Ipsen develops heat treating technologies for additively manufactured parts
October 1, 2019
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Peter Kerbel of Ipsen USA, Cherry Valley, Ill., will discuss heat treating procedures that Ipsen has developed for additively manufactured parts in collaboration with AM component manufacturers, at Heat Treat 2019. As the industry works to optimize mass production, it is necessary to develop safe, reliable, and repeatable additive manufacturing solutions.
The focus on additive manufacturing is at an all-time high, which means innovators need innovative heat treating solutions for additively manufactured components. Collaborative efforts in which furnace manufacturers work with component manufacturers to understand the process, result in the best possible outcomes.
In this presentation, Mr. Kerbel provides information for those interested in 3D printing for additive manufacturing, so that they will consider the critical role heat-treating plays in this rapidly growing industry.
Presentation title: “Balancing the Speed and Technology of Additive Manufacturing with the Mature and Methodical Thermal Processing Industry.â€
Author: Mr. Pete Kerbel, Ipsen USA, Cherry Valley, Illinois
Tuesday, October 15, 2019: 2:40 PM
251A (TCF Center), Detroit
https://www.asminternational.org/web/heat-treat-2019
Peter Kerbel of Ipsen USA, Cherry Valley, Ill., will discuss heat treating procedures that Ipsen has developed for additively manufactured parts in collaboration with AM component manufacturers, at Heat Treat 2019.
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Seco Vacuum multi-chamber vacuum systems reduce carburizing gas consumption
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Don Marteeny, Technical Director at Seco Vacuum Technologies, Meadville, Pa., will present a discussion of multi-chamber vacuum systems developed for high-throughput, highly precise low-pressure carburizing applications at Heat Treat 2019.
Compared with traditional gas carburizing in continuous or batch integral quench atmosphere style furnaces, low-pressure carburizing (LPC) run in modern vacuum furnaces reduces carburizing gas consumption while providing more consistent results when considering case depth, surface hardness, and core hardness. Multi-chamber furnaces provide this level of precision, while also maintaining the high production level required in automotive or aerospace applications.
To understand the potential benefits of these systems, two sample applications will be presented using a triple chamber semi-continuous vacuum carburizing system. Both oil and gas quenching capabilities are considered. The results show the semi-continuous, triple chamber design is capable of similar results, if not superior, while providing increased productivity and uptime versus more traditional multi–furnace or continuous furnace systems.
Title: “Triple Chamber Vacuum Furnace Systems – The Low Pressure Carburizing Workhorseâ€
Speaker: Don Marteeny, Seco Vacuum Technologies Technical Director
Thursday, October 17, 2019 at 10:20 am in Room 251C (COBO Center)
https://www.asminternational.org/web/heat-treat-2019
Don Marteeny, Technical Director at Seco Vacuum Technologies, Meadville, Pa., will present a discussion of multi-chamber vacuum systems developed for high-throughput, highly precise low-pressure carburizing applications at Heat Treat 2019.
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One Minute Mentor: Effect of tempering temperature on Type 440C
September 26, 2019
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The graph (Figure 18) shows the effect of tempering temperature on the hardness and retained austenite content of Type 440C stainless steel austenitized at 1065°C (1950°F). To achieve maximum corrosion resistance, it should be tempered at lower temperatures, avoiding tempering near the secondary-hardening temperatures.
Very rapid quenching (oil or gas) is necessary to avoid grain boundary precipitation of chromium carbides, which also have an adverse effect on corrosion resistance. BG-42 typically is used in high-temperature applications where hot hardness (high-temperature hardness) and corrosion resistance are required. A typical thermal treatment designed for high-temperature applications for BG-42 is:
Austenitize 1115–1130°C (2040–2065°F) 30 min + 30 min/each additional inch of thickness, salt bath or in vacuum under partial pressure of argon;
Quench in oil to room temperature, or in salt to 565°C (1050°F), then AC to room temperature;
Snap temper 150°C (300°F) for one hour;
Subzero cool to −75°C (−100°F);
Double temper at 525°C (975°F) for two hours.
For more information, click on the link below (subscription required), then scroll down the Chapter Contents column on the left of the page, and click on "Special Purpose Through-Hardening Bearing Steels."
https://dl.asminternational.org/handbooks/book/9/chapter/110017/Heat-Treatment-of-Bearings
The graph shows the effect of tempering temperature on the hardness and retained austenite content of Type 440C stainless steel austenitized at 1065°C (1950°F).
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Excillum Metaljet X-ray tube replaces solid anode with molten metal jet for longer life
September 25, 2019
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Excillum AB, Sweden, has developed the MetalJet x-ray tube, in which a conventional microfocus tube with a solid-metal anode, is replaced by a liquid-metal jet. This type of anode is continuously regenerated and already in the molten stage. Therefore, the classical power limit of an x-ray source, reached when the anode is permanently damaged by the electron beam, may be disregarded. Especially in the microfocus x-ray spot size range, from about 5 µm diameter to a few tens of µm, a source based on a liquid-metal-jet anode significantly outperform a classical solid anode x-ray source.
