Solar Atmospheres of California is awarded Nadcap 24-month Merit status
August 9, 2016
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Solar Atmospheres of California, Fontana, announces that it has been awarded Nadcap 24-month Merit status for Heat Treating, which means that instead of having its next Nadcap audit in eighteen months, it has been granted an accreditation that lasts until July 31, 2018.
"We are extremely pleased PRI has recognized our corporate commitment to quality," says a company news release. "Achieving 24-month Merit status has been a goal set by Solar's employees since the company opened its doors in 2011. The adherence to strict specification requirements, flawless process execution, and a daily commitment to quality processing is evident among all employees."
The company has held Nadcap accreditation since 2011. Having demonstrated its ongoing commitment to quality by satisfying customer requirements and industry specifications, the Nadcap Task Group has determined that Solar Atmospheres of California has earned this special recognition.
According to PRI's VP and COO Joe Pinto, "Benefitting from a less frequent audit schedule reduces audit costs and associated pressures, and demonstrates the trust that the aerospace industry has in Solar Atmospheres of California based on past performance in Nadcap audits. PRI is proud to support continuous improvement in the aerospace industry by helping such companies be successful, and we look forward to continuing to assist the industry moving forward."
www.solaratm-ca.com
Solar Atmospheres of California, Fontana, announces that it has been awarded Nadcap 24-month Merit status for Heat Treating, which means that instead of having its next Nadcap audit in eighteen months, it has been granted an accreditation that lasts until July 31, 2018.
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Chromium-aluminum PVD coating protects jet engine compressor vanes and seals
August 4, 2016
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Wallwork Heat Treating Co., England, has developed Nitron CA, a PVD vacuum process in which a material comprised of chromium and aluminum bound with nitrogen is deposited on complex surfaces. Thicker than normal PVD films, the dense amorphous architecture of the coating provides an excellent environmental barrier.
The resulting film is said to have high hot hardness and good resistance to high-temperature oxidation, making it ideal for components in the hot section of the aero-engine, such as compressor blades/vanes and engine ring seals.
Nitron CA also has a low coefficient of friction, which would enhance the performance of cylindrical roller thrust bearings. The lower sliding friction of the coated surface reduces the shear stresses in the slippage zones of bearing systems.
These conformal films can be applied to complex surfaces, and they impart a range of properties said to far exceed those of hard chrome plating.
The combination of well-adhered film, high hardness, and a low-friction surface make these films ideal for sliding and rolling wear applications such as bearing and seal surfaces. In addition, the high thermal integrity of Nitron CA renders the film ideal in high-temperature applications.
http://www.wallworkht.co.uk
Wallwork Heat Treating Co., England, has developed Nitron CA, a PVD vacuum process in which a material comprised of chromium and aluminum bound with nitrogen is deposited on complex surfaces.
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Norsk Titanium to build 3D printed parts for aerospace and deliver RPD machines to New York
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Norsk Titanium, Norway, recently announced agreements with Mecachrome, Thales, Boeing, and the state of New York regarding its Rapid Plasma Deposition (RPD) additive manufacturing process. Norsk says that these titanium parts have strengths equivalent to those of forgings, but at lower cost and shorter design-to-market times.
Mecachrome: Norsk will deliver finished aerospace titanium structural components produced by its RPD additive manufacturing process to current Mecachrome aerospace OEMs and their Tier One suppliers.
Thales: Norsk has signed a contract with Thales Alenia Space to develop, produce, and test RPD components weighing more than 3 kg for spaceflight.
Boeing: The engineering test article order involves Norsk Titanium producing titanium Ti-6Al-4V additive manufactured preforms, and delivering them to Boeing for further testing and evaluation.
The state of New York: In partnership with SUNY Polytechnic Institute, the state has placed an order for an initial lot of 20 Norsk Titanium Merke IV Rapid Plasma Deposition machines for the world's first RPD factory, to be located in Plattsburgh, New York. Planned to be operational by the end of 2017, the first 20 machines are to establish a baseline production level of 400 metric tons per year of aerospace-grade structural titanium components.
In the Rapid Plasma Deposition process, titanium wire is melted in a cloud of argon gas and precisely and rapidly built up in layers to a near-net-shape (up to 80% complete) that requires very little finish machining. Production cost is less than legacy forging and billet manufacturing techniques, due to significantly less waste and machining energy. Part build size: 900mm x 600mm x 300mm; Layer dimensions: H=3-4mm / W=8-12mm; Deposition rate: 5-10kg/hour.
www.norsktitanium.com
Norsk Titanium, Norway, recently announced agreements with Mecachrome, Thales, Boeing, and the state of New York regarding its Rapid Plasma Deposition (RPD) additive manufacturing process. Norsk says that these titanium parts have strengths equivalent to those of forgings, but at lower cost and shorter design-to-market times.
