Optomec awarded $4.0 million to implement 3D printing for aircraft repair
July 7, 2014
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Optomec, Albuquerque, N.M., announces that the company has been awarded $4 million from AmericaMakes, the National Additive Manufacturing Innovation Institute. Specifically, the team led by Optomec will leverage the unique advantages of LENS 3D metal printing technology and the expertise of some of the world's leading aerospace companies to advance a reliable, cost-effective approach to replace conventional repair processes such as manual welding. The potential benefits of using additive manufacturing to repair high-value metal components include lower costs, higher quality, longer life, and faster return to service.
The "Re-Born in the USA" project will focus on advancing additive manufacturing technology for the repair of aerospace metal components for the U.S. Air Force.
Optomec will lead a project team consisting of 23 partners, including aerospace industry leaders GE Aviation, Lockheed Martin, United Technologies Research Center, and Rolls-Royce, as well as a group of technical experts serving as lead contributors, including EWI, Connecticut Center for Advanced Technology, TechSolve, the Pennsylvania State University Applied Research Lab, and Concurrent Technologies Corporation. The term of the project is two years and is valued at $4 million ($2.6 million public share and $1.4 million private cost share). This is the third America Makes project awarded to Optomec this year.
The goal of the project is to develop a set of specifications and a knowledge base of best practices in advancing additive manufacturing methods to repair aerospace metal components. This includes definition of optimum powder feedstock characteristics, improvements in process monitoring and control, and recommendations for part repair and sustainment applications specifically for the Air Force.
At the core of the project is Optomec's LENS metal 3D printing technology. Unlike "powder-bed" additive manufacturing approaches, the LENS process can add metal onto an existing substrate of almost any three-dimensional shape. Powder-bed processes require a flat, two-dimensional horizontal base. This makes the LENS Additive Manufacturing process well qualified to perform repair operations. LENS machines are already in use around the world conducting repairs of ground based high value components for defense and other industries.
www.optomec.com
Optomec, Albuquerque, N.M., announces that the company has been awarded $4 million from AmericaMakes, the National Additive Manufacturing Innovation Institute.
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Vac Aero announces two HVOF systems based on carbide jets installed in Poland
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Vac Aero, Boucherville, Quebec, announces that fully integrated high-velocity oxygen fuel (HVOF) systems based on a new generation Carbide Jet System have been installed in two of its plants in Poland. In each system, a specially designed combustion chamber is fed by hydrogen, kerosene, and oxygen fuel.
They are optimized for spraying MCrAlY coatings on turbine engine components, and tungsten carbide coatings on landing gear components, as well as many other coating applications. Precise combustion and fuel configuration settings control particle temperature and velocity, to achieve optimal coating efficiency in less time and lower fuel consumption than other HVOF systems. The system was installed in a soundproof booth 13 by 13 by 13 feet in size.
The CJS torch is set in motion by a new Fanuc M20 robot with eight axis movement. These axes include six axes on the robot, and two axes on a tilting turntable integrated into and controlled by the robot. The torch's wide range of spraying temperatures prevents parts from overheating. An ID torch allows for spraying of parts with inner diameters as small as six inches.
The system is equipped with a CPF2 powder feeder that can achieve reproducibility in powder flow with tolerances lower than 1% and accuracy of ±2%. It can also feed very fine (even nano) powders, measured by mass-flow-controllers. The new HVOF system complements Vac Aero's existing plasma spray and inorganic paint coating capabilities. The company continues to invest in new special processing technologies to provide customers with a wider scope of services.
www.vacaero.com
Vac Aero, Quebec, announces that fully integrated high velocity oxygen fuel (HVOF) systems based on a new generation Carbide Jet System have been installed in two of its plants in Poland.
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Corex tungsten chromium carbide thermal spray coating optimizes cylinder durability
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Apex Hydraulics, U.K., has developed a Corex tungsten chromium carbide thermal spray coating that provides hardness up to 1400 HV and bond strength of about 10,000 psi. Designed to optimize durability of cylinders and pistons, porosity is less than 1% with no micro-cracks such as those associated with hard chrome plating (HCP). It also provides higher resistance to impact and wear. As a thermal spray process, it also takes less time to apply than HCP.
The Corex tungsten chromium carbide compound is an extremely hard, dense, cohesive rod coating with extremely high bond strength. Whilst outperforming HCP on the core metrics of cylinder impact, corrosion and wear, the cylinder application process for Corex is shorter in duration and provides ecological advantages over HCP.
Corex reduces by more than half theimpact damage to cylinders through small repeated impacts and large impacts. These can dent the substrate and in turn leads to cracking and peeling of the coating. Material flex in hydraulic pistons has also been carefully considered and the technology adapted to accommodate.
