Ford’s Lightweight Concept vehicle includes aluminum, high-strength steel, magnesium
June 10, 2014
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Ford Motor Company, Dearborn, Mich., has developed a Lightweight Concept vehicle in which advanced materials are applied to explore weight-reduction solutions that could improve performance and fuel efficiency while reducing carbon dioxide emissions. This Lightweight Concept vehicle represents a comprehensive blend of advanced materials, including strategic application of aluminum, ultra-high-strength steels, magnesium, and carbon fiber.
Ford engineers took a holistic approach to weight reduction by incorporating advanced materials into the entire design of the vehicle, including powertrain, chassis, body, battery and interior features such as seats. The research vehicle was developed with the U.S. Department of Energy's Vehicle Technologies Program, together with Cosma International – a subsidiary of Magna International – to illustrate long-term potential light-weighting solutions. Magna's design and development of the multi-material body-in-white, closures, and chassis components are a significant contribution in light-weighting the concept vehicle.
"Our goal was to investigate how to design and build a mixed-materials, lightweight vehicle that could potentially be produced in high volume, while providing the same level of safety, durability and toughness as our vehicles on the road today," said Matt Zaluzec, Ford technical leader, Global Materials and Manufacturing Research. "There's not a one-size-fits-all approach to light-weighting. The Lightweight Concept gives us the platform to continue to explore the right mix of materials and applications for future vehicles."
www.ford.com
Ford Motor Co., Dearborn, Mich., has developed a Lightweight Concept vehicle in which advanced materials are applied to explore weight-reduction solutions that could improve performance and fuel efficiency while reducing carbon dioxide emissions.
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Ipsen loading system for large furnaces eliminates need to disconnect heating elements
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Ipsen, Cherry Valley, Ill., has been awarded a patent for a new vacuum heat-treating furnace-loading system that eliminates the need to disconnect the heating elements each time the system is used. Chief Engineer Craig Moller, the named inventor on the patent, began formulating this design five years ago for a large vacuum heat-treating furnace used by a company in the aerospace industry.
Ipsen's loading system functions as an alternative with its ability to leave the furnace's heating elements intact in the bottom of the hot zone. The newly patented system contains other notable elements, including: unrestricted length or load weight, and jackscrew mechanisms that gently raise and lower loads onto the hearth to avoid any potential damage.
The loading system also uses wheels that permit sideways movements, allowing it to function as a cross-transfer unit between furnaces. The loader's sideways position is pinpointed with encoder strips mounted in the floor.
In addition to these options, the system incorporates advanced safety features. By utilizing scanning lasers, the operator is able to prevent the loader from running over anything in its path. This helps prevent unnecessary damage to valuable equipment or injuries to employees.
www.IpsenUSA.com/products
Ipsen, Cherry Valley, Ill., has been awarded a patent for a new vacuum heat-treating furnace-loading system that eliminates the need to disconnect the heating elements each time the system is used.
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Army Research Laboratory project to develop U.S. supply chain for rare-earth elements
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A team led by Technology Metals Research LLC, Carpentersville, Ill., has been awarded $1.2M in funding from the U.S .Army Research Laboratory, to help develop the key components for a domestic rare-earth supply chain for heavy and other critical rare-earth elements. The funding was awarded through a sub-award agreement with Worcester Polytechnic Institute. The project involves a dozen companies and research institutions in the United States, Canada, and Australia,
In recent years the rare-earth sector has been dominated by China, which provides approximately 90% of global supply. The heavy rare earths dysprosium and yttrium were recently mandated for inclusion in the DOD's National Defense Stockpile, despite not being produced in the United States from U.S.-based sources.
Project partners include Innovation Metals Corp.= and researchers at Argonne National Laboratory, the University of Illinois at Chicago, the University of South Australia, and the ARL itself. A number of 'stealth-mode' companies and researchers with promising new technologies will also participate in the program.
Gareth Hatch, co-founder of TMR and president of IMC, is the Principal Investigator for the 12-month program. "Besides validating IMC's process-flow diagrams for the bulk solvent extraction of heavy and critical REEs," he says, "this award from the ARL will allow the team to evaluate new process technologies that have the potential to revolutionize the speed and efficiency of REE extraction and separation. These are exciting, materials-science-based approaches that have not been seen by the rare-earth sector before."
In addition to coordinating the existing program activities, TMR remains open to looking at additional processes and to collaborations with other groups, which could contribute to the overall objectives of the project.
www.techmetalsresearch.com
A team led by Technology Metals Research LLC, Carpentersville, Ill., has been awarded $1.2M in funding from the U.S .Army Research Laboratory, to help develop the key components for a domestic rare-earth supply chain for heavy and other critical rare-earth elements.
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Wayne State develops technology for high-strength bainitic steels and austempered ductile irons
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Wayne State University, Detroit, has finalized a license agreement with a new start-up company, Detroit Materials Inc., for a Wayne State-patented portfolio of high-strength low-alloy steels and cast irons for demanding applications. The portfolio includes bainitic steels and austempered ductile irons exhibiting a combination of excellent mechanical properties currently available only in costly exotic steels.
