Composite steel foam stops 50-caliber rounds as well as solid steel at half the weight
June 7, 2019
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North Carolina State University, Raleigh, announces its researchers have demonstrated that a steel composite metal foam can stop armor-piercing 50-caliber rounds as well as conventional steel armor, even though it weighs less than half as much.
Composite metal foam (CMF) consists of hollow metallic spheres made of materials such as stainless steel or titanium that are embedded in a metallic matrix made of steel, titanium, aluminum, or another metallic alloy. This can be made by bubbling gas through molten metal to produce a frothy mixture, which can then be cooled to form a lightweight matrix and embedded with hollow metallic spheres. The result is a material much lighter than conventional metals but with comparable strength. In this study, the researchers fabricated a composite in which both the spheres and the matrix were made of steel.
For the study, researchers manufactured a hard armor system consisting of a ceramic faceplate, a CMF core, and a thin back plate made of aluminum. The armor was tested using 50-caliber ball and armor-piercing rounds. The rounds were fired at impact velocities from 500 up to 885 meters per second.
The CMF layer of the armor was able to absorb 72 to 75% of the kinetic energy of the ball rounds, and 68 to 78% of the kinetic energy of the armor-piercing rounds. "We could stop the bullet at a total thickness of less than an inch, while the indentation on the back was less than 8 millimeters," says Afsaneh Rabiei, a professor of mechanical and aerospace engineering at NC State.
https://news.ncsu.edu/2019/06/metal-foam-stops-50-caliber/
North Carolina State University, Raleigh, announces that its researchers have demonstrated that a steel composite metal foam can stop armor-piercing 50-caliber rounds as well as conventional steel armor, even though it weighs less than half as much.
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George Krauss to present Keynote Session at ASM International’s Heat Treat 2019
May 30, 2019
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George Krauss, University Emeritus Professor at the Colorado School of Mines in Golden, is to present the keynote session at Heat Treat 2019 in Detroit. He will discuss Heat Treated Carbon Steels: Great Versatility, Excellent Performance, but Beware of Embrittlements.
Low-alloy carbon steels quenched to martensite and tempered, provide many excellent combinations of strength and fracture resistance, depending on carbon content and tempering temperature. Heat treated microstructures that enable strain hardening to eventual ductile fracture provide outstanding performance. Hardness, which is a good quality control measure, correlates well with ultimate tensile strength.
However, there are chemical and tempering factors that cause the development of microstructures for which the hardness/ultimate tensile strength correlation breaks down, caused by what are termed “embrittlement phenomena.â€
This presentation will address embrittlement phenomena that cause brittle intergranular fracture between prior austenite grains, namely quench embrittlement, tempered martensite embrittlement, temper embrittlement, and hydrogen embrittlement. The microstructural components and conditions that produce good mechanical performance and those that reduce performance by intergranular fracture will be discussed.
www.mines.edu
George Krauss, University Emeritus Professor at the Colorado School of Mines in Golden, is to present the keynote session at Heat Treat 2019 in Detroit. He will discuss Heat Treated Carbon Steels: Great Versatility, Excellent Performance, but Beware of Embrittlements.
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Wisconsin Oven’s soluble mandrel curing oven quickly heats 8000 pounds of steel to 350°F
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Wisconsin Oven, East Troy, has built an electrically heated soluble mandrel curing oven in which 8000 pounds of steel and 20,000 pounds of soluble material are heated from 80° to 350°F at an average rate of 0.1°F per minute. To maximize heating rates and temperature uniformity of the product, horizontal and vertical upward airflow are featured in this oven.
Shipped to a manufacturer in the aerospace industry, the curing oven has a maximum oven operating temperature of 400°F and work chamber dimensions of 12 x 12 x 20 feet. Guaranteed temperature uniformity of ±10°F at set points 150°, 200°, 250°, 300°, 350°, and 400°F was documented with a fifteen-point temperature uniformity survey in an empty oven chamber under static operating conditions.
