ALD Vacuum describes SyncroTherm small-batch process at AeroMat 25
June 24, 2014
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ALD Vacuum Technologies, Germany, recently developed a heat treatment cell called ALD-SyncroTherm, which provides synchronized heat treatment by small batch processing. Presented at the AeroMat 25 conference, it is described as "One Piece Flow," and includes the following steps: parts are taken one by one from the soft machining unit, then heat treated in synchronization with the cycle time of soft machining, the passed down one by one to the hard machining unit.
The title of the presentation was "New Possibilities of Synchronized Heat Treatment by Using Small Batch Processing," by Dr. Volker Heuer and Dr. Klaus Loesser.
If case hardening is the process of choice, then the components are low-pressure carburized at high temperature (1050°C), followed by gas quenching. The authors pointed out that the technology has been used in the automotive industry for the past three years, but testing for aerospace parts has just begun.
The main advantages of the treatment are improved homogeneity, better distortion control, reduced throughput times, and lower cost.
www.ald-vt.com
ALD Vacuum Technologies, Germany, recently developed a heat treatment cell called ALD-SyncroTherm, which provides synchronized heat treatment by small batch processing.
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Nitrex presents Nano-S nitriding technology at AeroMat 25
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Nitrex Metal Inc., Montreal, Quebec, reported at the AeroMat 25 conference on its Nano-S nitriding technology designed primarily for surface hardening of stainless steels to improve wear and galling resistance. The key to its success a precise atmosphere control, which translates to accurate control of the nitriding potential. Therefore, engineers developed process technologies that allow for tight control of low-temperature nitriding parameters. The goal of this control is to produce a supersaturated nitrogen surface layer by adapting the potential set point to various process temperatures and stages.
Authored by Jack Kalucki and Dimitri Koshel, the presentation was titled "Nano-S: Controlled Low-Temperature Nitriding, an Alternative to Thermal Spray Coatings." The authors discussed various aspects of gas atmosphere control and metallurgical results. They also reported on the evolution of microstructures, microhardness profiles, fatigue, and electrochemical corrosion test data.
www.nitrex.com
Nitrex Metal Inc., Montreal, Quebec, reported at the AeroMat 25 conference on its Nano-S nitriding technology designed primarily for surface hardening of stainless steels to improve wear and galling resistance.
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Seco-Warwick commissions roller hearth furnace system for ABB
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Seco-Warwick, Meadville, Pa., has commissioned a roller hearth furnace system to ABB, Pinetops, North Carolina, an instrument transformer facility. The system replaces three batch pit-style vacuum furnaces with a high efficiency, fully automated continuous operating system. The new furnace has more than doubled annealing capacity. The furnace control system allows engineers to track the furnace temperature throughout the annealing cycle and detect problems at once. This information and control system provides ABB the ability to produce a stable anneal, which is critical to the electrical performance of its products.
The installation of the new furnace gives ABB the ability to offer lower lead times to OEM customers. The furnace and conveyor orientation was custom designed to fit in ABB's operational space. This new layout has positively changed the flow process in the annealing area by reducing work in process and transportation time. The new system also includes safety devices that provides a safe work environment for operators and ergonomically friendly. Altogether the new roller hearth furnace has positively affected the business in Pinetops and met our needs and goals."
www.secowarwick.com
Seco-Warwick, Meadville, Pa., has commissioned a roller hearth furnace system to ABB, Pinetops, North Carolina, an instrument transformer facility.
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Natural-gas conveyor oven system designed to heat treat auto engine components
June 17, 2014
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Davron Technologies Inc., Chattanooga, Tenn., has designed and manufactured the DTI-1140, a natural gas-heated indexing conveyor oven system that heat treats engine components for a Tier 1 automotive supplier. The system includes an indexing conveyor oven, a quench tank, and a rinse tank. It also includes an automated pick-and-place system, which had to be precisely calibrated to streamline the heat treating process and meet demanding production requirements.
The heated chamber in the system includes four index positions that process 840 parts (530 pounds) in an eight-hour cycle. In the first zone, product ramps to temperature, and then soaks in the next three positions. For the heat-treat process to be successful, the product must never dip below the temperature reached in the first zone. Upon exiting the heated chamber, the product must be submersed in the quench tank within seconds. The DTI-1140's sophisticated heating and air distribution system, along with its pick-and-place system, ensure that both of these critical requirements are met.
The system features two zones of temperature control in the heated chamber. Each zone is individually controlled to enable flexibility in the temperature profile, and utilizes its own natural gas burner and circulation fan. It also includes one exhaust fan to meet NFPA standards for gas-fired equipment. The maximum operating temperature is 1000°F. The indexing conveyor oven features PLC control, and all motion functions are controlled by servo for accuracy and speed. Both the quench and rinse tanks include electric heaters to ensure that the solutions are the required temperatures prior to the start of production. The quench tank also features a chiller to cool the solution after each cycle.
