Constellium forms partnership to develop 3D printing of aluminum aircraft fuselage
July 8, 2015
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Constellium N.V., Amsterdam, announces that it has formed a partnership with Stelia Aerospace and CT Ingenierie to optimize large aluminum aerostructures via additive manufacturing. Called Fast, the goal of the project is to make large aerospace structures and parts more efficiently and cost effectively by developing 3D printing on a large scale. In particular, 3D printing of a fuselage has the potential to transform the aerospace industry, allowing for easy design modification, duplication, and customization at a lower cost.
"The goal of the Fast project is to change the way innovative technologies are implemented and to expand the usage of 3D printing. 3D printing will allow us to create metal shapes and properties that were previously impossible to produce," said Bruno Chenal, Director of R&D, Constellium Research and Technology. Fast is a long-term project that was formed last year and currently remains in early stages of development.
Constellium will act as the primary material supplier, while Stelia Aerospace will lead the design and production efforts and CT Ingenierie will optimize the design. 3D printing is already used widely in technology and extrusion manufacturing, but the large scale and the holistic optimization approach make this project unique.
www.constellium.com
Constellium N.V., Amsterdam, announces that it has formed a partnership with Stelia Aerospace and CT Ingenierie to optimize large aluminum aerostructures via additive manufacturing.
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Houghton International celebrates 150-year anniversary
July 2, 2015
Source: ASM International
Open House at Valley Forge Headquarters Kicks Off a Year of Worldwide Events
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C.I. Hayes installs humpback furnace for annealing stainless steel
July 1, 2015
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C.I. Hayes, a Gasbarre Furnace Group Company, Cranston, R.I., announces the recent installation of a Humpback Conveyor Belt Furnace for bright annealing of stainless steel materials. The furnace operates with hydrogen atmosphere at a low dewpoint (-60°F range), and has a maximum operating temperature of 2100°F.
The C.I. Hayes Humpback is an inclined mesh belt conveyor furnace designed to allow large door openings while providing extremely low furnace dewpoints. This combination assures minimal gas consumption and maximized operational cost savings. The Humpback's name is derived from the appearance of the equipment, with inclined entrance and exit tunnels between which are positioned horizontal heating and cooling sections. Parts up to 24 inches high can be processed without negative effects on the furnace atmosphere integrity.
www.cihayes.com
C.I. Hayes, a Gasbarre Furnace Group Company, Cranston, R.I., announces the recent installation of a Humpback Conveyor Belt Furnace for bright annealing of stainless steel materials.
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Missouri S&T developing high-strength TRIP steel for autos
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Missouri University of Science and Technology, Rolla, announces that a third-generation high-strength steel being developed by Missouri S&T metallurgical engineers should be lighter, easier to make, and strong enough to address automotive safety concerns. The technology is based on TRIP – transformation-induced plasticity. It involves the transformation of austenite, which normally exists at high temperatures, into martensite, a harder phase that develops as the steel deforms.
Because of their high fatigue strength and ability to absorb high amounts of energy, TRIP steels are well suited for automotive structures and safety components such as cross members, longitudinal beams, B-pillar reinforcements, and bumper reinforcements.
"We are currently refining the steel design to achieve ‘Gen 3' mechanical property goals while also maintaining manufacturability," says center director Dr. Ronald J. O'Malley, the F. Kenneth Iverson Endowed Chair of Steelmaking Technologies at Missouri S&T. "The alloy design is based on a two-stage or ‘dual TRIP' mechanism that leads to extreme work hardening and energy absorption, so it's very good for automotive crash-worthiness."
Under the direction of Dr. David C. Van Aken, Curators' Teaching Professor of metallurgical engineering, the Missouri S&T team has used an atomic modeling method known as "density functional theory" to identify alloying elements to create the dual TRIP character of these new steels.
The real challenge, however, lies with the large-scale production of these new steels. With the help of industrial partners, the researchers at Peaslee Steel Manufacturing Research Center are examining all aspects of the steel manufacturing – "from melt practice to final formability by the automotive producer," Prof. O'Malley says. A committee of representatives from four steel manufacturers – Nucor, U.S. Steel, AK Steel and ArcelorMittal – oversees the project.
One benefit of conducting the research at Missouri S&T is the ability of researchers to create and test small batches of steel. In S&T's labs, researchers can create 200 pounds of steel at a time, whereas big steel manufacturers like Nucor, where Prof. O'Malley was chief metallurgist before joining S&T, would have to make 170 tons of steel for testing.
www.mst.edu
Missouri University of Science and Technology, Rolla, announces that a third-generation high-strength steel being developed by Missouri S&T metallurgical engineers should be lighter and easier to make, while being strong enough to address automotive safety concerns.
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TimkenSteel opens SBQ steel development tech center
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TimkenSteel, Canton, Ohio, recently opened a $5 million technology center for developing clean special bar quality (SBQ) steel and new steel grades. The TimkenSteel Technology Center features a dozen laboratories, including a new scanning electron microscope, an ultrasonic lab, a physical process modeling lab, and additional labs where metallurgists and materials scientists can test steel and find inclusions less than the width of a human hair.