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Alcoa’s new facility to produce titanium, nickel, aluminum powders for 3D printing
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Alcoa, Pittsburgh, has committed to 3D printing technology with the opening of a new powder atomization building at the Alcoa Technology Center in New Kensington, Pa. Proprietary titanium, nickel, and aluminum powders are to be produced in quantities and blends optimized for designing, manufacturing, and certifying aerospace components.
In addition to producing powders, Alcoa is focused on advancing a range of additive techniques, including its recently unveiled Ampliforge process, a hybrid technique that combines additive and traditional manufacturing. Using the Ampliforge process, Alcoa engineers design and 3D print a near-complete part, then treat it by a traditional manufacturing process such as forging. The process enhances the properties of 3D printed parts, increasing toughness and strength versus parts made solely by additive manufacturing, and significantly reduces material input. Alcoa is piloting the technique in Pittsburgh and Cleveland.
Alcoa also has invested in a range of technologies to further develop additive processes, product design, and qualification. "Alcoa is forging a leadership path in additive manufacturing with a sharp focus on the critical input material—metal powders," says Alcoa Chairman and Chief Executive Officer Klaus Kleinfeld. "We are combining our expertise in metallurgy, manufacturing, design, and product qualification to push beyond the possibilities of today's 3D printing technologies for aerospace and other growth markets." Through this expansion, announced in September 2015, Alcoa will develop materials with the specific properties needed to 3D-print high-performance components.
The facility will form part of Arconic following separation from Alcoa's traditional commodity business in the second half of 2016. The plant is part of a $60 million investment in advanced 3D printing materials and processes that builds on the Company's 3D printing capabilities in California, Georgia, Michigan, Pennsylvania, and Texas.
Airbus recently selected Alcoa to supply 3D printed titanium fuselage and engine pylon parts for commercial aircraft. Alcoa expects to deliver the first additive manufactured parts under the agreement later this year.
www.alcoa.com
Alcoa, Pittsburgh, has committed to 3D printing technology with the opening of a new powder atomization building at the Alcoa Technology Center in New Kensington, Pa.
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One Minute Mentor: Annealing of Austenitic and Duplex Stainless Steels
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The lower carbon content in an austenitic stainless steel slows the kinetics of carbide precipitation. This allows longer time at temperature before the onset of sensitization. The graph shows the Time-Temperature-Sensitization diagram (TTS) for 304 austenitic stainless steel with various amounts of carbon. Decreasing carbon content significantly delays the formation of chromium carbides and the onset of intergranular corrosion. In low-carbon grades, defined as those with carbon content below 0.030%, an exposure of about 8 hours is necessary before sensitization occurs
Carbon content of 0.03% and lower allows short excursions of several hours into the sensitizing temperature range without loss of corrosion resistance. Carbon in austenite can be retained in supersaturation for extended periods of time. This is why austenitic L grades do not sensitize even though they are slightly supersaturated. Sensitization occurs at higher levels of carbon by prolonged heating at 600 to 850°C.
Volume 4D, Heat Treating of Irons and Steels ⇒ Heat Treated High-Alloy Steels ⇒ Heat Treating of Austenitic and Duplex Stainless Steels ⇒ Annealing
The lower carbon content in an austenitic stainless steel slows the kinetics of carbide precipitation.
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AMG Titanium Alloys to supply titanium aluminides for PW1100G-JM engine
August 3, 2016
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AMG Advanced Metallurgical Group N.V., Amsterdam, announces that AMG Titanium Alloys and Coatings (AMG TAC) has been selected by MTU Aero Engines to provide titanium aluminides for the production of the Pratt & Whitney PurePower PW1100G-JM engine. The value of the long-term supply contract exceeds$40 million.
The TiAl intermetallic combines the heat resistance of nickel alloys with the lightweight characteristics of titanium. AMG's TiAl materials will be used to produce low-pressure turbine blades for the PurePower PW1100G-JM engine for single-aisle aircraft, including the Airbus A320neo.
According to Pratt & Whitney, the ultra-efficient PurePower PW1100G-JM engine delivers double-digit improvements in fuel efficiency, reduces noise by 20 dB, and slashes CO2 and NOX emissions.