The furnace is 4 feet wide by 2 1/2 feet high and 29 2/3 feet long. The interior of the oven is made of 16-gauge aluminized steel, backed by 10 inches of eight-pound density mineral wool insulation. The exterior is constructed of 16-gauge carbon steel backed by a structural steel frame and finished with high-temperature paint. The oven features four access doors for explosion relief and access to the heated chamber. Pneumatically operated vertical doors cover both the entrance and exit of the oven chamber.
www.davrontech.com
Davron Technologies Inc., Chattanooga, Tenn., has designed and manufactured the DTI-1140, a natural gas-heated indexing conveyor oven system that heat treats engine components for a Tier 1 automotive supplier.
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Timken announces date for spinoff of its steel business as independent company
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The Timken Co., Canton, Ohio, announces record and distribution dates for the spinoff of its steel business, which will be effected through the distribution of 100% of the common shares of TimkenSteel Corp. to holders of Timken Company common shares. Following the distribution, TimkenSteel will be an independent, publicly traded company; it has received approval to list its common shares on the New York Stock Exchange under the symbol TMST.
Timken shareholders will receive one TimkenSteel common share for every two common shares of Timken held at the close of business on the record date of June 23, 2014. Timken shareholders entitled to receive the June 30 distribution will receive a book-entry account statement or a credit to their brokerage accounts reflecting their new ownership of TimkenSteel common shares.
After the spinoff, Timken will continue to focus on its core bearings business as well as related power transmission products and services.
"With this strategic value-building initiative soon behind us," said Richard G. Kyle, Timken president and chief executive officer, "we will continue to manage the business for profitable growth while maintaining our focus on delivering products and services that keep the world's industries working reliably and efficiently. We're certainly encouraged by our progress and confident in our future prospects."
www.timken.com
The Timken Co., Canton, Ohio, announces record and distribution dates for the spinoff of its steel business, which will be effected through the distribution of 100% of the common shares of TimkenSteel Corp. to holders of Timken Company common shares.
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ATI acquires Hanard Machine for its precision machining of aerospace alloys
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Allegheny Technologies Inc., Pittsburgh, Pa., has acquired Hanard Machine Inc., Salem, Ore., which specializes in precision machining of parts and components made of titanium, nickel-base alloys, superalloys, aluminum, and specialty steels. The business will operate as ATI Cast Products, Salem Operations, and will be a part of ATI's titanium investment casting business, which is located in Albany, Ore., approximately 40 miles south of Hanard's location.
"The acquisition of Hanard Machine is consistent with our strategy to create value for our customers and stockholders by expanding our capabilities to produce finished specialty materials parts and components," said Rich Harshman, ATI's Chairman, President and Chief Executive Officer. "With this acquisition, ATI is now integrated in the production of titanium investment castings from titanium sponge to precision machined finished parts.
"The acquisition reinforces ATI's important aerospace supply chain role. Our strategic investments, acquisitions, and new product development provide the capacity and unique capability to produce the alloys, parts, and components that enable the next-generation airframe and jet engines."
www.ATImetals.com.
Allegheny Technologies Inc., Pittsburgh, Pa., has acquired Hanard Machine Inc., Salem, Ore., which specializes in precision machining of parts and components made of titanium, nickel-base alloys, superalloys, aluminum, and specialty steels.
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Temperature-sensing friction stir welding tool enables complex joints
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Researchers at University West in Trollhättan, Sweden, have invented a friction-stir-welding tool that also functions as a temperature sensor. The temperature is measured continuously and, if it becomes too hot, the heat is reduced by controlling the force and tool rotation. With the aid of an industrial robot and the temperature sensor, the researchers have been able to weld advanced three-dimensional joints. This enables the welding of small and more complex components with curved surfaces.
The robot welds with higher precision, and with the temperature controller, it takes only a few hours to program 3D joints. Manual programming of a similar component took up to a week.
The research project at University West was initiated through a collaboration between Volvo Aero, SAAB Automobile, and the welding equipment company ESAB.
In FSW, a rotating non-consumable cylinder is pressed into the material. The combination of frictional heat and the mechanical "stirring" creates a high-quality welding joint, without melting the material. However, one of the problems with this method has been that if the temperature becomes excessively high, the metals can reach the melting point and the welding tool can sink through the sheets. To achieve good welds with a FSW robot, both the process forces and the temperature must be properly controlled.
http://www.hv.se/en/research
Researchers at University West in Trollhättan, Sweden, have invented a friction-stir-welding tool that also functions as a temperature sensor.
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Hydro may build pilot plant to test more-efficient aluminum electrolysis technology
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Norsk Hydro ASA, Norway, reports that Enova, a Norwegian government agency, has decided to contribute $250 million toward Hydro's full-scale next-generation electrolysis pilot project, which is said to have the potential to significantly reduce energy consumption. The pilot plant is to have a capacity of 70,000 metric tons of aluminum per year, and could begin production in 2017, at the earliest.
