Prof. Zi-Kui Liu, FASM, Receives 2014 J. Willard Gibbs Phase Equilibria Award
January 9, 2014
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ASM is pleased to announce that Zi-Kui Liu, FASM, Professor of Materials Science and Engineering, The Pennsylvania State University, University Park, is the 2014 J. Williard Gibbs Phase Equilibria Award recipient. He is cited "For his contributions in computational thermodynamics through integrated first-principles caluclations and the CALPHAD method and for the advancement of phase-equilibria theory, database development, materials design and promotion of thermodynamics."
The Gibbs Award was established in 2007 to recognize outstanding contributions to the field of phase equilibria. The award honors J. Willard Gibbs, one of America's greatest theoretical scientists.
In addition to many other contributions, Gibbs laid the thermodynamics foundations of phase equilibria with his brilliant essay, "On the Equilibrium of Heterogeneous Substances," published in 1876 and in 1878 in the Transactions of the Connecticut Academy.
Prof. Liu will receive his award at MS&T'14 in October 2014 in Pittsburgh, Pa.
ASM is pleased to announce that Zi-Kui Liu, FASM, Professor of Materials Science and Engineering, The Pennsylvania State University, University Park, is the 2014 J. Williard Gibbs Phase Equilibria Award recipient.
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NanoSteel weld overlay improves wear rate of concrete slick line by a factor of 30
January 7, 2014
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The NanoSteel Company, Providence, R.I., announces that its Super Hard Steel weld alloy has been selected by Trimay Wear Plate Ltd. as cladding within the steel piping of a concrete slick line to provide wear protection at an underground mine in northern Canada. The alloy has been shown to improve wear rate by a factor of 30 over the previous solution. Combined with Trimay's unique casing design, this project represents the second line of identical configuration for the customer and will be installed during the first quarter of 2014.
The slick line is a 600 meter vertical borehole system of 9-5/8 in. diameter casing used for delivering concrete to backfill mined out sections and reinforce rock walls so the next ore body segment can be mined safely. It consists of NanoSteel clad API L80 grade steel casing and Trimay's proprietary threaded joint system.
In its initial installation, thickness loss for the NanoSteel cladding was measured at 0.9 mm (0.035 in.), after delivering 120,000 cubic meters (288,000 metric tons) of concrete over 30 months of service. With this demonstrated wear rate of 320,000 metric tons delivered per millimeter of thickness loss, the coated pipe has provided a 30× improvement over the previous solution—an uncoated API L80 bare casing with a wear rate of 10,500 metric tons per millimeter. Service life for the system is projected to achieve full "life of mine" duration, exceeding 19 years.
"The high hardness and toughness properties provided by our weld overlay result in the improved wear performance for this application," said Tom Santos, vice president and general manager of coatings. "Because of this, a slick line clad with our material eliminates several replacement cycles for a life of mine solution."
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The NanoSteel Company, Providence, R.I., announces that its Super Hard Steel weld hardfacing alloy has been selected by Trimay Wear Plate Ltd. as cladding within the steel piping of a concrete slick line to provide wear protection at an underground mine in northern Canada. The alloy has been shown to improve wear rate by a factor of 30 over the previous solution. Combined with Trimay’s unique casing design, this project represents the second line of identical configuration for the customer and will be installed during the first quarter of 2014.
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3D Systems acquires Solid Ink Engineering and Development teams from Xerox
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3D Systems, Rock Hill, S.C., has completed the acquisition of Xerox's Oregon solid ink engineering and development teams and state of the art development labs and relevant patent portfolio for $32.5 million in cash. As part of this agreement, 3D added more than 100 experienced Xerox engineers and contractors specializing in product design and materials science to its global R&D team, and plans to immediately begin to operate its own facility within the Xerox campus in Wilsonville, Oregon.
The company expects the acquisition to catapult its printer development and manufacturing capabilities a full decade forward and to substantially accelerate its revenue growth-rate over time.
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3D Systems, Rock Hill, S.C., has completed the acquisition of Xerox’s Oregon solid ink engineering and development teams, state- of-the-art development labs, and relevant patent portfolio for $32.5 million in cash. As part of this agreement, 3D added more than 100 experienced Xerox engineers and contractors specializing in product design and materials science to its global R&D team.
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ASB develops cold spray 3D printing and painting technology
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ASB Industries, Barberton, Ohio, has developed and patented an advanced high pressure cold spray system and related equipment that enables 3D printing and 3D painting. In this system, metal powders are sprayed onto part surfaces at high velocities to repair the surface and restore the part to its original dimensions. Applications can also include the manufacture of new parts, without the need for casting or bulk material removal.
These new parts, too, can be refurbished as needed using cold spray technology. The sprayed metal powder bonds to the existing part, for seamless repairs that can be repeated multiple times. The process makes it possible to restore parts using materials that blend in and mirror the properties of the original part itself, extending the part's working life by years or decades. ASB has been developing advanced surfacing technology since 1946. The company offers a range of comprehensive, cost-effective industrial coating solutions that enable their customers to improve operation efficiencies and reduce maintenance costs.
