One Minute Mentor: Heat Treatment of a Premium Grade H13 Die
February 4, 2016
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The graph shows a continuous cooling test in which the austenitizing temperature was approximately 1040°C (1900°F). It shows the effect of intermediate cooling rates on the microstructure and toughness of H13 tool steel austenitized at 1075°C (1970°F). (a) Continuous cooling transformation (CCT diagram) shows variation in microstructure with varying cooling rates. (b) Variation in toughness as a function of carbides ejected from austenite. Hardness was maintained at a constant value.
Hot-work die steels containing 5% Cr are normally used (H13 is the most common in the United States) because they have:
• A good combination of toughness and strength for safety and service
• Good hardenability in thick sections
• Good hot hardness and strength to resist cyclic stressing at operating temperatures up to 400 °C (750 °F)
• Good resistance to tempering during service that gradually lowers the surface hardness and the fatigue strength
Carbide precipitation, other than that produced during tempering, is known to be deleterious to the fatigue life of H13 tool steel. Fast quenching rates required to suppress intermediate precipitation of carbides (such as proeutectoid grain-boundary carbide, pearlite, or bainite) also produce large thermal gradients within the tool. Fast quenching rates can cause distortion or even cracking. The larger the tool, the greater the risk of cracking.
Volume 4D, Heat Treating of Irons and Steels ⇒ Tool Steels ⇒ Heat Treating of Hot-Work Tool Steels ⇒ Examples of Heat-Treating Procedure for Hot-Work Tools
The graph shows a continuous cooling test in which the austenitizing temperature was approximately 1040°C (1900°F).
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Additive-manufactured components printed via melting metal alloy filaments
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3D MakerJet Inc., Orlando, Fla., announces that, after a year and a half in research and development, functioning prototypes of metal components made via melting metal alloy filaments, including copper, have successfully met industry standards. Concentrating on both laser and extruder 3D printers, the company is committed to development of powderless wire-feed additive manufacturing.
"On site, on the job, these printers have the potential to eliminate the high prices and long lead times of back-ordered, hard-to-source, and even obsolete parts. The market for metal printing is continuing to grow and 3D MakerJet is poised to introduce a true breakthrough," said John Crippen, 3D MakerJet President.
The company intends to file a patent in the United States.
Simultaneously, 3D MakerJet is also working on a line of medical grade bioprinters, as well their continued dedication to perfect industrial materials including polypropylene, resins, and waxes.
According to Research and Markets, the market size of metal 3D printing is expected to grow to $2.24 billion by the year 2020 at double digit CAGR.
3D MakerJet Inc., Orlando, Fla., announces that, after a year and a half in research and development, functioning prototypes of metal components made via melting metal alloy filaments, including copper, have successfully met industry standards.
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Steel forgings for windmills to be produced in joint venture
February 3, 2016
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Sumitomo Corp., Japan, and the Japan Steel Works have formed a joint venture with Gerdau Steel, Brazil, to manufacture forged steel products for wind power generation. Gerdau is the largest long steel manufacturer in Brazil. Production of these forged parts is expected to begin in 2017.
The joint venture (tentative name "Gerdau Summit"), in addition to the existing business of Gerdau, plans to expand the business into the production and sale of wind power generation forged products.
Currently, the Brazilian government's policy is to almost double the ratio of wind power generation from a national total power supply of 6% in 2015 to 11% in 2024, in order to meet future electricity demand. To achieve this goal, the government provides support for wind power generation projects and encourages domestic manufacturing of wind power generation-related parts.
"We're working to transform Gerdau into a more efficient and profitable company, given the current and future challenges of the global steel industry," said Gerdau CEO Andre B. Gerdau Johannpeter. "We're seeking to join forces with partners who have recognized experience in their industries in order to create new business opportunities. With Sumitomo Corporation and JSW, we will develop higher-value products for our clients, which will enable them to generate higher profit margins."
JSW has long been leading the world's forging industry with its manufacturing technologies, mainly in the energy field such as power generation. Sumitomo also has significant experience and knowledge within the renewable energy and wind-related business, which has been cultivated through many infrastructure projects and related parts sales respectively. By bringing the strengths of these two companies together with Gerdau's strong production base,"Gerdau Summit" will focus on the production and sale of forged products for wind power generation in the Latin American market with a focus on Brazil. JSW has plenty of experiences to transfer its forging and casting techniques to foreign countries. Based on such experiences, JSW launches its overseas joint venture project for the first time in the forging and casting field.
www.sumitomocorp.com
Sumitomo Corp., Japan, and the Japan Steel Works have formed a joint venture with Gerdau Steel, Brazil, to manufacture forged steel products for wind power generation.
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Solar Atmospheres builds home for world’s largest vacuum furnace
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Solar Atmospheres of Western Pennsylvania, Hermitage, announces that the construction project to house the largest commercial vacuum furnace in the world is progressing on time. Aided by an unseasonably warm winter, the new 18,000 square foot building was fully enclosed by the end of January, within a short period of 2½ months from breaking ground.
