Keough to Present AFS Honorary Lecture
February 29, 2016
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John R. (Chip) Keough, FASM, of Applied Process Inc., Ann Arbor, Mich., was selected by the American Foundry Society (AFS) to present the Cast Iron Division Honorary Lecture at its upcoming Metalcasting Congress in April. The lecture was established in 1993 to honor distinguished members of AFS who have contributed to the knowledge base of cast iron. Keough was selected by the leadership of the Cast Iron Division Programs and Papers Committee to present the invited lecture. Past talks have been delivered by both metal casting professors and industry leaders. Keough's lecture, entitled "The Stuff Matters," will take place on April 17 at the AFS Metalcasting Congress in Minneapolis. Keough is director of the technologies division at Applied Process Inc. and also serves as ASM board liaison on the ASM Heat Treating Society Board.
For more information, visit afsinc.org.
John R. (Chip) Keough, FASM, of Applied Process Inc., Ann Arbor, Mich., was selected by the American Foundry Society (AFS) to present the Cast Iron Division Honorary Lecture at its upcoming Metalcasting Congress in April.
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One Minute Mentor: Tempering Tool Steels
February 26, 2016
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As shown in the graph for an M2 steel austenitized at 2225°F, the hardness of high-speed steel is directly affected by tempering temperature and time. From the slopes of the curves, it can be seen that M2 undergoes secondary hardening at temperatures above approximately 700°F, and that secondary hardening proceeds at higher temperatures up to about 1100°F, depending on time at temperature.
These temperatures approximate the practical limits for most tempering operations; lower temperatures do not evoke the secondary hardening response, and higher temperatures produce hardness considerably lower than usually desired.
Volume 4D, Heat Treating of Irons and Steels -> Tool Steels -> Heat Treating of High-Speed Tool Steels -> Recommended Heat-Treating Procedures
As shown in the graph for an M2 steel austenitized at 2225°F, the hardness of high-speed steel is directly affected by tempering temperature and time.
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Aluminum alloy with high recycled content integrated into automotive structures
February 25, 2016
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Novelis, Atlanta, announces that its RC5754 alloy, a new automotive product designed to contain up to 75% recycled aluminum content, has been successfully integrated into the structural components of high-volume production passenger vehicles. RC5754 was developed with Jaguar Land Rover and serves as a key component of Jaguar's REALCAR (REcycled ALuminum CAR) project. First introduced in the new Jaguar XE, the RC5754 alloy will also be featured in all new and legacy Jaguar Land Rover models.
Results of the collaboration in developing this new product are documented in"Collaboration for a Closed-Loop Value Chain," a case study issued in January following the companies' participation in the University of Cambridge Institute for Sustainability Leadership's Postgraduate Certificate in Sustainable Value Chains.
"As a leader in alloy innovation and aluminum recycling, Novelis is honored to work with Jaguar Land Rover to help lead the automotive industry in sustainable vehicle manufacturing," said Pierre Labat, Vice President, Automotive, Novelis Europe. "The new RC5754 alloy not only meets the high recycled content threshold required by Jaguar Land Rover's REALCAR project, but also it delivers the strength, durability and formability specified by world-leading Jaguar Land Rover engineers."
Launched in 2008 by Jaguar Land Rover, the REALCAR program is a multi-stakeholder initiative established to create a closed-loop vehicle production model that recycles automobiles at the end of their lifecycles. The RC5754 aluminum alloy, uniquely developed by Novelis to serve the REALCAR program, is designed to absorb higher levels of processed automotive aluminum scrap than ever before.
With more than 40 years of experience in the automotive industry, Novelis pioneered many of the common aluminum alloys used in automotive manufacturing today – including 6111, 6016 and the original 5754 – in addition to its own Novelis Advanz™ family of alloys. The RC5754 alloy further enhances the Novelis portfolio.
Novelis currently works with many of the world's leading automakers to deliver a variety of strong, formable and lightweight aluminum sheet products that are used in more than 180 vehicles in production today, including the new aluminum-bodied Ford F-150 and Range Rover. Novelis expects double-digit growth in the global use of automotive aluminum by the end of the decade, and the company is growing to meet this demand with manufacturing expansions ramping up in Europe, North America and Asia.
www.novelis.com
Novelis, Atlanta, announces that its RC5754 alloy, a new automotive product designed to contain up to 75% recycled aluminum content, has been successfully integrated into the structural components of high-volume production passenger vehicles.
