Sandvik super-duplex stainless steel selected for prototype boat
September 7, 2016
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Sandvik Materials Technology, Sweden, announces that its Sandvik SAF 2507 high-strength super-duplex stainless steel has been selected for Project P16 Prototype, an innovative 56-foot prototype boat being built by Swedish Steel Yacht AB. The aim of the project is to evaluate an entirely new technology for constructing more efficient, stronger, and maintenance-free vessels. On completion, the new boat can potentially open up a whole new market for vessels of this type. The prototype boat is aimed to be used by the Coast Guard and sea-rescue services, or as a civilian transport boat.
The new boat will be built of high-strength, maintenance-free stainless steel under a partnership agreement signed by Swedish Steel Yachts AB (SSY), Sandvik Materials Technology, AGA Gas, Saab, and Scania CV.
Sandvik SAF 2507 (UNS S32750) is a super-duplex stainless steel; a high-alloy duplex steel with a PRE (pitting resistance equivalent) value of min. 42. The grade is characterized by very good resistance to chloride corrosion, combined with very high mechanical strength. Sandvik SAF 2507 is particularly suited for service in aggressive environments such as warm chlorinated seawater and acidic, chloride-containing media.
"This is a very exciting development and evaluation project between four major Swedish companies," says Pasi Kangas, Head of Research and Development at Sandvik Materials Technology. "it could solve several key challenges in the boatbuilding industry, by providing more efficient, safer, and greener boats in the future."
The shipping industry currently accounts for a substantial portion of air and sea environmental impact around the world. This is a key factor in the design of the new boat, which requires less material, thereby lightening the vessel and reducing fuel consumption. In addition, the shipbuilding material, Sandvik's advanced steel Sandvik SAF 2507, is 100% recyclable stainless steel and will not need to be painted with poisonous antifouling paint, as is the case with traditional shipbuilding materials.
The vessel will be delivered in the first quarter of 2017 and is being built in Gävle, Sweden, by SSY. On completion, the vessel will be used mainly by Saab and based in Karlskrona.
www.smt.sandvik.com
Sandvik Materials Technology, Sweden, announces that its Sandvik SAF 2507 high-strength super-duplex stainless steel has been selected for Project P16 Prototype, an innovative 56-foot prototype boat being built by Swedish Steel Yacht AB.
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Materion receives Nadcap Merit Status for Heat Treatment
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Materion Corp., Mayfield Heights, Ohio, has earned Nadcap Merit Status from the Performance Review Institute for heat treatment and tensile/hardness testing at its plant in Lorain, Ohio. Nadcap accreditation is important, and in many cases it is required, for companies producing materials or providing services to the aerospace and defense industries.
"This achievement required the focused effort of our technical and quality staff, as well as the commitment of our shift leaders and operators. They had to understand the demands of a Nadcap-accredited system and to work closely together to prepare for the audit and maintain their contribution to the quality management system year round," said W. Glenn Maxwell, President of Materion Performance Alloys and Composites.
Materion has held Nadcap accreditation since 2009. Having demonstrated ongoing commitment to quality by satisfying customer requirements and industry specifications, the Nadcap Heat Treat Task Group determined that Materion earned special recognition with Merit Status. This means that, instead of having their next Nadcap audit in twelve months, Materion has been granted an accreditation that lasts eighteen months.
"Achieving Nadcap accreditation is not easy: it is one of the ways in which the aerospace industry identifies those who excel at manufacturing quality product through superior special processes. Companies such as Materion go above and beyond achieving Nadcap accreditation to obtain Merit Status, and they should be justifiably proud of it," said Joe Pinto, Executive Vice President and Chief Operating Officer at the Performance Review Institute. "Benefitting from a less frequent audit schedule reduces audit costs and associated pressures and demonstrates the trust that the aerospace industry has in Materion, based on their past performance in Nadcap audits. PRI is proud to support continual improvement in the aerospace industry by helping companies such as Materion be successful and we look forward to continuing to assist the industry moving forward."
www.Materion.com
Materion Corp., Mayfield Heights, Ohio, has earned Nadcap Merit Status from the Performance Review Institute for heat treatment and tensile/hardness testing at its plant in Lorain, Ohio.
