Lindberg/MPH pit furnace designed for steam heat treating tool steel
April 26, 2016
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Lindberg/MPH, Riverside, Mich., has shipped a pit furnace to a leading manufacturer of mechanical components for steam treating tool steels. Steam treating produces an oxide film on the surface of the part, which improves wear resistance and corrosion resistance, and provides a uniform blue-black finish.
The heat treating furnace has a maximum temperature rating of 1250°F. The work chamber has diameter of 39 inches with a depth of 36 inches and a total load capacity of 3700 pounds. Vacuum-formed ceramic fiber modules have low heat storage and allow for fast heat-up rates. The pit furnace utilizes a high limit controller to protect from over-temperature conditions, and an actuator for atmosphere flow control.
This furnace utilizes nickel-chromium heating elements on the interior of an alloy retort to efficiently heat treat parts in a steam atmosphere. A thermocartridge recirculating fan and solid wall baffle provide uniform atmosphere and heat distribution.
This new Lindberg/MPH design features a maintenance-friendly fan and motor assembly, which allows for reliable and easy maintenance when needed, compared to the old Leeds and Northrup furnace design.
www.lindbergmph.com
Lindberg/MPH, Riverside, Mich., has shipped a pit furnace to a leading manufacturer of mechanical components for steam treating tool steels.
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Dual-beam laser spike anneal system enables process flexibility in chip production
April 24, 2016
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Ultratech Inc., San Jose, Calif., announces a follow-on order from a major foundry for its LSA101 laser spike anneal system equipped with the dual-beam option, which provides a second low-power laser that adds flexibility to chip production. The dual beam enhances yield and enables low thermal budget processing that is required for advanced applications such as gate stack formation, silicide, or post-silicide anneal.
The system will be used for 28nm production, and is expected to ship in the second quarter of 2016.
The industry is experiencing a second wave of growth in the advanced planar node technologies, including 28nm logic. This is due to the high cost and challenges to manufacturing chips at leading-edge FinFET nodes; lithography alone represents close to 45% of the overall spending when considering triple patterning and other advanced lithography techniques. As a result, many foundries, especially those in China, are expanding their 28nm capacity as end customers take advantage of the optimal performance-to-cost ratio at this node. This trend may extend the 28nm node longer and at larger volumes than previously expected.
"This LSA system order is an example of the growing manufacturing opportunities for cost-effective nodes such as 28nm and above," says Arthur W. Zafiropoulo, Ultratech Chairman and Chief Executive Officer. "When comparing the different nodes, 28nm was the last strong planar node and provided the lowest cost per transistor. As a result, customers around the world are increasing their 28nm capacity." Built on the customizable Unity Platform, LSA101 with the dual beam option expands the process space by adding a second low-power laser beam that adds process flexibility and enables millisecond annealing with a low thermal budget process.
Inserting a millisecond anneal step post-junction formation, such as gate stack formation, silicide, or post-silicide anneal, has been shown to improve leakage and device reliability, while reducing contact resistance and improving both performance and yield.
Compared to competing millisecond annealing technologies, LSA with dual beam offers the lowest thermal budget millisecond anneal process, along with superior within-die uniformity for different layouts. This performance is provided at a significantly lower cost of ownership, due to higher throughput and low cost of consumables. The LSA101 delivers high flexibility and extendibility for advanced annealing applications, and is currently in high-volume production for 28nm and below logic devices.
www.ultratech.com
Ultratech Inc., San Jose, Calif., announces a follow-on order from a major foundry for its LSA101 laser spike anneal system equipped with the dual-beam option, which provides a second low-power laser that adds flexibility to chip production.
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One Minute Mentor: Carburizing Tool Steels
April 22, 2016
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P20 mold steel is seldom carburized for molds used in compression molding, particularly for molding the more abrasive plastics. Carburizing temperatures no higher than 1650°F are recommended for this steel because higher temperatures may impair polishability; otherwise, conventional carburizing practice is used, and molds may be quenched in oil directly from the carburizing temperature. A common working range is 54 to 58 HRC.
The graph shows tempering characteristics of carburized mold steels.
(a) Upper curve represents steel carburized in hardwood charcoal 1675 to 1700°F for 8 hours, air cooled in pack, reheated at 1725 to 1750°F, cooled in air, and tempered. Middle curve represents steel carburized in cast iron chips at 1725 to 1750°F, removed from pack, cooled in air, and tempered.
(b) Surface hardness after heating at temperature for 2 hours in 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
P20 mold steel is seldom carburized for molds used in compression molding, particularly for molding the more abrasive plastics.
