Nanocomposite coating imparts anti-icing properties to substrate
November 6, 2016
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NEI Corp., Somerset, N.J., reports that it has enhanced the performance of its anti-ice coating, Nanomyte SuperAi, a nanocomposite coating that imparts anti-ice properties to the underlying substrate. Rigorous testing has confirmed its efficacy under a variety of icing conditions. As a consequence of the engineered properties of the anti-ice coating's formulation, it reduces ice buildup on surfaces, and provides a hard, dense, smooth finish.
Treated surfaces exhibit reduced ice adhesion, thereby reducing ice buildup. Precisely calibrated Ice Adhesion measurements showed that SuperAi has an Ice Adhesion Reduction Factor of greater than 5 (relative to a polished metal surface), indicating that Nanomyte SuperAi reduces the adhesion of ice by more than 80%, compared to smooth bare metal and painted surfaces. The performance remains unaltered after repeated icing-deicing cycles, as well as after mechanical abrasion. Further, icing wind tunnel experiments show that SuperAi allows ice to be removed with minimal force, confirming its usefulness under real-world conditions.
The coating can be applied to a variety of substrates, including plastic, metal, glass, and ceramic. In some instances, a suitable primer may be required for long term durability.
SuperAi is a single component coating that is easily applied by spray or brush. The dry film thickness can be adjusted to be in the range of 5 to 25 microns, and only one coat is required to cover the substrate. Current applications include structures where ice removal is a challenge: e.g., wind turbine blades, power transmission lines and cables, cellular phone towers, windshields and other glass surfaces in automobiles, aircraft wings, and unmanned aerial vehicles. SuperAi also provides corrosion protection, which is an added benefit. SuperAi enhances productivity for the user and provides rapid payback, as well as a good return on investment.
www.neicorporation.com
NEI Corp., Somerset, N.J., reports that it has enhanced the performance of its anti-ice coating, Nanomyte SuperAi, a nanocomposite coating that imparts anti-ice properties to the underlying substrate.
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Optomec LENS hybrid vertical milling system combines 3D printing, machining
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Optomec, Albuquerque, N.M., announces that the Center for Remanufacturing and Resources Recovery (C3R) at the Rochester Institute of Technology in New York is restoring legacy components with the Optomec LENS 3D Hybrid Vertical Milling Center system. The hybrid system utilizes LENS 3D printing technology integrated within a conventional CNC vertical mill, providing additive and subtractive capabilities in a single machine tool. With this system, engineers are restoring metal components not possible with other repair methods such as thermal spray.
C3R is considered one of the world's leaders in remanufacturing, which involves restoring worn or damaged in-service parts to extend their useful life. At the end of life, complex components within modern machinery contain significant value in the form of raw materials, material processing, logistics management, and intricate machining. Remanufacturing of components provides a method of capturing the intrinsic value of a part and sometimes an entire machine if parts cannot be sourced.
The LENS 3D Hybrid VMC is a way to remanufacture complex components in equipment. The LENS process, combined with a traditional mill, allows damaged parts to be removed, their surfaces prepped, and their structure restored by machining, all within a single setup. Current projects at C3R involve investigating application of the LENS system for restoring the original capability of cast iron and steel parts for another lifecycle. Preliminary results have shown minimal modification of the substrates' subsurface microstructure, low porosity, and quality adhesion.
The LENS process enables either fully building 3D metal parts, when replacement parts are no longer available; or selectively and precisely adding materials onto an existing metal component of almost any three-dimensional shape – making it ideally suited for repair/remanufacturing operations. The process leverages LENS Directed Energy Deposition technology, which is an industry-proven method to add metal directly onto an existing metal part. The LENS print head delivers powdered metal and a highly focused laser beam to the damaged part area, enabling repair of components in a way not possible with traditional repair methods such as welding and thermal spray. The highly focused heat input of the LENS process minimizes the heat affected zone in the part under repair, and reduces the chance of distortion, while also improving adhesion.
http://www.rit.edu/gis/remanufacturing/
www.optomec.com
Optomec, Albuquerque, N.M., announces that the Center for Remanufacturing and Resources Recovery (C3R) at the Rochester Institute of Technology is restoring legacy components with the Optomec LENS 3D Hybrid Vertical Milling Center system.
