The Boeing Co., Seattle, released a video showcasing the lightest metal structure ever, called Microlattice—"the world's lightest material."
Sophia Yang, a research scientist at HRL Laboratories, Malibu, Calif., who worked with Boeing on the creation of the material, says the metal is 99.99% air. She compares the material to bone, which has a rigid outside and mostly hollow inside, creating an open-cellular structure, which means it's remarkably strong and light. The structure is composed of a network of super thin, hollow struts. The struts are around 100 μm in diameter and have walls just 100 nm thick. It's this design that makes Microlattice 10 times lighter than Styrofoam. However, despite it being extremely light, it is also tremendously strong.
Yang also highlights the material's ability to absorb high levels of impact. Using the "egg challenge" as an example, she says: "You need to drop an egg from 25 stories and protect that egg ... What we can do is design the microlattice to absorb the force that the egg feels. So instead of having an egg that's wrapped in three feet of bubble wrap, now you have a much smaller package that your egg can sit in."
The material has been made primarily for use in in aerospace engineering. Engineers intend to use the microlattice for plane interiors in places such as side panels, overhead cabins, or walkway areas. This would dramatically reduce the weight of the aircraft, making it more fuel-efficient and cheaper to run.
Microlattice was first announced in 2011 when a nickel-phosphorous alloy prototype was developed in collaboration between University of California, Caltech, and HRL Laboratories—the Boeing-owned lab that built the first laser in 1960. As the video explains, this development has many possibilities, ranging from use in aerospace, high-performance vehicles, as well as shock absorption and vibration insulation.
Air Products to highlight latest gas technologies at Heat Treat 2015
October 14, 2015
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Air Products, Lehigh Valley, Pa., will highlight the company's latest gas technologies for the metals processing industry at the Heat Treat 2015 Conference and Exhibition in Detroit, October 20-22. The company will also share its latest developments in furnace atmospheres — including plasma-activated case hardening of steels at atmospheric-pressure.
Zbigniew Zurecki, FASM and senior research associate at Air Products, will share new developments in atmosphere treatments as part of the "New Directions and Opportunities in Heat Treating" panel session on Wednesday morning, October 21. In addition, Air Products' Dr. Liang He, principal application engineer, will present the results of original research titled "Optimization of Protective Atmospheres for Annealing and Hardening Operations in Continuous Furnaces" during the Atmosphere Technology Session on Wednesday afternoon.
Metals processors are invited to stop by Air Products booth 508 to speak with a knowledgeable representative about their particular heat treating challenges. With over 50 years of heat treating experience, Air Products' applications engineers can work with customers to learn their specific annealing, brazing, hardening, or sintering process and make recommendations to help improve their overall operation.
Air Products' industrial gases are available in a variety of supply modes to match each customer's requirements efficiently and cost-effectively. The company also offers gas handling equipment and technology, as well as process audits and troubleshooting, to help metals processors optimize gas use, lower operating costs, maximize uptime, increase throughput, and improve product quality.
Air Products, Lehigh Valley, Pa., will highlight the company’s latest gas technologies for the metals processing industry at the Heat Treat 2015 Conference and Exhibition in Detroit, October 20-22.
Lockheed Martin awards Alcoa titanium supply contract for Joint Strike Fighter
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Alcoa, Pittsburgh, announces that Lockheed Martin has awarded it a contract to supply titanium plate and billet for the F-35 Lightning II aircraft program, also known as the Joint Strike Fighter. Under the contract, Alcoa becomes the titanium supplier for airframe structures for all three variants of the F-35 over nine years, from 2016 to 2024. At current projected build rates, the contract has an estimated value of approximately $1.1 billion.
"Through our expansion in titanium, Alcoa is sharpening its leadership edge on state-of-the-art aircraft, including the most advanced fighter jet in the world—the F-35," said Alcoa Chairman and Chief Executive Officer Klaus Kleinfeld. "We are expanding Alcoa's range of multi-material offerings for this program while helping Lockheed Martin meet aggressive weight, range, and fuel efficiency targets."
