Siemens acquires Materials Solutions for superalloy additive manufacturing
September 14, 2016
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Siemens AG, Germany, has acquired a majority stake (85%) in Materials Solutions Ltd., England, for its capabilities in additive manufacture of superalloy parts. Materials Solutions is a pioneer in the use of selective laser melting technology for the production of high-performance metal parts. A specialty of the company is making turbomachinery parts, particularly for high-temperature applications in gas turbines, where accuracy, surface finish, and the highest quality of the materials is critical to ensure operational performance.
According to Willi Meixner, CEO of Siemens Power and Gas Division, "With the acquisition of Materials Solutions, we are able to secure world-leading expertise in materials and additive manufacturing process development with focus on high-temperature superalloys. The company's strength is to turn models into high-quality components in record time. Clearly Materials Solutions fits perfectly within our vision for growth and application of advanced technologies within our Power & Gas portfolio."
Founded in 2006, Materials Solutions has proven applications in demanding fields such as aerospace, power generation, and motor sports. "Materials Solutions is developing the applications knowhow and a supply chain for the world's most advanced engineering companies," says Carl Brancher, CEO of Materials Solutions. "We deliver processes and precision parts from 3D CAD models, using software, lasers, and metal powders." Materials Solutions will continue to focus on supporting external customers in those highly demanding environments in order to continuously drive and leverage innovations across different industries.
Siemens uses AM technology extensively for rapid prototyping, and has introduced serial production solutions for rapid manufacturing of small fuel mixers and for rapid repair of burner tips for mid-size gas turbines. Siemens in Finspång, Sweden, already started using Additive Manufacturing technology in 2009 and opened a production facility for metal 3D printed components in February 2016. This investment was the first step in the company's plans for mass manufacture and repair of metal parts with Additive Manufacturing. The first 3D printed burner component (shown in the photo) for a Siemens heavy-duty gas turbine is in successful commercial operation in a power plant in Brno, Czech Republic.
Additive manufacturing is a process that builds parts layer-by-layer from sliced CAD models to form solid objects. Recent advancements in the technology have enhanced the potential of additive manufacturing for fully manufactured production parts. Fiber lasers are now available with enough power to melt high performance metal alloys to manufacture gas turbine or jet engine parts.
www.energy.siemens.com/hq/en/services/industrial-applications/additive-manufacturing.htm
Siemens AG, Germany, has acquired a majority stake (85%) in Materials Solutions Ltd., England, for its capabilities in additive manufacture of superalloy parts.
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Solar Atmospheres forms Vacuum Pump Services Corporation
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Solar Atmospheres, Souderton, Pa., announces the formation of Vacuum Pump Services Corp., a service center in which skilled technicians will repair, rebuild, recondition, and service all brands of vacuum pumps. Prior to servicing, all pumps will be disassembled and inspected thoroughly to provide an accurate quote.
The new company will be operated by Bob Sandora, Vice President of Operations, a longtime Solar Atmospheres employee with over 40 years of mechanical vacuum pump experience; and Steve MacInnes, Manager of Operations, with 15 years of mechanical vacuum pump experience.
According to William R. Jones, CEO of the Solar Atmospheres family of companies, "We know vacuum pumps: when to have the pumps serviced, and how to service them correctly. This is the base reason for establishing our own organization. We have also serviced pumps for other organizations, even including our competitors. So we are eager to share our knowledge and expertise, and to offer our services broadly across industry."
The photo shows Steve MacInnes, Manager of Operations, final testing a Stokes mechanical pump – torn down, repaired, and tested with a helium mass spectrometer
www.vacpumpservices.com
Solar Atmospheres, Souderton, Pa., announces the formation of Vacuum Pump Services Corp., a service center in which skilled technicians will repair, rebuild, recondition, and service all brands of vacuum pumps.
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ASM Appoints New Managing Director
September 13, 2016
Source: ASM International
The ASM International Board of Trustees announces the appointment of William T. (Bill) Mahoney as Managing Director effective immediately.
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Bodycote acquires Nitrex Metal Technologies for precision gas nitriding
September 12, 2016
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Bodycote, Macclesfield, England, announces that it has acquired Nitrex Metal Technologies, which specializes in precision gas nitriding and ferritic nitrocarburizing in both batch and continuous processes.
Nitrex potential-controlled gas nitriding and potential-controlled gas nitrocarburizing heat treatment technologies are applied in industries such as precision parts, automotive, aluminum extrusion, defense, gears, tool & die, plastics, machinery, and many others. Continuous gas nitriding and ferritic nitrocarburizing are unique in the industry and are particularly suited to high-volume automotive work.
The addition of Nitrex Metal Technologies to the Bodycote Group broadens the range of thermal processing services that Bodycote offers. These services range from conventional atmosphere heat treatments such as batch IQ, vacuum, and induction, to more exotic specialty technologies such as LPC, BoroCote, and Corr-I-Dur.