Hydro's technology center in Ã…rdal, Norway, is a global leader in developing new and more energy-efficient electrolysis cell technology. It is this technology that Hydro wants to test in the pilot plant. The project is projected to cost $580 million, of which $250 million would come from Enova. This contribution is subject to approval by the European Free Trade Association's surveillance authority ESA. "We have been in an application process with Enova over the past year. Hydro's goal is to realize a groundbreaking new technology that can reduce energy consumption and emissions from Norwegian industry. The support from Enova makes it possible to continue to put all the elements in place before potentially making a final decision on the project and starting construction," says Hydro President and CEO Svein Richard Brandtzaeg.
Enova will send its decision to ESA for approval. Other conditions that must be in place before Hydro can make an investment decision include that the state power grid company Statnett can ensure that the regional grid can support the industrial growth and planned electrification of offshore energy installations. The company must also be able to secure sufficient electricity at competitive prices. In addition, market conditions for aluminum must indicate a satisfactory profitability outlook.
http://www.hydro.com
Norsk Hydro ASA, Norway, reports that Enova, a Norwegian government agency, has decided to contribute $250 million toward Hydro’s full-scale next-generation electrolysis pilot project, which is said to have the potential to significantly reduce energy consumption.
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ASB’s modernized Mesta grinder enables more accurate two-axis grinding
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ASB Industries, Barberton, Ohio, has completed the upgrade of its Mesta Roll Grinder to provide extremely accurate two-axis grinding for complex roll crowns, as well as a wide range of other thermal spray surfacing options. The grinder was completely remanufactured from the ground up. Upgrades retain its original capacity and capabilities, with the benefit of numerous usability and performance improvements The machine is capable of processing workpieces up to 60 in. (1524 mm) in diameter and 288 in. (7315 mm) long.
A new Fagor 8065T CNC control system, specially designed for two-axis grinding operations, utilizes autotuning software that allows for fine-tuned grinding processes. The updated controls create more accurate finishes and are fully integrated to achieve two linear axes on both spindles for complex roll crown profiles. Roll profiles can be programmed via G-Code programming, CAD/CAM software, or Fagor's onboard profile editor.
ASB also added a Renishaw touch probe for data collection purposes. All roll history data is documented during refurbishments and is transferable to Excel files for easy reference. Data and inspection reports are made available to ASB's customers.
Additional upgrades include a new Dodge MagnaGear parallel shaft reducer gearbox unit, new bearings and belt drives, a Torit Mist Collector to minimize airborne grinding dust, and a Barnes Kleenall coolant cleaning unit and Rosedale secondary bag filter. Modifications to the grinding head will enable ASB to achieve near-theoretical grinding to center, improving the contact plane and the grinder's versatility.
Alignment and levels of all of the Mesta grinder's components were adjusted as needed and verified using a Hamar L-730 precision laser level. Lubrication lines and way covers were replaced, and custom wear guards were also installed.
http://www.asbindustries.com.
ASB Industries, Barberton, Ohio, has completed the upgrade of its Mesta Roll Grinder to provide extremely accurate two-axis grinding for complex roll crowns, as well as a wide range of other thermal spray surfacing options.
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RTI International Metals acquires Dynamet Technology
June 13, 2014
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RTI International Metals Inc., Pittsburgh, acquired Dynamet Technology Inc., an industry innovator in titanium powder metallurgy and a supplier of near-net shape titanium and titanium alloy preforms and components to commercial aerospace, defense, biomedical and industrial customers. Based in Burlington, Mass., Dynamet Technology will be included in RTI's Titanium Segment. Purchase terms of the transaction were $15.5 million in cash, plus potential future cash consideration.
Dynamet Technology's products are manufactured from the company's proprietary titanium alloys, standard titanium alloys, and metal matrix composites using Dynamet Technology's advanced powder metallurgical process. Near-net shape preforms and products that have been successfully produced and commercialized by Dynamet Technology include various missile parts as well as CermeTi metal matrix composite material for medical implant products.
In February 2012, Dynamet Technology began supplying powder metal Ti-6Al-4V alloy products for structural components on commercial aircraft to a large commercial aerospace OEM. After that, the company received AS9100C certification in April 2013—a widely adopted and standardized quality management system certification that aerospace and defense manufacturers require of their suppliers. Last September, Dynamet received the International Titanium Association's Titanium Applications Development Award for 2013.
Additional details regarding the transaction were not disclosed.
RTI International Metals Inc., Pittsburgh, acquired Dynamet Technology Inc., an industry innovator in titanium powder metallurgy and a supplier of near-net shape titanium and titanium alloy preforms and components to commercial aerospace, defense, biomedical and industrial customers.
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