One Minute Mentor: Nitriding Potential
February 17, 2017 Source:
The nitriding potential controls the amount of nitrogen in the metal. The graph shows the atomic concentration of nitrogen as a function of nitriding potential (Kn) and depth.
The nitriding potential controls the amount of nitrogen in the metal. The graph shows the atomic concentration of nitrogen as a function of nitriding potential (Kn) and depth.
Continue readingCompuCore expands controls retrofit options for vacuum heat treating systems
February 16, 2017 Source:
Ipsen, Cherry Valley, Ill., introduces CompuCore, a competitively priced option for controls retrofits available for installation on most brands of vacuum heat-treating systems. These newly enhanced controls reduce the potential for human error and maximize uptime, allowing users to achieve greater efficiencies.
The controls software package is a cost-effective option for those who want to automate their manual system with the latest technology. It helps users gain comprehensive control of all furnace functions, while also achieving repeatable throughput and results.
CompuCore features five main screens, which allow operators to monitor and control operations – including viewing and editing an entire recipe – while it monitors and controls vacuum levels and temperatures. Other key features:
Capability to meet applicable AMS 2750 requirements
Greater control over temperature uniformity with DigiTrim and DigiPID heat-zone control (five temperature ranges each)
Ability to easily create, edit, store, and execute process recipes be means of a menu-driven screen that shows the entire recipe
Ipsen, Cherry Valley, Ill., introduces CompuCore, a competitively priced option for controls retrofits available for installation on most brands of vacuum heat-treating systems.
Continue readingSolar Atmospheres adds new furnace with 5×10-6 Torr vacuum and all-moly hot zone
February 15, 2017 Source:
Solar Atmospheres of Western Pennsylvania, Hermitage, recently added a state-of-the-art vacuum furnace with an all-molybdenum hot zone having dimensions 24 x 24 x 36 inches. The all-stainless steel chamber rated at 2500°F is equipped with an oversized pumping system. Unlike other vacuum furnaces, this pumping system has a series of isolation valves that concentrate the critical vacuum levels within the location that matters most – the vacuum chamber.
This furnace was built exclusively for the critical materials often encountered in the aerospace, medical, and semiconductor arenas that are sensitive to vacuum levels and the potential contact of carbon particles. To enhance the unshielded processing of critical parts at vacuum levels lower than 5x10-6 Torr without any contamination, Solar Atmospheres will construct an environmentally controlled room surrounding this furnace. The room will feature tightly controlled temperature, humidity, and positive pressure, which will aid in eliminating water vapor, dust, and debris concerns. New and clean dedicated fixturing will be used exclusively for this furnace, never leaving the premises.
According to Bob Hill, President of Solar Atmospheres of Western Pennsylvania, "This brand new furnace and environs will enable us to guarantee bright clean work while eliminating the safety hazard of handling razor sharp stainless steel foils. Now that this furnace is fully operational, in 2017 we look forward to adding the MedAccred medical accreditation to our ever expanding list of approvals. I would like to thank our sister company Solar Manufacturing for designing and constructing this outstanding, pristine furnace that will enable us to produce parts that will significantly add even more value to our customer's operations."
Solar Atmospheres of Western Pennsylvania, Hermitage, recently added a state-of-the-art vacuum furnace with an all-molybdenum hot zone having dimensions 24 x 24 x 36 inches.
Continue readingHeavy Carbon president awarded patent for Endocarb carburizing system
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The Heavy Carbon C., Pittsford, Mich., announces that its president, George Barbour, has been awarded a patent for "A method of carburizing which allows a carburizing process in a furnace at high temperatures in a protective atmosphere." Called Endocarb, the primary function of this method is soot control, with an atmosphere flow providing constant low methane (CH4 ) to produce a strong reaction for a high quality atmosphere regardless of carbon-potential set point
This method is said to carburize at a carbon potential well into the soot range, while maintaining a controllable carbon potential with stable CH4. This stability maintains a constant reaction, cracking an air/gas mix in a self-heated retort to a temperature of 1825°F before entry into the furnace. The high carbon potential penetrates the steel surface at a rate up to 30% faster, saving time and money while producing higher quality parts. The system can be added to existing furnaces or built into a furnace at the time of manufacture.
