Ultralight auto door made of aluminum, polymers, and electronic latch system
January 17, 2017
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Magna International Inc., Troy, Mich., in cooperation with the U.S. Department of Energy and partners FCA US and Grupo Antolin, announces that the team has developed an ultralight door that achieves the project objective of 42.5% mass savings over an average current production door. This was developed in less than ten months, while keeping the cost within accepted industry parameters and providing a solution that applies to approximately 70% of the light vehicle market.
Magna built on its know-how from the development of the Multi-Material Lightweight Vehicle (MMLV) with the DOE and Ford in 2014, and took it a step further in creating a solution for this advanced ultralight door project.
A key innovation includes integration of Magna's SmartLatch electronic latch system. This eliminated the need for mechanical hardware and enabled the development of a unique carrier module with integrated glass guides and lift capability of a lightweight hybrid glass laminate, an industry first.
The door-in-white assembly makes extensive use of aluminum, which achieves approximately half of the total mass reduction of the door assembly. Overall, the project makes use of materials readily available today that can easily be made using existing manufacturing processes, without a significant increase in production costs or changes in body-shop infrastructure.
Grupo Antolin contributed its know-how in the design and manufacture of interior trim components to contribute to the significant mass reduction. The application of advanced molding technologies and polymers contributed approximately 7% to the total mass reduction.
The ultralight door development included intensive simulation efforts, passing all safety and durability testing in the process. The next steps include manufacturing full-scale prototype door assemblies, performance tests and safety tests to validate the design, with the goal of being available for use in production vehicles by the fall of 2020.
www.magna.com
Magna International Inc., Troy, Mich., in cooperation with the U.S. Department of Energy and partners FCA US and Grupo Antolin, announces that the team has developed an ultralight auto door that achieves the project objective of 42.5% mass savings over an average current production door.
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One Minute Mentor: Radio-Frequency Plasma
January 16, 2017
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Glow-discharge plasma nitriding is carried out in nitrogen-hydrogen atmospheres at pressures in the range of 100 to 1000. At pressures below 10 Pa, the glow-discharge technique is not used, but plasma can still be generated by radio-frequency (RF) excitation, microwave energy, or electrons produced by a heated filament. These low-pressure plasmas diffuse through the treatment chamber with a large number of active species, which increases the nitriding efficiency. The uncoupling of plasma generation from the part being treated allows independent control of the energy and flux of ions against the substrate surface, and the temperature can be kept low.
In the RF plasma process, plasma is generated by high frequency, in the range of 13.56 MHz, is applied to an inductive antenna inside the vacuum chamber. The part is heated by heating the chamber and the working table with standard electrical resistance. One of the limiting factors for the commercial exploitation of the process is the high vacuum required, and the subsequent cost. The diagram shows a schematic of RF plasma equipment.
Volume 4D, Heat Treating of Irons and Steels ⇒ Nitriding of Stainless Steels ⇒ Thermochemical Nitriding Treatments
Glow-discharge plasma nitriding is carried out in nitrogen-hydrogen atmospheres at pressures in the range of 100 to 1000. At pressures below 10 Pa, the glow-discharge technique is not used, but plasma can still be generated by radio-frequency (RF) excitation, microwave energy, or electrons produced by a heated filament.
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NIST awards $12 million to MEP centers in 11 states to support manufacturers
January 15, 2017
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The National Institute of Standards and Technology, Gaithersburg, Md., announces that its Hollings Manufacturing Extension Partnership (MEP) program has awarded a total of nearly $12 million in first-year funding to 11 organizations that will operate MEP centers in Delaware, Hawaii, Iowa, Kansas, Maine, Mississippi, Nevada, New Mexico, North Dakota, South Carolina, and Wyoming.
MEP centers in all 50 states and Puerto Rico support small and medium-size manufacturers and are dedicated to enhancing the productivity and technological performance of U.S. manufacturing. The agreements have five-year periods of performance that begin April 1, 2017, and they will provide nearly $60 million in total funding during that time.