According to Dan McCurdy, President of Bodycote Automotive and General Industrial Heat Treating in North America and Asia, "Nitrex Metal Technologies is a great addition to the Bodycote Group. Along with the rest of Bodycote's existing service offerings, this acquisition really cements our position as the go-to expert source for all things nitriding."
www.bodycote.com
Bodycote, Macclesfield, England, announces that it has acquired Nitrex Metal Technologies, which specializes in precision gas nitriding and ferritic nitrocarburizing in both batch and continuous processes.
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Chromium Nitride in Duplex Stainless Steels
September 9, 2016
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Because of the use of nitrogen as an alloying element in these stainless steels, chromium nitrides (CrN) may be present on α/α grain boundaries, on γ/α boundaries, and within the α grains. If formed in large quantities and under conditions in which the chromium-depleted areas do not have time to repair themselves during annealing, the presence of CrN may adversely affect corrosion resistance.
However, because higher nitrogen promotes more γ- phase, which has a high solubility for nitrogen, most modern DSS steels seldom contain significant amounts of CrN. Furthermore, duplex stainless steels are made with very low carbon content, so that carbide formation to a detrimental extent is not usually a concern. The only exceptions to this are the very lean grades, such as S32101, S32022, and S82011, which can lose corrosion resistance and toughness due to carbide and nitride formation. This is most likely to occur in the 1130 to 1475°F range.
With these very lean grades, the rate of formation of intermetallic compounds is sufficiently slow that the phases most likely to cause a loss of properties are the carbides and nitrides. The kinetics of carbide and nitride formation is similar to that of σ/χ precipitation in the 2205 grade.
Volume 4D, Heat Treating of Irons and Steels ⇒ Heat Treated High-Alloy Steels ⇒ Heat Treating of Austenitic and Duplex Stainless Steels ⇒ Duplex Stainless Steels
Because of the use of nitrogen as an alloying element in these stainless steels, chromium nitrides (CrN) may be present on ?/? grain boundaries, on ?/? boundaries, and within the ? grains. If formed in large quantities and under conditions in which the chromium-depleted areas do not have time to repair themselves during annealing, the presence of CrN may adversely affect corrosion resistance.
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Strong scandium-aluminum-magnesium powder-metal alloy designed for 3D printing
September 7, 2016
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Airbus Group APWorks GmbH, Germany, in cooperation with Airbus Group R&D, has developed Scalmalloy, a high-performance scandium-aluminum magnesium powder metal alloy designed for additive manufacturing of high-strength aerospace structures. In addition to its high strength, Scalmalloy is also very tough, and has exceptional high-fatigue properties.
Scalmalloy is corrosion-resistant, and combines the low weight of aluminum with specific strength approaching that of titanium. In comparison, the AlSi10Mg aluminum silicon powder, widely used for additive manufacture, is only half as strong.
Airbus Group's continued work in AlMgSc alloy technologies has resulted in development of the second-generation Scalmalloy. The maximum profile cross-sections for parts depend on the billet size, with possible diameters up to 15-18 inches. Scalmalloy provides robust solutions when high specific strength and exceptionally high corrosion resistance are needed – while also offering the additional advantages of robust manufacturing chains and low-cost production schemes. Additionally, it has the highest microstructure material stability for "low carbon footprint" applications.
This unique combination makes the alloy especially interesting for high-performance applications in the robotics, automotive, and aerospace industries. Together with the design freedom provided by metallic 3D printing, products can also have levels of functionality that were previously unattainable.
http://www.apworks.de/en/scalmalloy/
Airbus Group APWorks GmbH, Germany, in cooperation with Airbus Group R&D, has developed Scalmalloy, a high-performance scandium-aluminum magnesium powder metal alloy designed for additive manufacturing of high-strength aerospace structures.
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Sandvik super-duplex stainless steel selected for prototype boat
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Sandvik Materials Technology, Sweden, announces that its Sandvik SAF 2507 high-strength super-duplex stainless steel has been selected for Project P16 Prototype, an innovative 56-foot prototype boat being built by Swedish Steel Yacht AB. The aim of the project is to evaluate an entirely new technology for constructing more efficient, stronger, and maintenance-free vessels. On completion, the new boat can potentially open up a whole new market for vessels of this type. The prototype boat is aimed to be used by the Coast Guard and sea-rescue services, or as a civilian transport boat.
The new boat will be built of high-strength, maintenance-free stainless steel under a partnership agreement signed by Swedish Steel Yachts AB (SSY), Sandvik Materials Technology, AGA Gas, Saab, and Scania CV.
Sandvik SAF 2507 (UNS S32750) is a super-duplex stainless steel; a high-alloy duplex steel with a PRE (pitting resistance equivalent) value of min. 42. The grade is characterized by very good resistance to chloride corrosion, combined with very high mechanical strength. Sandvik SAF 2507 is particularly suited for service in aggressive environments such as warm chlorinated seawater and acidic, chloride-containing media.
"This is a very exciting development and evaluation project between four major Swedish companies," says Pasi Kangas, Head of Research and Development at Sandvik Materials Technology. "it could solve several key challenges in the boatbuilding industry, by providing more efficient, safer, and greener boats in the future."
The shipping industry currently accounts for a substantial portion of air and sea environmental impact around the world. This is a key factor in the design of the new boat, which requires less material, thereby lightening the vessel and reducing fuel consumption. In addition, the shipbuilding material, Sandvik's advanced steel Sandvik SAF 2507, is 100% recyclable stainless steel and will not need to be painted with poisonous antifouling paint, as is the case with traditional shipbuilding materials.
