Solar partners with Refrac to build system for superplastic forming/diffusion bonding
March 20, 2016
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Solar Manufacturing, Souderton, Pa., announces that it has contracted with Refrac Systems, Chandler, Ariz., to help design and build a large 100-ton-load gas fan quench vacuum hot press (GFQVHP) system for its aerospace structures diffusion bonding operation. Refrac engineers, working with Solar's engineering team, selected a derivative of the Solar Manufacturing standard HLF-5748-2IQ internally quenched two-bar vacuum furnace as the base design. The new system contains many new engineered designs that are needed to build a versatile and robust system that can process aerospace structures by both automated vacuum hot pressing and by superplastic forming/diffusion bonding.
Amity Industries, Douglassville, Pa., built the furnace chamber for the unit. Beckwood Press & Machinery/Triform, Saint Louis, Mo., was selected to build the large 100-ton "Four Post" hydraulic press frame. Optima Stantron, Lawrenceville, Ga., built the control console unit.
According to Norm Hubele, President of Refrac Systems, "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."
"Norm put together a team of engineers to design and build this furnace back in 2013," says William Jones, CEO of the Solar Atmospheres family of companies. "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 are projected for the 4th quarter 2016 in Chandler.
www.solarmfg.com
www.refrac.com
Solar Manufacturing, Souderton, Pa., announces that it has contracted with Refrac Systems, Chandler, Ariz., to help design and build a large 100-ton-load gas fan quench vacuum hot press (GFQVHP) system for its aerospace structures diffusion bonding operation.
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One Minute Mentor: Effects of Different Cooling Rates on Corrosion-Resistant Tool Steels
March 18, 2016
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The graph shows the effects of different cooling rates on the toughness properties (un-notched samples) of AISI 420 and nitrogen-alloyed M333 tool steels.
The cooling parameter λ8/5, which is the cooling time from 1470° to 930°F in seconds, divided by 100, is used. Besides the general trend of falling toughness with rising cooling time, it is clearly evident that the nitrogen-alloyed steel grade M333 (420Mod), which has a lower carbon content, shows significantly higher toughness values. These can be further improved by lowering the austenitizing temperature. This behavior correlates well with the reduced tendency to form proeutectoid carbides at grain boundaries. A similar correlation can be found for the steel grades AISI 440B and the nitrogen-alloyed M340 (440Mod).
Volume 4D, Heat Treating of Irons and Steels ⇒ Tool Steels ⇒ Heat Treating of Mold Steels and Corrosion-Resistant Tool Steels ⇒ Recommended Heat Treating Practices
The graph shows the effects of different cooling rates on the toughness properties (un-notched samples) of AISI 420 and nitrogen-alloyed M333 tool steels.
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Alcoa chooses the name Arconic for its future value-add company
March 16, 2016
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Alcoa, Pittsburgh, announces that the name for its future company dedicated to value-added products will be Arconic, in which "A" represents Alcoa, "arc" represents the arc of progress, and "-conic" speaks to the company's history of creating iconic products. The logo also includes a tagline, "Innovation, Engineered" to communicate the company's goal to invent, develop, and deliver products and solutions through precision engineering and advanced manufacturing.
The future upstream company will operate under the Alcoa name. The company's separation into two independent publicly-traded companies in the second half of 2016 remains on track.
"The ‘Arconic' brand fuses our extraordinary heritage with our highly promising future," said Alcoa Chairman and Chief Executive Officer Klaus Kleinfeld. "It echoes our 127-year history of invention – and reinvention. Our logo depicts the realm of possibility brought to life. It reflects our vision of limitless innovation solving complex engineering challenges, to transform the way we fly, drive, build, package and power. And it represents the ingenuity of our people, who are dedicated to inventing, developing, and delivering high-quality, innovative products and solutions that contribute to our customers' success and create shareholder value."
Both Arconic and Alcoa will be based in the United States and listed on the New York Stock Exchange: Arconic as ARNC, and Alcoa as AA. The upstream company (Alcoa) will comprise the five business units that today make up Global Primary Products: Bauxite, Alumina, Aluminum, Cast Products, and Energy.
Arconic will include the three business segments that today comprise Alcoa's Value Add portfolio: Global Rolled Products, Engineered Products and Solutions, and Transportation and Construction Solutions.
www.alcoa.com/arconic
www.alcoa.com/alcoabrand
Alcoa, Pittsburgh, announces that the name for its future company dedicated to value-added products will be Arconic, in which “A” represents Alcoa, “arc” represents the arc of progress, and “-conic” speaks to the company’s history of creating iconic products.
