Solar Manufacturing partners with Refrac Systems for GFQVHP system
March 30, 2016
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Refrac Systems, Chandler, Ariz., has contracted with Solar Manufacturing, Souderton, Pa., and Beckwood Press & Machinery/Triform, Saint Louis, to help design and build a large 100-ton-load gas fan quench vacuum hot press (GFQVHP) system for its aerospace diffusion bonding operation. Solar Manufacturing was selected due to its world class experience in the design and use of vacuum furnaces with gas fan quench cooling capabilities. The furnace chamber for this unit was built by Amity Industries, Douglassville, Pa. Beckwood Press & Machinery/Triform was selected to build the large 100 ton "Four Post" hydraulic press frame for the system. The control console unit was built by Optima Stantron, Lawrenceville, Ga.
Refrac Systems, working with Solar's engineering team, selected a derivative of the Solar Manufacturing standard HLF-5748-2IQ internally quenched 2-bar vacuum furnace as the base design of the system. The new system contains many new engineered designs as needed to be both an automated vacuum hot press, and to be extra versatile for making super plastically formed and diffusion bonded (SPFDB) aerospace structures.
Norm Hubele, President of Refrac Systems, states "Solar Manufacturing and Beckwood Press & Machinery are both industry leaders with robust engineering experience. We have worked closely together to design and build this one of a kind GFQVHP."
William Jones, CEO of the Solar Atmospheres family of companies, notes "Norm put together a team of engineers to design and build this furnace back in 2013. This state-of-the-art GFQVHP contains many innovations that will be discussed at a later time. Throughout the entire process, Norm has personally reviewed all aspects of the design and added considerable insight to the development of this unique vacuum furnace system."
Solar Manufacturing expects to ship the GFQVHP unit in July, and final assembly, testing and startup is projected for the 4th quarter 2016 in Chandler.
www.solarmfg.com
www.refrac.com
Refrac Systems, Chandler, Ariz., has contracted with Solar Manufacturing, Souderton, Pa., and Beckwood Press & Machinery/Triform, Saint Louis, to help design and build a large 100-ton-load gas fan quench vacuum hot press (GFQVHP) system for its aerospace diffusion bonding operation.
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Composite foams of steel spheres embedded in aluminum insulate against heat
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North Carolina State University, Raleigh, reports that novel lightweight composite metal foams made of materials such as steel spheres embedded in aluminum are more effective at insulating against heat than solid conventional metals such as steel. The composite metal foam consists of metallic hollow spheres — made of materials such as carbon steel, stainless steel or titanium — embedded in a metallic matrix made of steel, aluminum, or other metallic alloy. These foams are especially promising for storing and transporting nuclear material, hazardous materials, explosives, and other heat-sensitive materials, as well as for space exploration.
"We have developed two technologies for manufacturing composite metal foams (CMF)," says Afsaneh Rabiei, a professor of mechanical and aerospace engineering at NC State and corresponding author of a paper on the work. "One is based on casting a low melting point matrix material, such as aluminum, around hollow spheres made of a material with a higher melting point, such as steel. This creates aluminum-steel CMFs, for example. The other technique is based on sintering the matrix powder around prefabricated hollow spheres. This creates CMFs such as steel-steel, which consist of steel hollow spheres in a steel matrix."
In one test, researchers exposed samples of 2.5 by 2.5-inch steel-steel CMF that were 0.75 inches thick to a fire with an average flame temperature of 800°C for a period of 30 minutes on one side, and monitored the material to see how long it would take for the heat to reach the opposite side of the sample.
For a piece of bulk stainless steel with the same dimensions as the CMF sample, it took only four minutes to reach 800°C, but it took eight minutes for the steel-steel CMF to reach the same temperature.
"We already knew the CMFs have outstanding high-velocity impact resistance, and effective radiation shielding. Now we know that it can withstand high heat," Prof. Rabiei says.
The researchers also found that the composite metal foam made entirely of stainless steel expands 80% less than bulk stainless steel at 200°C — and the differential increases at higher temperatures. Another noteworthy advantage is that the composite metal foam expands at a fairly constant rate when exposed to high heat — whereas conventional bulk metals and alloys such as stainless steel expand more rapidly as temperature increases.
www.ncsu.edu
North Carolina State University, Raleigh, reports that novel lightweight composite metal foams made of materials such as steel spheres embedded in aluminum are more effective at insulating against heat than solid conventional metals such as steel.
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Parker Trutec adds fourth AFC-Holcroft universal batch quench furnace
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AFC Holcroft, Wixom, Mich., announces that Parker Trutec Inc., Springfield, Ohio, has added a fourth UBQ 36-48-36 universal batch integral quench furnace to an existing line. This latest furnace will be equipped for carburizing, and will be made CQI-9 Compliant. The furnace has a capacity of 3500 pounds, has excellent temperature uniformity, and has a maximum operating temperature of 2000°F.
