Ipsen predictive maintenance for heat treating furnaces cuts costs, optimizes operations
November 2, 2015
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Ipsen, Cherry Valley, Ill., displayed the Titan 2.0 heat treating vacuum furnace and PdMetrics software platform for predictive maintenance at ASM International's Heat Treat 2015 conference. PdMetrics helps optimize operations while avoiding unnecessary costs and unplanned downtime. Ipsen also featured the Atlas batch atmosphere furnace line, which provides intelligent interfaces, advanced controls, and ease of integration.
The Titan 2.0 vacuum furnace incorporates years of customer feedback to deliver improved, user-friendly features, all while maintaining a global platform, small footprint, and short delivery times. It features intelligent silicon-controlled rectifiers (SCR) for efficient heating control with enhanced communication and diagnostic features. It also utilizes an integrated framework with a rigid, all-metal design that protects equipment from the surrounding work environment and provides a versatile platform for mounting accessories.
PdMetrics software platform for predictive maintenance utilizes proprietary sensors and control algorithms to determine the appropriate timing for replacing parts and servicing equipment. By monitoring critical data and key parameters such as temperature, vibrations, and pressure, users are able to improve the health and integrity of several systems: the hot zone, pumping system, cooling system, and vacuum integrity.
The stand-alone interface screen is capable of integrating with multiple furnaces; Furnace part replacement notifications are based on usage and wear characteristics; Smart connectivity allows users to receive alerts via email and/or text message; Diagnostic Helper provides access to weather station, leak diagnostics, vacuum level and more; Technical support via Ipsen's Service Cloud allows Ipsen experts to quickly access the necessary data
Two Ipsen experts presented papers at the conference. Aymeric Goldsteinas, Product Development Manager, presented "Growth of Predictive Maintenance and its Effect on Future Furnace Performance." Nathan Durham, Electrical Solutions Manger, presented "Obtaining Nadcap Accreditation: Helping You Pass Your Audit." Read the full technical papers at www.IpsenUSA.com/Articles.
www.IpsenUSA.com/Products
Ipsen, Cherry Valley, Ill., displayed the Titan 2.0 heat treating vacuum furnace and PdMetrics software platform for predictive maintenance at ASM International’s Heat Treat 2015 conference.
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Vaporized foil actuator welding produces bonds 50% stronger
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Engineers at Ohio State University, Columbus, report that they have developed vaporized foil actuator (VFA) welding, a technique that consumes 80% less energy than conventional techniques, yet produces bonds that are 50% stronger. In VFA, a high-voltage capacitor bank creates a very short electrical pulse inside a thin piece of aluminum foil. Within microseconds, the foil vaporizes, and a burst of hot gas pushes two pieces of metal together at speeds approaching thousands of miles per hour.
The pieces don't melt, preventing the formation of a seam of weakened metal between them. Instead, the impact directly bonds the atoms of one metal to atoms of the other. Seen under a high-powered microscope, the bond often features delicate curlicues in spots where veins of both materials extend outward and wrap around each other.
The technique needs less energy because the electrical pulse is so short, and because the energy required to vaporize the foil is less than that required to melt the metal parts.
So far, the engineers have successfully bonded different combinations of copper, aluminum, magnesium, iron, nickel, and titanium. They have created strong bonds between commercial steel and aluminum alloys--a feat which is impossible normally. Also, high-strength steel and aluminum join together with weld regions that are stronger than the base metals.
Glenn Daehn, a Fellow of ASM and professor of materials science and engineering at Ohio State, who helped develop the new technique, explained the new process in a keynote address at the ASM Materials Science & Technology 2015 meeting recently in Columbus.
www.osu.edu

Engineers at Ohio State University, Columbus, report that they have developed vaporized foil actuator (VFA) welding, a technique that consumes 80% less energy than conventional techniques, yet produces bonds that are 50% stronger.
