Hybrid additive manufacturing facility speeds application development and time to market
August 1, 2019
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Engineers from Polycontrols, Canada, and the National Research Council Canada, presented “Cold Spray Technology Into Industry: A New Hybrid Additive Manufacturing Centre to Address Production and Industrialization Challenges†at the ASM International ITSC 2019 conference in May.
Over the past two decades, cold spray has developed from a laboratory deposition technique to an established technology for numerous tailored applications in the military, aerospace, and energy sectors. However, its unique benefits as a coating and as an additive manufacturing process can potentially be leveraged to many more and diverse industries.
To realize such new opportunities, industries require better and broader access to the technology for application development, demonstration, and product validation. To bridge the gap from research centers to industrialization in a wider and more diversified market, a new Hybrid AM Facility has been created.
This state-of-the-art industrial facility integrates cold spray additive manufacturing (CSAM), in-situ machining, advanced robotics, and digital manufacturing concepts. At this facility, known as Poly/CSAM, companies can benefit from partnering with subject-matter experts in a confidential and customized production environment to address specific manufacturing and industrialization challenges, de-risk investment, and reduce time to market. Systematic data collection allows engineers to analyze performance and to evaluate costing and product quality in pre-production.
Current and projected activities include additive manufacturing of large-scale freeform stiffening structures; pre-production of high-volume and massive components, advanced CAD/CAM supported toolpath, build strategies and in-situ machining strategies for complex structures, near net-shape parts, and large components.
Mr. Luc Pouliot, Mr. Sylvain Desaulniers, Fernanda Caio, Polycontrols, Brossard, Quebec www.polycontrols.com
Jörg Oberste Berghaus, National Research Council Canada, Boucherville, Quebec
https://www.asminternational.org/web/itsc-2019/home
Engineers from Polycontrols, Canada, and the National Research Council Canada, presented “Cold Spray Technology Into Industry: A New Hybrid Additive Manufacturing Centre to Address Production and Industrialization Challenges” at the ASM International ITSC 2019 conference in May.
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Tecnar diagnostic tool enables monitoring particles during suspension plasma spray
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Engineers from Tecnar Automation and Concordia University, both of Quebec, presented “Accuraspray 4.0 to Characterize In-flight Particles in the SPS Process.†Suspension plasma spray (SPS) is a thermal spray technology that is in the process of being transitioned from research and development centers to everyday production lines. Monitoring the characteristics of in-flight particles during the coating process is essential for two domains, and it improves the repeatability and reproducibility of results.
Accuraspray 4.0 is a new version of a diagnostic tool in its family adapted for the SPS process to measure velocity and temperature of the in-flight particles. Previous versions of the system were specialized for monitoring atmospheric plasma spray (APS), and they used double point measurement to calculate the temperature. However, in the new version, the temperature reading has been improved by applying a single point measurement and enhanced signal filtering.
In this paper, temperature and velocity of the in-flight particles were measured and compared by two versions of Accuraspray. Validity of the temperature measurement was investigated by studying collected splats. The size and shape of splats was correlated to the online acquired temperature. This study showed that the new diagnostic system was correctly adjusted to the small size of particles and severe plasma spray.
Authors:
Mr. Ali Akbarnozari , Concordia University, Montreal, QC, Canada
Mr. Olivier Bamber , Mr. Jean-David Grenon , Mr. Marc Choquet , Mr. Luc Pouliot, Tecnar Automation Ltd., St-Bruno, QC, Canada www.tecnar.com
Prof. Christian Moreau , Concordia University
https://www.asminternational.org/web/itsc-2019/home
Engineers from Tecnar Automation and Concordia University, both of Quebec, presented “Accuraspray 4.0 to Characterize In-flight Particles in the SPS Process.”
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Spray Tips: Wire and Rod Feeders for Thermal Spray
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Materials that can be thermally sprayed include polymers, metals, metal alloys, intermetallics, ceramics, and composites. The feedstock material can take the form of wire, rod, powder, or, with emerging solution spraying, liquid and complex gases. This leads to two basic types of feed systems: one that feeds wires or rods, and another that feeds particulates.
Wire and rod feeders are simple mechanical devices consisting of electrical or air-driven motors, drive rolls, and associated speed controls. Wires and rods must be fed continuously and uniformly into the flame or arc.
The injection point of the wire/rod, and the feed rate are extremely important in controlling the coating quality. Uniformity of feed depends on motor drives having sufficient torque to overcome friction within the system, and in the case of wires, from the wire spools.