To support this next stage of expansion, AMG TAC will invest in new vacuum furnaces supplied by AMG Engineering. The combined value of current and future supply contracts for AMG's TiAl business, across all customers, exceeds $130 million.
www.amg-nv.com
AMG Advanced Metallurgical Group N.V, Amsterdam, announces that AMG Titanium Alloys and Coatings (AMG TAC) has been selected by MTU Aero Engines to provide titanium aluminides for the production of the Pratt & Whitney PurePower PW1100G-JM engine.
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Laser profile scanner evaluates high-strength steel welds during welding process
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SSAB Steel, Stockholm, announces that its engineers together with researchers from the Royal Institute of Technology have developed a quality assurance method for welds in high-strength steel in which a laser profile scanner assesses the welded surface and measures the quality of the weld. The most revolutionary aspect of this method is that the assessment takes place in real time – online – during the actual welding process.
"This system will provide instant feedback to the welding operator on whether the welded joint fulfills all its requirements," explains Dr. Thomas Stenberg. "If not, the welding robot will be able to adjust the process parameters to ensure that the weld quality complies with the desired result, without needing to disrupt the process or repeat the work."
As Anders Ohlsson, Manager of Joining & Thermal Cutting Technologies at SSAB's Knowledge Service Center explains, the new QA method has the potential to revolutionize the ways in which many of SSAB's customers utilize high-strength steel, opening up opportunities for more applications to benefit from its superior qualities, which include lower component weight and reduced fuel consumption.
"Minimizing the occurrence of failures caused by fatigue will enable us to use HSS in many applications in which they cannot be used today – such as in machines and components that are known to be subject to high stress concentrations. Examples of these applications may include chassis for manufacturing and forestry equipment, trailer chassis and components used in energy production," says Mr. Ohlsson.
According to Dr. Stenberg, who won the 2015 Swedish Steel Prize "University Challenge" award from SSAB for his groundbreaking work on the new QA method, the method will deliver significant benefits to the customers who implement it.
"Firstly, we expect productivity to increase by about 50% due to increased robot travel speed, coupled with a reduction of up to 30% in the consumption of weld filler material," he says. "It will also allow manufacturers to cut lead times, thanks to the reduced number of inspections, while the need to scrap or rework products will be minimized."
www.ssab.com
The Royal Institute of Technology in Stockholm announces that its researchers have developed a quality assurance method for welds in high-strength steel in which a laser profile scanner assesses the welded surface and measures the quality of the weld.
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New graphite board insulation enables more thermally efficient furnace hot zone
August 1, 2016
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Solar Manufacturing, Souderton, Pa., announces that it has been cooperating for the past year with Graphite Machining Inc., Topton, Pa., on the development and testing of a new graphite board material and its application in vacuum furnace hot zones. This new graphite board material has undergone extensive thermal and vacuum testing to prove its improved thermal efficiency and excellent vacuum performance compared to prior and present graphite board designs.
GMI intends to market this new graphite board under the name of Heatguard insulation, while Solar will incorporate this new material into its vacuum furnace hot zones under the trade name of Hefvac (High Efficiency Vacuum).
According to Frank C. Schoch, president of GMI, "After extensive testing against our existing and competitive insulating materials, Solar Manufacturing and Graphite Machining combined our respective experience and created this new thermally efficient graphite board insulation material."
By incorporating Hefvac board insulation, Solar Manufacturing has now developed a proven, more thermally efficient vacuum furnace hot zone design that is capable of achieving faster and better vacuum levels because of the Hefvac sealed and low-moisture-absorption structure.
William R. Jones, CEO of the Solar Atmospheres family of companies notes, "I will be giving a presentation at the 2016 FNA (Furnaces North America) show in Nashville, Tenn., to highlight the testing and comparisons of prior designs to this new board material and to illustrate not only the more thermally efficient aspect of the new material, but also the ease and advantages of its use. Hefvac will be on display at Solar Manufacturing's booth 301-303 with a full size hot zone."
www.solarmfg.com
Solar Manufacturing, Souderton, Pa., announces that it has been cooperating for the past year with Graphite Machining Inc., Topton, Pa., on the development and testing of a new graphite board material and its application in vacuum furnace hot zones.
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Buehler upgrades Wilson DiaMet hardness testing software
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Buehler, Lake Bluff, Ill., announces that it has extensively upgraded its Wilson DiaMet hardness testing software with features designed to facilitate and accelerate specific applications, such as the documentation of the hardness distribution in welds, or the depth of hardening in induction-hardened workpieces or in objects hardened with conventional processes. The upgraded DiaMet software is even more user friendly, and is internationally consistent.