A team of researchers led by Susil Putatunda, Ph.D., professor of chemical engineering in Wayne State University's College of Engineering, have been working to create advanced materials with high yield strength, fracture toughness, and ductility. Dr. Putatunda's research was initially funded by a grant from the National Science Foundation (award number 0854962), and more recently received funding from the New Economy Initiative's (NEI) Technology Development Incubator Program. This program is aimed at accelerating feasibility studies necessary for licensing, industry partnerships, and start-up opportunities.
The company was founded by Pedro Guillen in his role as entrepreneur-in-residence for the Detroit Technology Exchange, with direct financial and administrative support from Detroit Innovate, a new venture fund based in southeast Michigan.
Mr. Guillen, Chief Executive Officer of Detroit Materials, specializes in corporate innovation strategy and new technology commercialization. He has over 15 years of product development and innovation experience in automotive, defense, off-highway, and clean energy markets. He has led engineering teams developing proof-of-concept technologies and demonstrator vehicles for the Department of Defense, and founded two successful start-ups.
www.wayne.edu
Wayne State University, Detroit, has finalized a license agreement with a new start-up company, Detroit Materials Inc., for a Wayne State-patented portfolio of high-strength low-alloy steels and cast irons for demanding applications.
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Plansee applies selective laser melting to refractory metal powder
June 9, 2014
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Plansee, Franklin, Mass., has now developed a selective laser melting process for refractory metals. In this process, a thin layer of refractory metal powder is applied on a base plate. The laser fuses the powder exactly at the point directed by a CAD program, then another layer is applied and the laser fuses the next section of the part. The process continues until the part is built, and unmelted powder can be used for a new part. The first components have already been delivered to customers.
In addition to the high yield of material, the process of selective laser melting offers additional advantages: For the production of customer-specific components, neither special tools nor molds are needed.
"Nearly all geometries are possible. The only input we need is a 3D drawing from our customer," Bernhard Tabernig says enthusiastically. He is responsible for the development of new materials and technologies at Plansee.
The new process can be used, for example, in medical technology. "We have already constructed components for X-ray diagnostics. They have a particularly complex grid structure for absorbing scattering radiation as well as possible," explains Peter Singer, project engineer. " Without the new manufacturing process, we could not hold these products in our hands."
www.plansee.com
Plansee, Franklin, Mass., has now developed a selective laser melting process for refractory metals.
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Metco leaves the Sulzer Group, joins the Oerlikon Group.
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The Oerlikon Group, Switzerland, announces the successful closing of the transaction to acquire Metco from Sulzer AG ahead of schedule. After having received all required merger control approvals, the parties were able to close the transaction on June 2, 2014. Oerlikon Balzers and Oerlikon Metco now form Oerlikon's Surface Solutions Segment. Oerlikon Balzers is the global technology leader in the service-driven PVD Thin Film business. Oerlikon Metco is the global technology leader in the Thermal Spray and surface applications business.
Oerlikon Metco will access Oerlikon Balzers' well-established and highly successful service approach to further grow the Thermal Spray service business. Oerlikon Balzers' proven ability to replicate successful market penetration is a key enabler for acceleration of the Thermal Spray and Plasma Nitriding services and rapid geographic expansion – especially in emerging markets.
The combination will expand Oerlikon's addressable growth market in surface solutions to some CHF 9 billion. The two businesses are complementary in terms of their technological strengths, business models, market access, and geographical footprint, enabling them to increasingly meet customer requirements in the years to come. The combined businesses will operate some 130 facilities with over 110 coating centers in 35 countries around the world, employing around 6000 people.
Oerlikon is convinced that the combination provides substantial growth potential, significantly outperforming global GDP by exceeding growth rates of underlying markets. In addition to the integration of the two businesses, the key priority is to unfold the top-line opportunities. This is a multi-year agenda, as for example qualification processes in industries such as aviation or automotive normally take years, and changing a business model towards service business requires some time.
www.oerlikon.com/metco
Oerlikon Group, Switzerland, announces the successful closing of the transaction to acquire Metco from Sulzer AG ahead of schedule.
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RTI acquires Dynamet for its advanced titanium powder metal technology
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RTI International Metals Inc., Pittsburgh, has 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 will be included in RTI's Titanium Segment. Purchase terms of the transaction were $15.5 million in cash, plus potential future cash consideration.
"This acquisition, RTI's second new advanced technology investment this year, adds innovative titanium powder research and development, as well as a second distinct powder-based manufacturing technology to RTI's capabilities," says Dawne S. Hickton, Vice Chair, President, and CEO of RTI. "Together with our acquisition in January of RTI Directed Manufacturing, which specializes in 3D printing, the addition of Dynamet Technology enhances RTI's strategic positioning to capitalize on increasing customer demand for lower cost materials and innovative near-net shape preforms and components. RTI looks forward to working with the Dynamet Technology team to maximize the opportunities we are confident this combination of talents will create."