Drive roll design is another important aspect of uniform feed. Drive rolls must grip the wire/rod sufficiently to prevent slipping while not deforming the wire or crushing the rod. Drive rolls vary according to the wire properties. Rolls are usually made from metal or fiber-reinforced phenolic. Phenolic rolls are used for ceramic rods, whereas metal rolls are used for wires. Metal rolls can be knurled for hard wires or grooved for softer wires; many variations exist.
Figure 1 illustrates two concepts: V-groove and knurled.
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 Fig. 1.
https://dl.asminternational.org/handbooks/book/12/chapter/132769/Process-Control-and-Control-Equipment
https://dl.asminternational.org/handbooks/book/12/chapter/132769/Process-Control-and-Control-Equipment
Materials that can be thermally sprayed include polymers, metals, metal alloys, intermetallics, ceramics, and composites. The feedstock material can take the form of wire, rod, powder, or, with emerging solution spraying, liquid and complex gases. This leads to two basic types of feed systems: one that feeds wires or rods, and another that feeds particulates.
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Haynes Ni-Mo-Cr-W alloy designed for low thermal expansion at 1400°F in gas turbines
July 31, 2019
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Haynes International, Kokomo, Ind., announces that it has new alloy data for Haynes 244, a new Ni-Mo-Cr-W alloy developed for static parts in advanced gas turbine engines that require low thermal expansion at temperatures up to 1400°F.
Alloy 244 offers a higher maximum service temperature than other low thermal-expansion alloys currently available, including a 100 to 200°F improvement over Haynes 242 alloy. The alloy is age-hardenable by formation of Ni2 (Cr,Mo,W) domains, which are structurally similar to the strengthening domains in 242 alloy. Judicious alloying with tungsten increased the thermal stability of these domains and lowered the coefficient of thermal expansion. Other important properties such as oxidation resistance and low-cycle fatigue performance are comparable to or better than those of the 242 alloy.
The 244 alloy exhibits very good oxidation resistance at temperatures up to 1400°F, and should not require protective coatings for continuous or intermittent service at these temperatures. The alloy is not specifically designed for service at higher temperatures, but can tolerate short-term exposures.
To view Haynes data, please click here.
www.haynesintl.com
Haynes International, Kokomo, Ind., announces that it has new alloy data for Haynes 244, a new Ni-Mo-Cr-W alloy developed for static parts in advanced gas turbine engines that require low thermal expansion at temperatures up to 1400°F.
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Steel Dynamics to invest $1.9 billion to build EAF flat roll steel mill in Texas
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Steel Dynamics Inc., Fort Wayne, Ind., announces that it has selected Sinton, Texas, as the site for its new state-of-the-art, electric-arc-furnace (EAF) flat roll steel mill, with construction to begin in early 2020. The current estimated required investment is approximately $1.9 billion, which does not include the benefit of anticipated state and local incentives.
Sinton is located approximately 30 miles Northwest of the port of Corpus Christi, within the targeted Southwest United States and Mexico market regions, bringing numerous advantages to the project. Final determination is still subject to the anticipated receipt of necessary permits and continued state and local government support, which the company expects to be forthcoming.
"We have been developing a flat roll steel business strategy for this region and Mexico for several years," says Mark. D. Millett, President and Chief Executive Officer. “Our planned new EAF flat roll steel mill will be the most technologically advanced facility existing today. Our team has selected a suite of technologies that should allow us to achieve steel grades previously out of reach to thin-slab casting technology. Based on casting capability of up to 84 inches wide and up to a 5.5-inch cast thickness, it will be the world's largest thin-slab facility.â€
The steel mill will also have a unique rolling mill configuration, providing the capability to produce Advanced High Strength Steel grades, including some energy-sector products not available in the United States today. The mill will also have the capability to produce up to 52.5 ton coils, creating meaningful cost efficiencies for certain energy customers. These advances will further reduce the gap between existing EAF and integrated steel mill production capabilities.â€
The project will include value-added finishing lines, including a galvanizing line with an annual capacity of 550,000 tons, and a paint line with an annual coating capacity of 250,000 tons. The product offering is anticipated to include various flat roll steel products, including hot roll, cold roll, galvanized, Galvalume® and painted steel, primarily serving the energy, automotive, construction, and appliance sectors.
www.steeldynamics.com
Steel Dynamics Inc., Fort Wayne, Ind., announces that it has selected Sinton, Texas, as the site for its new state-of-the-art, electric-arc-furnace flat roll steel mill, with construction to begin in early 2020.