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Zero Flow gas nitrocarburizing enables better control and lower cost
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Seco Warwick, Meadville, Pa., is demonstrating its ZeroFlow controlled-gas nitriding at the Heat Treatment Exhibition in Moscow this week. Developed in cooperation with Prof. Leszek Małdziński from the Technical University in Poland, the technology is based on the adjusted double-component atmospheres NH3 + dissociated NH3, and NH3 + N2 .
The ZeroFlow method is based on a single-component atmosphere – raw ammonia (NH3). The adjustment of nitriding atmosphere chemical composition, and therefore the control of nitriding potential Np, is performed only by temporary stop and reactivation of NH3 flow into the furnace. The amount flowing into the retort is adjusted and controlled through a gas analyzer (NH3 or H2). Experimental research has shown that the ZeroFlow method is characterized by much lower consumption and emission of gases. It requires a simpler control system and allows for forming the layer phase structure with the same precision as in processes with double-component atmospheres.
"Even though nitriding of steel can be considered a byproduct of the dissociation of ammonia, there is no need to dissociate more ammonia than absolutely necessary," says Prof. Małdziński. "Zero flow nitriding is the first gaseous process that economizes the use of resources without compromising the added value to your product. It allows a targeted treatment of your components, independent of whether you do or do not want a compound layer. Zero flow nitriding gives you larger flexibility, better control, and lower cost of your nitriding process."
https://www.secowarwick.com/en/search?q=zeroflow
Seco Warwick, Meadville, Pa., is demonstrating its ZeroFlow controlled-gas nitriding at the Heat Treatment Exhibition in Moscow this week.
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Stratasys 3D printing consolidates 163-component part into a two-piece unit
September 4, 2016
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Marshall Space Flight Center, Huntsville, Ala., reports that Stratasys Direct Manufacturing, Minneapolis, helped build a rocket injector 15 times faster than traditional manufacturing with direct metal laser sintering. The part was manufactured of Inconel 625 in about 300 hours in an EOS M280 machine with proprietary build parameters. The technology enabled consolidating the traditionally manufactured 163-component part into a two-piece unit. This ability to rapidly create highly complex parts makes it attractive to the aerospace industry.
Traditional manufacturing requires holes drilled into each element of the injector inlet. Then, a fitting is machined with unique flow features and welded to the first element. The process requires multiple pieces to be welded, machined, cast, and otherwise bonded together to build the injector.
Conversely, the DMLS-built injectors allowed the intricate, unique swirl pattern to be built directly into the inlet of the injector in one print. The 3D printed injectors successfully passed hot fire, static, and strenuous mechanical property tests – all of which are critical stages in the validation process.
Typically, Marshall uses powder bed metal fusion (e.g. DMLS, electron beam melting, and selective heat sintering) for all its 3D printing, and the center also prints with direct powder injection. The latter form of manufacturing injects metal powder into a laser beam as the part is fabricated, and enables building larger parts.
https://www.stratasysdirect.com/case-studies/nasa-sls-propulsion-program/
Marshall Space Flight Center, Huntsville, Ala., reports that Stratasys Direct Manufacturing, Minneapolis, helped build a rocket injector 15 times faster than traditional manufacturing with direct metal laser sintering.
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Albert Kay receives ASM Distinguished Life Member award
September 3, 2016
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Mr. Albert Kay, FASM, president of ASB Industries, Barberton, Ohio, is the recipient of this year's ASM Distinguished Life Member Award.
The award is "in recognition of outstanding innovation and early commercialization of emerging thermal spray technologies, including high-velocity oxyfuel and cold spray; exemplary development of a business model that gained worldwide recognition; and for dedication and unselfishness, unstinting personal effort, and leadership on behalf of the Thermal Spray Society and ASM International."
The Distinguished Life Membership award was established in 1954 and is conferred on leaders who have devoted their time, knowledge, and abilities to the advancement of the materials industries. His award will be presented during a future Akron Chapter meeting.
www.asminternational.org/web/tss
Mr. Albert Kay, FASM, president of ASB Industries, Barberton, Ohio, is the recipient of this year’s ASM Distinguished Life Member Award.