In addition to the speed at a higher carbon potential at high temperatures, the atmosphere will also penetrate lower-grade steels at lower temperatures without using ammonia to raise the hardness (HRC). The air/gas mix is cracked in a retort outside the furnace to form the atmosphere, and is heated at the same high temperature of 1825°F before entry into the furnace. In this manner, the low furnace temperature does not hinder the reaction that must take place in the furnace.
Soot control takes place simultaneously while the carburizing cycle is in operation; therefore, no time is lost to clean soot from the furnace, instead of taking furnace time to remove soot and clean the furnace, loads can be run instead. Time is money and soot burnout takes time. Because less time is required per load, less gas and power is wasted, resulting in more cost savings.
The Heavy Carbon Company, Pittsford, Mich., announces that its president, George Barbour, has been awarded a patent for “A method of carburizing which allows a carburizing process in a furnace at high temperatures in a protective atmosphere.”
Continue readingAir Products installs nitrogen supply system for Boeing composite-wing autoclave
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Air Products, Lehigh Valley, Pa., recently installed an advanced nitrogen supply system at Boeing's new 777X Composite Wing Center in Everett, Washington. The nitrogen will be supplied to the world's largest autoclave, where it will create the inert atmosphere and rapid pressure required to form and cure large carbon fiber composite wings for Boeing's new 777X commercial jetliners.
"Boeing is a leader in their industry, and we are excited to build on our existing relationship by playing a part in the fabrication of the world's largest carbon fiber composite wings for their newest commercial jetliner,"
"Air Products has extensive experience in supplying the aerospace industry, particularly with autoclaves, says Paul Householder, vice president‒Western Region Americas for Industrial Gases at Air Products. "We appreciate Boeing's confidence in our ability to provide them with a reliable supply of high-quality nitrogen for this very critical application."
The advanced nitrogen supply system includes three 15,000-gallon liquid tanks and a steam sparged water bath vaporization system. Boeing's assembled wings are placed into the autoclave, which is closed, sealed, and flooded with nitrogen at specific flow rates, pressures and temperatures to purge out oxygen and create the atmosphere required for the curing process. This project represents the third major autoclave project Air Products has completed with Boeing in the last three years.
www.airproducts.com/aerospace.
Air Products, Lehigh Valley, Pa., recently installed an advanced nitrogen supply system at Boeing’s new 777X Composite Wing Center in Everett, Washington.
Continue readingQuesTek receives Tibbetts Award for Integrated Computational Materials Engineering
February 10, 2017 Source:
QuesTek Innovations, Evanston, Ill., announces that it was invited to the White House in early January to accept the U.S. Small Business Administration 2016 Tibbetts Award. This prestigious award is presented to small businesses, organizations, and individuals who have demonstrated excellence in leveraging Small Business Innovation Research (SBIR) funding to generate measurable impact through technological innovation, technology transfer, business impact, and product commercialization.
The 2016 Tibbetts Award was presented to 37 small businesses, and QuesTek was specifically recognized for its unique contributions to the field of Integrated Computational Materials Engineering (ICME) and President Obama's Materials Genome Initiative.
QuesTek received its first SBIR-funded project in 2001, and has since been awarded over $30 million across a total of 93 projects, all of which have focused on the modeling and design of novel materials.
QuesTek's reported commercialization value ranks it in the 95th percentile of all SBIR recipient companies. SBIR funding (from DOD, DOE, DARPA and NASA) has enabled QuesTek to create more than 30 jobs; transition its ICME technology and a team of engineers to a leading Silicon Valley consumer electronics corporation; form a joint venture with Thermo-Calc Software in Sweden to expand its ICME offerings into the European market; and enter into a strategic partnership with a major U.S.-based company to design and commercialize game-changing alloys.