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SSAB introduces five steel product families for specific applications
April 20, 2016
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SSAB, Stockholm, introduces five steel product families tailored for production processes and maximized end-product performance: SSAB Domex, SSAB Boron, SSAB Form, SSAB Laser Plus, and SSAB Weathering. The new SSAB brand families include hot rolled plate, hot and cold rolled strip, metal coated, and tubes and sections.
SSAB Domex comprises a wide range of versatile structural steels with excellent cold-forming properties for high productivity and reliable performance.
SSAB Boron is a hardenable steel made for the easy and consistent production of wear-resistant products quenched in the customer's own workshop.
SSAB Form is the right choice for stamping, stretching, deep drawing, bending, metal spinning, and other forming procedures, particularly in high-volume production requiring exact and consistent properties.
SSAB Laser Plus (shown in photo) is a structural steel for efficient laser, water, and plasma cutting, improving yield and product quality thanks to guaranteed flatness after cutting, low internal stresses, and smooth surface.
SSAB Weathering and COR-TEN provide customers with an exceptionally wide choice, and flexible ordering of high-strength corrosion-resistant steel grades.
"Customers want to know what a product can offer, so it makes sense to group our products according to how they are used," says Olavi Huhtala, Head of SSAB Europe. "This will make it much easier to identify the right product for the right application. We have created these optimized offers by combining recently-developed products with a selection of the best products from our earlier ranges."
The new product ranges also provide SSAB´s customers with direct access to the company´s extensive services and support. Customers are welcome to contact SSAB for workshop recommendations and technical support on how to improve productivity.
The merger between SSAB and Ruukki has resulted in a restructuring of SSAB's steel portfolio. Last year, SSAB announced some new offerings, and this product launch, together with a forthcoming relaunch of the Docol brand for the automotive industry, will complete SSAB´s new product portfolio.
www.ssab.com
SSAB, Stockholm, introduces five steel product families tailored for production processes and maximized end-product performance: SSAB Domex, SSAB Boron, SSAB Form, SSAB Laser Plus, and SSAB Weathering.
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Metallographic sample mounting system provides durability, speed, ease of use
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Buehler, Lake Bluff, Ill., introduces the SimpliMet 4000, a compression mounting system that eliminates bottlenecks at the mounting stage, rapidly transforming cut samples to specimens ready for grinding and polishing. Designed to be reliable in 24/7 manufacturing environments, the system has undergone rigorous testing to ensure function for long periods and many years.
Throughput time for the lab user is improved with the SimpliMet's fast mounting cycles and specimen duplex capabilities (where two specimens are produced simultaneously in the same mold). It is equipped with the SmartCool intelligent cooling system that optimizes cooling time while also ensuring operator safety and minimal water usage. The intuitive interface sets and stores temperature, pressure, and time, thus shortening set up.
The SimpliMet 4000 is also packaged within a small footprint to relieve overcrowding while producing more mounts. The single-handed closure mechanism engages quickly, and makes moving to the next task a breeze. These time-saving features, combined with rigorous accelerated lifecycle testing to 160,000 cycles, deliver a press that will perform day in and day out.
The SimpliMet 4000 was designed to meet the needs of the most demanding labs. Reliability and speed are critical for production labs, so Buehler designed the product with these features as the primary goal.
www.buehler.co.uk
Buehler, Lake Bluff, Ill., introduces the SimpliMet 4000, a compression mounting system that eliminates bottlenecks at the mounting stage, rapidly transforming cut samples to specimens ready for grinding and polishing.
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Atlas batch atmosphere furnace provides carburizing, neutral hardening, and carbonitriding
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Ipsen, Cherry Valley, Ill., recently shipped an Atlas batch atmosphere furnace and ancillary equipment – temper, washer, loader, endo generator, and load table – to Metal Treaters Inc., St. Paul, Minn. This complete atmosphere system will augment its existing atmosphere equipment and offer a higher level of flexibility, with the ability to provide several processes: carburizing, neutral hardening and carbonitriding.
This Atlas furnace features a 36 x 48 x 38-inch load size with a 3500-pound load capacity. It also operates at temperatures of 1450 to 1800°F, and has a quench-oil capacity of 3500 gallons. Equipped with Ipsen's newest design features and innovations, the furnace is configured for maximum compatibility and reliability to consistently produce quality parts.
With its ability to execute different processes in each sealed-quench furnace, the single-chain model offers a high level of versatility and helps streamline production. It also serves as an ideal option for replacing an older furnace or adding to an existing line to expand production.
www.ipsenusa.com
Ipsen, Cherry Valley, Ill., recently shipped an Atlas batch atmosphere furnace and ancillary equipment – temper, washer, loader, endo generator, and load table – to Metal Treaters Inc., St. Paul, Minn.