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Oerlikon sells its vacuum business to Atlas Copco
September 2, 2016
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Oerlikon, Switzerland, has signed an agreement to sell its vacuum business to Atlas Copco, Sweden, to be able to focus on its strategy of growing its global surface solutions and advanced materials businesses. After receiving all the required regulatory approvals in July, the closing of the sale has now been completed.
"The closing of the transaction marks a milestone in our strategy implementation," says Oerlikon CEO Dr. Roland Fischer. "The demand for surface solutions and advanced materials is growing and offers attractive opportunities. With the sale, we can concentrate our efforts and resources in developing and advancing this business."
The transaction is based on an enterprise value of $535 million. In the 2016 full-year financial statements, the vacuum business will be reported under discontinued operations. Depending on final adjustments post-closing, Oerlikon expects a net cash impact of around $336 million after transaction and tax costs. The result from discontinued operations in the Group's 2016 income statement is expected to be approximately $285 million, including deconsolidation effects.
www.oerlikon.com
Oerlikon, Switzerland, has signed an agreement to sell its vacuum business to Atlas Copco, Sweden, to be able to focus on its strategy of growing its global surface solutions and advanced materials businesses.
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Plasma spray titanium coatings on PEEK implants enhance bone fusion
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Centinel Spine, West Chester, Pa., has developed Ti-Active titanium plasma spray coatings on polyetheretherketone implants. The coating enhances the PEEK implants by providing an integrated microporous titanium surface designed to increase the coefficient of friction for enhanced insertion stability. The coating also enables cellular attachment and proliferation to maximize opportunities for fusion.
Retrospective studies show clinically favorable outcomes for hip stems with plasma spray titanium coatings that result in excellent bony on-growth and long-term stability. Recent literature shows that 100% titanium interbody cages have more cellular attachment and proliferation properties than traditional PEEK cages. However, all-titanium cages have a higher modulus of elasticity and an increased risk of subsidence.
Built on over 15 years of science and experience, Centinel Spine engineered the Ti-Active technology to merge the translucent and biomechanical advantages of PEEK with the hydrophilic and cell-friendly properties of titanium. Ti-Active devices are 20 times rougher than uncoated PEEK devices, and the 3D topography increases the surface area in contact with the bony endplates, maximizing the potential for fusion.
"When titanium is added to the PEEK implant it makes the implant easier for cells to adhere and proliferate," says Celeste Abjornson, Ph.D., project coordinator with the Integrated Spine Research Programs at Hospital for Special Surgery in New York City. These scientists recently published a paper examining the different roughness profiles of titanium coatings. They reported that when the titanium coating achieves the right roughness, the cells are able to express different growth factors and proteins.
www.centinelspine.com
Centinel Spine, West Chester, Pa., has developed Ti-Active titanium plasma spray coatings on polyetheretherketone implants.
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One Minute Mentor: Duplex Stainless Steels
September 1, 2016
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Complex compounds of iron, chromium, and molybdenum are highly detrimental to toughness and corrosion resistance, particularly the resistance to localized chloride attack. The graph shows the time-temperature exposures required for a 50% reduction in impact strength due to isothermal precipitation of undesirable secondary phases for various duplex stainless steels.
The kinetics of σ/χ precipitation is greatest in the range of about 1500 to 1700°F. The time required to degrade properties depends on the temperature and the alloy content. The increased N content of modern duplex stainless steels significantly decreases the rate of the σ/χ precipitation reactions making it possible to weld these grades without loss of properties due to formation of intermetallic phases. Once intermetallic phases have formed, the only means of removing them and restoring properties is a full solution anneal followed by rapid cooling.
Volume 4D, Heat Treating of Irons and Steels ⇒ Heat Treated High-Alloy Steels ⇒ Heat Treating of Austenitic and Duplex Stainless Steels ⇒ Duplex Stainless Steels
Complex compounds of iron, chromium, and molybdenum are highly detrimental to toughness and corrosion resistance, particularly the resistance to localized chloride attack.