The oven features a Eurotherm 6100A paperless digital recorder with a 5.5-inch graphic touch screen display and Ethernet communication capabilities. It includes a 576 kW heat input with SCR power control and a digital Eurotherm 3504 temperature controller
“Our ability to customize our standard lines of equipment is part of the reason we have so many repeat customers,†says Nick Toci, Sales Engineer. “They know that we will be able to meet all of their requirements and that our quality and customer service is unbeatable.â€
www.wisoven.com
Wisconsin Oven, East Troy, has built an electrically heated soluble mandrel curing oven in which 8000 pounds of steel and 20,000 pounds of soluble material are heated from 80° to 350°F at an average rate of 0.1°F per minute.
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Retech supplies vacuum induction melting systems to Siemens for casting turbine blades
May 29, 2019
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Retech Systems LLC, a subsidiary of Seco Warwick Group, Meadville, Pa., announces that two of its furnace systems have been installed at a new Siemens Power and Gas plant. These include a vacuum induction melting directional solidification/single crystal/equiax pitless (VIM DS/SC/EQ) combo casting furnace; and a vacuum induction melting directional solidification /single crystal (DS/SC) solidification casting furnace system.
Pitless DS/SC furnaces are said to greatly reduce or eliminate costs, time, disruptions to facility production, and confined space entry to pits required with the installation of the new Pitless VIM furnaces at the facility.
“The melting systems that Retech is delivering to Siemens incorporate industry-leading special design features,†says Earl Good, VP – Global Vacuum Melting Managing Director, Retech Systems LLC. “These include vacuum induction melting; a reliable and maintenance friendly design ideal for faster and more flexible operation; superb process control for repeatability and high yields; and Retech’s new pitless mold elevator that can be utilized on directional solidification/single crystal furnaces.â€
www.secowarwick.com
Retech Systems LLC, a subsidiary of Seco Warwick Group, Meadville, Pa., announces that two of its furnace systems have been installed at a new Siemens Power and Gas plant.
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Nitrex enables heat treater to add nitriding, nitrocarburizing, and oxidation treatments
May 28, 2019
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Nitrex Metal, Montreal, announces that Italian heat treater GalvanoTechnik has expanded its surface treatment services portfolio to include Nitreg controlled nitriding, Nitreg-C nitrocarburizing, and ONC in-process oxidation treatments.
The company invested in a compact Nitrex system, model NXK-609, configured to process workloads that are 23.5 inches in diameter by 35.5 inches high that weigh up to 1300 pounds. The system complies with the temperature uniformity requirements of AMS 2750E. It also meets specifications ASM 2759/10, which make it possible to consistently achieve the required metallurgical and mechanical properties for controlled nitriding. Other advantages of the NXK series include a reduced footprint and a system configuration that combines three process technologies into one platform.
The move to add nitriding and nitrocarburizing to its portfolio was the result of GalvanoTechnik engaging in deeper dialogue with its customers and identifying these new needs. Applications range from firearms components, such as magazines and barrels, to automotive components, with recipes tailored to meet the exact requirements of each part.
Working with GalvanoTechnik, the Nitrex Research & Technology team designed and tested process recipes to find the right match. All control recipes are stored to the Nitrex system process library, and the operator simply selects the process for the specific application. The control system then takes over, automatically monitoring and adjusting parameters such as time, temperature, atmosphere composition, Kn nitriding potential, and many more.
www.nitrex.com
Nitrex Metal, Montreal, announces that Italian heat treater GalvanoTechnik has expanded its surface treatment services portfolio to include Nitreg controlled nitriding, Nitreg-C nitrocarburizing, and ONC in-process oxidation treatments.
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One Minute Mentor: Stress relieving ductile iron
May 27, 2019
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When not otherwise heat treated, complex engineering castings of ductile iron may be stress relieved at 510 to 675°C (950 to 1250°F). Temperatures at the lower end of this range are satisfactory for many applications; temperatures at the higher end will eliminate virtually all residual stress, but also will effect some reduction in hardness and tensile strength.