In addition to complete thermal spray and cold spray services, ASB also designs, develops, and manufactures high-performance cold spray technology for 3D painting and 3D printing applications.
ASB's 3D printing and 3D painting technology is useful in a variety of markets, and the company has supplied High Pressure Cold Spray technology and R&D support to some of the world's largest OEMs and industry innovators. Cold spray is used to repair and refurbish components for aerospace applications, oil and gas, electronics, medical, and more. The process has also been used to successfully restore targets and other components of sputtering equipment that are used to manufacture plasma screen televisions, smartphones, and similar devices.
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ASB Industries, Barberton, Ohio, has developed and patented an advanced high pressure cold spray system and related equipment that enables 3D printing and 3D painting. In this system, metal powders are sprayed onto part surfaces at high velocities to repair the surface and restore the part to its original dimensions. Applications can also include the manufacture of new parts, without the need for casting or bulk material removal.
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Alcoa surface treatment enables high-strength color-anodized aluminum mobile devices
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Alcoa, Pittsburgh, has developed ProStrength Finishing Technology, a surface treatment that allows mobile device manufacturers to design clear or color-anodized durable surfaces of high-strength, heat treatable aluminum alloys. High strength alloys could reduce the thickness and weight of a device by more than 50%.
"ProStrength's anodized finish creates the metallic look and feel that consumers prefer," said Ray Kilmer, Executive Vice President and Alcoa Chief Technology Officer, "and the high-strength aluminum allows manufacturers to produce thinner, lighter, and more durable enclosures."
Alcoa developed its ProStrength Finishing Technology at the Alcoa Technical Center, the world's largest light metals R&D facility located outside Pittsburgh. The company has worked with the world's leading consumer electronics companies and designers to enable the use of aluminum in mobile devices. Aluminum's penetration in the CE market has grown as OEMs look to its aesthetic qualities, light weight and ability to dissipate heat, all of which enhance the durability, performance and attractiveness of devices for consumers.
Last year, Alcoa announced another consumer electronics breakthrough with its ColorKast Die Cast Technology that is used by Samsung. As a result of this innovative technology, Alcoa can produce color anodizable aluminum die cast components with high-end cosmetics. The first use of the ColorKast technology appears on Samsung's new digital camera NX210. Other consumer electronic OEMs are preparing to apply this technology to their products.
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Alcoa, Pittsburgh, has developed ProStrength Finishing Technology, a surface treatment that allows mobile device manufacturers to design clear or color-anodized durable surfaces of high-strength, heat treatable aluminum alloys. High strength alloys could reduce the thickness and weight of a device by more than 50%.
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Direct reduced iron facility begins production at Nucor Louisiana
January 6, 2014
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Nucor Corp., Charlotte, N.C., announces the successful start-up of production at its direct reduced iron (DRI) facility in St. James Parish, Louisiana. Production began on Tuesday, December 24, and has continued at planned ramp-up levels since that time. Within the first 24 hours of operation, output quality began matching the best-in-class levels routinely achieved at the DRI plant in Trinidad.
"We are very pleased to announce this important step in executing our raw materials strategy," said John Ferriola, Nucor's President and CEO. "I want to personally thank our team in St. James Parish for their commitment and perseverance working right through the holiday season in achieving this important success."
Nucor and affiliates are manufacturers of steel products, with operating facilities primarily in the U.S. and Canada. Products produced include: carbon and alloy steel -- in bars, beams, sheet and plate; steel piling; steel joists and joist girders; steel deck; fabricated concrete reinforcing steel; cold finished steel; steel fasteners; metal building systems; steel grating and expanded metal; and wire and wire mesh. Nucor, through The David J. Joseph Company, also brokers ferrous and nonferrous metals, pig iron and HBI/DRI; supplies ferro-alloys; and processes ferrous and nonferrous scrap.
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Nucor Corp., Charlotte, N.C., announces the successful start-up of production at its direct reduced iron (DRI) facility in St. James Parish, Louisiana. Production began on Tuesday, December 24, and has continued at planned ramp-up levels since that time. Within the first 24 hours of operation, output quality began matching the best-in-class levels routinely achieved at the DRI plant in Trinidad.
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Digital image correlation system optically detects strain
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Instron, Norwood, Mass., announces digital image correlation (DIC) hardware and software designed to optically detect strain and displacement. The DIC system enables users to visualize these changes in real-time on a computer screen, so that they can be traced over the entire duration of the test.
Image and calibration data are supplied by an Instron Advanced Video Extensometer (AVE). The associated DIC-software provides visualization and also saves the data at an adjustable rate of up to 50 Hz in the form of individual images for subsequent analysis in post-processing mode. The software runs independently of other programs, and leverages the graphical layout and tabbed style of Instrons Bluehill materials testing software – making the user interface familiar and easy to use.
