GE Aviation to build cobalt-chrome aircraft power door bracket by additive manufacturing

November 2, 2018
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GE Aviation, Cincinnati, announces that the Federal Aviation Administration (FAA) has given ‘change in design’ approval to GE Additive and GE Aviation to replace a conventionally manufactured power door opening system (PDOS) bracket, used on GE Aviation’s GEnx-2B commercial airline engines, with an additively manufactured bracket.

 

The new additively manufactured brackets will enter mass production at GE Aviation’s facility in Auburn, Alabama, using GE Additive Concept Laser M2 cusing Multilaser machines, this month. GE Aviation anticipates the first GEnx engines installed with the new brackets will be shipped in January 2019.

 

GEnx-2B commercial airline engines power the Boeing 747-8. The PDOS is used on the ground to open and close the fan cowl doors to enable access to the fan compartment for maintenance reasons. The original PDOS brackets on GEnx-2B engines were produced from a solid block of metal, using conventional methods such as milling; this technique resulted in around 50% of the material being wasted.

 

Using Laser Beam Powder Bed Fusion (LB-PBF) additive technology (referred to by GE as Direct Metal Laser Melting) to manufacture the new brackets, waste generated during the part’s manufacture has been reduced by as much as 90%. GE Aviation stated that it has also improved the design to reduce the bracket’s weight by 10%. In addition, the decision to mass produce using a cobalt-chrome alloy over a traditional nickel-based superalloy has enabled a faster build. To make this approach as efficient as possible, GE stated that four brackets will be printed at the same time.

 

Using a custom interlocking design to house all four brackets on a single build plate, the Concept Laser M2 cusing machine’s pair of lasers can additively manufacture an aircraft’s worth of brackets in one build, before post-processing and inspection. Finally, by taking production of the brackets entirely in-house, GE Aviation also expects to reduce its production costs.

 

www.ge.com/additive

 

GE Aviation to build cobalt-chrome aircraft power door bracket by additive manufacturing

GE Aviation, Cincinnati, announces that the Federal Aviation Administration (FAA) has given ‘change in design’ approval to GE Additive and GE Aviation to replace a conventionally manufactured power door opening system (PDOS) bracket, used on GE Aviation’s GEnx-2B commercial airline engines, with an additively manufactured bracket.

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Siemens and Chromalloy invest $139 million in Advanced Airfoil Components joint venture


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Siemens, Munich, and Chromalloy Gas Turbine Corp., Palm Beach Gardens, Fla., have opened their new joint venture, Advanced Airfoil Components (AAC), near Tampa, Florida. The AAC casting facility is 210,000 square feet, and will enable production of the entire range of blades and vanes for Siemens gas turbine fleet, including the newest 9000HL. The facility equipment build-out is being done in stages and will be completed over the next four years. The stand-alone manufacturing plant, which began construction last year, was established to exclusively supply Siemens with casting components for its gas turbines. 

 

The partnership represents a capital investment of $139 million and will add 350 jobs. Advanced Airfoil Components will hire workers for a range of skilled positions, including technical engineers, manufacturing technicians, and production workers, as well as human resources, finance, procurement and logistics, and operations roles.

 

“This new facility demonstrates Siemens' commitment to delivering state-of-the-art technology solutions for our power and gas customers in the United States and throughout the world,” said Lisa Davis, CEO Energy, Siemens AG. “Not only does this joint venture help reduce costs and support our supply chain needs, but also it will create 350 high-wage, skilled positions, including technical engineers, manufacturing technicians, and production workers, and will expand Siemens more than 5000 employees footprint in Florida.”

 

“Advanced Airfoil Components is proud to exclusively deliver innovative, high-tech casting components for Siemens gas turbines at this new, state-of-the-art site,” said Kevin Updegrove, CEO, Advanced Airfoil Components. “The new space will allow Advanced Airfoil Components to grow this new business with Siemens and Chromalloy, taking our partnership to the next level.”

 

www.siemens.com

 

Siemens and Chromalloy invest $139 million in Advanced Airfoil Components joint venture

Siemens, Munich, and Chromalloy Gas Turbine Corp., Palm Beach Gardens, Fla., have opened their new joint venture, Advanced Airfoil Components (AAC), near Tampa, Florida.

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SSAB to increase capacity to make quenched and tempered steels in its Alabama plant


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Swedish steelmaker SSAB says it plans to invest about $110 million in its steel plant in Mobile, Ala., to increase capacity to make quenched-and-tempered (Q&T) steels and other products. The company says it is planning a number of targeted improvements to its formatting, blasting and painting, and shipping operations to boost its Q&T capacity.