Utilizing thermal spraying techniques, Corex can be applied to large surface areas with a thicker coating. Not only does this reduce the application time from a full day to within hours, but also it provides a continuous surface, preventing the micro-cracks associated with HCP that lead to corrosion. HCP porosity is 5 to 10%, with additional micro-cracks.
http://www.apexhydraulics.co.uk/product/corex-coatings/
Apex Hydraulics, U.K., has developed a Corex tungsten chromium carbide thermal spray coating that provides hardness up to 1400 HV and bond strength of about 10,000 psi.
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25th AeroMat Conference Features Tuskegee Airman
June 27, 2014
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The 25th AeroMat Conference and Exposition, held June 16-19 in Orlando, Fla., featured a theme of "the latest word in aerospace materials." The well attended conference offered forward looking plenary sessions, multiple presentations about additive manufacturing, and more than 200 papers on topics ranging from aluminum, magnesium, and titanium to high-strength steels, high-temperature alloys, and thermomechanical processing.
As part of the festivities, ASM International, Materials Park, Ohio, and Allegheny Technologies Inc. (ATI), Pittsburgh, partnered to put on an outstanding VIP reception featuring Lieutenant Colonel Leo Gray, one of 27 remaining Tuskegee Airmen from World War II. Gray shared some very interesting, funny, and personal stories from his time flying P-51 Mustangs over Germany, during nearly four years of active duty. Several tales involved combat missions, downing of German aircraft, and the oppressive racial prejudice so prevalent during the 1940s. Many audience members asked questions and encouraged Gray to keep telling stories, which he gladly did. As a parting gift, ASM and ATI gave away custom prints of a P-51 aircraft drawing made by aviation artist Ernie Boyette and signed by Lt. Col. Gray.
The catered event was enjoyed by all attendees and serves as a stark reminder of why aerospace innovation remains such an important endeavor. For more information, visit asminternational.org and atimetals.com.
Image caption - Tuskegee Airman Lt. Col. Leo Gray (left) with Phil Morton of ATI.
The 25th AeroMat Conference and Exposition, held June 16-19 in Orlando, Fla., featured a theme of “the latest word in aerospace materials.”
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MGI strategic plan released for public comment
June 25, 2014
Source: ASM International
The National Science and Technology Council’s subcommittee on the MGI released for public comment a draft of its first strategic plan, to serve as a roadmap for Federal agencies as they execute on the initiative vision going forward.
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Alcoa to expand investment casting of superalloy jet engine blades
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Alcoa, Pittsburgh, announces that it is investing $25 million at its Alcoa Power and Propulsion facility in Hampton, Virginia, to scale up its enhanced equiax investment casting technology. Alcoa will add equipment for a new production line and modify existing machinery at the Hampton facility to produce nickel-base superalloy jet-engine blades that weigh 20% less and significantly improve aerodynamic performance.
Alcoa developed this enhanced equiax investment casting following five years of research and development. The technology involves preheating the ceramic molds to a temperature below the metal solidification temperature, so that when the mold is filled the solidification rate can be controlled. Made primarily of nickel-based superalloys, the lighter and more aerodynamically efficient blades can be used to retrofit existing or build next-generation aircraft engines. The casting facility in Hampton is the leading producer of complex investment cast turbine airfoils for the industrial gas turbine industry, as well as large nickel and titanium structural castings for aerospace engines.
The Company will use the latest in advanced manufacturing technology such as robotics and digital x-ray for enhanced product inspection. The expansion will begin this month and is expected to be complete by the fourth quarter of 2015. The Company expects to add at least 75 new, full-time employees over three years.
http://www.alcoa.com/hampton
Alcoa, Pittsburgh, announces that it is investing $25 million at its Alcoa Power and Propulsion facility in Hampton, Virginia, to scale up its enhanced equiax investment casting technology.
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Vac Aero vacuum furnace with six-bar argon-nitrogen quench system shipped to aerospace manufacturer
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Vac Aero International Inc., Burlington, Ontario, announces that it has shipped a VAV 7260 HV-6 vertical bottom loading vacuum furnace with a work chamber 72 in. diameter by 60 in. high to an aerospace manufacturer. The furnace includes a high-vacuum pumping system and a six-bar argon and nitrogen quench system designed to incorporate unique performance features. The cooling nozzle configuration and location have been engineered to improve gas penetration into the workload, gas velocity, and cooling speed.