The titanium will be used to manufacture airframe structures for all three F-35 JSF variants: The F-35A Conventional Takeoff and Landing (CTOL) aircraft, the F-35B Short Takeoff/Vertical Landing (STOVL) aircraft, and the F-35C Carrier Variant (CV). Under a different existing contract, Alcoa will use the metal to forge all of the largest titanium bulkheads—the "backbone" of the aircraft structure—for the CTOL variant at its Cleveland, Ohio operations. Approximately 75 percent of all F-35s produced are CTOLs.
"This contract with Alcoa is a key element in securing our supply chain with a strong U.S. partner for a critical, strategic raw material," said Dan Pleshko, vice president of Lockheed Martin Aeronautics' Enterprise Supply Chain Management.
The F-35 Lightning II is an advanced fighter aircraft combining stealth, speed and agility, designed for many kinds of missions. Lockheed Martin's full-rate production goal is 13 aircraft a month by the mid-2020s, up from an average of three aircraft delivered per month in 2014.
Alcoa has been growing its multi-material aerospace business to capture growth in the global aerospace market in support of its broader transformation. Alcoa recently acquired global titanium leader RTI International Metals, aerospace components manufacturer Tital, and global jet engine parts leader Firth Rixson.
Alcoa, Pittsburgh, announces that Lockheed Martin has awarded it a contract to supply titanium plate and billet for the F-35 Lightning II aircraft program, also known as the Joint Strike Fighter.
Ipsen introduces Quick Ship program for heat treating furnace parts
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Ipsen USA, Cherry Valley, Ill., introduces the Quick Ship program, which provides one-day shipment of high-demand heat treating furnace replacement parts such as gas nozzles, power feedthrough assemblies, pumps, and much more. "Our ultimate goal, and reason that we created the Quick Ship program, is to provide customers with the tools and support needed to minimize downtime and keep their furnaces operating at peak performance," says Aaron Bolhous, Aftermarket Parts Manager at Ipsen USA.
With rapid turnaround times and on-time deliveries, the Quick Ship program provides access to specific parts during standard business hours: Monday through Friday, 8 a.m. – 5 p.m. EST. Customers can call 1-844-Go-Ipsen to receive immediate support. Customers are guaranteed same-business-day shipment for Quick Ship parts orders placed by 10 a.m. EST.
Find the full list of Quick Ship parts and learn more about Ipsen's 360° support for furnaces at www.IpsenUSA.com/Parts
Ipsen USA, Cherry Valley, Ill., introduces the Quick Ship program, which provides one-day shipment of high-demand replacement heat treating furnace parts such as gas nozzles, power feedthrough assemblies, pumps, and much more.
Expanite opens a new heat treatment center in Ohio
October 13, 2015
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Expanite, Denmark, announces that it has established a subsidiary in the United States known as Expanite Inc., and has opened a new heat treatment center in Twinsburg, Ohio, for surface hardening of stainless steel. According to the company, the Expanite process makes it possible to increase the material's surface hardness tenfold, while at the same time maintaining and even increasing corrosion properties.
Expanite can now offer its North American customers the same superior gaseous surface hardening treatment options as in Europe. Customers can choose to have their material processed in its facilities in Ohio on a day-to-day basis, or opt for a fully automatic solution installed directly in their production line.
The Expanite treatment is said to remove the oxide film, which allows controlled incorporation of carbon and nitrogen atoms into the underlying metal. The hardened layer is characterized by an interstitial hardened zone known as expanded austenite, expanded martensite, or simply Expanite. Unlike other technologies, this method not only coats the surface, but also enables carbon and nitrogen to go into and beneath the surface to create a hardness profile with an optimal concentration of carbon and nitrogen. This is said to significantly improve resistance to corrosion, galling, fatigue, and wear.
Expanite also welcomes its new North American Sales Manager, Dr. Christian Dalton, who has a Ph.D. in Materials Science and Engineering from Case Western Reserve University in Cleveland.
Expanite, Denmark, announces that it has established a subsidiary in the United States known as Expanite Inc., and has opened a new heat treatment center in Twinsburg, Ohio, for surface hardening of stainless steel.