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Thermex Metal Treating expands plant capacity with Seco Warwick gas nitriding system
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Thermex Metal Treating Ltd., Edmonton, is expanding its capacity with the purchase of a Seco Warwick gas nitriding system with vertical pit-style loading and proprietary ZeroFlow control technology. This new system features precise control of the gas nitriding process by using continuous in-process atmosphere analysis to provide ongoing feedback and information. This allows for close control of properties such as case depth and compound (white) layer formation, including control of the thickness and phase of the white layer. A key feature of this new system is a significant reduction in ammonia gas consumption, which leads to reduced emissions.
The work zone size is 39 inches diameter and 75 inches deep. A maximum gross weight of 6600 pounds can be processed in a load.
ZeroFlow control is based on nitriding with a single-component atmosphere – raw ammonia (NH3). The adjustment of nitriding atmosphere chemical composition, and therefore the control of nitriding potential, is done only by analyzing and metering ammonia into the furnace. The ZeroFlow method is characterized by much lower consumption and emission of gases, and it requires a simpler control system, while allowing for forming the hardened layer phase structure with the same precision as processes with more complex two-component atmospheres.
Thermex offers a wide range of ferrous metal heat treating processes and services in Western Canada from its base in Edmonton.
The purchase of this state-of-the-art equipment is in keeping with the company's ongoing commitment to continuous improvement, integration of new technology, and high quality customer service. According to Thermex president Norm Hanson, "Combined with Seco Warwick's R&D testing capabilities and its experience in gas nitriding, we felt this was our best option to offer precise nitriding solutions for our customers and our large load requirements."
www.thermexmetal.com
www.secowarwick.com
Thermex Metal Treating Ltd., Edmonton, is expanding its capacity with the purchase of a Seco Warwick gas nitriding system with vertical pit-style loading and proprietary ZeroFlow control technology.
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Instron celebrates 70 years in business
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Instron, Norwood, Mass., celebrated its 70th anniversary on March 15, 2016. This milestone marks continued success in providing customers with the highest quality products, expert support, and world-class service.
Instron was established in 1946 by Harold Hindman and George Burr, who were working together at the Massachusetts Institute of Technology to investigate suitable substitutes for silk that could be used in the manufacture of parachutes. After discovering that there was no testing machine available with enough accuracy to meet their requirements, Mr. Hindman and Mr. Burr designed a materials testing instrument.
The prototype was so successful that Instron Corporation was formed. Instron has continuously been at the forefront of the industry, earning recognition as one of the first companies to use video strain measurement, and as the first in its industry to offer automatic transducers and reverse stress loading, among many other accomplishments.
In October of 2005, Instron was acquired by ITW as the first company in their Test and Measurement platform, under the guidance of Steve Martindale, Executive Vice President of ITW. Today, Instron thrives under the leadership of Darcy Hunter, Graham Rogers, and KC Goh.
"ITW arrived at a crucial time in Instron's seventy-year history," says Yahya Gharagozlou, Group President - ITW Test and Measurement. "As we made the transition from a largely family-owned business, ITW's philosophy guided us to maintain the high standards envisioned by the original owners, and at the same time taught us to run a more responsive organization to best serve our customers. I see our management's role as custodians of our innovative culture."
Throughout its 70 years in business, Instron has opened offices across the Americas, Europe, and Asia Pacific. With an expansive network of nearly 1700 employees globally, Instron employees collectively speak more than 40 languages, enabling communication with customers in their local languages around the world.
Instron remains committed to delivering leading-edge technologies and services designed to push the boundaries of research, quality control, and service-life testing.
www.instron.com
Instron, Norwood, Mass., celebrated its 70th anniversary on March 15, 2016, marking continued success in providing customers with the highest quality products, expert support, and world-class service.
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Direct gas-fired ovens temper tire molds for auto industry supplier
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Wisconsin Oven Corp., East Troy, Wis., has shipped two direct gas-fired batch ovens with load capacity of 6000 pounds each to a leading automotive supplier for tempering tire molds to produce longer mold life. This industrial oven allows easy access for loading and unloading tire molds by fork truck.
Each tempering batch oven has a maximum operating temperature rating of 800°F, work chamber dimensions of 5 x 5 x 8 feet, and a six-inch reinforced insulated floor. The recirculation system utilizes combination airflow, which provides both horizontal and vertical upward airflow to maximize heating rates and temperature uniformity.
The batch oven is equipped with a 10,850 CFM @ 15 HP belt-driven blower. Supply air is delivered through fully adjustable boxed ducts that are side-mounted along the length on each side of the work chambers. The heating system features an industrial air heat burner rated at 850,000 BTU per hour.