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Alcoa to supply aluminum, aluminum-lithium, and titanium parts to Boeing
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Alcoa, Pittsburgh, announces a long-term supply agreement with Boeing for multi-material aerospace parts for the 777X, Boeing's newest commercial airplane; the 737 MAX, scheduled for first delivery in 2017; and the 787 Dreamliner. The deal draws on capabilities gained through the Firth Rixson acquisition and the new aluminum-lithium facility in Lafayette, Indiana. Under the new agreement, Alcoa Forgings and Extrusions will supply differentiated components for Boeing's airplanes, including the wing, fuselage, and landing gear.
These include advanced titanium landing gear parts and complex titanium nacelle fittings for the 737 MAX, made using specialized presses gained through the Firth Rixson acquisition; Boeing's first-ever aluminum-lithium extrusion produced at Alcoa's Lafayette facility for the 777X cargo floor, helping save weight and improve corrosion resistance; and large, near-net-shape parts that improve the efficiency and help reduce the costs of Boeing's in-house machining.
This transaction is the fourth multi-year agreement recently announced with Boeing. In December 2015, Alcoa announced long-term supply contracts with Boeing for fastening systems and titanium seat track assemblies. In September 2014, Alcoa announced a significant Boeing contract win which established Alcoa as a sole supplier of wing skins on all of Boeing's metallic structure airplanes.
Alcoa has secured approximately $10 billion in aerospace contracts since the start of 2015, including the Boeing transactions, drawing on the Company's growing aerospace portfolio.
www.alcoa.com
Alcoa, Pittsburgh, announces a long-term supply agreement with Boeing for multi-material aerospace parts for the 777X, Boeing’s newest commercial airplane; the 737 MAX, scheduled for first delivery in 2017; and the 787 Dreamliner.
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TimkenSteel develops faster process for manufacturing high-pressure tubing
February 24, 2016
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TimkenSteel, Canton, Ohio, reports that it has developed a new process to manufacture high-pressure tubing for the production of low-density polyethylene and recently received its first order, from a major petrochemical producer. TimkenSteel's process begins in Canton where its special bar quality (SBQ) steel is forge-rolled and heat treated. It is then sent to TimkenSteel Material Services in Houston where it is bored and honed.
"We have developed a more streamlined process using the assets and operations we have in place to create cost efficiencies. High-pressure tubing (HPT) that previously took more than a year to produce now takes a matter of months," said Shawn Seanor, TimkenSteel's executive vice president of sales and business development. "Another advantage our process offers is flexibility, allowing customers to buy smaller lot sizes."
TimkenSteel recently entered into a supply agreement with A&A Machine & Fabrication LLC, of La Marque, Texas, to further process, market, and sell HPT for low-density polyethylene customers. A&A completed reliability testing to ASME code on prototype tubing and processed that material to industry fabrication requirements in order to illustrate material performance. A&A and TimkenSteel then met with end-users to gain market acceptance of the material.
"HPT users will be able to plan projects with a more accurate forecast due to the shorter lead times and ease of inspection and oversight of the manufacturing process," said C. Alan Hutchins, President and CEO of A&A.
www.timkensteel.com
TimkenSteel, Canton, Ohio, reports that it has developed a new process to manufacture high-pressure special bar quality tubing for the production of low-density polyethylene.
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MetalMaster furnace processes catalytic converter parts for a variety of industries
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Ipsen, Cherry Valley, Ill., recently shipped a horizontal-loading MetalMaster vacuum furnace with two-bar gas quenching to a company in the Southwest United States for processing catalytic converter products, which are then used by such industries as aerospace, automotive and power generation. Ideal for brazing and other high-vacuum applications, this vacuum furnace line performs distinctively well with thin section parts and lighter pieces.
This customized furnace features a 36 x 36 x 72-inch graphite work zone, with a carbon steel gas distribution plenum and graphite heating elements, as well as a 3000-pound load capacity. It operates at temperatures of 1000 to 2400°F with ±5°F temperature uniformity.