Steel cleanliness is important for high performance in critical products such as gears, bearings, axles, crankshafts, downhole drilling equipment, and military applications. The 20,000-square-foot facility, in combination with the company's steelmaking capabilities, allows TimkenSteel to integrate learning and knowledge and achieve high levels of steel performance from the company's new $200 million jumbo bloom vertical caster at the Faircrest Steel Plant in Canton.
"TimkenSteel is the global leader in clean steels because we understand the science and measurement of inclusions better than anyone, and we're the only steelmaker that can take that understanding and use it to predict component life," said Ray Fryan, vice president of technology and quality at TimkenSteel. "The new TimkenSteel Technology Center, along with the talent across our entire team, enhances our ability to develop the SBQ steel that our customers need to solve their toughest challenges."
www.timkensteel.com
TimkenSteel, Canton, Ohio, recently opened a $5 million technology center for developing clean special bar quality (SBQ) steel and new steel grades.
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Sandvik chromium-nickel steel extends pulverized coal injection lance life
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Sandvik Materials Technology, Sweden, reports that its Sandvik 253 MA tubing has extended the service life of pulverized coal injection (PCI) lance tubes to a year at a Chinese iron and steel plant. Previous tube materials lasted as little as one month. Sandvik 253 MA is an austenitic chromium-nickel steel that is designed for good high temperature strength and excellent resistance to high-temperature oxidation and carburization corrosion.
"Sandvik 253 MA has higher creep rupture strength, abrasion resistance, and corrosion resistance at higher temperatures. The grade has improved high-temperature strength and structural stability to give added safety benefits," said David Zhou, Technical Marketing Specialist, Sandvik.
Whereas standard grades last between one and two months, or for as little as two-to-three weeks with standard AISI 304L, Sandvik 253 MA can increase PCI lance tube life by more than three times. It has been widely used abroad to replace familiar PCI lance tubes manufactured from conventional materials such as 310S, TP 321H and 316L. The increased cost can be quickly offset by the extended lifecycles and reduced maintenance costs.
The Sandvik material exhibits high oxide scale density and strong adhesion due in part to its extra 0.05% cerium (Ce) content. In combination with added 1.5% silicon (Si), this gives the grade excellent high-temperature oxidation resistance and high temperature carburization resistance properties. Added 0.17% nitrogen (N) improves high temperature creep rupture strength over standard grades like AISI 310.
www.smt.sandvik.com
Sandvik Materials Technology, Sweden, reports that its Sandvik 253 MA tubing has extended the service life of pulverized coal injection (PCI) lance tubes to a year at a Chinese iron and steel plant.
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SecoWarwick to deliver equipment for recycling aerospace titanium in Europe
June 24, 2015
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Seco-Warwick Europe, Poland, together with Retech Systems, Ukiah, Calif., have signed a contract for delivery of a comprehensive melt-shop equipment package to a new European facility for recycling aviation-grade titanium. EcoTitanium, launched in France in April, will provide the aerospace industry with a new titanium supply channel, independent of American and Russian sources.
The equipment package includes three metallurgical units: one plasma arc melting (PAM) furnace, two vacuum arc remelting (VAR) furnaces, and associated equipment. Plasma melting systems have the proven commercial ability to consistently produce titanium alloy ingots and castings more efficiently than competing technologies. This is primarily because plasma melting systems operate under an inert gas atmosphere, which allows the alloy composition of the metal to be maintained easily with minimal evaporative losses, as opposed to other processes that operate in a vacuum.
The Retech PAM system fully integrates simple, robust mechanisms with proven melting systems and control techniques. The feed system consists of a proven rotary can feeder and vibratory chute combination that delivers turnings to the melt hearth. Also included is a bar feeder for feeding titanium scrap.
Once in the melt hearth, the material is thoroughly melted by Retech's robust transferred-arc plasma torch. Material continues on to a series of refining hearths where both high-density and low-density inclusions are removed under the action of the plasma torches and the residence time provided by the refining hearths.
An ingot is formed within the water-cooled copper mold, on top of a matching water-cooled copper puller. As the puller withdraws out the bottom of the mold, the titanium alloy solidifies as new liquid continues to flow into the top of the mold. The system will be able to produce large ingots that will be then used as electrodes for the VAR system.
Two vacuum arc remelting furnaces Retech, each equipped with two melt stations, are designed to melt and refine titanium and titanium alloy final ingots. These ingots will be produced from fully dense electrodes produced by Retech's Plasma Cold Hearth Melting process. New ingots will be formed in copper crucibles by melting the consumable electrode under vacuum conditions by the electric arc.
www.secowarwick.com
Seco-Warwick Europe, Poland, together with Retech Systems, Ukiah, Calif., have signed a contract for delivery of a comprehensive melt-shop equipment package to a new European facility for recycling aviation-grade titanium.
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Dual chamber furnace enables simultaneous hardening and tempering
June 23, 2015
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Lucifer Furnaces, Warrington, Pa., announces that a Red Devil dual chamber furnace has been added to the line of analytical equipment at Laboratory Testing Inc., Philadelphia. Dual chamber furnaces allow hardening in the upper chamber while tempering in the lower oven, without waiting for a single-chamber unit to cool. The furnace is capable of meeting AMS 2750 requirements for aerospace, and its large work zone can accommodate larger parts.
