Dorfman to be Inducted into Thermal Spray Hall of Fame
March 31, 2014
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Mitchell R. Dorfman, FASM, Sulzer Metco Fellow, will be inducted into the Thermal Spray Hall of Fame on May 21, 2014 during the ITSC Plenary Session in Barcelona, Spain.
The Hall of Fame was established in 1993 by the ASM Thermal Spray Society to recognize and honor outstanding leaders who have made significant contributions to the science, technology, practice, education, management and advancement of thermal spraying. "The Hall of Fame is a bond between our industry's past and its future," said TSS President Luc Pouliot, Tecnar Automation Limited.
Mr. Dorfman is being recognized "for innovations in thermal spray turbine engine coatings, and for exceptional contributions to the thermal spray industry and technical community, and for dedicated mentoring of next generation thermal sprayers."
Mitch received his B.S. in Mechanical Engineering in 1978 and M.S. in Materials Science in 1979 from State University of New York at Stony Brook. He has held a number of positions with Sulzer Metco US since 1994 and prior to that he was with Metco Perkin Elmer from 1979 to 1994. He is internationally known for his development of materials for thermal spray, particularly carbides for wear resistance, zirconias for thermal barriers, and various materials for abradables. He holds 16 patents and over 60 publications or presentations. Mitch served on a number of TSS committees, is a Past President of TSS and is currently serving on the ASM Board. He was named ASM Fellow in 2010.
Mitchell R. Dorfman, FASM, Sulzer Metco Fellow, will be inducted into the Thermal Spray Hall of Fame on May 21, 2014 during the ITSC Plenary Session in Barcelona, Spain.
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Reinventing heavy-duty wheels for fleets
March 27, 2014
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Alcoa, N.Y., rolled out what is said to be the world's lightest heavy-duty truck wheel. This latest innovation, the Ultra ONE, will help trucks shed pounds for increased payload and fuel efficiency. Unveiled at the mid-America Trucking show in Louisville, the 40-lb wheel is 47% lighter than steel wheels of the same size.
Ultra ONE can help save up to 1400 lb per rig, enabling fleets to carry more goods while meeting stringent federal emissions regulations. Underscoring the importance of lightweighting to the industry, TMC Transportation, is converting its fleet to the Ultra ONE starting in 2014.
Fleets increasingly convert to aluminum wheels that offset the weight of necessary pollution-control equipment used to meet federal emissions regulations. Lighter wheels also improve fuel economy, making up for rising fuel prices and helping move goods in a cleaner way. And if trucks burn less fuel, they emit fewer greenhouse gases.
Replacing steel wheels with aluminum wheels on an 18-wheeler offsets the annual carbon footprint of an average family of four in America. In addition, Alcoa's aluminum wheels are six times brighter than competitors' wheels, giving them strong aesthetic appeal, and because they are corrosion resistant and do not require stripping and repainting, lower operators' maintenance and operating costs.
"As the largest privately owned flatbed trucking company in the United States, TMC Transportation trucks haul heavy loads across America every day, and each pound we can reduce helps us lower costs and move more goods," said Harrold W. Annett, Chairman and CEO of TMC transportation. "Ultra ONE wheel is part of our total commitment to quality, through which we reduce waste and ensure customer satisfaction."
To take out five pounds out of its lightest heavy-duty truck wheel, experts invented a new alloy, the patent-pending MagnaForce alloy. It is on average 17% stronger than Alcoa's 6061 alloy, in similar applications.
The Ultra ONE Wheel with MagnaForce alloy is available in the industry standard 22.5 in. × 8.25 in. size for heavy-duty, commercial transportation, and is being readied in all OEM customer data books. Truck manufacturers can specify Ultra ONE using the product code ULTRAx. Ultra ONE wheels are available in all popular Alcoa finish options.
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Ultra ONE Wheel
Alcoa
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Image caption — What is said to be the world's lightest heavy-duty truck wheel: The Ultra ONE forged aluminum wheel. Courtesy of Business Wire.
Alcoa, N.Y., rolled out what is said to be the world’s lightest heavy-duty truck wheel.