 

The upgrades would eliminate production bottlenecks and lift capacity by 33% to about 440,000 tons annually. Additionally, SSAB is planning a parallel project in which it will install a new, accelerated cooling system on the rolling mill. The investment has been designed to include the potential to build additional Q&T capacity through direct quenching similar to the technology currently used at SSAB’s production facilities in Finland and Sweden.

 

“With this planned investment, we not only increase our production, but also improve our quality and efficiency performance as well,” said SSAB Americas president Chuck Schmitt.
 

“Over the past 20 years, we have increased Q&T volumes by an average of 7% a year,” said SSAB president and chief executive Martin Lindqvist. “There is great market potential as Q&T penetration is still relatively low, for example in North and South America, where we now plan to increase capacity.”

 

https://www.aist.org/news/steel-news/2018/october/29-october-2-november/ssab-looks-to-increase-q-t-capacity-through-us$110

www.ssab.com

SSAB to increase capacity to make quenched and tempered steels in its Alabama plant

Swedish steelmaker SSAB says it plans to invest about $110 million in its steel plant in Mobile, Ala., to increase capacity to make quenched-and-tempered (Q&T) steels and other products.

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Novelis to build Solution Centers near auto makers to accelerate aluminum applications


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Novelis Inc., Atlanta, plans to establish a global network of Customer Solution Centers (CSCs) to accelerate collaborative innovation between Novelis and automakers for the next generation of vehicle design. Novelis will work with OEMs to determine how to maximize lightweight, high-strength aluminum to design the best solutions for specific applications at the right cost to better compete against steel and other materials.

 

The facilities will be led by teams of industry-leading researchers, designers and engineers located in close proximity to manufacturing sites in North America, China, and Europe. In addition, Novelis CSCs will provide an environment to demonstrate product concepts, simulate customer processes and performance, and leverage data to educate stakeholders throughout the supply chain about elements ranging from forming to costing.

 

The first center is scheduled to open in Novi, Michigan, with China and Europe to follow.

Customer Solution Centers will bring research and technical platforms, operations and commercial development together to increase collaboration and innovation. Each center will include high-tech development machinery ranging from computer-aided design (CAD) software to virtual collaboration capabilities and visualization technologies.

 

As the facilities come online, cross-regional teams will be in place to ramp up product development in critical stages for the auto industry.

 

www.novelis.com

Novelis to build Solution Centers near auto makers to accelerate aluminum applications

Novelis Inc., Atlanta, plans to establish a global network of Customer Solution Centers (CSCs) to accelerate collaborative innovation between Novelis and automakers for the next generation of vehicle design.

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Carpenter acquires U.K. powder manufacturer for its additive manufacturing capability

November 1, 2018
Source:

Carpenter Technology Corp., Philadelphia, has acquired LPW Technology Ltd. for its advanced metal powders and lifecycle management solutions for metal additive manufacturing.  

 

According to Tony R. Thene, Carpenter’s President and Chief Executive Officer, “Our aggressive development in key aspects of additive manufacturing demonstrates our commitment to build on our industry-leading position in this space. The acquisition combines LPW’s metal powder lifecycle management technology and processes, with our technical expertise in producing highly engineered metal powders and additively manufactured components.”

 

Carpenter says that lifecycle management technology is becoming increasingly important to understanding how materials behave before, during, and after production in powder bed fusion additive manufacturing. Understanding powder behavior will continue to be critical as AM becomes more widely adopted and implemented across various industries.

 

“LPW’s innovative platforms and enabling technology further solidify Carpenter’s position as a preferred provider of end-to-end next generation additive manufacturing solutions,” commented Phil Carroll, LPW’s founder.

 

Carpenter’s AM portfolio also includes recent investments in Puris, a titanium powder producer; CalRAM, a leader in Electron Beam and Laser Beam Powder Bed Fusion AM services; and the construction of an Emerging Technology Center in Athens, Alabama.

 

www.cartech.com

Carpenter acquires U.K. powder manufacturer for its additive manufacturing capability

Carpenter Technology Corp., Philadelphia, has acquired LPW Technology Ltd. for its advanced metal powders and lifecycle management solutions for metal additive manufacturing.

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Tenaris invests $7 million to re-activate its steel line pipe and OCTG mill in Texas

October 28, 2018
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Tenaris, Luxembourg, announces that it has re-activated its steel line pipe and OCTG plant in Conroe, Texas, following a three year suspension of operations. The Conroe mill is now heat treating and finishing pipe from the Tenaris mill in Bay City, Texas, to support the ramp-up of domestic production. Tenaris invested approximately $7 million to ready the plant for operations, including safety, training, equipment, and systems upgrades.

