Ipsen Titan 2.0 heat treating furnace line features predictive maintenance
September 29, 2015
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Ipsen USA, Cherry Valley, Ill., will unveil its Titan 2.0 vacuum furnace and PdMetrics software platform for predictive maintenance during the ASM Heat Treating Conference and Exposition/Gear Expo in Detroit. Three horizontal two-bar models are available, all with PdMetrics for monitoring critical data from the hot zone, pumping system, cooling system, and vacuum system. Furnace processes include hardening, annealing, tempering, brazing, and more.
The hot-zone power supply features intelligent silicon-controlled rectifiers (SCR), which provide accurate and efficient heating control with enhanced communication n and diagnostics. An integrated framework with a rigid, all-metal design protects equipment from the surrounding work environment, helping extend its lifespan. Standard options and additional features are available.
The Titan 2.0 provides optimized maintenance and ease of access with an improved furnace layout. It features a compact design that allows for ease of installation and requires 25% less floor space. It enables lower cost per part by using high-efficiency components and 20% less quench gas. The high-definition, windows-based display includes a touchscreen and scrolling marquee that makes critical furnace parameters visible from a distance.
During ASM 2015, Ipsen experts will also present two papers: The Growth of Predictive Maintenance and its Effect on Future Furnace Performance; and Obtaining Nadcap Accreditation: Helping You Pass Your Audit.
www.IpsenUSA.com/ASMHeatTreat2015
Ipsen USA, Cherry Valley, Ill., will unveil its Titan 2.0 vacuum furnace and PdMetrics software platform for predictive maintenance during the ASM Heat Treating Conference and Exposition/Gear Expo in Detroit.
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Alcoa to separate into Upstream Company and Value-Add Company
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Alcoa, Pittsburgh, announces that it will separate into two companies: the Upstream Company, which will consist of the Bauxite, Alumina, Aluminum, Casting, and Energy businesses; and the Value-Add Company, which will include the current Global Rolled Products, Engineered Products and Solutions, and Transportation and Construction Solutions.
The Upstream Company's asset base will include the world's largest bauxite mining portfolio, with 46 million bone-dry metric tons of production in 2014. It has a low 19th percentile position on the global bauxite cost curve. The company will be the world's fourth largest aluminum producer with a highly competitive second quartile cost curve portfolio. It will have an unrivalled casthouse network in close proximity to customers, and a substantial portfolio of energy assets with power production capacity of approximately 1550 megawatts and operational flexibility to profit from market cycles.
The Value-Add Company will be a premier provider of high-performance multi-material products and solutions with 157 globally diverse operating locations and approximately 43,000 employees. The company will be a differentiated supplier to the high-growth aerospace industry with leading positions on every major aircraft and jet engine platform, underpinned by market leadership in jet engine and industrial gas turbine airfoils and aerospace fasteners. Additionally, the Value-Add Company will be a leader in aluminum commercial truck wheels and will hold the number one market position in North American architectural systems.
The transaction is expected to be completed in the second half of 2016. At that point Alcoa shareholders will own all of the outstanding shares of both the Upstream and Value-Add Companies.
http://www.alcoa.com/two-strong-companies/default.asp
Alcoa, Pittsburgh, announces that it will separate into two companies: the Upstream Company, which will consist of the Bauxite, Alumina, Aluminum, Casting, and Energy businesses; and the Value-Add Company, which will include the current Global Rolled Products, Engineered Products and Solutions, and Transportation and Construction Solutions.
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One Minute Mentor: Sinter Hardening
September 24, 2015
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Sinter Hardening
Sinter hardening refers to a process in which the cooling rate in the cooling zone of the sintering furnace is fast enough to transform a significant portion of the powder metal steel matrix into martensite.
The sinter hardening route has become increasingly widespread due to its cost effectiveness. Advantages include:
Volume 4D, Heat Treating of Irons and Steels ⇒ Heat Treating of Carbon and Low-Alloy Steels ⇒ Heat Treatment of Powder Metallurgy Steels ⇒ Sinter Hardening
Sinter hardening refers to a process in which the cooling rate in the cooling zone of the sintering furnace is fast enough to transform a significant portion of the powder metal steel matrix into martensite.
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Advancing development of thermal manufacturing technologies
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A new roadmap outlines a near-term strategy for the accelerated development and implementation of advanced technologies across the many industries that rely on thermal manufacturing, which collectively employ more than 5.4 million people and generate almost $3 trillion in economic activity. By providing specific actions for a more coordinated cross-sector approach to advanced thermal manufacturing in the next five years, this roadmap aims to enable the more than 100,000 businesses involved in and impacted by thermal manufacturing—97% of which are small and medium-sized companies—to improve the efficiency of their operations as well as the performance of the U.S. manufacturing sector as a whole.