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One Minute Mentor: Gas Nitriding and Nitrocarburizing
October 30, 2015
Source: ASM International
Gas nitriding is based on the decomposition of ammonia (NH3) at temperatures between 500 and 600°C (930 and 1110°F) according to:
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ASM Handbooks Online now includes Volume 5B: Protective Organic Coatings
October 29, 2015
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ASM International, Materials Park, Ohio, recently released ASM Handbooks Online, which features the addition of ASM Handbook, Volume 5B: Protective Organic Coatings. This all new volume addresses a need for comprehensive information on organic coatings, including coating materials, surface preparation, application processes, industrial uses, and coating evaluation and analysis methods. It is an essential reference for industrial coating users, specifiers, and contractors. Industry respected authors and reviewers make this latest entry to ASM's handbook series the authoritative source for industrial coating information worldwide. See below for content included.
COATING MATERIALS:
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Alkyd resins
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Acrylic coatings
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Epoxy resins and curatives
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Polyvinylidene fluoride-based coatings technology
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Fluoroethylene vinyl ether resins for high-performance coatings
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Phenolic coatings
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Polyester and vinyl ester coatings
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Polyurethane coatings
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Polyurea-based coatings
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Polyaspartic coatings
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Polymeric floor coatings
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Powder coatings: Pipelines
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Powder coatings: Other industries
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Silicon-based technologies in coatings
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Polysiloxane hybrid coatings
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Smart coatings and nanotechnology applications in coatings
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Bitumens – coal tar and asphalt coatings
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Wax-based coating systems
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Zinc-rich coatings
SURFACE PREPARATION AND COATING APPLICATION:
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Surface preparation
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Soluble salts beneath coatings
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Coating application methods
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Shop and field quality control and quality assurance
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Worker health and environmental hazards associated with coating application and removal
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Green coatings
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Coating various substrates
INDUSTRIAL USES:
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Pipeline industry coatings
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Marine coatings
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Coatings used in the nuclear industry
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Bridge coatings
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Transportation-railcar coatings
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Guidance for the use of protective coatings in municipal potable water systems
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Protective coatings for corrosion control in municipal wastewater systems
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Guidelines for maintenance coating of steel structures in pulp and paper mills
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Coatings for commercial structures and building deficiencies that affect performance
COATING ANALYSIS AND EVALUATION:
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Estimating the cost of industrial painting projects
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Coating deterioration
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Coating failure analysis
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Laboratory testing
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Coating failures and defects
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Overview of other protection methods
ASM Handbooks Online is the industry's best known and most comprehensive source of information on ferrous and nonferrous metals and materials technology. Features the complete content of 34 ASM Handbook volumes, ASM Handbook supplements, and ASM Desk Editions—more than 25,000 pages of articles, illustrations, tables, graphs, specifications, and practical examples, providing peer-reviewed, trusted information in every area of materials specialization.
Quick and advanced search features enable users to search across the complete ASM Handbook collection in seconds. Additionally, a Contents Tree provides users with an intuitive way to browse and drill down to specific handbook volumes, articles, and sections of interest. The database provides aspiring and practicing engineers with instant, anytime access to the most trusted and comprehensive materials information resource available.
"ASM Handbooks are unique and valuable resources for the engineering community," says Scott D. Henry, ASM Director of Content and Knowledge Based Solutions. "They are written and edited by volunteers, assisted by ASM staff, to provide practical, in-depth technical information that is not readily available from other sources. This latest update to ASM Handbooks Online adds a wealth of information on organic coatings to the series."
For more information, or to schedule a customized demonstration via WebEx for your organization, please contact Denise Sirochman at 440.338.5409.
ASM International, Materials Park, Ohio, recently released ASM Handbooks Online, which features the addition of ASM Handbook, Volume 5B: Protective Organic Coatings.
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Unraveling structural ambiguities in lithium-rich transition metal oxides
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Using complementary microscopy and spectroscopy techniques, researchers at Lawrence Berkeley National Laboratory (Berkeley Lab), Calif., say they have solved the structure of lithium- and manganese-rich transition metal oxides, a potentially game-changing battery material and the subject of intense debate in the decade since it was discovered.