Dynamet's products are manufactured from the company's proprietary titanium alloys, standard titanium alloys, and metal matrix composites by its advanced powder metallurgical process. Near-net-shape preforms and products that have been successfully produced and commercialized by Dynamet include various missile parts and CermeTi metal matrix composite material for medical implant products.
In February 2012, Dynamet received qualification approval from a large commercial aerospace OEM for the supply of powder metal Ti-6Al-4V alloy products for structural components on commercial aircraft. This was followed by 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, the company received the International Titanium Association's Titanium Applications Development Award for 2013.
According to, "We look forward to becoming part of the innovative team and culture at RTI," says Stanley Abkowitz, founder of Dynamet Technology. "Our common view of the vast market opportunities and applications for the continued development and use of Dynamet Technology's advanced powder metal technology make joining with RTI the ideal path forward to accelerate progress and market acceptance."
www.rtiintl.com
RTI International Metals Inc., Pittsburgh, has 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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Al-Fe Wadsworth receives Nadcap accreditation for glycol quenching
June 2, 2014
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Al-Fe Heat Treating, Fort Wayne, Ind., has added glycol quenching to its list of Nadcap-accredited aluminum heat treat services at its plant in Wadsworth, Ohio. All aerospace and military applications are processed at the Wadsworth plant. Glycol reduces distortion, which makes it ideal for certain metals and applications. Different metals need different media, and glycol is an option for those that are not optimized by standard water or air treatment.
Cold water works for most metals, but will also give the most distortion. Warm water reduces distortion, but metals lose strength, hardness and flexibility. Glycol can cost more, but it is worth it when products are finished with less distortion and the required mechanical properties.Both the Wadsworth and Wabash plants provide both low- and high-volume aluminum heat treating with glycol quenching for automotive and commercial applications where water or air just won't do.
www.al-fe.com
Al-Fe Heat Treating, Fort Wayne, Ind., has added glycol quenching to its list of Nadcap-accredited aluminum heat treat services at its plant in Wadsworth, Ohio.
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Selective laser melting to produce aerospace components
June 1, 2014
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Fraunhofer Institute for Laser Technology IPT, Germany, is developing Selective Laser Melting technology to build aerospace components via additive manufacturing. Step by step laser radiation is scanned across a powder bed and traces out the form of the component within this specific layer. Wherever the laser radiation impacts the powder, the powder initially melts and then solidifies to form a solid mass. In this way, the component is built-up layer by layer.
The researchers are now working with their colleagues from the Fraunhofer Institute for Production Technology IPT on the integration of additive manufacturing into an entire, continuous process chain. To illustrate what the new process chain can achieve, they have produced a Nozzle Guide Vane (NGV) cluster that consists of six double vanes, as shown in the photo. Previously, the vanes for turbines could only be produced in pairs, as twin blades. Now, they can be installed much more easily and quickly.
An important step toward automation of repair is also under development. Called the "CAx framework," this software approach allows all the various repair technologies to be operated from a single platform. "CA" stands for computer aided, "x" for the individual technologies of the production. First, the geometric data of damaged or worn-out blade is acquired by digitizing. Second, a milling machine blends out the defect; and third, laser radiation builds up the blade again layer by layer via Laser Material Deposition (LMD). The researchers have already implemented this method for gas turbines; now, they can also transfer it to engine blades.
http://www.fraunhofer.de/en/press/research-news
Fraunhofer Institute for Laser Technology IPT, Germany, is developing Selective Laser Melting technology to build aerospace components via additive manufacturing.
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Nikon 750kV microfocus X-ray source enables NDT inspection of steel parts
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Nikon Metrology Inc., Brighton, Mich., announces a unique 750 kV x-ray source with micron level spot size. This high power x-ray source enables nondestructive inspection or measurement of large or dense objects such as engine castings, turbine blades, large composite parts with unprecedented resolution. It is the only 750 kV microfocus source on the market providing superior resolution and accuracy compared to traditional minifocus sources.
The 750kV source targets NDT inspection and CT metrology of small and large turbine blades, precision high density components used in high-temperature and/or high-pressure applications (e.g. turbo chargers, compressors, etc.) and automotive aluminum castings. Also for Carbon Fiber Reinforced Polymer (CFRP) components such as helicopter or jet engine fan blades, this unique source offers sufficient penetration power and accuracy for in-depth inspection. Typical material penetration values are 160mm for aluminum and 60mm for steel.
X-ray sources are at the heart of x-ray and CT technology and are designed and manufactured in-house. A key element of the source is a unique high speed rotating transmission target that allows the source to be operated at maximum power with a fine spot size. The 750 kV microfocus source features a spot size of 30 to 50 µm depending on the power, at least ten times smaller than corresponding minifocus sources. By integrating the high voltage generator into the vacuum chamber, high voltage cables and their associated problems are eliminated. Thanks to its open-tube design with user-replaceable filaments, the source has a virtually unlimited lifetime with a low maintenance cost.
http://www.nikonmetrology.com/News
Nikon Metrology Inc., Brighton, Mich., announces a unique 750 kV x-ray source with micron level spot size.
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