"Designing a solution for our customers that improves their production process is always a top priority. Improved work flow and ease of loading/unloading was a focus for this project to increase production efficiencies," says Tom Trueman, Senior Application Engineer.
www.wisoven.com
Wisconsin Oven Corp., East Troy, Wis., has shipped two direct gas-fired batch ovens with load capacity of 6000 pounds each to a leading automotive supplier for tempering tire molds to produce longer mold life.
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One Minute Mentor: Tempering Characteristics of P20 Mold Steel
March 11, 2016
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Tempering characteristics for P20 mold steels carburized at two different temperatures are shown in the graphs. In (a), the upper curve represents steel carburized in hardwood charcoal at 1675 to 1700°F for eight hours, air cooled in pack, reheated at 1725 to 1750°F, cooled in air, and tempered. The middle curve represents steel carburized in cast iron chips at 1725 to 1750°F, removed from pack, cooled in air, and tempered. Graph (b) shows surface hardness after heating at temperature for two hours in a carburizing compound, followed by oil quenching and tempering.
Volume 4D, Heat Treating of Irons and Steels ⇒ Tool Steels ⇒ Heat Treating of Mold Steels and Corrosion-Resistant Tool Steels ⇒ Recommended Heat Treating Practices
Tempering characteristics for P20 mold steels carburized at two different temperatures are shown in the graphs.
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Harper issued patent for heat treatment of carbon fibers
March 9, 2016
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Harper International, Buffalo, N.Y., announces that it has received a patent for its advanced carbon fiber oxidation oven technology that enables changing the airflow direction within the oven to produce down-flow and center-to-end flow throughout the process. The primary air distributed inside the tube is not affected by the secondary air that circulates around the tube, keeping thermal uniformity within the tube.
Titled an "Oven for Fiber Heat Treatment," the patent is for an oven designed to be easy and safe to use for new entries into the marketplace, says Dr. Renee Bagwell, Senior Process Technology Engineer .
Harper's most recent three-meter wide production scale oxidation oven demonstrates air velocity uniformity measuring 2.2%, and temperature uniformity of +/-2.5°C throughout the entire heated length. This design enables enhanced performance with higher and more efficient rates of production.
For the customer, technology advancements equal faster oxidation through elimination of the chimney effect, improved velocity uniformity and range, assurance of temperature uniformity at a variety of flow rates, and optimal control of the reaction, ultimately enhancing fiber quality.
The most distinctive feature of Harper's cutting-edge design, the innovative atmospheric end seal, reduces fugitive emissions, increases the active volume of the oven, and offers reduced energy consumption over alternatives. The seals have independent adjustment of the top and bottom inside and outside slots. Each pass has an independent vent with adjustable draw control, and the exhaust plenum connects to a dedicated fan/VFD. As a result of these innovative design features, there is no vertical mixing in the seal, less air ingress, and virtually no process gas escape.
Harper's instrumentation improvements include a two-tier balancing methodology, responsive quench system and rapid cool down system, emissions monitoring, and inherently safer pressure relief system.
www.harperintl.com
Harper International, Buffalo, N.Y., announces that it has received a patent for its advanced carbon fiber oxidation oven technology that enables changing the airflow direction within the oven to produce down-flow and center-to-end flow throughout the process.
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Specialty stainless steel with 23% chromium provides higher corrosion resistance
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Crompion International, Baton Rouge, La., reports that it has developed Cromgard C23, a specialty stainless steel with 23% chromium, 3.5 - 5% nickel, and 1 - 2% molybdenum. When Cromgard is heat treated properly, it develops a microstructure of nearly equal proportions of austenite and ferrite. This microstructure ensures that the grade is much more resistant to stress-corrosion cracking than austenitic stainless steels.
This grade is engineered to be a specialty stainless alternative to 316L, which contains approximately 17% chromium, 10 - 14% nickel, and 2 - 3% molybdenum.
According to the company, C23 is a duplex specialty stainless steel that provides higher pitting and crevice corrosion resistance along with enhanced strength. It is said to be less susceptible to price fluctuations due to the low nickel content. Also, as Cromgard C23 is twice as strong as 316L, many parts can be downgauged, which results in cost reductions in the multi-thousands or more for tank and vessel applications.
Cromgard C23 is available in multiple widths and lengths to fit a wide range of customer needs.
www.crompion.com
Crompion International, Baton Rouge, La., reports that it has developed Cromgard C23, a specialty stainless steel with 23% chromium, 3.5 – 5% nickel, and 1 – 2% molybdenum.
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Alcoa awarded U.S. Army contract to reduce weight of combat vehicles
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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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