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James Webb space telescope relies on beryllium mirrors
March 26, 2014
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NASA Goddard Space Flight Center, Greenbelt, Md., is building the James Webb space telescope, whose unique beryllium mirror system will enable it to examine the earliest times of the universe when launched in 2018. The primary mirror is about 21 feet across, and is composed of 18 segments. Each segment is made of reflective gold-coated beryllium supported by a beryllium frame.
The beryllium mirror substrate is the part of each mirror segment that acts as a mirror. Each substrate is nearly two inches thick with a highly-polished and exquisitely smooth "front" reflective side and a "back" side that is precision machined into a sort of egg crate-looking structure to make it lighter weight than it would be if solid. The reflective surface is polished to an "average" roughness of only 20 nanometers (i.e., 20 billionths of a meter) and coated with a microscopically thin layer of pure gold to maximize its ability to reflect infrared light. Beryllium is the material of choice because is it extremely stiff and lightweight, and it behaves very stably and predictably at Webb's extremely cold operating temperatures.
The mirrors were built by Ball Aerospace & Technologies Corp., Boulder, Colo. Ball is the principal subcontractor to Northrop Grumman for the optical technology and lightweight mirror system. Ball Aerospace also developed the secondary mirror, tertiary mirror and fine-steering mirror.
"The complexity of the mirror assemblies comes from the fact that they are designed to be very lightweight, work at cryogenic temperatures below -400°F, survive launch vibration and forces, be align-able on-orbit via actuators, and then stay aligned for up to two weeks as though they are a single large mirror," said Lee Feinberg, NASA Optical Telescope Element Manager for the James Webb Space Telescope at the Goddard Space Flight Center.
For much more information, visit
http://nasasearch.nasa.gov/search?utf8=%E2%9C%93&affiliate=nasa&query=webb+space+telescope
NASA Goddard Space Flight Center, Greenbelt, Md., is building the James Webb space telescope, whose unique beryllium mirror system will enable it to examine the earliest times of the universe when launched in 2018.
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Lockheed Martin opens materials and thermal sciences R&D lab in Palo Alto
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The Lockheed Martin Space Systems Advanced Technology Center, Palo Alto, Calif., has opened an Advanced Materials & Thermal Sciences Center for research and development. Engineers will focus on 3-D printing, thermal sciences, nanotechnology, and high temperature materials.
With 82,000 square feet of floor space, it will house 130 engineers, scientists and staff. Advanced materials include CuantumFuse nano-copper, which promises to make more reliable electrical connections in space and other applications. The new microcryocooler is said to be the smallest satellite cooler ever developed.
This building replaces two other buildings that are each 50 years old, and will save $1 million in annual maintenance costs and cut energy costs by more than 60% percent.
Headquartered in Bethesda, Md., Lockheed Martin is a global security and aerospace company that employs approximately 115,000 people worldwide and is principally engaged in the research, design, development, manufacture, integration and sustainment of advanced technology systems, products and services. The Corporation's net sales for 2013 were $45.4 billion.
www.lockheedmartin.com
The Lockheed Martin Space Systems Advanced Technology Center, Palo Alto, has opened an Advanced Materials & Thermal Sciences Center for research and development.
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MMFX Steel and Williams Form Engineering to develop corrosion-resistant bar products
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MMFX Steel Corporation of America, Irvine., Calif., and Williams Form Engineering Corp., Belmont, Mich., are partnering to expand the Williams Form line of high-strength and corrosion-resistant products for the construction industry. MMFX Steel achieves its unique steel properties through a combination of the alloying elements and a well-controlled manufacturing process. The resulting low-carbon chromium alloy steel has a microstructure that is strong yet ductile and inherently corrosion-resistant.
Williams Form will use MMFX2 and ChromX 4100 steels from MMFX to manufacture its new uncoated corrosion-resistant and high-strength threaded bar products. The line will complement Williams Form's existing threaded bar products for applications such as soil nails, tieback and rock anchors, micropiles, and wind turbine foundation bolts.
Under the new agreement, Williams Form will develop thread bar products using the innovative MMFX steel technology. The new product line will provide engineers with new design solutions for geotechnical, post tensioning and concrete accessory applications that can benefit from corrosion-resistance and high-strength properties.