LTI uses the furnace for heat treating to various specifications for ASTM, AMS, GE, ASME, and other customer requirements, including solution treatment cycles, aging cycles, post-weld heat treat, normalizing, hardening, and tempering. With both chambers 12x14x24 inches, the upper chamber is programmed to heat to 2200°F, while the lower oven reaches 1200°F. Both chambers are lined with 4.5 inches of multilayer lightweight firebrick insulation and mineral wool backup precision dry fit, to allow for thermal expansion while minimizing heat loss. Easy-to-replace heating elements simplify maintenance.
For this furnace, Lucifer customized a standard Red Devil Model RD8-KHE24 with Eurotherm 3204 programmable controllers and Honeywell UDC1200 over-temperature controllers. The upper chamber was modified with a gas spring vertical lift door.
Laboratory Testing Inc. specializes in metals testing through destructive testing methods, including mechanical, metallurgical, chemical, and corrosion testing, as well as nondestructive testing methods.
www.luciferfurnaces.com
Lucifer Furnaces, Warrington, Pa., announces that a Red Devil dual chamber furnace has been added to the line of analytical equipment at Laboratory Testing Inc., Philadelphia.
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ThyssenKrupp and Maxion to jointly develop aluminum/carbon-fiber wheels
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ThyssenKrupp Carbon Components, Germany, and Maxion Wheels, Novi, Mich., announce a cooperative agreement to develop and market ultra-lightweight aluminum and carbon fiber hybrid wheels for the premium vehicle OEM market. ThyssenKrupp brings its unique carbon fiber braiding technology, and Maxion brings its liquid-forged aluminum disks, which offer material properties comparable to forged wheels at lower cost.
Testing took place at certified Maxion Wheels test labs. In addition, the ThyssenKrupp - Maxion Wheels team is working with the Volkswagen Group to test prototypes on a vehicle. Public road tests have shown improved performance, which means superior damping, which leads to less vibration and road noise. Their combined technologies could generate a weight savings of up to 40% vs. forged aluminum wheels, and at the same time offer high value styling.
"With carbon fiber-aluminum hybrid wheels we offer a unique option to our customers in the luxury and sports car segment to differentiate themselves through technology and design. The cooperation agreement with Maxion Wheels marks an important milestone in the development of our carbon fiber wheel technology. It shows the technological maturity we have reached and combines our innovations with the leading player in the wheel industry. Commercialization is the logical next step," says Dr. Jens Werner, Managing Director at ThyssenKrupp Carbon Components.
"The aluminum/carbon fiber hybrid wheels we develop through our cooperation with ThyssenKrupp will fill an important niche in the ultra-lightweight vehicle market," says Kai Kronenberg, Vice President of Business Development & Global Innovation at Maxion Wheels. "It will benefit our customers by expanding our already extensive range of products and capabilities, while enhancing our leadership position in the industry."
The ThyssenKrupp Carbon Components - Maxion Wheels cooperation will include the development and commercialization of the ultra-lightweight aluminum/carbon fiber hybrid wheels. A joint sales initiative and support team will engage the market to bring new capabilities and wheels that will benefit customers far into the future.
http://www.thyssenkrupp.com/q00GRR
www.maxionwheels.com
ThyssenKrupp Carbon Components, Germany, and Maxion Wheels, Novi, Mich., announce a cooperative agreement to develop and market ultra-lightweight aluminum and carbon fiber hybrid wheels for the premium vehicle OEM market.
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The Bright World of Metals: Four trade fairs in Düsseldorf
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"The Bright World of Metals" trade fair quartet in Düsseldorf, Germany, closed to extremely positive results, with 78,000 visitors from more than 120 countries. The trade fairs included GIFA - 13th International Foundry Trade Fair with Technical Forum; METEC - 9th International Metallurgical Trade Fair with Congresses; THERMPROCESS - 11th International Trade Fair and Symposium for Thermal Processing Technology; and NEWCAST - 4th International Trade Fair for Precision Castings.
Attendees were ready to invest, and the 2214 exhibiting companies reported numerous business transactions with customers from all over the world. Especially in the Asian region, there is a great demand for European metallurgy and foundry technology due to current industry requirements regarding energy and resource efficiency. Two-thirds of the visitors are directly involved in investment decisions in the top and middle management of their companies. The majority of the international visitors came from India, Italy, Turkey, France, and China.
Exhibitors reported that they met their specific target groups at the trade shows. At GIFA, these were the experts from the ferrous and non-ferrous metal castings industries, as well as of the engineering sector. At METEC and THERMPROCESS, most of the visitors traditionally come from the iron and steel production, plant engineering and construction, equipment engineering, and tool making industries. At NEWCAST, visitors included experts from automotive and gear manufacturing, as well as the supplier industry.
http://www.mdna.com
“The Bright World of Metals” trade fair quartet in Düsseldorf, Germany, closed to extremely positive results, with 78,000 visitors from more than 120 countries.
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