One Minute Mentor: Steps for Hardening of Tools as a Function of Time, Temperature, and Phase Transformation
October 9, 2015
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Steps for Hardening of Tools as a Function of Time, Temperature, and Phase Transformation
After hot forming, tool steel usually is submitted to heat treatment processes that may be split into two major steps. The first step (shown last week) is done to produce a low-hardness condition. The second step involves this homogeneous microstructure being converted to a higher-hardness condition, usually by martensite formation during the hardening and tempering heat treatments.
In a graphical form, the graph shows the typical processing and heat treatment sequences for hardening of tool steels, as a function of time, temperature, and phase transformation.
The graph shows plots of temperature versus time showing sequence of operations required to produce tool steels. Hardening heat treatment. L, liquid; A, austenite; C, cementite; F, ferrite; Ms, temperature at which martensite starts to form on cooling; RT, room temperature.
Volume 4D, Heat Treating of Irons and Steels-> Heat Treating of Carbon and Low-Alloy Steels -> Introduction to Heat Treating of Tool Steels -> Heat Treatment Applied to Tool Steels
Lawrence E. Brown, executive director of LIFT—Lightweight Innovations for Tomorrow, welcomed the Institute for Advanced Composites Manufacturing Innovation (IACMI) as the two organizations confirmed that IACMI will open a scale-up facility at LIFT's headquarters in Detroit.
The facility will support production-scale composite materials development focused on vehicle lightweighting in collaboration with automotive companies. IACMI and LIFT are both part of President Barack Obama's National Network for Manufacturing Innovation (NNMI) initiative.
The composites scale-up facility will be run by Michigan State University, which leads IACMI's vehicle technology area in Detroit. LIFT is located at a previously abandoned and distressed facility in Corktown, the oldest neighborhood in Detroit. The 100,000 ft2 facility has been extensively renovated by LIFT through collaborative efforts with Michigan Economic Development Corp., The New Economy Initiative, and Mayor Mike Duggan's office.
"Taking weight out of vehicles will require different approaches; we are focused on metals and IACMI is focused on composites," says Brown. "But we are both working toward the same goal with many of the same industry partners, so it only makes sense for us to be physically together. All of the national institutes are based on collaborations, and we expect this one to be particularly strong."
At a recent event in Detroit, Vice President Joe Biden echoed Brown's lightweighting charge, saying, "Lightweighting is critical to our future. We want to own the 21st century in innovation, and composites are a big part of that goal. That's why this administration is making a $40 million investment in the Composites Institute (IACMI) co-locating in a facility in Detroit."
Michigan has more than 300 industrial technical centers related to automotive technology and conducts more than 70% of U.S. automotive research and development. "IACMI's technology areas are strategically located in America's manufacturing heartland to serve industry needs," says Craig Blue, IACMI's CEO. "Co-locating with LIFT in the Motor City reinforces our commitment to collaboration through partnerships that enhance the entire automotive ecosystem."
Both IACMI and LIFT are identifying applications for lighter materials in next generation vehicles, IACMI via advanced composites and LIFT via lightweight metals. Locating in the same facility provides a unique opportunity for collaboration between NNMI institutes and the transportation industry, which have identified the need of lightweight materials to meet goals for fuel efficiency, safety, and performance.
Support of this co-location is evidenced by numerous federal, state, industry, and local commitments to the city of Detroit and this shared facility. Approximately $12 million in Federal funding will come to Detroit for cost-shared development projects; the state of Michigan has committed $15 million for equipment and staffing; industrial support is valued at $18 million; and the city of Detroit is supporting IACMI's efforts to establish the vehicle scale-up facility.
Several hundred new jobs in the industrial sector are expected as a result of the commercialization successes facilitated by this pilot-scale facility managed by IACMI.
Bodycote expands capacity for treating specialty stainless steels in Ohio
October 6, 2015
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Bodycote, England, announces that it has expanded capacity for specialty stainless steel processes (S3P) at its facility in London, Ohio, and is building a new S3P facility in North Carolina that is to open in 2016. These technologies are dedicated to improving resistance to surface wear such as cavitation erosion, abrasion, and especially galling in stainless steels, nickel-base alloys, and cobalt-chromium alloys, while maintaining corrosion resistance.
Many surface treatments, when applied to stainless steel, negatively affect the metal's inherent corrosion resistance. However, the S3P process imparts increased mechanical and wear properties without adversely affecting corrosion resistance.