The following organizations will sign cooperative agreements to operate MEP centers:
Delaware Technical Community College (Newark) - $500,000
High Technology Development Corporation (Honolulu, Hawaii) - $500,000
Iowa State University of Science & Technology (Ames) - $1,859,206
Mid-America Manufacturing Technology Center (Overland Park, Kansas) - $1,864,950
Maine Manufacturing Extension Partnership (Augusta) - $863,522
Mississippi Manufacturers Association (Jackson) - $1,003,782
Board of Regents, Nevada System of Higher Education, University of Nevada-Reno - $756,001
New Mexico Manufacturing Extension Partnership (Albuquerque) - $1,360,802
The Dakota Manufacturing Extension Partnership Inc. (Bismarck, North Dakota) - $500,000
South Carolina Manufacturing Extension Partnership (Columbia) - $2,268,003
University of Wyoming (Laramie) - $500,000
https://www.nist.gov/mep
The National Institute of Standards and Technology, Gaithersburg, Md., announces that its Hollings Manufacturing Extension Partnership (MEP) program has awarded a total of nearly $12 million in first-year funding to 11 organizations that will operate MEP centers in Delaware, Hawaii, Iowa, Kansas, Maine, Mississippi, Nevada, New Mexico, North Dakota, South Carolina, and Wyoming.
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Heat treating conference/exhibition in England
January 13, 2017
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The UK's Contract Heat Treatment Association will again be partnering with the Surface Engineering Association and Wolfson Heat Treatment Centre in co-sponsoring the second "Surface Engineering & Heat Treatment Industry Conference/Exhibition" on October 13.
Meet your fellow industrialists, share experiences and discuss issues that you want your association to address. Members of the SEA National Committee and the CHTA Management Committee will be present throughout the conerence as will suppliers to our industry sector in the table top exhibition area. Tap into our knowledge and come and learn from the experiences of others. (Photo courtesy Heat Treatment Northampton)
Staged in England's historic Kenilworth, initial information about the event can be found at www.sea.org.uk/events/index.htm/surface-engineering-heat-treatment-industry-conference-2017. Offers of presentations on advances in industrial heat treatment processing will be welcomed by CHTA's Alan J Hick at [email protected].
The UK’s Contract Heat Treatment Association will again be partnering with the Surface Engineering Association and Wolfson Heat Treatment Centre in co-sponsoring the second “Surface Engineering & Heat Treatment Industry Conference/Exhibition” on October 13.
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Sandvik announces new Additive Manufacturing business
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Sandvik Group, Sweden, announces that a new Product Area called Additive Manufacturing will be formed within Sandvik Machining Solutions. The foundation for the new Product Area is the current Additive Manufacturing center in Sandviken, Sweden, which today is part of R&D at Product Area Sandvik Coromant.
With this change, additive manufacturing within Sandvik is moving from a mainly internal purpose into an external business of metal additive manufacturing.
The business will have full profit and loss responsibility and will step-by-step take a position on the market by organically growing as well as through acquisitions. In addition, the additive manufacturing and development performed for internal purposes in cooperation with the other Product Areas within Sandvik Machining Solutions will continue.
Sandvik Group, Sweden, announces that a new Product Area called Additive Manufacturing will be formed within Sandvik Machining Solutions.
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Questek to develop titanium, aluminum, steel alloys for military AM parts
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Questek Innovations LLC, Evanston, Ill., was recently awarded six separate projects from the U.S. Navy and U.S. Army to develop technologies and design new alloys specifically tailored to the unique processing conditions and materials-related challenges of additive manufacturing. These include one Small Business Innovation Research (SBIR) Phase II project, two SBIR Phase I projects, and three Small Business Technology Transfer (STTR) Phase I projects focused on aluminum, titanium, and steel systems. The combined funding contract value exceeds $2 million.