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Space robot to demonstrate additive manufacturing and assembly in near-Earth orbit
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Made In Space Inc., Moffett Field, Calif., announces that NASA’s Space Technology Mission Directorate has awarded the company a contract to demonstrate its autonomous robotic manufacturing and assembly platform, Archinaut, on a flight mission. The contract award marks the second phase of the NASA-funded Archinaut technology development program that was initially awarded in 2016.
This flight demonstration contract award follows a successful ground-based testing campaign of Archinaut’s core additive manufacturing and robotic technologies, qualifying the Archinaut platform for spaceflight.
“Autonomous, robotic manufacturing and assembly will reshape the landscape of space exploration and space infrastructure and we are taking a monumental step towards that future,†says Andrew Rush, MIS president and CEO. “Through our partnership with NASA, we will build a space-optimized asset on-orbit, for the first time, that will prove the efficacy of this technology, reduce the risk posture, and manifest new opportunities for in space manufacturing.â€
The objective of Archinaut’s flight demonstration mission, dubbed Archinaut One, is to construct two 10-meter solar arrays, on orbit, to power an ESPA-class satellite. Once on orbit, Archinaut One will employ its extended-structure additive manufacturing capabilities and advanced robotics to manufacture and assemble the satellite’s power system. The Archinaut-built solar arrays will yield nearly five times the power currently available to ESPA-class satellites.
In support of Archinaut’s flight demo mission, MIS will continue its partnership with Northrop Grumman while involving other companies and universities to successfully demonstrate this transformational technology. Northrop Grumman supported Archinaut development during phase I of the program.
www.madeinspace.us
Made In Space Inc., Moffett Field, Calif., announces that NASA’s Space Technology Mission Directorate has awarded the company a contract to demonstrate its autonomous robotic manufacturing and assembly platform, Archinaut, on a flight mission.
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Oerlikon Metco acquires AMT to focus and expand its market applications and services
July 30, 2019
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Oerlikon Metco, Switzerland, announces that an agreement has been signed to acquire AMT AG, a Swiss company that designs and builds integrated thermal spray coating systems. The acquisition is in line with Oerlikon’s strategy to focus and expand its surface solution technologies while increasing market applications and service accessibility to customers.
AMT AG will become part of the Oerlikon Metco Aero & Energy business unit, but will continue to operate as AMT AG until the end of 2020. “We are convinced that by combining Oerlikon Metco’s surface solutions portfolio and innovation power with the technology know-how and customized customer approach of AMT, we will be able to explore new business opportunities and to open up new markets,†said Dr. Wolfgang Konrad, Head Business Unit Metco Aero & Energy.
“As part of Oerlikon, AMT has the financial backing of a large corporation with access to capital to invest in growth, as well as gaining access to Oerlikon's application development and R&D resources,†states Dr. Alexander Schwenk, CEO of AMT AG.
“The acquisition is highly complementary with our current portfolio of thermal spray equipment,†added Carsten Schultes, Oerlikon Metco’s Head of Equipment Business. “AMT has established a competitive differentiation through its flexible and focused customer approach. We look forward to working with them and leveraging their expertise to further propel growth and to strengthen our market position in thermal spray.â€
www.oerlikon.com/metco
www.amt-ag.com
Oerlikon Metco, Switzerland, announces that an agreement has been signed to acquire AMT AG, a Swiss company that designs and builds integrated thermal spray coating systems.
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Zeiss adds ToF SIMS detection capability to Crossbeam 350/550 FIB-SEM microscopes
July 26, 2019
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Zeiss, Germany, introduces advancements in analytics, tomography, sample preparation, and data integrity for its new Crossbeam 350 and 550 focused ion beam SEM microscopes, as well as new time-of-flight secondary ion mass spectrometry (ToF-SIMS) detection. (The image shows nanoforsterite, Mg2SiO4.) This brings new possibilities in engineering materials, energy materials, soft materials, and geosciences, covering megatrends in additive manufacturing, battery and photovoltaic research, building materials, and nanomaterials.
As part of the introduction of its new focused ion beam scanning electron microscope (FIB-SEM), the Crossbeam 350, Zeiss introduces enhanced workflows for 3D tomography to ensure class-leading 3D data volume generation. Quantified and calibrated measurement of z-slice thickness allows for near-perfect reconstruction of tomogram slices into a reconstructed volume. An update of the Atlas 5 hardware and software package improves 3D analysis (static electron backscatter diffraction (EBSD)), correlative workflows, and definition of slice thickness. This so-called “True Z technology†ensures high quality FIB-SEM tomography.