The existing Williams Form threaded bar options for corrosion resistance include epoxy-coated, galvanized and grouted carbon steels. The uncoated steels from MMFX alleviate user concerns about damaging epoxy coatings or fastener thread fit-up issues that can result from galvanizing. The high-strength properties of the MMFX steel will also allow Williams Form to manufacture products that meet its wide range of tensile strength requirements.
By using the MMFX material properties, the Williams Form all-thread bar product line will conform to the high-strength properties of ASTM A1035. The finished products will have a tensile strength up to 150 ksi and feature the Williams Form proprietary thread.
www.mmfx.com
MMFX Steel Corporation of America, Irvine., Calif., and Williams Form Engineering Corp., Belmont, Mich., are partnering to expand the Williams Form line of high-strength and corrosion-resistant products for the construction industry.
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Exova awarded NADCAP accreditation for static tensile testing
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Exova, U.K., announces that its Newcastle laboratory has been awarded Nadcap accreditation for static tensile testing, primarily for the aerospace and industrial gas turbine industries. The Newcastle Laboratory, which is an integral part of the Exova Aerospace Division, provides onsite test specimen extraction and manufacture, plus deep experience in the testing of single crystal and high temperature nickel alloys. It can offer an extended service to the aerospace, oil and gas, and power generation sectors and related industries.
This expansion of testing services was undertaken in response to increased demand from the regional aerospace market. Newcastle can now provide high temperate creep, stress rupture, and creep crack growth testing, immediately qualifying the laboratory to work for aerospace primes and their global supply chain.
"By investing in our facility and equipment we can provide customers with an increased range of capabilities, as well as greater capacity and increased output."
Exova's facilities include a global network of aerospace testing facilities, all of which are Nadcap approved. Exova's NADCAP accredited services date back to 1994, when the Santa Fe Springs facility became the fourth laboratory in the world to be NADCAP accredited. The Glendale Heights site followed with accreditation in 1996.
To achieve accreditation, sites must undergo rigorous evaluation including interviews, inspections, and reviews of all procedures.
www.exova.com
Exova, U.K., announces that its Newcastle laboratory has been awarded Nadcap accreditation for static tensile testing, primarily for the aerospace and industrial gas turbine industries.
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Timken forms joint venture to manufacture rail bearings in Russia
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The Timken Co., Canton, Ohio, has entered into an agreement with United Wagon Company (UWC) to establish a joint venture to manufacture Timken AP-2 rail bearings in Russia. UWC is a Russian company that is a leader in building, leasing, engineering, and servicing freight cars in Russia. The JV will advance the safety, reliability, and efficiency of the local rail industry, equipping freight cars with premium Timken bearings. The JV is contingent upon various regulatory approvals and other commercial and customary conditions.
"Leveraging the expertise Timken provides as a global leader in high-performance bearing design is critical to our strategy to deliver modern, high-quality freight cars to our customers in Russia and the Commonwealth of Independent States," said Roman Savushkin, chief executive officer of UWC, based in Moscow.
As part of the agreement, Timken and UWC will establish dedicated manufacturing capacity, with construction expected to start within the next several months.
This JV expands upon an established relationship that was formalized in 2013 with a strategic partnership agreement covering technical and design support and an initial supply of Timken AP-2 bearings to UWC.
"The Russian and CIS rail markets present an incredible growth opportunity for Timken as the region is rapidly modernizing its fleet to support its expanding economy," said Brian Ruel, Timken vice president for rail, off highway and light vehicle systems.
The agreement provides both companies a strategic opportunity to capitalize on a surge in demand as the industry advances from using cylindrical roller bearings on freight car axles to the more efficient, reliable cartridge tapered roller bearing Timken originally designed for the rail industry. Russia expects to acquire nearly one million new freight cars by 2030 as part of an aggressive investment program to renew and upgrade its rolling stock.
"Timken is well-established in delivering engineering solutions for demanding environments like Russia, where the terrain and climate can be rugged," Mr. Ruel said. "Our AP-2 rail bearings carry the heaviest loads in the world, in the harshest of conditions. Together with UWC, we will set a new standard of performance for the Russian and CIS markets."
www.timken.com
The Timken Co., Canton, Ohio, has entered into an agreement with United Wagon Company (UWC) to establish a joint venture to manufacture Timken AP-2 rail bearings in Russia.