"A materials-based approach to addressing the challenges of additive manufacturing is crucial for accelerating the development of this technology and achieving, or even surpassing, the performance of traditionally-processed alloys," says ASM Fellow Aziz Asphahani, Questek's Chief Executive Officer. "We look forward to the outcomes of these projects, and the prospect of adopting ICME-designed alloys as the first-generation, high-performance additive manufacturing materials."
The awarded projects include the following:
Under an Office of Naval Research (ONR)-funded Phase II SBIR project (Topic N141-062) titled "Computational Design of Aluminum Alloys for use in Additive Manufacturing," Questek is furthering the development of three Questek-designed aluminum alloys specifically for processing by Direct Metal Laser Sintering AM. The goal of this program is to combine AlSiMg alloys, which can be printed without cracking but have low strength, with the 6061/7050 alloys, which have high strength but which crack during additive manufacturing. corrosion tests.
Under a U.S. Navy Phase I STTR project (Topic N16A-007) titled "Optimized High Performance Stainless Steel Powder for Additive Manufacturing," Questek is developing a new powder specification for high-strength martensitic precipitation-hardenable 17-4 stainless steel, optimized specifically for selective laser melting (SLM) technologies.
Under an ONR-funded Phase I STTR project (Topic N16A-022) titled "Integrated Computational Material Engineering Tool Set for Additive Manufacturing of Stainless Steel (316L)," Questek is developing an "Integrated Model Toolkit" that enables the modeling of AM process by predicting local composition, microstructure, residual stresses, defects, and mechanical properties for stainless steel 316L aerospace components.
Under a U.S. Army Phase I SBIR project (Topic A15-104) titled "Application of ICME to Optimize Processing of State-of-the-art Gear Steels in Additive Manufacturing," Questek atomized, built via LENS and DMLS AM processes and evaluated its high-performance carburizable Ferrium® C64® steel.
Under an ONR-funded Phase I SBIR project (Topic N161-071) titled "Additive Manufacturing Development of Naval Platform Heat Exchangers," Questek is extending its ICME tools to evaluate materials for the DMLS production of heat exchangers. The project includes fabrication of test specimens to address one of the unique challenges to AM of heat exchangers: minimum component thickness.
Under a U.S. Navy Phase I STTR project (Topic N16A-004) titled "Quantifying Uncertainty in the Mechanical Performance of Additively Manufactured Parts Due to Material and Process Variation," Questek is extending the Accelerated Insertion of Materials framework for managing the uncertainty of material properties to the mechanical performance of laser power bed additively manufactured Ti-6Al-4V materials.
www.questek.com
Questek Innovations LLC, Evanston, Ill., was recently awarded six separate projects from the U.S. Navy and U.S. Army to develop technologies and design new alloys specifically tailored to the unique processing conditions and material-related challenges of additive manufacturing.
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Dual chamber furnace designed for heat treating high-speed steels
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Lucifer Furnaces Inc., Warrington, Pa., has delivered a dual-chamber furnace built with 12-gauge sheet steel and reinforced throughout, designed for heat treating high-speed steels. The HS8 furnace heats to 2450°F in the upper chamber, and has silicon carbide heating elements mounted across the roof and below the hearth. Elements are a solid bar type with termination connections for easy service via removable covers on both sides of the furnace.
The upper chambers of these high temp furnaces are insulated with 6.5 inches of combined ceramic fiber hot face and mineral wool cold face insulation for lower power demand, with staggered seams to block direct heat flow to minimize outer shell temperature.
The lower chamber is a recirculating oven reaching up to 1600°F with a high volume rear-mounted fan directing air flow horizontally through the chamber for temperature uniformity. A stainless-steel liner isolates the coiled heating elements from the workload. Heating elements are mounted in removable holders for easy replacement. Lower chamber insulation consists of multilayered lightweight insulating firebrick hotface and mineral wool backup, dry fit to allow for thermal expansion.