The furnace is also equipped with a 35-inch diffusion pump and Ipsen's CompuVac control system. In addition, this MetalMaster furnace is capable of meeting applicable AMS 2750E requirements and providing tight temperature tolerances with DigiTrim control settings. It features an open heating element detection system, as well as a specially engineered heat exchanger and turbine blower that are designed to optimize gas flow for more efficient cooling.
The MetalMaster design has maintained ultimate performance and reliability for more than 45 years, with 500+ installations worldwide. It delivers the cleanliness and uniform cooling that customers request, while also providing a cost-effective, versatile, and adaptable vacuum furnace system. MetalMaster furnaces may also be ordered with several high-productivity options, including specialized instrumentation, increased pumping capability, and material handling systems.
www.IpsenUSA.com/MetalMaster
Ipsen, Cherry Valley, Ill., recently shipped a horizontal-loading MetalMaster vacuum furnace with two-bar gas quenching to a company in the Southwest United States for processing catalytic converter products, which are then used by such industries as aerospace, automotive and power generation.
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Bodycote breaks ground for aluminum solution treatment furnace in California
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Bodycote, England, held a ground breaking ceremony in February for a new aluminum solution treatment capability at its location in Westminster, California. With this new capability, Bodycote will be able to process aluminum alloy structures up to 21 feet in length at 1100°F, in multiple types of quench media. This new furnace, scheduled to be in service by the end of third quarter this year, will allow the treatment of large aerospace and commercial forgings weighing up to 20,000 pounds.
The mechanical properties of heat treatable aluminum alloy components can be optimized by the selection of an appropriate solution and age process sequence. For certain alloys, corrosion resistance can, for example, be improved at the expense of strength and vice versa.
Depending on the alloy and cross section at the time of solution treatment, various cooling methods can potentially be utilized to reduce distortion.
Solution treating is typically performed in the 842 to 1067°F range in air, followed by rapid quenching into cold water, hot water, boiling water (-T61 temper), water-polymer (glycol) solution, water spray, or forced air. Natural aging to the T4 temper will occur at ambient temperature for 2XXX, 6XXX, 2XX and 3XX alloys, with most reaching a stable temper after 96 hours. Artificial aging in the 199 to 473°F range is utilized to meet the T6 and T7X tempers.
Immediately after quenching from solution treating, all alloys are relatively soft and can be moderately formed or straightened if performed within a couple of hours. These alloys will naturally age harden at ambient temperature, with their hardness gradually increasing with time following quenching. This can be suppressed by refrigeration below about 0°C (32°F) if it is desired to form or straighten the material more than a couple of hours after quench. Cooling to below about minus 23°C (minus 10°F) or colder is required to retain the As-Quenched (AQ) temper for prolonged storage times beyond a few days.
For maximum formability prior to solution treating and ageing, these alloys must be fully annealed to produce a stable dead soft O temper by heating in the 400 to 425°C (752 to 797°F) range, then slow cooling (28°C or 50°F per hour or slower) to below 235°C (455°F), formed, then solution is treated and aged.
Wrought alloys in the 2XXX (Al-Cu), 6XXX (Al-Mg-Si), 7XXX (Al-Zn-Mg-Cr) and 8XXX (Al-Li) series and cast alloys in the 2XX (Al-Cu), 3XX (Al-Mg-Si-Cu) and 7XX (Al-Zn) series can be solution treated and aged.
Bodycote continues to invest in regional aerospace manufacturing markets across the United States in support of aerospace prime manufacturers and their supply chains.
www.bodycote.com
Bodycote, England, held a ground breaking ceremony in February for a new aluminum solution treatment capability at its location in Westminster, California.
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C.I. Hayes installs low-dewpoint humpback brazing furnace
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C.I. Hayes, Cranston, R.I., a Gasbarre Furnace Group company, recently installed a Humpback Conveyor Belt Furnace for brazing stainless steel parts for the electrical industry. The furnace operates with a low dewpoint hydrogen atmosphere and a maximum operating temperature of 2100°F. It also includes a dewpoint and oxygen monitoring system, as well as communications that allow for remote login and troubleshooting.