The vessel will be delivered in the first quarter of 2017 and is being built in Gävle, Sweden, by SSY. On completion, the vessel will be used mainly by Saab and based in Karlskrona.
www.smt.sandvik.com
Sandvik Materials Technology, Sweden, announces that its Sandvik SAF 2507 high-strength super-duplex stainless steel has been selected for Project P16 Prototype, an innovative 56-foot prototype boat being built by Swedish Steel Yacht AB.
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Materion receives Nadcap Merit Status for Heat Treatment
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Materion Corp., Mayfield Heights, Ohio, has earned Nadcap Merit Status from the Performance Review Institute for heat treatment and tensile/hardness testing at its plant in Lorain, Ohio. Nadcap accreditation is important, and in many cases it is required, for companies producing materials or providing services to the aerospace and defense industries.
"This achievement required the focused effort of our technical and quality staff, as well as the commitment of our shift leaders and operators. They had to understand the demands of a Nadcap-accredited system and to work closely together to prepare for the audit and maintain their contribution to the quality management system year round," said W. Glenn Maxwell, President of Materion Performance Alloys and Composites.
Materion has held Nadcap accreditation since 2009. Having demonstrated ongoing commitment to quality by satisfying customer requirements and industry specifications, the Nadcap Heat Treat Task Group determined that Materion earned special recognition with Merit Status. This means that, instead of having their next Nadcap audit in twelve months, Materion has been granted an accreditation that lasts eighteen months.
"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 Materion go above and beyond achieving Nadcap accreditation to obtain Merit Status, and they should be justifiably proud of it," said Joe Pinto, Executive Vice President and Chief Operating Officer at the Performance Review Institute. "Benefitting from a less frequent audit schedule reduces audit costs and associated pressures and demonstrates the trust that the aerospace industry has in Materion, based on their past performance in Nadcap audits. PRI is proud to support continual improvement in the aerospace industry by helping companies such as Materion be successful and we look forward to continuing to assist the industry moving forward."
www.Materion.com
Materion Corp., Mayfield Heights, Ohio, has earned Nadcap Merit Status from the Performance Review Institute for heat treatment and tensile/hardness testing at its plant in Lorain, Ohio.
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Zero Flow gas nitrocarburizing enables better control and lower cost
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Seco Warwick, Meadville, Pa., is demonstrating its ZeroFlow controlled-gas nitriding at the Heat Treatment Exhibition in Moscow this week. Developed in cooperation with Prof. Leszek Małdziński from the Technical University in Poland, the technology is based on the adjusted double-component atmospheres NH3 + dissociated NH3, and NH3 + N2 .
The ZeroFlow method is based on a single-component atmosphere – raw ammonia (NH3). The adjustment of nitriding atmosphere chemical composition, and therefore the control of nitriding potential Np, is performed only by temporary stop and reactivation of NH3 flow into the furnace. The amount flowing into the retort is adjusted and controlled through a gas analyzer (NH3 or H2). Experimental research has shown that the ZeroFlow method is characterized by much lower consumption and emission of gases. It requires a simpler control system and allows for forming the layer phase structure with the same precision as in processes with double-component atmospheres.
"Even though nitriding of steel can be considered a byproduct of the dissociation of ammonia, there is no need to dissociate more ammonia than absolutely necessary," says Prof. Małdziński. "Zero flow nitriding is the first gaseous process that economizes the use of resources without compromising the added value to your product. It allows a targeted treatment of your components, independent of whether you do or do not want a compound layer. Zero flow nitriding gives you larger flexibility, better control, and lower cost of your nitriding process."
https://www.secowarwick.com/en/search?q=zeroflow
Seco Warwick, Meadville, Pa., is demonstrating its ZeroFlow controlled-gas nitriding at the Heat Treatment Exhibition in Moscow this week.
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One Minute Mentor: Duplex Stainless Steels
September 1, 2016
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Complex compounds of iron, chromium, and molybdenum are highly detrimental to toughness and corrosion resistance, particularly the resistance to localized chloride attack. The graph shows the time-temperature exposures required for a 50% reduction in impact strength due to isothermal precipitation of undesirable secondary phases for various duplex stainless steels.
The kinetics of σ/χ precipitation is greatest in the range of about 1500 to 1700°F. The time required to degrade properties depends on the temperature and the alloy content. The increased N content of modern duplex stainless steels significantly decreases the rate of the σ/χ precipitation reactions making it possible to weld these grades without loss of properties due to formation of intermetallic phases. Once intermetallic phases have formed, the only means of removing them and restoring properties is a full solution anneal followed by rapid cooling.
Volume 4D, Heat Treating of Irons and Steels ⇒ Heat Treated High-Alloy Steels ⇒ Heat Treating of Austenitic and Duplex Stainless Steels ⇒ Duplex Stainless Steels
Complex compounds of iron, chromium, and molybdenum are highly detrimental to toughness and corrosion resistance, particularly the resistance to localized chloride attack.
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