Once the 20-ton crane is installed and the floor is poured, the building will be ready to accept delivery of the massive chambers in mid-February from Youngberg Industries located in Belvidere, Illinois. Due to the magnitude of the project, the vacuum furnace will be cooperatively built on site by both Solar Manufacturing and Solar Atmospheres of Western PA employees.
According to Bob Hill, President of Solar Atmospheres of Western PA, "We are all anxiously waiting to roll up our sleeves to build this one of a kind furnace. We continue to accept deliveries of all of the major components from our sister company Solar Manufacturing. Our warehouse next door is filling up fast with these critical items. It will be extremely exciting to assemble and ultimately place into production this one of a kind vacuum furnace which is primarily earmarked to serve the needs of the aerospace and nuclear markets around the world."
www.Solaratm.com
Solar Atmospheres of Western Pennsylvania, Hermitage, announces that the construction project to house the largest commercial vacuum furnace in the world is progressing on time.
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CEC supplies chain conveyor solution furnace for heat treating aluminum die castings
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Consolidated Engineering Co. (CEC), Kennesaw, Ga., announces that it has received a purchase order for a four-zone natural gas-fired chain conveyor solution furnace for the T4 treatment of aluminum high-pressure die castings. To be installed in a casting facility in Mexico, the furnace will heat treat automobile shock towers. The system includes a solution furnace, air quench, age oven, cool unit, and four load/unload gantry cranes, and will process the castings at a rate of 90 castings per hour.
High pressure die casting, in which molten aluminum is injected into a metal die, now accounts for more than half of all aluminum castings worldwide. This manufacturing method has shown to be particularly suitable for making complex part shapes for automobiles.
CEC manufactures a variety of industrial chain furnaces that allow for efficient conveyance of the product during heat treatment. A chain type furnace may describe one of several methods moving the casting or forging through the furnace.
The chain furnace concept allows the product to go directly into the furnace without a basket, rack, or tray. Wasted heat for heating up the tray or basket is eliminated. The processed part can come directly from the casting dies or the forging press without cool-down. CEC can automate a foundry or forge shop to the current state of the art for heat treatment with its broad array of chain furnace configurations.
www.cec-intl.com
Consolidated Engineering Co. (CEC), Kennesaw, Ga., announces that it has received a purchase order for a four-zone natural gas-fired chain conveyor solution furnace for the T4 treatment of aluminum high-pressure die castings.
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Harper to supply Australia with thermal processing system for nuclear waste
February 2, 2016
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Harper International, Buffalo, N.Y, has been awarded a contract to supply a hot cell Rotary thermal processing system to treat waste from nuclear medicine production at the Australian Nuclear Science and Technology Organisation (ANSTO). Synroc technology has been developed to provide a safe, secure matrix for the immobilization and final disposal of radioactive waste.
It will be utilized to encase radioactive wastes from the production of the radioisotope Molybdenum-99 (Mo-99), the isotope used for 80% of nuclear medicine procedures. This includes the diagnosis of cancers, heart disease, and muscular and skeletal conditions.
The Rotary thermal processing system includes an advanced heating element design for increased robustness and ease of remote operation, and an enhanced modular design of components for ease of remote maintenance in a hot cell.
"In addition to waste from nuclear medicine production, we foresee that this new technology can also benefit other applications in the future, such as processing spent fuel waste from other international power generating nuclear reactors," commented Dr. Prasad Apte, Director of Technology at Harper International.
Along with waste remediation, Harper offers technology solutions such as Pusher and Rotary furnaces for nuclear materials processing applications, including sintering UO2 pellets for reactor fuel rods, oxidation of UO2 pellets, swarf, and powder to U3O8, denitration of uranyl nitrate, and hydrofluorination of UO2 pellets.
ANSTO is one of Australia's largest public research organizations and is the center of Australia's nuclear science capabilities and expertise - operating the nation's only nuclear reactor, OPAL. Australian Mo-99 is produced with low enriched uranium (LEU) target plates in the LEU fueled OPAL reactor, leading the global push toward nuclear nonproliferation.
www.harperintl.com
Harper International, Buffalo, N.Y, has been awarded a contract to supply a hot cell Rotary thermal processing system to treat waste from nuclear medicine production at the Australian Nuclear Science and Technology Organisation (ANSTO).
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One Minute Mentor: Quenching of Hot-Work Tool Steels
January 28, 2016
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Hot-work steels range from high to extremely high in hardenability, so it is possible for them to achieve full hardness by cooling in still air. However, this is not recommended, because intense embrittlement occurs after slow cooling from hardening temperature.
Even with those types having the highest hardenability, sections of die blocks may be so large that insufficient hardening results. In such instances, pressurized nitrogen gas (in vacuum furnaces) or an oil quench is required to achieve full hardness. Hot-work steels are never water-quenched. The figure shows the Continuous Cooling Transformation (CCT) diagram for AISI 6F3.
Volume 4D, Heat Treating of Irons and Steels ⇒Tool Steels ⇒ Heat Treating of hot-Work Tool Steels ⇒ Heat Treatment of H Series and Low-Alloy Hot-Work Steels
Hot-work steels range from high to extremely high in hardenability, so it is possible for them to achieve full hardness by cooling in still air. However, this is not recommended, because intense embrittlement occurs after slow cooling from hardening temperature.