Developed by the Thermal Manufacturing Industries Advanced Technology Consortium (TMI ATC) initiative under the leadership of ASM International, Materials Park, Ohio, and through funding from the National Institute of Standards and Technology (NIST), Gaithersburg, Md., Advanced Manufacturing Technology Consortia (AMTech) program, Advancing Thermal Manufacturing: A Technology Roadmap to 2020 identifies common barriers that currently constrain the use of advanced technologies in thermal manufacturing—including limitations of current technologies and processes as well as widespread non-technical issues related to workforce development and training.
"We were very pleased to be able to bring together different constituencies to develop this first roadmap in the thermal manufacturing area", says Terry Mosier, Managing Director of ASM International.
To address these common barriers, the roadmap offers a two-fold strategy that combines focused technology development with activities designed to stimulate and support technology implementation. The roadmap identifies 50 activities and seven detailed action plans to accelerate the development, adaptation, and implementation of advanced technologies throughout the thermal manufacturing community in the next five years.
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The technology development activities identified in the roadmap aim to enhance the development and adaptation of heating methods and materials for thermal manufacturing equipment and products as well as improve the understanding, prediction, monitoring, and control of thermal manufacturing processes.
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The technology implementation activities identified in the roadmap focus on stimulating the widespread acceptance and adoption of advanced technologies throughout the thermal manufacturing community to ensure that even small and medium-sized companies with limited resources can effectively implement these technologies in their operations.
Implementation of this roadmap's critical actions and priority action plans will be led by the Metal Processing Institute (MPI) at Worcester Polytechnic Institute, Mass., in conjunction with ASM International. Together, these organizations will engage their diverse membership bases—including members from academia, national laboratories, and industry—to catalyze action in this nationally critical area.
"The increased development and implementation of advanced technologies can ultimately better position the U.S. thermal manufacturing in the global economy," says Diran Apelian, MPI Director. "This roadmap provides a compelling path forward that should be of interest to all stakeholders."
Cross-industry Consortium Leads the Way to Advanced Thermal Manufacturing
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Ford and Alcoa collaborate to make stronger, more formable Micromill aluminum alloys
September 23, 2015
Source: ASM International
Ford Motor Co., Dearborn, Mich., and Alcoa Inc., Pittsburgh, are collaborating to produce next-generation Micromill automotive aluminum alloys that are 40% more formable and 30% stronger.
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Atomic structure model enables prediction of metal combinations that can form metallic glasses
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Australia's University of New South Wales (UNSW) announces that a research team has developed a method for predicting the combinations of metals that can form metallic glass alloys The method has enabled researchers to successfully predict more than 200 such alloys based on magnesium, silver, copper, zinc, and titanium. The photo shows magnesium-based bulk metallic glass castings.
The team includes Prof. Kevin Laws and Prof. Michael Ferry of the UNSW School of Materials Science and Engineering, and ASM Fellow Dr. Daniel Miracle, Chief Scientist in the Materials and Manufacturing Directorate of the U.S. Air Force Research Laboratory.
They describe the method in "A Predictive Model for Metallic Glasses," published Sept. 15 in the journal Nature Communications. Here is the abstract:
"Great progress has been made in understanding the atomic structure of metallic glasses, but there is still no clear connection between atomic structure and glass-forming ability. Here we give new insights into perhaps the most important question in the field of amorphous metals: How can glass-forming ability be predicted from atomic structure?
"We give a new approach to modelling metallic glass atomic structures by solving three long-standing problems: we discover a new family of structural defects that discourage glass formation; we impose efficient local packing around all atoms simultaneously; and we enforce structural self-consistency.
"Fewer than a dozen binary structures satisfy these constraints, but extra degrees of freedom in structures with three or more different atom sizes significantly expand the number of relatively stable, ‘bulk' metallic glasses. The present work gives a new approach towards achieving the long-sought goal of a predictive capability for bulk metallic glasses."
The new structural model predicts the most stable binary metallic glass topologies, which allows scientists to predict the metal combinations that will have glass-forming ability.
"We will also be able to engineer these materials on an atomic scale so they have the specific properties we want," says Prof. Laws. "We can start to create many new useful metallic glass types and begin to understand the atomic fundamentals behind their exceptional properties."
https://newsroom.unsw.edu.au/news/science-tech/futuristic-alloys-three-times-stronger-steel-yet-malleable-chewing-gum
Australia’s University of New South Wales announces that a research team has developed a method for predicting the combinations of metals that will produce metallic glass alloys.
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Solar Atmospheres new Southeast plant receives Nadcap accreditation for heat treating
September 22, 2015
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Solar Atmospheres Southeast, Greenville, S.C., has received Nadcap (National Aerospace and Defense Contractors Accreditation Program) accreditation for heat treating only three months after opening by demonstrating ongoing commitment to quality. A heat treating company achieves Nadcap accreditation by proving that it effectively meets the most demanding and stringent customer requirements that exist in the aerospace industry.