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Surface Combustion adds 22,000 square feet to its Waterville facility
March 21, 2014
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Surface Combustion Inc., Maumee, Ohio, announces that it has made a major investment in its facility in Waterville, Ohio. The expansion includes an addition of 22,000 ft2 to its existing facility to enhance the flexibility and capacity to better serve the changing needs of its global customer base. The project doubled the amount of work bays, which are more expansive, to accommodate larger equipment assembly and testing.
Upgrades include 11 high-capacity jib cranes and two 20-ton overhead cranes. Planning for the future, the foundation and utilities have been designed to support a duplicate expansion adjacent to the current facility.
Surface Combustion offers a wide variety of configurations and equipment to carry out all processes common to the heat treating industry. It provides a complete complement of support services to assist customers prior to the purchase of their equipment, as well as after manufacture and delivery.
www.surfacecombustion.com
Surface Combustion Inc., Maumee, Ohio, announces that it has made a major investment in its facility in Waterville, Ohio.
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Vac-Aero commissions vacuum furnace at New Hampshire castings manufacturer
March 20, 2014
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Vac-Aero International Inc., Burlington, Ontario, has commissioned the first of two vacuum furnaces at a castings manufacturer in New Hampshire. The hot zone of the VAH5050 HV-2 is comprised of curved graphite elements and the heavy-duty hearth is constructed with easily removed rails of pure molybdenum designed to support a uniformly distributed load of 3000 lb at 2400°F.
The horizontal vacuum furnace has work zone dimensions 36 in. wide x 36 in. high x 50 in. deep. The lightweight design's low thermal mass enables faster quenching and longer life. The furnace is equipped with an external recirculating inert gas quenching system and includes gas storage and dual loop cooling systems. The furnace operating system is based on VAC AERO's versatile HC900 interactive hybrid control package with SCADA, complete network integration capabilities, and remote monitoring and control.
www.vacaero.com
Vac-Aero International Inc., Burlington, Ontario, has commissioned the first of two vacuum furnaces at a castings manufacturer in New Hampshire.
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EOS expands 3D printing materials with Ti64ELI and StainlessSteel 316L for medical devices
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EOS of North America, Novi, Mich., expands its metal materials portfolio with EOS Titanium Ti64ELI and EOS StainlessSteel 316L. The goal is to offer a broader range of titanium and stainless steel materials and open up new fields of application for components fabricated by laser sintering of powder metals. Ti64ELI provides high-detail resolution. StainlessSteel 316L provides high ductility for medical applications such as surgical instruments and orthopedics.
Parts built in EOS Titanium Ti64 have a chemical composition and mechanical properties corresponding to ASTM F136. Providing a high-detail resolution, this alloy can be processed on an EOSINT M 280 (400 Watt) metal laser-sintering system and shows an excellent corrosion resistance. Due to its biocompatibility and high grade of purity it is particularly suited for the additive manufacturing of medical implants.
EOS StainlessSteel 316L has been optimized specifically for processing on the EOSINT M 280 metal laser-sintering system. It shows a good corrosion resistance and a high ductility. Parts built from EOS StainlessSteel 316L have a chemical composition corresponding to ASTM F138 ("Standard Specification for Wrought 18Cr-14Ni-2.5Mo Stainless Steel Bar and Wire for Surgical Implants UNS S31673"). In the medical industry, this alloy is particularly suited for surgical instruments, endoscopic surgery, orthopedics and implants.
The material is also a good choice for use in the watch and jewelry industries, where the designer benefits from extensive freedom of design. Shaping and structural restrictions as such are a thing of the past. Parts such as watch cases (thanks to defined hollow spaces) can be manufactured more cost-efficiently and easily, saving resources. The material is also well suited for additive manufacturing applications such as spectacle frames or functional elements in yachts. In the aerospace industry, EOS StainlessSteel is a good choice for the manufacture of clamping elements or heat exchangers. Parts manufactured from that material can be mechanically post-processed or polished.
www.eos.info
EOS of North America, Novi, Mich., expands its metal materials portfolio with EOS Titanium Ti64ELI and EOS StainlessSteel 316L.
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