Excillum has now launched Dynamic Adaptation technology on its MetalJet range of x-ray sources. The technology enables MetalJet market-leading brightness for even longer operational periods. For industrial applications such as metrology, inspection, or nondestructive testing of automotive, aerospace, medical, and semiconductor components, the continuous and reliable operation of the test equipment is key.
Dynamic Adaptation technology continuously adapts the e-beam to the natural aging of the cathode. The development of the technology has been possible based on the experience and expertise that Excillum has gained in the area of advanced e-beam control. Dynamic Adaptation technology can enable more than one-year of 24/7 continuous operation (i.e. >8000 hours) before any cathode exchange is required.
This significant improvement will provide improved performance, reduced downtime, and lower operational cost. Dynamic Adaptation is from now on included in new MetalJet x-ray source shipments, and existing MetalJet sources can be upgraded to include the new technology.
www.excillum.com
Excillum AB, Sweden, has developed the MetalJet x-ray tube, in which a conventional microfocus tube with a solid-metal anode, is replaced by a liquid-metal jet.
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Fraunhofer builds functioning scale model of gas turbine via additive manufacturing
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The Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM) in Germany, reports that it has developed a fully-functional, true-to-scale gas turbine that demonstrates the potential and limitations of powder bed-based additive manufacturing technologies.
The demonstrator Siemens SGT6-8000 H, is a 1:25 scale model of a gas turbine for power generation. It was completely manufactured with additive processes in all areas except for the shaft. The component assembly consists of 68 parts made of aluminum, steel, and titanium. Through component optimization and the possibilities of Electron Beam and Laser Powder Bed Fusion (EB-PBF and L-PBF) technologies, these 68 parts replace the almost 3000 individual parts that make up the original component.
Fraunhofer IFAM was involved in the manufacturing of the component as well as the data modification for the technology-adapted production. The housing components, with stator stages, were manufactured directly on site at the Innovation Center Additive Manufacturing ICAM in Dresden using EB-PBF of Ti-6Al-4V in a GE Additive Arcam EBM Q20+ machine. The turbine stages and the other housing components were manufactured at H+E using L-PBF.
The components were modified constructively in order to be able to manufacture the turbine ‘first time right’. For example, it was made possible to manufacture the 316L housing segment by L-PBF without support structure.
www.ifam.fraunhofer.de
www.hedd.de
The Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM) in Germany, reports that it has developed a fully-functional, true-to-scale gas turbine that demonstrates the potential and limitations of powder bed-based additive manufacturing technologies.
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ASTM International supports research projects for additive manufacturing standards
September 24, 2019
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ASTM International, Conshohocken, Pa., announces its second round of funding to support research that helps expedite standards in additive manufacturing. This investment of $300,000 and in-kind contributions will support ASTM International Additive Manufacturing Center of Excellence’s goal of addressing pressing needs for technical standardization in this fast-growing industry. This round, approved by an ASTM International subcommittee, is focused on research and innovation and targets a vast array of topics.
“We are funding some of the most crucial and high-impact research projects in additive manufacturing to accelerate standardization,†said Dr. Mohsen Seifi, ASTM International’s Director of Global Additive Manufacturing Program. He added that these projects will complement the previous round of five projects, with all contributing towards a holistic approach to fill standard gaps in design, feedstock, process, post processing, testing, and qualification.
Auburn University will work to implement a rapid, efficient, and effective inspection process to detect potential part quality issues after fabrication through laser powder bed fusion (L-PBF). The study aims to identify and quantify deviations in build and material quality through a series of tests performed within a few hours after the part is removed from the 3D printing machine.
Applied technology developer EWI aims to leverage overall advances in digital data acquisition, automation, and data analysis. EWI will work to define a minimum subset of AM data entries and taxonomy of those entries. The resulting standard will help establish best practices for data sharing, a common data dictionary for AM, and a data management roadmap that integrates stakeholder needs.
Wichita State University’s National Institute for Aviation Research (NIAR) will gather information from existing polymer characterization activities to create a test plan and matrix incorporating the state of the art for these testing methods. Additional print, test, and analysis will be conducted to generate additional data. NIAR will share results and develop appropriate documentation based on its findings.
www.amcoe.org.
ASTM International, Conshohocken, Pa., announces its second round of funding to support research that helps expedite standards in additive manufacturing.
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Spray Tips: Fluidized-bed powder feeders
September 22, 2019
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In fluidized-bed powder feeders, a bed of powder is continuously agitated by a fluidizing gas, in this case the carrier gas. The intent by design is to suspend a controlled volume of powder in a bed using a controlled volume of gas such that a sample of powder can be drawn off at a uniform rate.
To accomplish this, the bed must be in continuous motion—that is, fluidized—and the volumes of gas and powder being removed must be continuously replaced. Vibrators and/or gravity feed are used to assist and maintain flow from the hopper into the bed. Figure 4 also illustrates how the powder-laden carrier gas is aspirated through openings in the carrier-gas tube, using the venturi effect created by gas flowing through the tube.
Powder feed rate in fluidized-bed feeders is affected by powder characteristics and particle size distribution. The degree to which a particle size distribution can be suspended in the bed and carried away by the carrier gas flow is determined by the drag forces exerted by the carrier gas.