The C.I. Hayes Humpback is an inclined mesh belt conveyor furnace designed to allow large door openings while providing extremely low furnace dewpoints. This combination assures minimal gas consumption and maximized operational cost savings.
The Humpback's name is derived from the appearance of the equipment, with inclined entrance and exit tunnels between which are positioned horizontal heating and cooling sections. Parts up to 24 inches high can be processed without negative effects on the furnace atmosphere integrity.
Each area of the furnace has been carefully engineered for ease of equipment operation, maintenance and long life under full production conditions. A helper belt allows heavier belt loading while reducing belt tension in the hot zone, resulting in dramatically improved furnace belt life. To ensure that intricate parts make a smooth, steady transition from and to the inclined sections, double rollers are provided in the transfer sections.
C.I. Hayes designs, manufactures and services industrial vacuum and atmosphere heat treating equipment and has been delivering custom solutions to the heat treating industry for 109 years.
www.cihayes.com
C.I. Hayes, Cranston, R.I., a Gasbarre Furnace Group company, recently installed a Humpback Conveyor Belt Furnace for brazing stainless steel parts for the electrical industry.
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Registration opens for aerospace materials show
February 23, 2016
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ASM International, Materials Park, Ohio, announces that early bird registration is open for the 27th AeroMat Conference and Exposition May 23-25 in Bellevue, Washington. AeroMat is the premier aerospace materials and processing conference in the world presented by top technology leaders in the industry. It includes an exposition of aerospace products and services from over 40 companies and organizations.
With over 125 presentations on multiple content areas, the Technical Program of the 2016 conference is one of the top reasons aerospace professionals attend AeroMat. Additive manufacturing, advanced aluminum alloys, integrated computational materials engineering, and many more topics will be covered. Additive manufacturing in particular will be covered extensively, with a track every day, including a parallel one on Wednesday morning.
Daily plenary sessions on the show floor at AeroMat will complement the technical programming and provide attendees a well-rounded view of the industry. Four talks from industry experts are scheduled, the first being "Redefining Natural Resources" from Chris Lewicki, President and Chief Engineer at Planetary Resources Inc. Other talks include a look into European launcher developments from Stefano Bianchi of the European Space Agency; a history of Boeing from corporate historian Mike Lombardi; and the future of aerospace metals from Dr. Daniel Miracle of the Air Force Research Laboratory.
"This year's AeroMat is a must-attend for anyone in the aerospace industry," says Conference Chair Dr. Michael Shemkunas of Boeing. "I really encourage those involved in aerospace materials and processing to join us in Bellevue to learn about where the industry is going. The programming will be current and informative, we have great companies in the expo hall, and the networking will be fantastic."
The AeroMat exposition will cover three days and include top companies in the aerospace industry. Exhibit spaces and sponsorships are still available. Contact Christina Sandoval, Global Exhibition Manager at ASM International at 440.338.5151 ext. 5625 or [email protected]
ABOUT ASM INTERNATIONAL
As the world's largest association of materials-centric engineers and scientists, ASM International is dedicated to informing, educating, and connecting the materials community. A member and volunteer based organization, ASM serves as a central resource that gathers the latest applied information from the field and disseminates it back to industry, academia, and government through published content, classes, conferences, expositions, and local chapter engagement.
www.asminternational.org
ASM International, Materials Park, Ohio, announces that early bird registration is open for the 27th AeroMat Conference and Exposition May 23-25 in Bellevue, Washington.
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One Minute Mentor: How Austenitizing Temperature Affects High-Temperature Hardness
February 18, 2016
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The austenitizing temperature affects not only the final hardness but also the grain size. Owing to the high amount of alloying elements dissolved in the matrix, prior austenite boundaries are preferentially etched instead of martensite structure, enabling the quantification of austenite grain size. A continuous increase in austenite grain size with the hardening temperature is observed.
The graph shows the reduction in high-temperature hardness of M2 tool steel that results from austenitizing at relatively low temperatures.
Volume 4D, Heat Treating of Irons and Steels ⇒ Tool Steels ⇒ Heat Treating of High-Speed Tool Steels ⇒ Recommended Heat-Treating Procedures
The austenitizing temperature affects not only the final hardness but also the grain size.
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