A pneumatic quench elevator with specially designed corner guides provides smooth motion and trouble-free operation. It has vertically mounted variable speed propeller type agitators. The Batchmaster II operating system provides operational control, standard recipes, and recipe management. The equipment is scheduled for installation in March of 2016.
The Parker Trutec Group operates six facilities in the United States and Mexico, specializing in metal treatments and products that improve the resistance to wear, corrosion, and fatigue of metal components.
www.afc-holcroft.com
www.parkertrutec.com
AFC Holcroft, Wixom, Mich., announces that Parker Trutec Inc., Springfield, Ohio, has added a fourth UBQ 36-48-36 universal batch integral quench furnace to an existing line.
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Solar Atmospheres to double size of California plant
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Solar Atmospheres of California Inc. (SCA), Fontana, plans to invest $5 million to expand its Fontana facility by adding another 25,000-sq.-ft. building to the current 25,000-sq. ft.-facility. The investment is part of a long-term corporate strategy to increase its west coast development and commercial capacity to meet the increasing demands of its customers.
The expansion will introduce multiple innovative vacuum furnaces specifically designed and manufactured to meet the growing needs of SCA's diverse customer base. All vacuum furnaces will be manufactured by SCA sister company, Solar Manufacturing Inc. in Souderton, Pa. In addition to vacuum processing, SCA is planning to install a state-of-the-art SCAQMD compliant cleaning line.
Construction on the new expansion will commence in the beginning of the 2nd quarter of 2016 and is expected to be fully operational by the end of the year.
According to Derek Dennis, President of Solar Atmospheres of California, "Expanding our presence in Southern California highlights our commitment to current customers who want to manufacture their parts locally, and to support the development needs of our ever-increasing customer base. The additional capacity will give us more flexibility and make us more agile to deal with our customers' increasing pressure to reduce lead times and increase throughput."
www.solaratm.com
Solar Atmospheres of California Inc. (SCA), Fontana, plans to invest $5 million to expand its Fontana facility by adding another 25,000-sq.-ft. building to the current 25,000-sq.-ft. facility.
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Ipsen ships heat treating furnaces for aerospace, automotive, and power applications
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Ipsen, Cherry Valley, Ill., recently shipped seven furnaces around the globe for applications in aerospace, automotive, and power-generation. Shipments included both custom-built furnaces and standard Titan furnaces, and they were sent to customers in Alabama, California, Missouri, and Texas, as well as China and Japan.
The equipment ranged from a vertical bottom-loading MetalMaster with an 84 x 84-inch molybdenum hot zone sent to California, to a Titan H2 vacuum furnace sent to Japan. Other furnaces included horizontal MetalMaster furnaces, H2- and H4-size furnaces from Ipsen's Titan line, and a Global Vertical furnace from the TurboTreater line. Overall, these shipments represent sophisticated and intuitive heat-treating solutions through an all-inclusive product line that supports a wide range of applications and processes.
To best support such diverse industries and needs around the world, Ipsen's Global Support Team facilitates furnace installations, and provides expert training, startup assistance, and 360-degree support throughout the entire lifespan of the equipment.
www.IpsenUSA.com/Products
Ipsen, Cherry Valley, Ill., recently shipped seven furnaces around the globe for applications in aerospace, automotive, and power-generation.
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One Minute Mentor: Tempering Behavior of Corrosion-Resistant Tool Steels
March 24, 2016
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During tempering, the combination of material properties such as hardness, toughness, and corrosion resistance, as well as residual stresses, can be adjusted within a wide range. Very low (<300°F) tempering temperatures are uncommon, as they result in very low impact toughness and high internal stresses.
With increased tempering temperatures, toughness properties can be improved significantly with only limited loss in hardness, as shown in the graph. The precise behavior strongly depends on the uniformity of the microstructure and on chemical composition, with advantages shown by nitrogen-alloyed lower-carbon grades. Typical tempering temperatures for small and simple-shaped tools vary between 390°and 750°F. In the case of large and complex dies, such tempering temperatures can still lead to very high internal stresses, resulting in early tool failure despite good impact toughness.
Volume 4D, Heat Treating of Irons and Steels -> Tool Steels -> Heat Treating of Mold Steels and Corrosion-Resistant Tool Steels -> Recommended Heat Treating Practices
During tempering, the combination of material properties such as hardness, toughness, and corrosion resistance, as well as residual stresses, can be adjusted within a wide range
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IBC to supply Beralcast components to semiconductor manufacturer
March 20, 2016
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IBC Advanced Alloys Corp., Vancouver, has signed an agreement with a leading global manufacturer of semiconductor and electronics assembly equipment to be its exclusive supplier of Beralcast beryllium-aluminum cast components. IBC will supply Beralcast 363 cast components for a four-year period, with the agreement expected to generate baseline sales of approximately $4,800,000 over the term of the contract.
Beralcast 363 is a metal matrix composite that consists of 65% Be (by weight) and 35% Al. It provides an ideal solution for weight, stiffness, and thermal-critical applications in aerospace, defense, and commercial markets. BeAl-363 is used primarily for high-strength/high-elastic modulus precision cast structural applications. This alloy is 22% less dense than Al-356 and is 3.5 times as stiff.