The DIC technology provides numerous benefits compared to traditional strain measurement, including, for example, the documentation of phenomena such as discontinuous strain, localized necking, and more. DIC enables the detection of strains and displacements in cases where conventional extensometers are impractical, and enables the visualization of the side profile of flat bending or compression specimens.
The system also reveals cracks that are not visible to the naked eye. Finally, the DIC technology helps with standard compliance, as it identifies local strain that falls outside the standard gauge length of conventional extensometers.
The DIC software comes with a large number of standard functions. These include the generation of surface maps containing information on local axial and transverse strains and displacements, shear strain, and maximum and minimum normal strain. Further standard features include saving of processing parameters, graphical processing and the capability of synchronization with Bluehill® test data such as load, crosshead position etc.
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Instron, Norwood, Mass., announces digital image correlation (DIC) hardware and software designed to optically detect strain and displacement. The DIC system enables users to visualize these changes in real-time on a computer screen, so that they can be traced over the entire duration of the test. The associated DIC-software provides visualization and also saves the data at an adjustable rate of up to 50 Hz.
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Missile canard for use in EAPS test flight
January 3, 2014
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Liquidmetal Technologies Inc., Rancho Santa Margarita, Calif., delivered missile canards that are being fitted for a future test of Lockheed Martin's (Bethesda, Md.) EAPS (Extended Area Protection and Survivability) missile, an advanced performance, highly affordable hit-to-kill missile interceptor designed to defeat rocket, artillery, and mortar (RAM) targets with significantly reduced probabilities for collateral damage.
Working in collaboration with Lockheed Martin's advanced design team, Liquidmetal's unique alloy and process methods yield parts with dimensional consistency and precision at an affordable cost. Canards made from the new alloy meet the close geometric tolerances required for supersonic flight. The parts consistently meet tolerances and the shape and weight of each part is nearly identical, which is desirable for this application. The parts also have greater strength to weight than steel or titanium. Once the design is finalized, parts can be produced in high volumes with short lead times.
"Lockheed Martin has been an ideal development partner for this breakthrough application for Liquidmetal Technologies, creating a high precision, high performance part at a lower cost," said Bruce Bromage, EVP of Business Development with Liquidmetal Technologies.
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Liquidmetal Technologies
Lockheed Martin
Liquidmetal Technologies Inc., Rancho Santa Margarita, Calif., delivered missile canards that are being fitted for a future test of Lockheed Martin’s (Bethesda, Md.) EAPS (Extended Area Protection and Survivability) missile.
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Compact modular furnace reduces heat loss by two thirds
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AP&T North America Inc., Monroe, N.C., has introduced a new energy-efficient modular furnace with automation for press hardening. The Multilayer Feeder Furnace reduces heat loss by two thirds compared to conventional roller hearth furnaces, and features several modules stacked on top of each other. Blanks are added and removed using SpeedFeeders, and stay completely motionless during the heating process. This enables a less sensitive process, making it easier to ensure a consistently high level of quality.
"In order to achieve a high level of reliability and low maintenance costs, we have simple and robust furnace modules that can be used independently of each other," says Dr. Martin Skrikerud, Vice Chief Technical Officer. "Thus, production can continue even if one of the furnace modules is not in operation."
Since the furnace does not require a roller conveyor, it needs only a third of the floor space required by a conventional solution. It is also primarily thanks to the compact dimensions that heat loss is so low. The furnace modules can be delivered with an airtight controlled atmosphere that allows several types of material and steel grades to be heated without the risk of scaling. The furnace is electric, which means simpler installation, and the disadvantages associated with combustion can be avoided entirely.
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AP&T North America Inc., Monroe, N.C., has introduced a new energy-efficient modular furnace with automation for press hardening.
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Granta announces advances from additive manufacturing projects
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Granta Design, U.K., announces Granta MI—Version 7, which includes its latest advances in simulation and materials information management for additive manufacturers to improve research, design, testing, and simulation. These developments are the result of Granta's involvement in two European Framework Seven (NanoMicro and AMAZE) projects focused on the field of additive manufacturing.
During the four-year NanoMicro project, ten partners have been developing a layer-wise manufacturing approach using highly focused powder/heat fluxes (with dimensions in the microns range) for metals and cermets. Granta's collaboration with the University of Cambridge enabled simulation work that informed the choice of build parameters in the additive manufacturing process, leading to a shorter production development time and fewer part failures. The work tested and validated Granta software as a means to apply materials models and analyze their results.
Granta is also a partner in the ongoing project "Additive Manufacturing Aiming Towards Zero Waste & Efficient Production of High-Tech Metal Products" (AMAZE). Led by the European Space Agency, this 30-partner project seeks to rapidly produce large defect-free additively-manufactured metallic components up to two meters in size for aeronautics, space, nuclear fusion, automotive, and tooling. The goal is a 50% reduction in power, consumables, raw materials, machining, and cost for finished parts, compared to traditional processing.
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Granta Design, U.K., announces Granta MI—Version 7, which includes its latest advances in simulation and materials information management for additive manufacturers to improve research, design, testing, and simulation.
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