Solar Atmospheres of California receives Safran/Snecma approval
February 11, 2015
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Solar Atmospheres of Fontana, Calif., announces that it has attained approved-supplier status for Safran/Snecma. Solar received approval for stress relieving, solution heat treating, normalizing, homogenization annealing, aging, stabilizing, and sub-zero processing. It has also been approved for austenitizing quenching for steel, nickel-base alloys, and cobalt-base alloys. Only a limited number of companies in the United States has received Safran/Snecma approved-supplier status.
"I'm very pleased to add Safran/Snecma approval to our growing list of quality approvals," says Derek Dennis, president of Solar Atmospheres of California. "Along with expanding our current capacity, our dedicated quality department continues to work diligently on obtaining new approvals to support new programs coming online in 2015. This approval was a long time in the making; Solar's internal quality system was capable of meeting all the detailed requirements of this world class aerospace supplier."
www.solaratm.com
Solar Atmospheres of Fontana, Calif., announces that it has attained approved-supplier status for Safran/Snecma.
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Evolution D6 two-chamber furnace enables 30% cost reduction
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Seco Warwick Corp., Meadville, Pa., announces that ZAP Mechanika, a Polish heat treating company, reduced its heat treatment costs by 30% with the installation of a CaseMaster Evolution D6 two-chamber furnace for vacuum carburizing and oil quenching. Both chambers are able to operate under vacuum or a partial pressure of inert gas. They are separated from each other with vacuum-tight and pressure-tight internal doors.
The system uses vacuum carburizing, which has the benefit of reducing process time while achieving excellent uniformity when carburizing complex shapes and high-density charges. The furnace also enables elimination of oxidation on the austenite grain boundaries, high accuracy, and repeatability of carburized layer shaping. It minimizes consumption of process gases (hydrocarbons) and energy, and is environmentally neutral. It allows operation at temperatures up to 1200°C (2200°F).
The charge is transferred between chambers with an internal transport mechanism. Integrated into the transport mechanism is a load elevator to quench and remove the load from the quench oil. The heating chamber is used for thermal and thermochemical processes, and is equipped with thermal insulation and a heating system.
Hands-on operation is limited to loading and unloading, selecting a recipe, and starting the process. The furnace operates in either a continuous or a task mode. If necessary, the equipment can be switched on and switched off immediately, and no time is needed for process atmosphere change or conditioning.
www.secowarwick.com
Seco Warwick Corp., Meadville, Pa., announces that ZAP Mechanika, a Polish heat treating company, reduced its heat treatment costs by 30% with the installation of a CaseMaster Evolution D6 two-chamber furnace for vacuum carburizing and oil quenching.
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Renishaw AM250 laser melting additive manufacturing machine enables parts up to 360 mm high
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Renishaw plc, U.K., introduces its AM250 laser melting additive manufacturing machine, which has an extended Z-axis option that enables building parts up to a height of 360 mm. It features a high-power ytterbium fiber laser that fuses fine metallic powders to form functional 3-D parts in layer thicknesses ranging from 20 to 100 µm. Vacuum chamber evacuation is followed by insertion of high-purity argon gas for reactive materials such as titanium.
The AM250 includes an external powder hopper with valve interlocks to allow additional material to be added while the process is running. It is possible to remove the hopper for cleaning or to exchange with a secondary hopper for materials change, using the universal lift. The powder overflow containers are outside the chamber and feature isolation valves so that unused materials can be sieved and reintroduced to the process via the hopper while the system is running. The safe change filter and system powder handling, via the glovebox, help to minimize user contact with materials and process emissions.
The AM250 has been designed with the manufacturing industry in mind, with a simple touch-screen user interface and robust construction. From series production of implantable devices to complex lattice structures or detailed aerospace geometries, the AM250 is capable of fulfilling the requirements of a manufacturing system.
All file and data preparation is done off-line in an office environment, and while the system can be a tightly controlled manufacturing cell, the file preparation software also features useful process development tools for high level users.
www.renishaw.com
Renishaw plc, U.K., introduces its AM250 laser melting additive manufacturing machine, which has an extended Z-axis option that enables building metal parts up to height of 360 mm.
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Better understanding of steel fracturing
February 10, 2015
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Better understanding of steel fracturing
Researchers from the Universidad Carlos III de Madrid (UC3M), Spain, visualized step-by-step and on a microscopic level how certain steels fracture when extreme loads are applied to them. This could help to improve these materials, used in the automobile industry.