Recommended ranges of stress-relieving temperatures for various types of ductile iron are as follows:
Unalloyed: 510 to 565°C (950 to 1050°F)
Low-alloy: 565 to 595°C (1050 to 1100°F)
High-alloy: 595 to 650°C (1100 to 1200°F)
Austenitic: 620 to 675°C (1150 to 1250°F)
The Figure 25 graph shows the stress relief obtained in ductile iron held at three temperatures for half an hour to eight hours. Initial hardness was 102 to 103 HRB. Hardness after holding at 1000, 1100, and 1200°F for eight hours, was 102 to 104; 101 to 103; and 90 to 93 HRB respectively.
The required time at temperature will depend on the temperature, the complexity of the casting, and the completeness of stress relief needed. However, one hour, plus one hour per inch of section thickness, is the recommended general practice.
Cooling should be uniform to avoid reintroducing stresses. Castings should be furnace-cooled to 290°C (550°F), after which they can be air cooled. In most instances, however, austenitic iron can be uniformly air cooled from the stress-relieving temperature.
Adapted from: K. Hayrynen, Heat Treating and Properties of Ductile Iron, Heat Treating of Irons and Steels, Vol 4D, ASM Handbook, ASM International, 2014, p 508–521. https://doi.org/10.31399/asm.hb.v04d.a0005937
For more information on this topic, visit the article via the link shown below, (subscription required), scroll down the Chapter Contents column on the left, and click on Stress Relieving of Ductile Iron.
https://dl.asminternational.org/books/book/9/chapter/109877/Heat-Treating-and-Properties-of-Ductile-Iron
When not otherwise heat treated, complex engineering castings of ductile iron may be stress relieved at 510 to 675°C (950 to 1250°F).
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Carpenter Technology announces formation of additive manufacturing business unit
May 24, 2019
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Carpenter Technology Corp., Philadelphia, announces the formation of a Carpenter Additive business unit, with capabilities that span the entire additive manufacturing process. These include highly engineered, gas atomized powders; Metal powder lifecycle management solutions; Finished component production; and Industrial-scale AM and full post-processing. Integrated AM and R&D facilities are focused on innovation and technical solutions.
“From powder production to manufacturing and finishing parts, the full spectrum of our capabilities is what differentiates Carpenter Additive from the rest of the AM industry,†said Chief Executive Officer Tony R. Thene. “We are revolutionizing how customers approach this disruptive technology by offering end-to-end solutions through an array of technical expertise, powder production, parts production, and material lifecycle management. Carpenter Additive is working with our customers and driving industry-wide change.â€
www.carpenteradditive.com
www.carpentertechnology.com
Carpenter Technology Corp., Philadelphia, announces the formation of a Carpenter Additive business unit, with capabilities that span the entire additive manufacturing process.
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Nucor wins GM Supplier of the Year Award, and announces bar mill investment
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Nucor Corp., Charlotte, N.C., was recognized as a General Motors Supplier of the Year for Non-Fabricated Steel at the automotive company's 27th annual Supplier of the Year awards ceremony held on May 15 in Detroit.
"This is a tremendous accomplishment for our team, as we are the first electric arc furnace steelmaker to receive this recognition," says John Ferriola, Chairman, CEO, and President of Nucor Corporation. "We have made significant investments to expand our automotive product portfolio and are focused on providing exceptional customer service. As a result, we continue to gain share in this important market. We are honored to be recognized by GM, and we value the business they do with us."
Nucor also announces a capital investment that will add vacuum degassing to its engineered bar capabilities at its bar mill in Darlington, South Carolina. Adding this capability will enable the mill to produce engineered bar products meeting some of the most stringent quality specifications in the industry. The vacuum degassing system is expected to begin operations in late 2020.