"IBC's Beralcast components are ultra-lightweight, with high modulus and excellent thermal characteristics, and are ideally suited to applications requiring high precision and performance," says IBC Engineered Materials President Chris Huskam.
"While IBC will continue to focus on near term growth opportunities in its core aerospace and defense business, we are pleased to be strengthening our relationship with a recognized global leader, and look forward to supporting them for many years to come," says General David Heinz, IBC's Chief Operating Officer. "Recent changes to our IBC Engineered Materials operations have resulted in improved production rates and operating efficiencies, and we are well positioned to continue and grow our sales in the precision manufacturing sector while we broaden our aerospace product offerings and customer base."
www.ibcadvancedalloys.com
IBC Advanced Alloys Corp., Vancouver, has signed an agreement with a leading global manufacturer of semiconductor and electronics assembly equipment to be its exclusive supplier of Beralcast beryllium-aluminum cast components.
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SSAB electrogalvanized martensitic steel designed for auto structures
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SSAB Steel, Sweden, introduces Docol 1500 MZE electrogalvanized martensitic grade high-strength structural steel for automotive applications. The ultra-high strength steel is appropriate for a range of applications in need of corrosion protection, energy absorption, and low weight.
"For many years now, our Docol series of martensitic grades have been contributing to low weight and sustainability without compromising performance," says Arnaud Guerendel, global director for the automotive segment at SSAB. "As knowledge and awareness spread, more designers see the possibilities of using our material. We have continual requests by different companies for our strongest and highest strength steels."
Docol 1500 MZE is a cold-rolled, electrogalvanized advanced high-strength steel developed for applications in cars with stringent requirements for low weight and high energy absorption. The steel is well suited for roll forming. The minimum tensile strength is 1500 N/mm² and the high strength is achieved in the manufacturing process, which uses a special heat treatment together with an extremely high cooling rate.
"When we develop new steel grades, we always have our customers' business in focus whether we're developing new products or adjusting the properties of our steel grades to fit specific applications," says José Puente, global product manager for the automotive segment at SSAB. "This is the strong driving force behind our continuous research and development efforts."
www.ssab.com
SSAB Steel, Sweden, introduces Docol 1500 MZE electrogalvanized martensitic grade high-strength structural steel for automotive applications.
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Large “hot box” system monitors wire coil temperature during annealing
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Phoenix Temperature Measurement, Clearwater, Fla., announces that a major steel coil manufacturer has taken delivery of a ‘hot box' system to monitor the temperature of steel wire coils through their annealing process.
This is the biggest system that Phoenix has ever built, and it has been engineered to fit inside a vertical steel coil as it travels through a continuous roller hearth annealing furnace. Weighing in at 500 pounds, the system is built to withstand temperatures of 1470°F for up to 30+ hours duration, in an NX atmosphere. The system is able to monitor up to 20 thermocouples placed within the coil, allowing full analysis of the heat treatment cycle on the Thermal View Plus software provided.
"The science behind ‘hot box' systems is not difficult to understand," says Ian Budden, Director of PhoenixTM Ltd. "The longer and hotter the process, the bigger the thermal barrier has to be. However, in this type of process, the system size may be limited by the internal dimensions of the wire coil, so barrier design and selection of the insulation materials is critical."
www.phoenixtm.com
Phoenix Temperature Measurement, Clearwater, Fla., announces that a major steel coil manufacturer has taken delivery of a ‘hot box’ system to monitor the temperature of steel wire coils through their annealing process.
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Paulo Products Kansas City Division becomes AS9100 certified
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Paulo Products Co., St. Louis, Mo., announces that its Kansas City Division is now AS9100 certified, and joins the Cleveland Division in being both AS9100 certified and Nadcap accredited. The AS9100 certification will reinforce the Kansas City Division's position as a leading aerospace heat treating facility.
"I am proud of the accomplishments of our Kansas City Division. AS9100 certification will further assure our aerospace customers that Paulo has the systems in place to provide the quality heat treating services required for the integrity and safety of parts used in aerospace applications," says Ben Rassieur, President.
Led by David Mailes, Director of Quality, the Paulo quality team worked hard through 2015 to secure the AS9100 certification. Kansas City Division Quality Assurance Manager Mark Affolter had a very busy 2015. In addition to working towards AS9100, Mark was faced with several audits, as the Kansas City Division maintained ISO9001 and ISO14001 while also securing Boeing approval.
Leveraging prior experience from the Cleveland Division certification, benchmarks were established that proved helpful for the Kansas City certification. Additional support came from the Kansas City Division sales team of Jeb Clement and Curt Heineck, as well as Plant Manager Tee Rassieur. The Kansas City Division is committed to growing with customers and meeting the stringent requirements of the aerospace industry.
www.paulo.com
Paulo Products Co., St. Louis, Mo., announces that its Kansas City Division is now AS9100 certified, and joins the Cleveland Division in being both AS9100 certified and Nadcap accredited.
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