Scientists from the UC3M Powder Technology Group (initialled GTP in Spanish) have carried out this research using a scanning electron microscope to obtain high-resolution images (around 10 nanometers; a nanometer is one millionth of a millimeter). The application of new techniques to characterize materials has made it possible to better understand the behavior of sintered steels (those produced from powders) on fracturing. In this way, they have been able to discover where the first cracks "‘nucleate' and where they particularly extend to," explain researchers.
The materials that are the subject of the research are commercial sintered steels obtained through powder metallurgy or powder technology and are widely used in the automobile industry. Mechanical and on-site characterization tests performed in the scanning electron microscope have been essential in "understanding the mechanisms of fracture," which, until this research, "we have never been able to determine, but instead only intuit," explains one of the authors, Elena Bernardo.
In this study several steels currently on the market were evaluated. Specifically, an Fe-C steel, a steel pre-alloyed with molybdenum (Astaloy Mo grade, Höganäs AB) and the well-known Distaloy AE (Höganäs AB), which is iron alloyed by diffusion with copper, nickel and molybdenum, were analyzed.
Results aid in understanding the connection between microstructure and properties which, in these materials, entails a technological challenge, as not only the phases but also the residual porosity that composes their microstructure come into play. José Manuel Torralba, full professor in the UC3M department of Materials Science and Engineering, stresses the fundamental role of porosity in these steels: "The research has revealed, among other things, that the most angular and irregular pores are the first points of ‘nucleation,' that is, those that initiate the breaking."
This study makes changes in the microstructure of the material visible while it is being tested, says Torralba. Moreover, the methodology used "is applicable to any type of alloy" and not only to test its behavior under pressure, but "also its behavior at high temperatures." Some of the research was carried out at the UC3M facilities and was completed at IMDEA Materials, a research institute financed by the regional government of Madrid and the European Union.
Researchers from the Universidad Carlos III de Madrid (UC3M), Spain, visualized step-by-step and on a microscopic level how certain steels fracture when extreme loads are applied to them.
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Optomec partners with Ceradrop to expand printed electronics
February 9, 2015
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Optomec, Albuquerque, N.M., has signed an agreement with Ceradrop to be its exclusive representative in France for Aerosol Jet systems used for printing electronics. Ceradrop, a subsidiary of the MGI Group, designs and markets materials deposition inkjet printers for advanced printed electronics systems. Optomec Aerosol Jet printers provide high-resolution 3D printing capabilities required to manufacture smaller, lighter-weight, high-performance devices used in industries such as aerospace, defense, and consumer electronics.
Aerosol Jet technology, which is scalable for high volume production applications, uses a patented process of aerodynamic focusing to precisely print electronic circuitry and functional components in dimensions ranging from as small as 10 microns or as large as several millimeters in a single pass.
Ceradrop services span the entire value chain from material requirements to printed components, providing Ceradrop customers with the best possible assistance for their development projects.
"Ceradrop has both leading-edge technology and global expertise in printed electronics and smart 3D printing, which make it an ideal partner for Optomec," said Mike Kardos, Director of International Sales at Optomec. "We are looking forward to working with Ceradrop to expand our European marketing network for Aerosol Jet."
"The market for printed electronics and smart 3D printing is expected to explode over the next five years, according to market research analysts, and we are well positioned to be part of that growth," said Rémi Noguéra, Executive General Manager at Ceradrop. "With the addition of Optomec's Aerosol Jet systems, we add in our product portfolio new printed electronics capabilities which are complementary to inkjet technology like high viscous pastes jetting, high-resolution printing, materials deposition on 3D components, and, more importantly we create a close partnership with Optomec to enable new additive technologies."
www.optomec.com
Optomec, Albuquerque, N.M., has signed an agreement with Ceradrop to be its exclusive representative in France for Aerosol Jet systems used for printing electronics.
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3D Systems to apply laser sintering for additive manufacturing of aerospace parts
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3D Systems, Rock Hill, S.C., has been awarded two research contracts worth over $1 million to develop advanced aerospace and defense 3D printing manufacturing capabilities on a commercial scale. The two contracts leverage Selective Laser Sintering and Direct Metal 3D Printing to meet the demanding advanced manufacturing road map of the U.S. Air Force. These contracts are administered by America Makes and funded by the Air Force Research Laboratory.