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Puris produces large, 100% dense, complex titanium aerospace part via 3D printing
January 27, 2016
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Puris LLC, Bruceton Mills, W.Va., announces that it recently achieved a major 3D-printing milestone by producing a 31-pound complex titanium aerospace part for commercial use to 100% density. Measuring an estimated 19 x 19 x 11 inches with a cross-section thickness of 0.375-inch, the part was printed using ExOne binder-jetting technology at room temperature.
It was produced for an aerospace customer on an ExOne M-Print 3D printer at the Puris Bruceton Mills plant under the direction of the Puris metallurgy team. Binder-jetting technology allowed printing the part at room temperature, eliminating residual stress buildup that could result from high-temperature technologies. It also prevented the chemical-property and microstructure changes that develop in other metal 3D-printing technologies.
"There is a lot of activity in this arena and larger parts have been printed, but we believe this is the largest complex titanium part to be printed to date," Puris CEO Craig Kirsch said. "The milestone was achieved by the combination of our team's deep metallurgical and powder-production expertise and ExOne binder-jetting technology. It was processed to full density and printed safely using affordable, available powder."
"We are actively working on a number of development programs with other customers interested in bringing large, 3D-printed parts into the additive manufacturing mainstream. Size is currently constrained only by the printer box itself, which presents advancement opportunities for ExOne to develop larger direct-printing machines," Mr. Kirsch added. The current ExOne M-Print print box is 32 x 20 x 16 inches.
Puris has printed large parts using Inconel alloy powder as well, and is able to print with other high-performance alloys.
www.purisllc.com
www.exone.com
Puris LLC, Bruceton Mills, W.Va., announces that it recently achieved a major 3D-printing milestone by producing a 31-pound complex titanium aerospace part for commercial use to 100% density.
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Harper awarded contract for nuclear material processing equipment
January 26, 2016
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Harper International, Buffalo, N.Y., was recently awarded a contract for a pusher furnace line with Kepco Nuclear Fuel (KNF), which is currently producing nuclear fuel for its pressurized heavy water reactors.
Over the past two years, Harper's Applications, Engineering, & Technology Groups have carefully developed an advanced heating system for KNF's pressurized heavy water reactors.
With this sixth furnace for KNF and all furnace iterations, Harper continuously aims to advance equipment performance. In addition to the advanced heating element that allows for higher temperature operation, an enhanced furnace shell cooling design has been developed, and both yield longer uniform operational life cycles. Additionally, advances have been made in exit water cooling design, insulation designs that reduce ambient heat release, and energy usage.
Harper is compliant with nuclear-specific control systems for mandated upgrades for increased security and reliability.
"Harper's global leadership in nuclear fuel production system technology continues to be validated by clients, who place their trust in our staff to conceive and implement the world's most advanced, efficient and reliable sintering thermal processing systems," commented Tom O'Connor, Sales Manager at Harper International. "Further, Harper is pleased to partner with KNF on this project which will play a role in providing reliable energy without greenhouse gas emissions."
In addition to nuclear material processing, Harper is a market leader in advanced Pusher systems for a wide range of materials, including metal oxides, powders, technical ceramics and energy device materials. Learn more about Harper Pusher furnaces here.
KNF is a group company of Kepco (Korea Electric Power Corporation) founded in 1982. KNF provides nuclear fuel, equipment and related services to all nuclear power plants in Korea and customers in the global nuclear energy industry.
www.harperintl.com
Harper International, Buffalo, N.Y., was recently awarded a contract for a pusher furnace line with Kepco Nuclear Fuel, which is currently producing nuclear fuel for its pressurized heavy water reactors.
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C.I. Hayes installs conveyor belt atmosphere furnace
January 25, 2016
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C.I. Hayes, a Gasbarre Furnace Group Company, Cranston, R.I., reports the installation of a Model BAC-M Conveyor Belt Atmosphere Furnace designed for various processes such as brazing, hardening, and annealing of stainless steel materials. The multi-zoned electric furnace is equipped with a conveyor belt drive and silicon carbide heating elements, as well as a controlled hydrogen atmosphere.
The furnace includes an analyzer used to monitor dewpoint and oxygen levels for process and safety purposes. The brick-lined heating chamber, which includes a silicon carbide hearth that supports an Inconel muffle, is designed to operate to 2100°F. The 18-inch wide conveyor belt provides a six-inch work clearance and travels through a 60-inch effective heated length.
C.I. Hayes designs, manufactures and services industrial vacuum and atmosphere heat treating equipment and has been delivering custom solutions to the heat treating industry for 109 years.
www.cihayes.com
www.gasbarrefurnacegroup.com
C.I. Hayes, a Gasbarre Furnace Group Company, Cranston, R.I., reports the installation of a Model BAC-M Conveyor Belt Atmosphere Furnace designed for various processes such as brazing, hardening, and annealing of stainless steel materials.
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