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PNNL to develop cold spray technology to repair turbines in hydropower dams
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Pacific Northwest National Laboratory, Richland, Wash., is working with several partners to develop cold spray technology for repair of cavitation-damaged turbines in hydropower dams to improve performance and service life .
High direct costs are associated with repair and replacement of cavitation-damaged turbine blades. Not only are the costs high, but also typical repair methods such as arc welding introduce new weaknesses to the repaired turbine blades. High heat input and melting associated with arc welding degrade properties in and around the repair. This results in increased frequency of repair and reduced turbine performance compared to a new turbine.
PNNL is researching cold spray as an alternative to arc welding repair. Cold spray works by shooting metal particles at supersonic velocities, or very high speeds. The impact energy created by these high speeds produces a solid state weld between the particle and the turbine surface. With this method, no melting or material degradation takes place, and the turbine blade is left in its original shape. Even better, cold spray repair is capable of depositing materials with hardness and wear resistance that match or exceed that of the turbine base metal—meaning cold spray repairs should produce superior performance.
"This project is generating the performance data and cost modeling to quantify the improved performance and value proposition of cold spray repair for hydro turbines, and the initial results are promising," says PNNL researcher Ken Ross. The project team is confident that cold spray repair will dramatically reduce the frequency of dam outages, resulting in less down time and reduced service and maintenance costs for dams across the nation.
The Bonneville Power Administration funded a partnership between PNNL, the U.S. Army Research Laboratory, equipment manufacturer VRC, and Moog, a cold spray repair contractor. The Bonneville Power Administration, The U.S. Bureau of Reclamation, and Idaho Power are also part of the project team. Input from engineers, project managers, and economists from these organizations is being used to guide technical development and create a foundation for commercialization of this technology. This includes performance benchmarking data, cost modeling tools, best-practice documents, and a group of companies ready to provide equipment and tailor to needs of turbine repair.
http://energyenvironment.pnnl.gov/highlights/highlight.asp?id=2368
www.pnnl.gov
Pacific Northwest National Laboratory, Richland, Wash., is working with several partners to develop cold spray technology for repair of cavitation-damaged turbines in hydropower dams to improve performance and service life.
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Electric oxidizing oven heat treats Inconel trays for nuclear power fuel cell rods
November 2, 2016
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Baker Furnace Inc., Yorba Linda, Calif., has shipped an electric oxidizing oven to a manufacturer of components for nuclear power plants to heat treat Inconel support trays that hold nuclear fuel cell rods in place. The heat treating process extends the life of the trays and reduces production costs for the manufacturer.
The heat treating oven has a maximum temperature rating of 1350°F and work zone dimensions of 5 x 5 x 5 feet. The unique Baker Furnace door design offers a lifetime no-sag guarantee along with a pneumatic door locking mechanism. A recirculation fan provides approximately 25 air changes per minute through adjustable air distribution via sidewall ducts, with the return air at the rear of the work chamber for temperature uniformity of ±25°F at 1300°F. The oxidizing oven utilizes a programmable temperature controller with ramp and soak capabilities.
Unique features of this oxidizing oven include a 316L stainless steel interior; pneumonic door locking mechanism; 90kW rod style heating elements; 3000 CFM recirculation fans.
www.bakerfurnace.com
Baker Furnace Inc., Yorba Linda, Calif., has shipped an electric oxidizing oven to a manufacturer of components for nuclear power plants to heat treat Inconel support trays that hold nuclear fuel cell rods in place.
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Alcoa completes separation from parent company Arconic
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Alcoa Corp., Pittsburgh, announces that it has completed the separation from its parent company Alcoa Inc. (now named Arconic Inc.) and has begun operating as an independent, publicly traded company listed on the New York Stock Exchange under the symbol AA. Alcoa Corporation is a globally cost-competitive industry leader in bauxite, alumina, and aluminum products, positioned to succeed throughout the market cycle.