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Nitride coatings based on titanium and other metals protect jet engine components
August 30, 2016
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Wallwork Heat Treating, England, reports that its Nitron Flight PVD-applied nitride coatings based on titanium, chromium, chromium-aluminum, and carbon/metal carbides improve the performance of key jet engine components. The graded coatings are precision engineered for thickness and composition, from 3 to 30 microns thick and hardness up to 3000HV. They are applied to critical flying parts such as turbine blades and other high-stress components.
Advantages include longer service life, extended service intervals, resistance to erosion and encrustation, and increased scope for material substitution to save weight.
Comparative wear tests carried out by Wallwork Cambridge on Ti-64 samples revealed that Nitron Flight coatings reduced abrasive wear by more than 75%. They can be applied to titanium, steel, and advanced alloy surfaces such as engine blades/vanes for operation at temperatures up to 1000°C. The coatings are applied in a duplex process using PVD in a variety of basic formulations of metal nitrides, and in a variety of single and multiple-layer coatings to suit specific applications.
Applications are many and include landing gear, engine bearings, high-temperature engine seals, engine compressor sections, valve components, and many others. The company offers both standard and customized coatings to meet special situations. Coating processes are Nadcap certified with complete documentation and traceability.
www.wallworkht.co.uk
Wallwork Heat Treating, England, reports that its Nitron Flight PVD-applied nitride coatings based on titanium, chromium, chromium-aluminum, and carbon/metal carbides improve the performance of key jet engine components.
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How manganese prevents oxidation in high-strength steel
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A team from the University of Warwick, UK, discovered that the amount of oxide that forms at the surface of automotive high-strength steels depends on the ratio between manganese and additional alloying elements. High-strength steels are obviously an important backbone for applications in the automotive industry, but cost-efficient manufacture requires the suppression of oxides within the steel during sheet production.
When steel sheet is produced in rolling mills at high temperatures, the surface oxidizes quickly, but the grain boundary oxides underneath define the depth of the corroded zone and also the forming limit. Hence, oxidation plays an essential role during the manufacture of high strength steels for automotive applications, because they often contain a higher amount of manganese. Due to their unique mechanical properties, this allows for a significant reduction of sheet thickness, allowing vehicles to be lighter in weight with lower carbon emissions.
The research was led by the Warwick Manufacturing Group (WMG) at the University of Warwick. The research, led by Dr. Michael Auinger of WMG, together with the Vienna University of Technology (Austria) and Voestalpine Stahl GmbH (Austria) developed a better understanding for the oxidation behavior inside steels during hot rolling, which could potentially help manufacturers to reduce the amount of steel lost during production. Therefore, adapted process parameters and knowledge about the admissible limits of alloy content would help to prevent negative effects of grain boundary oxidation during further steel processing and in-service properties of HSS car body parts.
Dr. Auinger and his co-researchers analyzed the oxidation behavior of different iron-based alloys. They found that particularly the combinations of iron-manganese and a second alloy addition - representing a simplified version of many high strength steels - undergo severe oxide formation along grain boundaries if not processed appropriately.
"Isotope exchange experiments verified that grain boundaries in manganese-containing steels are extremely susceptible to oxide formation. On the other hand, oxide particles inside the grains strongly bind their oxygen atoms. It means that new oxygen has to penetrate the entire oxide zone before forming a new oxide particle at the front," Dr. Auinger says. "The reduced depth of internal oxidation is suggested to be caused by lowering the oxygen diffusion due to trapping reactions at crystal imperfections."
Dr. Auinger argues that from a scientific point of view, this work is particularly important, since it indicates not that the oxidation along grain boundaries is enhanced, but that the oxidation of the alloy additions inside the metallic grains is significantly slower than predicted by theoretical simulations. This helps the understanding of the mechanisms of oxide formation. It also may enable inventing novel strategies that could help to prevent unwanted oxidation, which is currently determined by the cooling efficiency after hot rolling.
The University of Warwick, England, announces that a team of researchers has discovered that the amount of oxide that forms at the surface of automotive high-strength steels depends on the ratio between manganese and additional alloying elements.
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