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Advanced thermal imaging cameras can detect temperature differences of 1 mK
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Flir Systems, Wilsonville, Oregon, has developed X6000sc and X8000sc series thermal imaging cameras with Lock-In, Transient, and Pulse capabilities for advanced inspections such as nondestructive testing or stress mapping that resolve temperature differences as low as 1 mK.
Thermal imaging cameras offer the ability to detect internal defects through target excitation and the observation of thermal differences on a target's surface. In addition, thermal imaging cameras provide a valuable tool for detecting defects and points of failure in composites, solar cells, bridges, and electronics. They also enable thermal mapping of stress during materials testing.
The FLIR X8000sc/X6000sc Series thermal imaging cameras are designed to provide the best thermal measurement performance. Designed for scientists, engineers and researchers they can provide high resolution thermal images up to 1280 x 1024 pixels (FLIR X8400sc) that enable seeing the smallest of details with excellent measurement accuracy. These advanced thermal cameras detect temperature differences smaller than 25 mK (18 mK typically).
With Flir Systems proprietary "lock-in" process, temperature differences as small as 1mK will become clearly visible. The cameras automatically adjust their temperature range to best fit the thermal scene. Designed to unlock the secrets of almost any application, a Flir X8400sc camera can measure temperatures up to 3000°C with an accuracy of +/- 1°C, or +/- 1%, or faint thermal emissions from areas as small as 3x3 microns. The X8000sc and X6000sc Series cameras work seamlessly together with Flir ResearchIR Max software, enabling intuitive viewing, recording, and advanced processing of the thermal data provided by the camera. Each camera comes standard with this software.
www.flir.com
Flir Systems, Wilsonville, Oregon, has developed X6000sc and X8000sc series thermal imaging cameras with Lock-In, Transient, and Pulse capabilities that can resolve temperature differences as low as 1 mK for advanced inspections.
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ATI announces restructuring of Flat Rolled Products operations
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Allegheny Technologies Inc., Pittsburgh, announces the next phase in the restructuring of its Flat Rolled Products (FRP) operations with the reduction of approximately one third of FRP's salaried workforce through the elimination of over 250 positions. This workforce reduction will be completed by the end of the second quarter 2016. As a result of these actions, ATI will record a $9 million severance charge in first quarter 2016 results. These actions are expected to generate annualized cost savings benefits of over $30 million beginning in the third quarter 2016.
"Reducing our flat-rolled products business' dependence on unprofitable commodity products is a difficult process," said Rich Harshman, Chairman, President and CEO. "We believe in U.S. manufacturing. However, it is difficult for a U.S.-based company to compete in the global commodity markets, particularly when significant global overcapacity exists for products such as commodity stainless steel sheet and grain-oriented electrical steel (GOES). The restructuring and right-sizing actions we are taking, while painful for our employees and our company, are necessary to help secure the future of ATI Flat Rolled Products.
"We are in the process of creating a smaller, more agile, streamlined, cohesive, and efficient FRP business that will focus on products and markets with significant technical barriers to entry. As previously announced, our stainless steel facility in Midland, Pa., has been idled to reduce our exposure to commodity stainless steel sheet. Our GOES operation will be idled this month. These actions improve ATI's focus on differentiated flat-rolled products that serve growing global markets. The future restart of the idled operations depends on future business conditions and ATI's ability to earn an acceptable return on invested capital on products manufactured at these operations.
"The reduction in FRP's salaried workforce is another step in our journey to return the FRP business to profitability as quickly as possible, and to execute our strategy for sustainable long-term profitable growth. We expect the FRP business to be modestly profitable in the second half of 2016."
www.ATImetals.com.
Allegheny Technologies Inc., Pittsburgh, announces the next phase in the restructuring of its Flat Rolled Products (FRP) operations with the reduction of approximately one third of FRP’s salaried workforce through the elimination of over 250 positions.
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Solar Atmospheres receives first MedAccred re-accreditation
April 13, 2016
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Solar Atmospheres Inc., Souderton,Pa., announces that it has become the first company to receive MedAccred critical process re-accreditation. Furthermore, the company expanded its scope of accreditation to include Hardness Testing and Metallography & Microindentation Hardness. MedAccred is an industry-managed critical process supply chain oversight program developed by leading medical device companies to improve device quality and enhance patient safety.