Specialty stainless steel processes (S3P) featuring Kolsterising and Nivox technology, offer unique surface hardening solutions for austenitic stainless steel, nickel-base alloys, and cobalt-chromium alloys. Benefits include higher surface hardness to 900-1300 HV0.05, depending on base material and surface conditions. Treated alloys are highly resistant to surface wear environments such as sliding combined with abrasive wear and cavitation erosion. The paramagnetic properties of austenitic materials remain unchanged after treatment.
Bodycote's S3P process presents engineering benefits for industries such as medical/pharmaceutical, automotive, and chemical engineering
Bodycote, England, announces that it has expanded capacity for specialty stainless steel processes (S3P) at its facility in London, Ohio, and is building a new S3P facility in North Carolina that is to open in 2016.
Harper’s three-meter PAN oxidation oven provides uniform air velocity
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Harper International, Buffalo, N.Y., announces that initial data on its three-meter wide production-scale oxidation oven for carbon fiber manufacturing shows outstanding performance for key metrics, including air-velocity uniformity and temperature uniformity.
Data was acquired at temperatures up to 280°C and air velocities up to 4 m/s, with uniformity measured at 2.2%. Air velocity uniformity across the entire tow band is essential, as the PAN stabilization phase is an exothermic reaction, and any low-velocity regions can run away, causing deflagration. High-velocity regions can cause damage to the delicate PAN fiber.
Harper's design also demonstrated temperature uniformity of +/-2.5°C throughout the entire heated length. Temperature uniformity is critical in carbon fiber manufacturing because it enables higher and more efficient rates of production.
As greater production rates have led to wider, taller, and longer oxidation ovens, it is a critical challenge to improve velocity and temperature uniformity while simultaneously increasing the oven size.
"Harper's oven design offers our customers enhanced performance and increased confidence in their fiber manufacturing," commented Bill Stry, PhD, and Renee Bagwell, PhD, Senior Process Technology Engineers at Harper. "We took on the task of engineering an oxidation oven that addresses today's and tomorrow's market demands for efficiency and quality, and the data from full scale testing shows our success."
Harper International is a global leader in complete thermal processing solutions and technical services essential for the production of advanced materials.
Harper International, Buffalo, N.Y., announces that initial data on its three-meter wide production-scale oxidation oven for carbon fiber manufacturing shows outstanding performance for key metrics, including air-velocity uniformity and temperature uniformity.
Nitrex low-pressure carburizing furnace features precise parameter control
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Nitrex Metal Inc., Quebec, began operation of a new low-pressure carburizing (LPC) furnace at its plant in Franklin, Indiana. It was built and installed by vacuum and LPC furnace specialist ECM of France. It features ECM's Infracarb technology, a process that guarantees the reduction of the cycle time, the absence of oxidation, and precise and repeatable control of the carburizing parameters.
The furnace has a nameplate capacity of 1650 pounds and a work chamber of 24 x 26 x 39 inches. The system is fully automated and is currently configured with two heat treat/carburizing cells and a load transfer system that is completely under vacuum. Additionally, this particular setup has the unique capability of quenching in both high-pressure gas (20 bar) and in oil to address most specifications. Because of its modular design, additional process chambers can be simply integrated to this system to meet high volume demand.
The LPC furnace features cold-wall technology, so the exterior surface stays at a low temperature, reducing the amount of heat emitted into the plant. Without any flames or hot walls, the furnace can be located in the middle of the machining area within the plant. This allows for better part flow and eliminates the need for a fireproof wall enclosing the heat-treat area.
With cold-wall technology, dangers specific to hot-wall technology such as open flames and hot surfaces are also eliminated. In addition, the plant does not need ventilation hoods to get rid of the burned gas. For these reasons, the LPC furnace occupies less plant floor space, especially as it allows a higher throughput.
Efficiency and energy savings are further advantages of the LPC furnace. Vacuum technology is the most efficient with only 35 kW to maintain 2200 pounds of steel at temperature. Gas usage is reduced because it is used in the most efficient way. LPC furnaces can be ready for production in as little as 90 minutes, and each chamber can be turned on or off at any time to be ready for production in 30 minutes.