DiaMet is designed for operation under Windows 10, and can interface with Office spreadsheet applications. It fulfills the requirements for industrial hardness measurement in a production-related environment – an application requiring high precision along with a maximum degree of automation in handling extensive test programs.
Designed for operation by mouse or touchscreen, the system offers expert users the required flexibility and broad feature set for planning, running, analyzing, documenting and archiving of individual measurements and measurement series, while at the same time enabling less extensively trained operators to work quickly and efficiently.
DiaMet is optimized for evaluating Macro-Vickers, Micro-Vickers, Knoop, and Brinell indents according to ISO 6507, ISO 4545, ASTM E384, ISO 6506 and ASTM E10. It is designed to work with all models of the current Wilson VH and UH hardness tester series, as well as some legacy systems.
As an international software package offered in multiple languages, the current Wilson DiaMet software addresses all relevant national and international hardness testing standards requirements.
"DiaMet users in global organizations can now share and compare results worldwide – regardless of where the measurements were made," says Marcel van Banning, Product Manager Hardness, Buehler ITW Test & Measurement GmbH. "With this new release, we are providing test engineers with a tool enabling them to supply detailed and reliable results, even when work assignments are time sensitive. In addition, the high degree of automation enables even less trained staff to conduct comprehensive test series and produce highly accurate results."
The new design of the DiaMet testing software substantially facilitates the process of meeting ISO 9015 and ISO 15614 hardness testing of welds. The software guides the operator through the setup process by adapting a fixed test pattern to the sample in hand with only a few clicks – strictly in accordance with the standards. The software produces a graphical image of the complete weld, including indent positions and associated measurement values, which can be used in a test report.
ISO 9015 and ISO 15614 describe the test loads, number of indents in the parent material, heat affected zone (HAZ) , distances between each indent and the depth below the surface of the welded joint. Fulfilling these test requirements traditionally requires a time-consuming setup and an experienced operator, not least due to the fact that no two weld samples are completely identical. DiaMet saves time and improves accuracy.
www.buehler.com
Buehler, Lake Bluff, Ill., announces that it has extensively upgraded its Wilson DiaMet hardness testing software with features designed to facilitate and accelerate specific applications, such as the documentation of the hardness distribution in welds, or the depth of hardening in induction-hardened workpieces or in objects hardened with conventional processes.
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Hardness testers feature high accuracy and deadweight loads from 10 g to 2 kg
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Buehler, Lake Bluff, Ill., introduces two universal hardness testers: the Wilson VH1102 and VH1202, both equipped with the extensively upgraded version of DiaMet software. They offer cost-efficient and reliable solutions for Knoop and Vickers micro-hardness testing in accordance with ISO 6507, 9385, and 4546, or ASTM E384 and E92.
The instruments meet the highest standards in terms of accuracy, and can be used both in quality control and research and development. They feature deadweight loads from 10 g up to 2 kg, and nine different, automatically selectable loading stages. Both models feature an ergonomic, adjustable 7-inch color touchscreen for rapid test method selection and data collection.
The system is highly intuitive and can be operated by less extensively trained staff after a brief period of training. The wide load range with test scales from HV/HK0.01 to HV/HK2 is the same for both models. The usual knob for manual selection of test weights has been replaced by a durable, software-controlled electric motor to automatically change test weights, thereby providing a level of operator convenience that is normally found only on higher-end instruments.
The two models differ with regard to the electrically driven, high-speed, low-noise turret. The VH1102 model is equipped with a turret providing four positions, including an indenter for Knoop or Vickers, and two standard objectives for 10x and 50x magnification at normal working distance.
The VH1202 model is equipped with a six-position turret, including two indenters for both Knoop and Vickers, and an additional objective with 5x magnification at long working distance. For both models, the turret can be set to the magnification selected on the touch screen by simply pushing the Start button. They can be configured to meet a wide range of requirements, from a stand-alone version for laboratories with a relatively low sample volume, up to a fully equipped system for high sample volumes in an industrial environment.
The system includes the extensively upgraded version of its DiaMet software. Designed for operation by mouse or touchscreen, the system offers expert users the required flexibility and broad feature set for planning, running, analyzing, documenting, and archiving of individual measurements and measurement series. At the same time, the new software enables less extensively trained operators to work quickly and efficiently. The new version contains features designed to facilitate and accelerate specific applications, such as the documentation of the hardness distribution in welds, or the depth of hardening in induction-hardened workpieces, or parts treated with conventional hardening processes.
www.buehler.com
Buehler, Lake Bluff, Ill., introduces two universal hardness testers: the Wilson VH1102 and VH1202, both equipped with the extensively upgraded version of its DiaMet software.
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