Together with some of the nation's leading military suppliers—including Honeywell, Northrop Grumman, and Lockheed Martin—3D Systems will develop a precision closed-loop and advanced manufacturing and monitoring platform, designed to deliver the accuracy, functionality, and repeatability specifications demanded for flight-worthy aerospace parts.
The first contract is led by 3D Systems in partnership with the University of Delaware's Center for Composite Manufacturing, Sandia National Laboratory, and Lockheed Martin Corp. The project is designed to integrate predictive technologies with SLS 3D printers to dynamically monitor parts at the layer level during the manufacturing process, ensuring optimum accuracy and repeatability of aerospace parts.
The second contract, in collaboration with the Applied Research Laboratory of Pennsylvania State University in partnership with Honeywell International and Northrop Grumman Corporation, leverages Direct Metal 3D printing. As a result of this project, aerospace and defense manufacturers will gain full control of every aspect of the direct metal manufacturing process at the layer level, delivering fully dense, chemically pure, flight worthy metal parts.
Both projects are set to commence in early 2015.
www.3dsystems.com
3D Systems, Rock Hill, S.C., has been awarded two research contracts worth over $1 million to develop advanced aerospace and defense 3D printing manufacturing capabilities on a commercial scale.
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European Space Agency sponsors cold spray project at Trinity College Dublin
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Trinity College Dublin announces that a team of its engineers is to lead a four-year, $565,000 European Space Agency (ESA) project to fine-tune cold spray technology for both coatings and additive manufacturing for space science missions. The goal is to develop new capabilities in coated materials, as well as to design multi-material combinations currently not possible.
Potential applications include, for example, the ExoMars, Juice, Euclid, and Solar Orbiter missions, as well as the James Webb Space Telescope, and the International Space Station. Meanwhile, on Earth, cold spray could improve the surface properties of engineering components and create novel multi-material parts. A number of national companies will collaborate with the Trinity team on the technical side of the project.
Leader of the project is Dr. Rocco Lupoi, Assistant Professor in Mechanical and Manufacturing Engineering in Trinity's School of Engineering. "This is the largest ESA research project awarded to Trinity," he says. "Not only will we bring down the cost of cold spray through the development of innovative solutions, but also we will enhance its technical capabilities for additive manufacturing."
According to Prof. David Jarvis, Head of the Strategic and Emerging Technologies Team at ESA, "Once developed, the new form of cold spray manufacturing could unlock new capabilities in coated materials, as well as multi-material combinations currently not possible."
http://www.tcd.ie/
http://www.tcd.ie/news_events/articles/engineers-to-fine-tune-cold-spray-the-next-gen-3d-printing-tech-for-spacemen/5279#.VNggdoQo5dg
Trinity College Dublin announces that a team of its engineers is to lead a four-year, $565,000 European Space Agency project to fine-tune cold spray technology for both coatings and additive manufacturing for space science missions.
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New magazine is focused on metal additive manufacturing
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Metal Additive Manufacturing is a new business-to-business magazine that focuses on commercial and technical developments in the metal additive manufacturing industry. Published by Inovar Communications in England, the launch of this new magazine follows the success of the metal-am.com website and e-newsletter.
Besides the latest business and applications news, technical developments in the industry are also highlighted.
The magazine is targeted at Metal AM part manufacturers, end-users and product designers, equipment and technology suppliers, materials suppliers, and researchers. It is published on a quarterly basis and is available from the website as a free digital download or by a print subscription. Print copies will also be distributed free of charge at key international events worldwide.
http://www.metal-am.com/magazine
Metal Additive Manufacturing is a new business-to-business magazine that focuses on commercial and technical developments in the metal additive manufacturing industry.
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Release agent designed for lightweight composite materials
February 6, 2015
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Chem-Trend, Howell Mich., is helping the aerospace industry remove mass, lower fuel consumption, and respect the environment with a release agent targeted for use with composite materials. Zyvax TakeOff is a newly developed water-based, semi-permanent release agent specifically formulated for aerospace manufacturers. It is especially effective for vacuum bagged and autoclave molding of epoxy carbon fiber prepreg. This water-based release agent does not require a sealer in most cases when used on high-quality mold surfaces in aerospace and other epoxy prepreg applications.