Under SBIR-funded projects, QuesTek designed and commercialized two ultra-high performance steels: Ferrium M54 steel and Ferrium C64 steel. Ferrium M54 steel was successfully qualified and transitioned into the U.S. Navy T-45 fleet for the safety-critical hook shank component application, and is bringing an estimated $3 million in savings to the Navy based on an order of 60 components. Ferrium C64 steel is being qualified by Bell Helicopter and Sikorsky/Lockheed Martin for next generation helicopter transmissions, replacing lower-performing steels and allowing for significant increases in power density.
Both of these steels have received U.S. patents and are commercially available through a license agreement from leading specialty steel producer, Carpenter Technology.
QuesTek Innovations, Evanston, Ill., announces that it was invited to the White House in early January to accept the U.S. Small Business Administration 2016 Tibbetts Award.
Continue readingCarpenter buys Puris for its titanium powder capabilities
February 6, 2017 Source:
Carpenter Technology Corp., Philadelphia, announces that it has agreed to purchase substantially all of the assets and business of Puris LLC, a producer of titanium powder for additive manufacturing and advanced technology applications. The assets and business to be acquired include Puris' titanium powder operations and business, additive manufacturing assets, patents, and related intellectual property.
"This acquisition will provide Carpenter with immediate entry into the rapidly expanding titanium powder market, and is consistent with our strategic focus on strengthening our leadership position in important growth areas," said Tony Thene, Carpenter's President & CEO. "Puris brings industry leading technology and processes for the production of titanium powder, additive manufacturing part production capabilities, a talented team, attractive intellectual property, and established customer relationships. The strengths of Puris, coupled with Carpenter's reputation as an industry leading producer of premium alloys and our global commercial reach, will allow us to further deliver on the growing needs of our customers."
As a result of the transaction, which cost $35 million, Carpenter will enter the titanium powder market significantly earlier than previously planned, and will reduce its planned fiscal year 2017 capital expenditures by approximately $20 million.
Operations will continue at the existing site, which is well positioned for future expansion and will operate as a functional unit of Carpenter Powder Products, complementing Carpenter's existing broad portfolio of well-established powder metallurgy portfolio.
According to Stephen Peskosky, Vice President of Corporate Development at Carpenter, "The addition of titanium powder to Carpenter's existing capabilities is significant due to the current and anticipated demand increases from the additive manufacturing industry, which produces mission-critical parts supplied to Aerospace and Medical markets, as well as other markets."
Carpenter Technology Corp., Philadelphia, announces that it has agreed to purchase substantially all of the assets and business of Puris LLC, a producer of titanium powder for additive manufacturing and advanced technology applications.
Continue readingSteel Dynamics invests $28 million to expand rolling capacity at its Roanoke facility
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Steel Dynamics, Fort Wayne, Ind., recently invested $28 million for a reheating furnace and a new finishing area in its Roanoke Bar Division to increase rolling capacity from the current 500,000 tons to over 600,000 tons per year.
"With the addition of this equipment, which allows for multi-strand slitting and rebar finishing, we expect the added product diversification and our existing highly competitive cost structure to allow us to quickly grow market share. Additionally, we will be one of the largest independent rebar suppliers without our own rebar fabricating business, which we believe will be a positive for our new customer base," said Joe Crawford, Vice President and Roanoke Bar Division General Manager.
The supply package is comprised of a pusher-type high capacity reheating furnace designed to process 140 tons of billets per hour. The plan is to roll the billets into light sections and reinforcing bars from sizes #4 to #11, as well as corresponding round bars. The objective of the new reheating furnace is not only to increase productivity, but also to significantly improve energy efficiency, with the adoption of a smart combustion management system.
After the upgrade, the Roanoke Bar Division expects to increase production of rebar to over 200,000 tons per year. Commissioning is expected to commence at the end of 2017.