 

“I want to thank our employees, many of whom have returned to the plant and those who are new to Tenaris, for their dedication to completing a safe and successful, start-up,” said Luca Zanotti, President, Tenaris USA. “Our Conroe facility is playing an important role in the resurgence of U.S. manufacturing.”

 

Production at Conroe was temporarily stopped in 2015 due to record levels of unfairly traded oil country tubular goods (OCTG) imports and the collapse of the oil and gas market. In June, Tenaris announced it would restart specific manufacturing processes at the Conroe mill as a result of improved market conditions and actions by the U.S. government in support of domestic manufacturing.

 

www.tenaris.com

 

Tenaris invests $7 million to re-activate its steel line pipe and OCTG mill in Texas

Tenaris, Luxembourg, announces that it has re-activated its steel line pipe and OCTG plant in Conroe, Texas, following a three year suspension of operations.

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Ipsen ships Titan vacuum furnaces, custom furnaces, and box furnaces in third quarter

October 26, 2018
Source:

Ipsen USA, Cherry Valley, announces strong third quarter furnace shipment results. The shipments include several Titan  vacuum furnaces from the platform product line, several custom horizontal and vertical vacuum furnaces, and multiple atmosphere box furnaces, all designed to meet customer specifications. Many of these shipments also included PdMetrics software for predictive maintenance.

 

“I think the diverse products shipped in the last few months really show the range of solutions Ipsen has available to meet our customers’ needs,” said Pete Kerbel, Vice President of Sales. “These furnaces shipped across the United States and to six countries worldwide, to help mission-critical applications across a variety of industries. We continue to listen closely to our customers and find the solution that best fits their needs.”

 

www.ipsenusa.com

 

 

 

 

Ipsen ships Titan vacuum furnaces, custom furnaces, and box furnaces in third quarter

Ipsen USA, Cherry Valley, announces strong third quarter furnace shipment results.

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One Minute Mentor: Types of Cast Irons


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The ease with which graphite forms on cooling is determined largely by the temperature of the iron and the silicon content. High carbon and silicon are the primary alloying elements that increase the graphitization potential of the iron as well as its castability. Carbon and silicon composition ranges of common cast irons are plotted in the graph. The higher the silicon content, the lower the solubility of carbon in austenite and the more readily carbon is precipitated as graphite on slow cooling.

 

The carbon in cast irons can solidify into graphite with different shapes during casting. Cast irons also are classified according to the shape of graphite that forms during solidification.

 

There are three basic types of cast iron with distinct forms of graphite shape:

  • Gray iron contains carbon in the form of graphite flakes. Gray iron exhibits a gray fracture surface because fracture occurs along the graphite plates (flakes).
  • Ductile iron, also known as spheroidal or nodular graphite iron, contains rounded graphite in which the graphite flakes form into balls (like cabbage leaves). Ductile iron is so named because in the as-cast form it exhibits measurable ductility.
  • Compacted graphite iron contains graphite in the form of thick, stubby flakes. Its mechanical properties are between those of gray and ductile iron.
  •  

The shape of graphite has important effects on properties that can be easily discerned. For example, ductile iron castings have a definite ring when struck with a hammer, but it is not the clear ring of steel. Gray iron castings have a damped sound. Breathing on a fresh surface (filed, ground, or machined) of ductile iron releases the smell of acetylene gas, which is formed by moisture reacting with the magnesium carbide in ductile iron.

 

There are three other important categories of cast irons:

  • White iron essentially is free of graphite, and most of the carbon content is present as separate grains of hard Fe3C. White iron exhibits a white, crystalline fracture surface because fracture occurs along the iron carbide plates. It is only stress relieved, or heat treated to cause decomposition of cementite into graphite.
  • Malleable iron contains compact nodules of graphite flakes. These are called “temper carbon” because they form during an extended annealing of white iron of a suitable composition.
  • High-alloy (special) iron contains over 3% alloy content and is commercially classified separately. These include the wear-resisting white irons, the austenitic high-alloy irons, and the alloyed self-hardening types. The special irons may be, but usually are not, heat treated, except for precipitation hardening, stress relieving, or surface hardening.

Volume 4D, Heat Treating of Irons and Steels -> Introduction to Cast Iron Heat Treatment -> Types of Cast Irons

 

 

One Minute Mentor: Types of Cast Irons

The ease with which graphite forms on cooling is determined largely by the temperature of the iron and the silicon content.

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