The separation was completed through a pro rata distribution by Alcoa Inc. of 80.1% of the outstanding shares of the newly formed Alcoa Corporation. Arconic will retain 19.9% of Alcoa Corporation common stock.
"We are launching Alcoa Corporation as a world leader in the aluminum industry with distinct competitive advantages across the value chain," says Roy Harvey, Chief Executive Officer of Alcoa. "Our bauxite and alumina portfolios enjoy strong first quartile cost positions and our aluminum portfolio has a highly competitive second quartile position. We've made a commercial success of our cast products business. Our can sheet business is a leader in North America, and our substantial energy assets are also driving value for maximum profitability."
"Today we launch Arconic as a strong independent company," said Arconic Chairman and CEO Klaus Kleinfeld on Nov. 1. "Our multi-year transformation while part of Alcoa Inc. substantially improved our competitiveness and profitability. Today, we are very well positioned as a leader in attractive markets."
Within aerospace, which accounts for approximately 40% of Arconic total revenues, the company develops and manufactures high-performance, engineered products and solutions for airframe structures and aero engines. Since 2008, the company has significantly grown its capabilities through a combination of organic and inorganic technology and innovation-focused investments.
As a result, Arconic has gained significant share on next generation aero engines and aero structures. The company can today supply over 90% of the components within the jet engine, and it is a leader in structural parts for both metallic and carbon fiber reinforced plastic (CFRP) aircraft. In fact, 85% of aerospace revenues come from products where it holds either the number one or number two market position.
In the North American automotive market, Arconic invented the bonding process to enable the mass-market shift from steel to aluminum, and it is today at the forefront of capturing growing demand for aluminum sheet as the industry shifts to light-weighting. The Company expects its North American automotive sheet revenues to grow six-fold, from $229 million in 2013 to $1.3 billion in 2018. Across its North American automotive portfolio, 96% of the company's revenues come from products where it is number one or number two in its market.
www.alcoa.com
www.arconic.com
Alcoa Corp., Pittsburgh, announces that it has completed the separation from its parent company Alcoa Inc. (now named Arconic Inc.) and has begun operating as an independent, publicly-traded company listed on the New York Stock Exchange under the symbol AA.
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Buehler IsoMet High Speed precision cutter enables consistent metal sample sectioning
November 1, 2016
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Buehler, Lake Bluff, Ill., introduces the IsoMet High Speed, a precision sectioning machine designed specifically to create consistent and efficient cuts in metals and other materials using diamond or abrasive blades. It features a robust saw that provides consistent sectioning performance for busy laboratories with the following key features:
Automated three-axis movement allows precise alignment and quick cutting.
Automatic dressing system maintains consistent cut quality and reduces the frequency of changing the dressing stick.
Rapid laser alignment saves time with instant visual alignment with laser.
Intuitive controls allow programming for repeatable and consistent single or serial sections.
Quick sample adjustments offer easy adjusting of sample with the Rapid Rail and tool-less vising system.
According to Product Manager Chelsea Frid, "The IsoMet High Speed is available in two formats – the High Speed and the High Speed Pro. Both provide strength and power to produce quality cut surfaces. In the High Speed Pro version, Buehler has added additional abilities to improve user experience with a laser for visual blade alignment and an automatic dressing system to maintain diamond blade quality throughout the cut."
Buehler offers a complete selection of IsoMet High Speed accessories, including Rapid Rail Vise Holder, Single Saddle Chuck, Double Saddle Chuck, quick clamp vises, dressing wheels, and external recirculation tank.
Buehler is a leading provider of scientific equipment, supplies, consumables and analysis techniques for use in materials preparation, image analyses and hardness testing.
www.buehler.com
Buehler, Lake Bluff, Ill., introduces the IsoMet High Speed, a precision sectioning machine designed specifically to create consistent and efficient cuts in metals and other materials using diamond or abrasive blades.
