parts
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Ipsen USA, Cherry Valley, Ill., introduces the Quick Ship program, which provides one-day shipment of high-demand heat treating furnace replacement parts such as gas nozzles, power feedthrough assemblies, pumps, and much more. "Our ultimate goal, and reason that we created the Quick Ship program, is to provide customers with the tools and support needed to minimize downtime and keep their furnaces operating at peak performance," says Aaron Bolhous, Aftermarket Parts Manager at Ipsen USA.
With rapid turnaround times and on-time deliveries, the Quick Ship program provides access to specific parts during standard business hours: Monday through Friday, 8 a.m. – 5 p.m. EST. Customers can call 1-844-Go-Ipsen to receive immediate support. Customers are guaranteed same-business-day shipment for Quick Ship parts orders placed by 10 a.m. EST.
Find the full list of Quick Ship parts and learn more about Ipsen's 360° support for furnaces at www.IpsenUSA.com/Parts
Ipsen USA, Cherry Valley, Ill., introduces the Quick Ship program, which provides one-day shipment of high-demand replacement heat treating furnace parts such as gas nozzles, power feedthrough assemblies, pumps, and much more.
Expanite opens a new heat treatment center in Ohio
October 13, 2015
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Expanite, Denmark, announces that it has established a subsidiary in the United States known as Expanite Inc., and has opened a new heat treatment center in Twinsburg, Ohio, for surface hardening of stainless steel. According to the company, the Expanite process makes it possible to increase the material's surface hardness tenfold, while at the same time maintaining and even increasing corrosion properties.
Expanite can now offer its North American customers the same superior gaseous surface hardening treatment options as in Europe. Customers can choose to have their material processed in its facilities in Ohio on a day-to-day basis, or opt for a fully automatic solution installed directly in their production line.
The Expanite treatment is said to remove the oxide film, which allows controlled incorporation of carbon and nitrogen atoms into the underlying metal. The hardened layer is characterized by an interstitial hardened zone known as expanded austenite, expanded martensite, or simply Expanite. Unlike other technologies, this method not only coats the surface, but also enables carbon and nitrogen to go into and beneath the surface to create a hardness profile with an optimal concentration of carbon and nitrogen. This is said to significantly improve resistance to corrosion, galling, fatigue, and wear.
Expanite also welcomes its new North American Sales Manager, Dr. Christian Dalton, who has a Ph.D. in Materials Science and Engineering from Case Western Reserve University in Cleveland.
Expanite, Denmark, announces that it has established a subsidiary in the United States known as Expanite Inc., and has opened a new heat treatment center in Twinsburg, Ohio, for surface hardening of stainless steel.