Steel Dynamics, Fort Wayne, Ind., recently invested $28 million for a reheating furnace and a new finishing area in its Roanoke Bar Division to increase rolling capacity from the current 500,000 tons to over 600,000 tons per year.
Continue readingPlasma-sprayed aluminum-titanium coating to protect U.K. aircraft carrier deck
February 4, 2017 Source:
The Aircraft Carrier Alliance, U.K., reports that a plasma spray aluminum-titanium coating has been developed by British companies specifically to protect the flight deck of the new Queen Elizabeth Class aircraft carriers from the heat that results from the immense thrust of the engines of its F-35B Lightning II fighter jets.
The specialized thermal spray coating is being applied to sections of the vast flight deck of HMS Queen Elizabeth using a specially developed robotic spray that fires powdered metal through a jet of plasma at temperatures of almost 18,000°F. The molten droplets then flatten and quickly solidify, creating a tough but rough coating 2 to 2.5 mm thick that is bonded to the steel beneath. Approximately 2000 square meters of the 19,000 square-meter flight deck will be coated, with the work due to be completed prior to sea trials in early 2017.
The coating is made of a combination of aluminum and titanium powders, and can withstand temperatures of up to 2700°F. Developed in partnership with Monitor Coatings, based in Tyne and Wear, the material is expected to provide long-term protection through the 50-year life of the carriers. It is an important part of the work underway to prepare HMS Queen Elizabeth for sea trials this year and flight trials in 2018.
The QE Class ships, which include the Queen Elizabeth and the Prince of Wales, will each provide eight acres of sovereign territory to be deployed around the world. They will be versatile enough to be used for operations ranging from supporting war efforts to providing humanitarian aid and disaster relief.
According to Captain Simon Petitt, Senior Naval Officer of HMS Queen Elizabeth, "The new flight deck coating is one of the many 21st Century engineering innovations being incorporated in the Queen Elizabeth Class program. As the largest warships ever built for the Royal Navy, these powerful ambassadors will protect U.K. interests around the globe for the next 50 years."
The Aircraft Carrier Alliance has four members, three of which are industrial: Babcock, BAE Systems, and Thales UK. The fourth, the UK Ministry of Defence, has a dual role, acting as a member of the Alliance as the customer.
While both aircraft carriers will enter service under the white ensign of the Royal Navy, they will ultimately be utilized by all three sectors of the UK Armed Forces.
http://www.aircraftcarrieralliance.co.uk/media/latest-news
The Aircraft Carrier Alliance, U.K., reports that a plasma spray aluminum-titanium coating has been developed by British companies specifically to protect the flight deck of the new Queen Elizabeth Class Aircraft Carriers from the heat that results from the immense thrust of the engines of the F-35B Lightning II fighter jets.
Continue readingAdditive manufacturing survey shows growth in Defense, Aircraft, and Space
February 3, 2017 Source:
Defence IQ, London, recently conducted a wide-ranging survey of additive manufacturing in the defense, aerospace, and space industries to explore what has changed in the last 12 months and what the future holds. The findings are summarized in an infographic that shows much more than the section shown here. This section refers only to answers to the question, "Which companies are the leaders in applying additive manufacturing?"
The graph compares the results of the 2015 survey to the results of the 2016 survey. The outcome displayed here shows that GE Aviation has moved firmly into the lead at 63%. Last year's leader Airbus, at 53% in 2015, fell to 40% in 2016.
One section of the infographic shows that 37% of respondents think that international bodies should lead additive manufacturing certification efforts, down from last year's survey. The trend for 2017 shows that more people think it should be led by cross-sector working groups.
Other sections of the survey ask what are the industry's biggest challenges, how many stakeholders are aware of the benefits of AM, and how many respondents think that AM will be "standard and ubiquitous" over the next years and decades.
Download the full infographic here: http://bit.ly/2hMibdi
Defence IQ, London, recently conducted a wide-ranging survey of additive manufacturing in the defense, aerospace, and space industries to explore what has changed in the last 12 months and what the future holds.
Continue reading