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Iowa State wins $2.8 million DOE grant to make ductile 6.5% Si electrical steel
October 31, 2016
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Iowa State University and its Ames Laboratory report that researchers have received a three-year, $2.8 million grant to develop a ductile electrical steel containing 6.5% silicon, twice the amount in electric motor steel today. The extra silicon increases the electrical resistivity of the material by about 50%, helping to make the motors smaller, lighter, more powerful, and more cost effective. Associate Professor of Materials Science and Engineering Jun Cui says he thinks these motors could run at much higher frequencies – jumping from today's 60 hertz all the way to 400 hertz — but the alloy is currently too brittle and too expensive to make.
Therefore, the U.S. Department of Energy is supporting the work with a three-year, $3.8 million grant from the DOE's Vehicle Technologies Program. Of that, $2.8 million will support research at Iowa State. The project also includes research partners from the United Technologies Research Center in East Hartford, Connecticut; and the University of Delaware in Newark.
The Iowa State-Ames Laboratory researchers will study and characterize different processes for making the new electrical steel to increase ductility and reduce manufacturing costs. Prof. Cui says that the researchers are also committed to developing materials and motors that do not depend on magnets made with rare-earth materials, which are rising in cost.
"The fundamental drive for this project is that we want more cost-effective and efficient electric motors," Prof. Cui says. "In about ten years, if we're lucky, we should see a real impact of this work. We should see these motors on the road." (Image courtesy Nucor)
http://www.news.iastate.edu/news/2016/09/27/electricalsteel
Iowa State University and its Ames Laboratory report that researchers have received a three-year, $2.8 million grant to develop a ductile electrical steel containing 6.5% silicon, twice the amount in electric motor steel today.
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One Minute Mentor: Variations in Heat-Treating Cycles of PH Stainless Steels
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One of the principal advantages of these materials is their versatility. Although certain heat treatments are classified as standard, there are applications where deviations from these standards are desirable.
The graphs show the effect of variations in annealing temperature on typical mechanical properties of 17-7 PH sheet, strip, and plate.
Heat Treating of Precipitation-Hardenable Stainless Steels and Iron-Base Superalloys ⇒ Heat Treated High-Alloy Steels ⇒ Heat Treating of Martensitic Stainless Steels ⇒ General Procedures
One of the principal advantages of these materials is their versatility.
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Thermo-Calc and QuesTek partner for advanced modeling and materials design
October 28, 2016
Source: ASM International
Thermo-Calc Software AB, Stockholm, and QuesTek International LLC, Evanston, Ill., have partnered to establish a joint company, QuesTek Europe AB, which will offer Integrated Computational Materials Engineering modeling services and novel materials design and development to the European market.
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Harper teams with Oak Ridge to improve carbon fiber production
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Harper International, Buffalo, N.Y., announces that in partnership with Oak Ridge National Laboratory, it has been awarded funding for a project through the U.S. Department of Energy Advanced Manufacturing Office's HPC4Mfg Program. The program was designed to spur the use of high-performance supercomputers to advance U.S. manufacturing via public-private partnerships.
Specifically, the Harper International/ORNL project, titled "Development and Validation of Simulation Capability for the High Capacity Production of Carbon Fiber," will focus on analysis of critical processing factors, such as temperature, gas flow, and chemical reaction, in carbon fiber production equipment. The purpose is to ensure that designs provide the necessary uniformity to produce fiber of a certain quality, output, and cost ideal for automotive applications. Results will then be validated at the pilot scale equipment designed and installed by Harper at ORNL's Carbon Fiber Technology Facility, followed by testing in a commercial production facility.
"This project allows Harper to continue its work as a champion of innovative carbon fiber processing technologies to meet the needs of future markets, such as mass automotive applications, now with access to world-class supercomputers and deeper scientific expertise," commented Dr. Prasad Apte, Director of Technology at Harper International. "We are proud to be collaborating with the pioneering thought leaders at ORNL in continuation of our strong relationship."
www.harperintl.com
Harper International, Buffalo, N.Y., announces that in partnership with Oak Ridge National Laboratory, it has been awarded funding for a project through the U.S. Department of Energy Advanced Manufacturing Office’s HPC4Mfg Program.
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