"Our South Carolina plant just opened in June 2015 and we were extremely motivated to better serve our customers by becoming Nadcap accredited," says President Steve Prout. "In three months we have achieved a goal that typically takes double that amount of time. The quick turnaround in reaching this quality milestone is a testament not only to our corporate commitment, but also to the expertise and dedication of our staff."
"Achieving Nadcap accreditation is not easy. It is one of the ways in which the aerospace industry identifies those who excel at manufacturing quality product through superior special processes. Companies such as Solar Atmospheres work hard to obtain this status and they should be justifiably proud of it," says Joe Pinto, Executive Vice President and Chief Operating Officer at the Performance Review Institute. "PRI is proud to support continual improvement in the aerospace industry by helping companies such as Solar Atmospheres be successful, and we look forward to continuing to assist the industry moving forward."
www.solaratm.com
Solar Atmospheres Southeast, Greenville, S.C.
Has received Nadcap (National Aerospace and Defense Contractors Accreditation Program) heat treating accreditation only three months after opening by demonstrating its ongoing commitment to quality.
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Ipsen ships horizontal MetalMaster to heat treater for brazing and high-vacuum work
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Ipsen USA, Cherry Valley, Ill., recently shipped a horizontal-loading MetalMaster vacuum furnace with two-bar gas quenching to a commercial heat treating company in South Carolina for brazing and other high-vacuum applications. This vacuum furnace line performs extremely well treating thin sections and lighter parts.
This customized furnace features a 36 x 30 x 48-in. graphite work zone with a carbon steel gas distribution plenum and molybdenum heating elements. The furnace has a 2000-pound load capacity, and operates at temperatures of 1000 to 2400°F with ±10°F temperature uniformity.
The furnace is equipped with a 20-in. diffusion pump and Ipsen's CompuVac control system. In addition, it is capable of meeting applicable AMS 2750E requirements and providing tight temperature tolerances with DigiTrim control settings. It includes 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 be ordered with several high-productivity options, including specialized instrumentation, increased pumping capability, and material handling systems.
www.IpsenUSA.com/MetalMaster
Ipsen USA, Cherry Valley, Ill.
Recently shipped a horizontal-loading MetalMaster vacuum furnace with two-bar gas quenching to a commercial heat treating company in South Carolina for brazing and other high-vacuum applications.
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Heat Treat expo sells out
September 18, 2015
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The exposition for Heat Treat 2015 has sold out for the second time in a row. Hundreds of heat treating companies and gear manufacturers will be displaying their latest and greatest products and services next month at the 28th annual ASM Heat Treating Society Conference and Exposition in Detroit, Mich.
With over 290 booths on the sold out floor - an increase of over 20 booths from 2013 - attendees will have plenty of opportunities to see the latest technology in action. A new addition this year are scheduled live demonstrations on the expo floor, which will educate attendees about new equipment in a hands-on way. Other exciting events happening on the show floor are plenary talk from Dr. Alan Taub of the LIFT consortium on Tuesday afternoon, and the exhibitor reception on Tuesday evening. Exhibitors are encouraged to invite their clients and prospects to attend, particularly if they are local.
Heat Treat 2015 is a biannual conference recognized by industry, academia and government professionals as the premier heat treating gathering in North America. This year it is taking placing in Detroit Michigan, a place with deep roots in heat treating and the birthplace of the ASM Heat Treat Society.
To see a list of the exhibitors, visit this page.
To register for Heat Treat 2015, visit here on the Heat Treat event website.
The exposition for Heat Treat 2015 has sold out for the second time in a row.
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One Minute Mentor: Tempering Powder Metallurgy Steels
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Tempering Powder Metallurgy Steels
Usually, powder metallurgy steel parts having a density greater than 6.7 g/cm3 (0.242 lb/in.3) should be tempered after hardening. Recommended tempering temperatures for PM parts range from 150 to 200°C (300 to 390°F) with 175°C (350°F) being common. The effect of tempering temperature on impact properties is shown in the graph for FL-4205 at various densities.
Tempering above 200°C results in improved toughness and fatigue properties of the hardened part, while making a compromise in tensile strength and impact resistance. However, when tempering at temperatures higher than 200°C, care should be exercised as entrapped oil can ignite.
Volume 4D, Heat Treating of Irons and Steels -> Heat Treating of Carbon and Low-Alloy Steels -> Heat Treatment of Powder Metallurgy Steels -> Quenching and tempering
Usually, powder metallurgy steel parts having a density greater than 6.7 g/cm3 (0.242 lb/in.3) should be tempered after hardening. Recommended tempering temperatures for PM parts range from 150 to 200°C (300 to 390°F) with 175°C (350°F) being common.
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