Researchers have been divided into three schools of thought on the material's structure, but a team led by Alpesh Khushalchand Shukla and Colin Ophus spent nearly four years analyzing the material and concluded that the least popular theory is in fact the correct one. This material is important because the battery capacity can potentially be doubled compared to the most commonly used Li-ion batteries today due to the extra lithium in the structure. "However, it doesn't come without problems, such as voltage fade, capacity fade, and DC resistance rise," says Shukla. "It is immensely important that we clearly understand the bulk and surface structure of the pristine material. We can't solve the problem unless we know the problem."
A viable battery with a marked increase in storage capacity would not only shake up the cell phone and laptop markets, it would also transform the market for electric vehicles (EVs). "The problem with the current lithium-ion batteries found in laptops and EVs now is that they have been pushed almost as far as they can go," says Ophus. "If we're going to ever double capacity, we need new chemistries."
Using state-of-the-art electron microscopy techniques at the National Center for Electron Microscopy (NCEM) at Berkeley Lab's Molecular Foundry and at SuperSTEM in the UK, researchers imaged the material at atomic resolution. Because previous studies have been ambiguous about the structure, the researchers minimized ambiguity by looking at the material from different directions, or zone axes. "Misinterpretations from electron microscopy data are possible because individual two-dimensional projections do not give you the three-dimensional information needed to solve a structure," Shukla says. "So you need to look at the sample in as many directions as you can."
Scientists have been divided on whether the material structure is single trigonal phase, double phase, or defected single monoclinic phase. The "phase" of a material refers to the arrangement of the atoms with respect to each other; Ophus, a Project Scientist at the Molecular Foundry, explains how easy it is for researchers to reach different conclusions: "The two-phase and one-phase model are very closely related. It's not like comparing an apple to an orange—it's more like comparing an orange and a grapefruit from very far away. It's hard to tell the difference between the two."
In addition to viewing the material at atomic resolution along multiple zone axes, the researchers made another important decision, that is, to view entire particles rather than just a subsection. "Imaging with very high fields of view was also critical in solving the structure," Shukla said. "If you just look at one small part you can't say that the whole particle has that structure."
Putting the evidence together, Shukla and Ophus are fairly convinced that the material is indeed defected single phase. "Our research gives strong support for the defected single-phase monoclinic model and rules out the two-phase model, at least in the range of compositions used in our study," says Ophus, whose expertise is in understanding structure using a combination of computational methods and experimental results.
"We need to know what goes on at the atomic scale in order to understand the macroscopic behavior of new emerging materials, and the advanced electron microscopes available at national facilities such as SuperSTEM or NCEM are essential in making sure their potential is fully realized," he adds.
In addition to solving the structure of the bulk material, which has been studied by other research groups, they also solved the surface structure, which is different from the bulk and consists of just a few layers of atoms on select crystallographic facets. "The intercalation of lithium starts at the surface, so understanding the surface of the pristine material is very important," Shukla says.
On top of the STEM (scanning transmission electron microscopy) imaging that they used for the bulk, they had to use additional techniques to solve the surface, including EELS (electron energy loss spectroscopy) and XEDS (x-ray energy dispersive spectroscopy). "We show for the first time which surface structure occurs, how thick it is, how it's oriented in relation to the bulk, and in particular on what facets the surface phase does and doesn't exist," Ophus says.
An important part of the study was the quantity and quality of the samples studied. They started with lab-made samples. They used a molten-salt method that produces high-quality discrete primary particles that are impurity-free, making them ideal candidates for performing fundamental characterization. Taking a conservative approach, the researchers also decided to procure and analyze two commercial samples from two different companies.
"We could have finished the paper a year earlier, but because there was so much controversy we wanted to make sure we didn't leave any stone unturned," says Shukla. In the end, it took nearly four years to complete the research. Ophus calls it a "tour de force of microscopy" because of its thoroughness.