Zyvax mold release systems from Chem-Trend are developed specifically to address the molding needs of premium aerospace composites materials. A distinct advantage of TakeOff is its ability to be applied to molds at varying temperatures, thus reducing the required downtime to allow the mold to cool, as is sometimes needed when using solvent-based release agents. TakeOff needs only a minimal number of coats to become effective, with short dry times between applications. It also provides multiple release capability, potentially contributing to improved productivity in the manufacturing process.
Zyvax TakeOff is ideal for aircraft application because it is specifically formulated to work on extremely large epoxy molded parts and uses an environmentally conscious water-based carrier. Additionally, there is very low transfer of the release agent to the molded part. That can eliminate or significantly reduce any cleaning process that might be required prior to a post-molding procedure, such as painting and gluing. This saves material, time and money for manufacturers.
For those parts that do require cleaning, only a mild detergent and water are needed to easily remove any transferred release material. TakeOff is virtually solvent-free, exceeds the most demanding environmental requirements and provides employees a more pleasant plant environment.
"Aerospace manufacturers are not alone in their use of lightweighting solutions to increase fuel economy and decrease emissions," said Barton. "Manufacturers in the marine, rail and automotive sectors are also increasing their use of composite materials to gain the same economic advantages. With as much as 50% of today's aircraft comprised of composite material, release agents play a major role in production.
Chem-Trend is helping the aerospace industry remove mass, lower fuel consumption, and respect the environment with a release agent targeted for use with composite materials.
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Floating in affordable energy
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It's a balloon that lifts a wind turbine. That's the easiest way to describe the technology being developed by Altaeros Energies, Cambridge, Mass., led by Ben Glass, inventor and CEO. Glass has reimagined the possibilities of balloon and airship technology to lift a wind turbine.
Most wind turbine manufacturers are competing to build taller turbines to harness more powerful winds above 500 ft (150 m). Altaeros is going much higher with their novel Buoyant Airborne Turbine—the BAT. The Altaeros BAT can reach 2000 ft (600 m). At this altitude, wind speeds are faster and have five to eight times greater power density. As a result, the BAT can generate more than twice the energy of a similarly rated tower-mounted turbine.
The BAT's key enabling technologies include a novel aerodynamic design, custom-made composite materials, and an innovative control system. The helium-inflatable shell channels wind through a lightweight wind turbine. The shell self-stabilizes and produces aerodynamic lift, in addition to buoyancy. Multiple high-strength tethers hold the BAT in place and a single conductive tether transmits power to a mobile ground station.
The BAT's automated control system ensures safe and efficient operation, the highlight of which is the capability to adjust altitude autonomously for optimal power output. The first BAT model is approximately 15 × 15 m, is containerized, and does not require a crane or foundation for installation.
Reaching customers
Diesel generators are the standard in power generation for rural and off-grid areas. However, diesel fuel is expensive to deliver to these locations, and diesel generators, though inexpensive to install, are expensive to operate and maintain. As a result, remote customers typically pay more than 30 cents per kilowatt-hour for electricity. The BAT has the potential to bring affordable wind energy to these communities and industries. The first model will provide enough electricity for a small community, or about a dozen American homes.
Combined with significant increases in energy output and the ability to install the unit in 24 hours, the BAT substantially reduces the cost of energy and time to reach customers' energy needs. In the future, Altaeros expects to deploy the BAT alongside first responders in emergency response situations when access to the electric grid is unavailable. Much like other tethered balloons, the Altaeros BAT can lift communication, Internet, and sensory equipment alongside the turbine to provide additional services for customers. The addition of payload equipment does not affect the BAT's performance.
Scaling up
Altaeros was founded in 2010 at the Massachusetts Institute of Technology. The company has received NSF Small Business Innovation Research (SBIR) grants (Phase I and Phase II) to test a novel low-cost, high-performance fabric suitable for the BAT's shell, and to develop its modular wind turbine for power performance and ease of installation.
Altaeros recently received Series A funding of $7 million dollars for the continued development and commercialization of its technology. "The new products being developed by the team at Altaeros are exciting because they have the potential to offer a new method for energy generation which is portable, reliable, quick to deploy, and environmentally-friendly," says Ben Schrag, NSF SBIR program director. "This technology has the potential to avoid many of the key challenges facing traditional wind turbines."
Image caption —The Buoyant Airborne Turbine (BAT) can reach 2000 ft (600 m).
It’s a balloon that lifts a wind turbine.
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