The energy-efficient graphite hot zone is capable of processing temperatures up to 2400°F. The heavy duty hearth is constructed with quickly removable rails of pure molybdenum capable of handling distributed loads up to 4000 lb. The furnace operating system is based on VAC AERO's versatile HC900 interactive hybrid control package with SCADA and complete network integration capabilities and remote monitoring and control.
www.vacaero.com
Vac Aero International Inc., Burlington, Ontario, announces that it has shipped a VAV 7260 HV-6 vertical bottom loading vacuum furnace with a work chamber 72 in. diameter by 60 in. high to an aerospace manufacturer.
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Seco-Warwick presents “Low-Pressure Carburizing of Pyrowear Alloy 53” at AeroMat 25
June 24, 2014
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Engineers from Seco-Warwick, Poland, discussed a low-pressure-carburizing simulator dedicated to Pyrowear Alloy 53 at AeroMat 25. The simulator is said to provide an accurate carbon-concentration profile in the layer, or it can determine the process parameters required to produce the required profile. Pyrowear Alloy 53 is characterized by high surface hardness and abrasion resistance, while maintaining a ductile core able to transmit high-impact loads. Pyrowear Alloy 53 components can function at elevated temperatures and with limited lubrication.
The foundation for heat treatment of such parts is case hardening, based on surface carburizing. The presentation described the low pressure carburizing technology developed for Pyrowear products. It discussed themethods ofr forming various carbon concentration profilesin the layer, and its effect on the hardness profile. It also considered the impact of sub-zero treatment and tempering processes on the properties of the case.
www.secowarwick.com
Engineers from Seco-Warwick, Poland, discussed a low-pressure-carburizing simulator dedicated to Pyrowear Alloy 53 at AeroMat 25.
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Sandvik hyper-duplex stainless steel tube extends heat exchanger tube life by 2 to 15 years
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Sandvik Materials Technology, Sweden, reports that a major Caribbean producer of furfural, an organic compound derived from agricultural byproducts, chose to replace the existing tube in its heat exchangers with hyper-duplex stainless steel by Sandvik. As a result, its tube lifecycles have extended from two to 15 years, with a profound impact on material costs.
Sandvik SAF 2707 HD is a hyper-duplex stainless steel with excellent resistance to pitting corrosion and chloride-induced stress corrosion cracking. It is an alternative to nickel alloys with similar performance, but is more attractive economically in terms of material and lifecycle costs.
"Our hyper-duplex stainless steel was selected for its mechanical strength, which is higher than all the super-duplex stainless steel grades available on the market. Its excellent chloride corrosion resistance is well-suited to much more aggressive service conditions," explained Marcelo Senatore, global Technical marketing, Sandvik Materials Technology.
After two years of successful operation, the heat exchangers were inspected and found to be as good as new, showing no signs of pitting corrosion. The furfural producer will introduce periodic washing of metal surfaces to keep the equipment free from seawater debris.
www.smt.sandvik.com
Sandvik Materials Technology, Sweden, reports that a major Caribbean producer of furfural, an organic compound derived from agricultural byproducts, chose to replace the existing tube in its heat exchangers with hyper-duplex stainless steel by Sandvik.
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MTS buys Roehrig Engineering for its electromagnetic actuation technology
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MTS Systems Corp., Eden Prairie, Minn., announces that it has acquired 100% of the shares of Roehrig Engineering Inc., Lexington, N.C., the leader in testing systems utilizing electric and electromagnetic actuation technology. MTS says that Roehrig's innovative electric technologies and products are highly complementary to its servo hydraulic technologies and expertise.
According to Dr. Michael Jost, VP of MTS, "REI's innovative electric technologies and products are highly complementary to our servo hydraulic technologies and expertise. The combination of our advanced software and controls, global sales organization, and service network with REI's proven electrically actuated test systems are an ideal fit. Together, we have unmatched technical capability and product offerings to serve the global ground vehicles market."
"REI is very excited about joining MTS, a world class test company," said Kurt Roehrig, CEO of REI. "Our entrepreneurial spirit and customer-focused business approach are just two of the many attributes that make us a good cultural fit. Together, we will create significant advancements in testing technologies." Mr. Roehrig founded REI in 1988 with the development of unique expertise in shock absorber testing to serve the requirements of NASCAR racing teams. In the years since, applications for this technology have expanded well beyond racing to broadly encompass both laboratory and factory test environments in the global ground vehicle testing market. REI is based in Lexington, North Carolina.
"We are very excited about the addition of REI to the company," said Dr. Jeffrey Graves, President and Chief Executive Officer of MTS. "Their electric and electromagnetic actuation technology is well-aligned with the energy conservation and environmental megatrends, specifically the need for clean, low cost, energy efficient testing solutions."
www.mts.com
MTS Systems Corp., Eden Prairie, Minn., announces that it has acquired 100% of the shares of Roehrig Engineering Inc., Lexington, N.C., the leader in testing systems utilizing electric and electromagnetic actuation technology.
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