The work was funded by the Vehicle Technologies Office under the U.S. Department of Energy. The Molecular Foundry is a DOE Office of Science User Facility.
Image caption — The cube on the right represents the structure of lithium- and manganese- rich transition metal oxides. The models on the left show the structure from three different directions, which correspond to the STEM images of the cube.
Using complementary microscopy and spectroscopy techniques, researchers at say they have solved the structure of lithium- and manganese-rich transition metal oxides.
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New welding technique welds “unweldable” metals
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Engineers at The Ohio State University, Columbus, developed a new welding technique that consumes 80% less energy than a common welding technique, yet creates bonds that are 50% stronger. The new technique could have a huge impact on the auto industry, which is poised to offer new cars which combine traditional heavy steel parts with lighter, alternative metals to reduce vehicle weight.
Despite recent advances in materials design, alternative metals still pose a challenge to manufacturers in practice. Many are considered unweldable by traditional means, in part because high heat and re-solidification weaken them, said Glenn Daehn, professor of materials science and engineering at Ohio State, who helped develop the new technique.
"Materials have gotten stronger, but welds haven't. We can design metals with intricate microstructures, but we destroy the microstructure when we weld," he says. "With our method, materials are shaped and bonded together at the same time, and they actually get stronger." Daehn explained the new process in a keynote address at the Materials Science & Technology 2015 meeting recently in Columbus.
In a common technique called resistance spot welding, manufacturers pass a high electrical current through pieces of metal, so that the metals' natural electrical resistance generates heat that partially melts them together and forms a weld. The drawbacks: generating high currents consumes a lot of energy, and the melted portions of metal are never as strong afterward as they were before.
Over the last decade, Daehn and his team have been trying to find ways around those problems. They've amassed more than half a dozen patents on a system called vaporized foil actuator (VFA) welding. In VFA, a high-voltage capacitor bank creates a very short electrical pulse inside a thin piece of aluminum foil. Within microseconds (millionths of a second), the foil vaporizes, and a burst of hot gas pushes two pieces of metal together at speeds approaching thousands of miles per hour.
The pieces do not melt, so there is no seam of weakened metal between them. Instead, the impact directly bonds the atoms of one metal to atoms of the other. Seen under a high-powered microscope, the bond is actually quite beautiful, and often features delicate curlicues in spots where veins of both materials extend outward and wrap around each other. The technique uses less energy because the electrical pulse is so short, and because the energy required to vaporize the foil is less than what would be required to melt the metal parts.
So far, the engineers have successfully bonded different combinations of copper, aluminum, magnesium, iron, nickel and titanium. They have created strong bonds between commercial steel and aluminum alloys—a feat which is impossible normally. Also, high-strength steel and aluminum join together with weld regions that are stronger than the base metals.
The technique is powerful enough to shape metal parts at the same time it welds them together, saving manufacturers a step. Daehn and his team now want to join with manufacturers to further develop the technology, which will be licensed through Ohio State's Technology Commercialization Office.
This project is funded by the Department of Energy and the National Science Foundation (NSF), and was one of the first to participate in I-Corps@Ohio, a new collaboration modeled after and approved by NSF's successful I-Corps commercialization program. Ohio is the first to have a statewide collaboration that is based on the NSF model, yet fully funded by the state. The program is funded and supported by the Ohio Department of Higher Education.
The Materials Science & Engineering annual meeting is organized by the American Ceramic Society, the Association for Iron & Steel Technology, ASM International, and the Minerals, Metals & Materials Society.
Image caption — Microscope view of steel (top) welded to aluminum alloy (bottom) using a new technique developed at The Ohio State University. Courtesy of Glenn Daehn/OSU.
Engineers at The Ohio State University developed a new welding technique that consumes 80% less energy than a common welding technique, yet creates bonds that are 50% stronger—creating a huge impact on the auto industry.
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SSAB launches high-strength steels designed for auto chassis
October 28, 2015
Source:
SSAB, Sweden, announces that during the next 12 months it will release two hot-rolled advanced high-strength steel grades that exceed 800 and 1000 MPa in tensile strength for automobile chassis applications.