"This strategic investment complements our existing bar mills that primarily produce engineered bar products in Norfolk, Nebraska, Memphis, Tennessee, and Wallingford, Connecticut. It will position us to better serve our customers in the Southeastern United States and support the growing demand in the region for higher quality automotive and other specialty steel applications," says Mr. Ferriola.
Nucor Steel South Carolina is the first steel mill Nucor built. Producing steel by means of melting recycled scrap in an electric arc furnace (EAF), the mill started a revolution in the way steel is made in the United States. Today, approximately 70 percent of the steel made in this country is produced using EAFs. Next month, the Darlington facility will hold an event to celebrate its 50th anniversary.
www.nucor.com
Nucor Corp., Charlotte, N.C., was recognized as a General Motors Supplier of the Year for Non-Fabricated Steel at the automotive company’s 27th annual Supplier of the Year awards ceremony held on May 15 in Detroit.
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Protolabs manufacturing facility features 3D printing, CNC machining, injection molding
May 23, 2019
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Protolabs, Maple Plain, Minn., celebrates its 20-year anniversary with a grand opening of its state-of-the-art advanced manufacturing facility in Brooklyn Park, Minn. The 215,000 sq.-ft. CNC machining facility, which currently houses nearly 300 mills and lathes, is Protolabs’ eighth manufacturing plant in the United States, and twelfth around the globe.
The company says that its digital approach to manufacturing enables accelerated time to market, reduces development and production costs, and minimizes risk throughout the product life cycle. It produces custom parts and assemblies in as little as one day using automated 3D printing, CNC machining, sheet metal fabrication, and injection molding processes. Its manufacturing model couples digital front-end part analysis with automated toolpathing to produce some custom machined components in only 24 hours.
It now serves more than 45,000 unique product developers each year, across three continents and 60 countries. Over the past 20 years, Protolabs has grown in capabilities with four flagship services and 11 manufacturing technologies, and has added capacity with more than a million square feet of manufacturing space that houses over 1000 machines producing nearly four million parts each month.
“Protolabs has exceeded my wildest dreams,†says Larry Lukis, Protolabs’ founder. “The company was born out of personal frustration that manufacturing parts took months, when it could take days or even minutes. There needed to be a way to make it easier and faster for product developers to get prototype parts and accelerate development cycles. Protolabs has achieved that goal and made advanced manufacturing technologies accessible for everyone, from makers to startups to Fortune 500 companies.â€
www.protolabs.com
Protolabs, Maple Plain, Minn., celebrates its 20-year anniversary with a grand opening of its state-of-the-art advanced manufacturing facility in Brooklyn Park, Minn.
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The Effect of Rapid Heat Treatment on the Mechanical Properties of Cold Spray Coatings
May 17, 2019
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This ITSC 2019 paper details the mechanical testing of Al 6061 cold spray coatings before and after a rapid heat treatment with a novel focused IR device. The focused IR device was used to heat treat the cold spray coatings in-process with the aim of improving ductility and substrate-coating bond strength, and reducing residual stresses.
The treated samples were compared to a controlled annealing process, which was carried out in a furnace after cold spray. The power output of the IR device was set to the maximum level of 220 W/cm2, which was focused over a 10 mm diameter outlet area. The number of passes and traverse speed of the heat treatment process were varied in order to optimize the effect of the heat treatment.
The mechanical properties of the coating were tested by tensile testing of dog-bone samples and by performing pull off tests. Residual stresses were evaluated using strain measurement changes, before cold spray and after heat treatment. It was found that the rapid IR heat treatment process delivered advantages with regard to mechanical properties when compared to the untreated state.
Mr. Richard Jenkins, Dr. Barry Aldwell, Mr. Jonathan Cassidy, Prof. Rocco Lupoi, Trinity College Dublin, Ireland
Tuesday, May 28, 2019: 11:00
Annex Hall/F202 (Pacifico Yokohama)
www.tcd.ie
This ITSC 2019 paper details the mechanical testing of Al 6061 cold spray coatings before and after a rapid heat treatment with a novel focused IR device.
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