The double pivot horizontal swing door on the upper chamber and lower chamber horizontal swing door are both insulated and secured with cam locks for a tight seal. Safety switches shut off power when doors open. Temperature sensing in the upper chamber is achieved with a type R platinum thermocouple for fast, accurate response and extended life at elevated temperatures; the lower chamber is standard with a type K thermocouple. Standard controls, mounted in a side mounted NEMA 1 panel, include a Honeywell DC2500 time proportioning controller for each chamber as well as an SCR power supply for the upper chamber to regulate power demand for steady state control, an alternative to tap switches.
This furnace, model HS82-M24 with inside chamber dimensions of 12 x 12 x 24 inches, will be used at a large corporation in a newly built tool room.
www.luciferfurnaces.com
Lucifer Furnaces Inc., Warrington, Pa., has delivered a dual chamber furnace built with 12-gauge sheet steel and reinforced throughout, designed for heat treating high-speed steels.
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Message from the President: Welcome to 2017!
January 9, 2017
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It's hard to believe that the calendar has turned and we now find ourselves in 2017. I hope everyone had a wonderful and relaxing holiday season, and now off we go for another year of thermal spray!
It was great to see many of you at the North American Cold Spray Conference in Edmonton. The Alberta Innovates venue was amazing, and the quality of the presentations was equally impressive. A special thank you to André McDonald and his team at the University of Alberta for hosting us all and showing off the Donadeo Innovation Centre for Engineering. It's wonderful to see such amazing research being performed at a graduate and undergraduate level.
2017 is going to be a very exciting year for TSS. In April we will be in Charlotte, South Carolina, co-locating with Aeromat for the Thermal Spray Characterization: Materials, Coatings and Processes topical event. In June, we'll be heading to Düsseldorf, Germany for our flagship event, ITSC 2017. And finally, we are planning a second topical event, this time at the GE Research Center in Schenectady, New York. This event will be Thermal Spray of Suspensions & Solutions Symposium (TS4).
As you can see, 2017 is going to be an outstanding year for TSS. I wish you all a very prosperous 2017, and I hope to see you at one or more of our upcoming events. As a reminder, please visit asminternational.org to learn more about changes happening under the Dome, and to #JoinTheRenewal.
Doug Puerta
President, ASM Thermal Spray Society
It’s hard to believe that the calendar has turned and we now find ourselves in 2017. I hope everyone had a wonderful and relaxing holiday season, and now off we go for another year of thermal spray!
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Spray Tips: Thermal Spray Coating Features
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This diagram shows the important thermal spray coating features that combine to determine the properties of a coating. These features include the lamellar or layered splat structure; entrapped, unmelted, or resolidified particles; pores, oxide inclusions, grains, phases, cracks, and bond interfaces.
The diagram schematically illustrates typical coating characteristics and a representative deposit/coating microstructure.
Volume 5A, Thermal Spray Technology ⇒ Thermal Spray Processes and Coatings ⇒ Coating Structures, Properties, and Materials
This diagram shows the important thermal spray coating features that combine to determine the properties of a coating.
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One Minute Mentor: Active Screen Plasma Nitriding
January 6, 2017
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Recently, a process called active screen plasma (ASP) has been developed for the purpose of minimizing or avoiding some of the limitations of conventional plasma nitriding. One such limitation is the edge effect, in which the regions near the edges of the pieces may not be nitrided to the same standard as the rest of the part.
In the conventional glow-discharge process, the plasma is produced by the voltage between the wall of the chamber (positive potential) and the workpieces (negative potential). By contrast, in the ASP process, the plasma is produced by the voltage between the chamber (positive) and a screen (negative) placed around the parts. The nitriding species produced on the screen are then transferred and deposited on the part, which is then heated to the treatment temperature by radiation from the active screen, which itself is under ion bombardment.
The schematic shows active-screen plasma nitriding equipmernt. (a) Floating potential (b) Anodic potential.
Volume 4D, Heat Treating of Irons and Steels ⇒ Nitriding of Stainless Steels ⇒ Thermochemical Nitriding Treatments
Recently, a process called active screen plasma (ASP) has been developed for the purpose of minimizing or avoiding some of the limitations of conventional plasma nitriding.
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