Powder may fall out at a given carrier gas flow, if the particle size is too large or too dense. In addition, particle mass, size, and morphology determine how quickly powders can be aspirated and reach the carrier-gas flow velocity. Smaller, lighter, and/or irregularly shaped particles move faster and are carried out of the bed before larger, denser, or spherical par
This information is from ASM Handbooks Online, Vol. 5A Thermal Spray Technology, Coating Structures, Properties, and Materials. To find this information (subscription required), click on the link below and scroll down to Figure 4.
https://dl.asminternational.org/handbooks/book/12/chapter/132769/Process-Control-and-Control-Equipment
In fluidized-bed powder feeders, a bed of powder is continuously agitated by a fluidizing gas, in this case the carrier gas.
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Wisconsin Oven Ferris wheel batch oven contains 20 rotating spindles for part rotation
September 19, 2019
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Wisconsin Oven Corp., East Troy, announces that it has built an electrically heated heavy duty Ferris wheel batch oven for a manufacturer in the aerospace industry to cure epoxy resins and varnishes on assorted aerospace parts.
"The Ferris wheel inside the oven chamber will run continuously to process the product load," says Tom Trueman, Senior Applications Engineer. "It is 34 inches in diameter and contains twenty rotating spindles for part rotation."
The design capacity of the Ferris wheel batch oven, when the configuration of the workload is such that it is capable of absorbing the heat, has sufficient capability to heat 200 pounds of product to a specified temperature range within two hours. The body of the oven is constructed with Wisconsin Oven’s patented, high efficiency panel seams. This includes a 20-gauge carbon steel exterior and a 20-gauge aluminized steel interior.
The maximum operating temperature is 500°F, and the work chamber dimensions are 3.3 x 3.5 X 3.5 feet. The furnace is heated by Incoloy-sheathed tubular heating elements for a total of 72 kW.
www.wisoven.com
Wisconsin Oven Corp., East Troy, announces that it has built an electrically heated heavy duty Ferris wheel batch oven for a manufacturer in the aerospace industry to cure epoxy resins and varnishes on assorted aerospace parts.
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Seco Vacuum dual-chamber hybrid furnace provides low pressure carburizing/hardening
September 16, 2019
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Seco Vacuum Technologies, Meadville, Pa., is supplying its signature CaseMaster Evolution dual-chamber vacuum oil quench furnace to an aerospace equipment manufacturer to improve lead times and quality objectives. SVT is working with the company to bring its low-pressure carburizing and hardening work in-house.
“We developed the CaseMaster Evolution to help customers in aerospace and other critical industries solve some of the more challenging issues with traditional integral-quench furnaces, as well as to produce clean parts typical of vacuum furnaces,†says Maciej Korecki, VP Vacuum Heat Treatment Furnaces, Seco Warwick. “So, the CMe is a hybrid combining the best of both worlds, resulting in clean parts from a nontoxic work environment, providing greater repeatability of workloads, with no CO/CO2 emissions, exhaust hoods, or endothermic generators.â€
The CaseMaster Evolution vacuum oil quench furnace is uniquely positioned to improve efficiency in many heat treatment operations by providing multi-chamber capabilities. These include a sealed oil and gas quench chamber that opens new processing opportunities for heat treaters. The CMe utilizes one chamber for vacuum heat treatment, and a second chamber for oil or gas quenching.
In contrast to the company’s current procedure – brining in vacuum LPC and hardening – the CMe’s vacuum LPC heating and quench chambers produce uniform, bright, and high quality parts at high-speeds for an economical workflow, all while using very low consumption of processing media.
www.secovacusa.com
Seco Vacuum Technologies, Meadville, Pa., is supplying its signature CaseMaster Evolution dual-chamber vacuum oil quench furnace to an aerospace equipment manufacturer to improve lead times and quality objectives.
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Lindberg three-chamber furnace integrated with robot transfer and hydraulic press
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Lindberg MPH, Riverside, Mich., has built an integrated, stacked, three-chamber furnace that offers a significantly smaller footprint than a continuous system. Supplied to a hot-stamping company, the furnace features three independent heating zones per chamber, which allows for multiple blanks to be preheated simultaneously, resulting in reduced cycle times.
The unique stacked design offers a significantly smaller footprint compared to a continuous system. The installed furnace is integrated with a robotic transfer system and a hydraulic press, and the system features fully automated cells with PLC controls and optional data acquisition.
Lindberg hot stamping furnaces provide uniform heating for a wide range of high-strength steels or aluminum materials prior to hot stamping or hydroforming operations. They are available in batch or multiple batch configurations, and are designed to heat any structural size or shape part. They can be designed with rapid and selective heating areas, fast-opening doors to meet any loading/unloading speeds, and data acquisition systems for full process reporting.
https://www.lindbergmph.com/heat-treat-furnaces/hotstamping-press-hardening-furnace
www.lindbergmph.com
Lindberg MPH, Riverside, Mich., has built an integrated, stacked, three-chamber furnace that offers a significantly smaller footprint than a continuous system.
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