"The steels offer a unique combination of properties for maximized hole expansion and edge ductility," says José Puente Cabrero, Portfolio manager, automotive products.
SSAB is a producer of advanced high-strength steels for the transport and automotive industries. These steels help designers and manufacturers meet new, exacting demands from industry and customers to reduce weight and COâ‚‚ emissions, increase cost efficiency, and improve crashworthiness. Through close collaboration with customers, research institutes, and universities, the R&D department at SSAB has created a series of new alloys.
SSAB will also introduce new cold-rolled martensitic steels with improved flatness. The latest Docol martensitic steels for cold-formed applications, with a tensile strength above 1700 MPa, are being designed into upcoming car models.
Up to now, higher tensile strength has affected the ductility of advanced high-strength steel products. "Now we are going to introduce new press-hardening steels. These are optimized to reach tensile strengths above 2000 MPa, but with retained good ductility," says Mr. Cabrero.
www.ssab.com
SSAB, Sweden, announces that during the next 12 months it will release two hot-rolled advanced high-strength steel grades that exceed 800 and 1000 MPa in tensile strength for automobile chassis applications.
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Seco-Warwick case-hardening system reduces distortion in gears
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Seco Warwick, Meadville, Pa., introduces UniCase Master, a single flow, precision case-hardening system said to reduce distortion in gears; and the ZeroFlow gas nitriding process. ZeroFlow is an ammonia-only nitriding process characterized by extremely low gas consumption and low emission of post-process gases. It features a simpler control system and reportedly delivers even better precision than processes with double-component atmospheres.
UniCase Master is said to offer not only a step forward in minimizing production cost and maximizing reliability, but also a real breakthrough in quality and repeatability in case hardening of gears by high-pressure gas quenching. It was created in collaboration with Professor Leszek Małdziński from the Institute of Work Machines and Vehicles of the Technical University in Poznan as a new method of controlled gas nitriding and nitrocarburizing.
The ZeroFlow method is based on performing the nitriding process in a single-component atmosphere: raw ammonia (NH3). The adjustment of nitriding atmosphere chemical composition and therefore control of nitriding potential Kn is performed only by a temporary stop and reactivation of NH3 feeding into the furnace.
www.secowarwick.com
Seco Warwick, Meadville, Pa., introduces UniCase Master, a single flow, precision case-hardening system said to reduce distortion in gears; and the ZeroFlow gas nitriding process.
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MTS provides test equipment to engineering lab at Penn State
Source: ASM International
MTS Systems Corp., Eden Prairie, Minn., has provided Penn State University, State College, with a suite of advanced materials testing equipment and software for its Department of Engineering Science and Mechanics laboratory.
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Constellium launches Aeral aluminum for aerosol cans
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Constellium N.V., Amsterdam, has launched Aeral, an aluminum solution designed for making aerosol containers by the "drawn and ironed" technology currently used to produce beverage cans. Aeral enables a minimum of 30% weight savings versus traditional impact-extruded containers, all while maintaining the same level of performance in terms of ductility and resistance to pressure.
According to the company, Aeral is based on an alloy that can be used efficiently throughout the D&I canmaking process, including the necking operation, while meeting the pressure resistance and aesthetic requirements of cosmetics companies.
Aeral is said to demonstrate Constellium's commitment to sustainability and the development of innovative, lighter, and infinitely recyclable solutions. It was developed through a combination of cutting-edge research at C-TEC, Constellium's world-class technology center in Voreppe, France, and strong industrial capabilities at the company's rolling mill in Neuf-Brisach, France, which has long experience in manufacturing light-weighting products, including beverage cans. Constellium is already in advanced discussions with some key players in the market.
www.constellium.com
Constellium N.V., Amsterdam, has launched Aeral, an aluminum solution designed for making aerosol containers by the “drawn and ironed” technology currently used to produce beverage cans.
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