The effort to establish MedAccred began in 2010 when the Performance Review Institute (PRI) was asked to consider the development of a Nadcap style special process supplier accreditation program for the medical device industry.
An industry roundtable was organized and convened in 2012 among interested medical device companies and PRI. Following this roundtable meeting, briefings were held with the FDA Center for Devices and Radiological Health's (CDRH) Office of Compliance and the FDA's Office of Global Operations within the Office of the Commissioner. The program purpose and scope was discussed, along with the results of proof of concept audits conducted to demonstrate the program's viability. The FDA provided positive feedback and strong encouragement to pursue the development of the program.
By 2014, several critical process Task Groups were operating on a formal basis. Program documents were drafted, circulated, and approved by the executives of the participating companies, and audit criteria had been published in several critical process areas. Solar Atmospheres committed to hosting the first MedAccred audit. In early 2015, the first MedAccred critical process accreditation was issued to Solar Atmospheres or Heat Treating.
Today's functioning critical process Task Groups include Cable & Wire Harnesses, Heat Treating, Plastics Injection Molding, Printed Circuit Board Assemblies, Sterilization, and Welding. The industry-managed task groups develop audit criteria, conduct audits, and award MedAccred Critical Process Accreditations to leading suppliers at all tiers in the Medical Device Supply Chain. Many companies are seeking MedAccred Accreditation to demonstrate their commitment to quality and patient safety.
Future MedAccred Task Groups under consideration for development include Material Testing Laboratories, Assemblies, PCBs, Batteries, Chemical Processing, NDT, Cleaning, Coating, Optics, and Packaging.
Active OEM and Contract Manufacturer participants include Johnson & Johnson, Philips, Stryker, GE Healthcare, Medtronic, NYPRO Jabil, Steris, etc. The list of participating suppliers is growing steadily.
www.solaratm.com
Solar Atmospheres Inc., Souderton, Pa., announces that it has become the first company to receive MedAccred critical process re-accreditation, an industry-managed critical process supply chain oversight program developed by leading medical device companies to improve device quality and enhance patient safety.
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Heat-treated powder metallurgy titanium alloy has higher strength, lower cost
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Pacific Northwest National Laboratory, Richland, Wash., announces that its research team has improved the strength of a titanium alloy by producing it via powder metallurgy and heat treating it at different temperatures, then quenching in cold water.
Five decades ago, metallurgists created an alloy named Ti185 by blending titanium with low-cost iron, aluminum, and vanadium. However, superior strength was observed for this alloy only in some places, and the alloy had a tendency to clump. Iron clustered in some areas, leading to beta fleck defects, making the alloy unsuitable for reliable commercial production.
Subsequently, in a study carried out about six years ago, the PNNL researchers and its collaborators devised a low-cost powder metallurgy process for the industrial-scale production of the alloy. They used titanium hydride powder instead of molten titanium as the starting material, reducing the energy requirements significantly and cutting the process time in half. ADMA co-developed the method with PNNL metallurgist Curt Lavender. The company sells advanced materials such as the titanium hydride powder to industries, including aerospace.
In their earlier study, the researchers had already demonstrated the superior mechanical properties of the titanium alloy created from their low-cost process. In the new study, they explored how to make even stronger titanium alloys. The team was able to gain insights into the nanostructure of the alloy by using a unique atom probe imaging approach and powerful electron microscopes.
Using electron microscopy, the team observed the microstructure of the alloy at a resolution of hundreds of nanometers. The atom probe tomography system at the Environmental Molecular Sciences Laboratory, a DOE Office of Science User Facility located at PNNL, was used to observe the arrangement of individual atoms in 3D.
The researchers found that their optimized heat-treating process produced an alloy with an alpha phase, consisting of micron and nanometer -size precipitate regions, in a matrix of beta phase. Each region has higher concentrations of certain elements. The aluminum and titanium atoms are found inside the nano-sized alpha phase precipitates, whereas vanadium and iron are in the beta phase.
"We found that if you heat treat it first at a higher temperature before a low -temperature heat treatment step, you could create a titanium alloy 10 to 15% stronger than any commercial titanium alloy currently on the market, and that it has roughly double the strength of steel," says Arun Devaraj, Materials Scientist at PNNL
"This alloy is still more expensive than steel, but with its strength-to-cost ratio, it becomes much more affordable with greater potential for lightweight automotive applications," added Vineet Joshi, who serves as a metallurgist at PNNL.
www.pnnl.gov
Pacific Northwest National Laboratory, Richland, Wash., announces that its research team has improved the strength of a titanium alloy by producing it via powder metallurgy and heat treating it at different temperatures, then quenching in cold water.
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