The new loading station and sample holder for transmission electron microscopy (TEM) lamella preparation brings more ease-of-use to the TEM lamella preparation workflow, and ensures a smooth transition of the sample to the TEM for further analysis.
High-speed and high-quality data acquisition are further complemented with a release of Zeiss ZEN Intellesis, a machine learning-based segmentation software. Crossbeam 3D datasets are fully compatible with this suite of image processing and segmentation software. This ensures that data integrity is maintained as data acquisition speed and quality are improved. Texture-based classification provided by this software enables previously hidden information to be extracted from samples ranging from fiber composites to reservoir rocks.
www.zeiss.com/newsroom
Zeiss, Germany, introduces advancements in analytics, tomography, sample preparation, and data integrity for its new Crossbeam 350 and 550 focused ion beam SEM microscopes, as well as new time-of-flight secondary ion mass spectrometry (ToF-SIMS) detection.
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Buehler’s AbrasiMet M cutter features 10- to 12-inch blades, enclosed cutting arm
July 25, 2019
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Buehler, Lake Bluff, Ill., introduces the AbrasiMet M Medium abrasive cutter, a compact tabletop manual saw with a powerful 5.5 hp motor designed for heavy use. It has a sliding hood design, and can accommodate 10- to 12-inch blades inside a maximized cutter chamber space.
The casting is designed to be durable, with a corrosion-resistant steel T-slot table. The hood design is reinforced for repeated opening/closing, and the enclosed motor/cutting-arm system keeps debris and coolant out to maximize life of the motor.
Lab technicians can reduce cutting time and change blades easily without tools. In addition, cleaning the new high-capacity, 30-gallon recirculation tank is simplified with its nested tank and filtration screen design, complete with a rugged metal frame with wheels. The AbrasiMet M saves time in the sectioning process in busy production environments, allowing users to quickly move to the next steps of the preparation process.
In designing the AbrasiMet M, Buehler engineers:
Increased chamber space by locating the motor outside of the cutting chamber;
Optimized RPM settings for 10- and 12-inch abrasive blades to maximize cut quality;
Increased visibility by adding bright LED light strips;
Enhanced user ergonomics with adjustable cutting arm handle;
Ensured parallel cuts for difficult-to-vise parts with dual blade application; and
Improved cleanability with easy-access valve and washdown hose.
https://www.buehler.com/abrasimet-m-manual-abrasive-cutter.php
Buehler, Lake Bluff, Ill., introduces the AbrasiMet M Medium abrasive cutter, a compact tabletop manual saw with a powerful 5.5 hp motor designed for heavy use.
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Höganäs launches iron-based Rockit welding powders to combat impact/abrasive wear
July 24, 2019
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Höganäs AB, Sweden, launches its new Rockit 606/706 welding powders, which prolong component lifetime in tough wear environments such as the oil & gas and mining & construction industries. The new welding powders feature a unique combination of high impact and abrasive wear resistance, and are robust to process variations. Rockit 606 is recommended for laser cladding, while Rockit 706 is the suitable choice for the plasma transferred arc (PTA) welding process.
“Rockit 606/706 are iron-based and have a martensitic structure with finely dispersed vanadium carbides,†says Hans Keller, President of Product Area Surface & Joining Technologies at Höganäs. “This combination provides excellent wear characteristics and a consistent high hardness, together with a good impact resistance. The materials have excellent welding properties and achieve a smooth deposit.â€
“Rockit 606/706 applied on wear plates for dozer blades during field tests showed that cladding material costs can be reduced by 30%, while maintaining the same lifespan achieved with other industry solutions,†says Martin Lohrman, application specialist at the Höganäs ArcX coatings center in Johnstown.
With this product launch, Höganäs adds new materials to the Rockit family, a series of specialty alloys to extend component lifetime. “We are building on the success of the previously launched Rockit 401 material, a sustainable solution to replace hard chrome plating. The material has quickly become a standard in the mining and construction industry,†says Mr. Keller.
Rockit is part of Höganäs’ extensive portfolio of surface coating solutions that grew rapidly through its acquisition of H.C. Starck’s Surface Technology division in 2018.
www.hoganas.com
Höganäs AB, Sweden, launches its new Rockit 606/706 welding powders, which prolong component lifetime in tough wear environments such as the oil & gas and mining & construction industries.
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