Carpenter Technology, BMT Aerospace partner to produce additively manufactured parts
June 16, 2019 Source: ASM International
Carpenter Technology Corp., Philadelphia, and Belgium-based BMT Aerospace announce that they are cooperating in the development of an additively manufactured aerospace pinion made of Carpenter’s Custom 465 Stainless.
Continue readingSeco Warwick introduces new integral quench furnace and gas quench system
June 13, 2019 Source:
Seco Warwick, Meadville, Pa., introduces its Super IQ integral quench furnace and UCM 4D Quench system.
The Super IQ (integral or sealed quench furnace), offers all of the benefits of low pressure carburizing and vacuum hardening, with none of the added costs. The system combines clean processing with the exceptional performance of oil quenching in the industry’s most innovative integral quench furnace design in decades. With a Super IQ, users get super clean parts while still getting the benefit of a simple atmosphere oil quench.
The UCM 4D Quench enables customers with gas quenchable materials to replace oil quenching with an environmentally friendly, cost-effective technology. It provides a solution that eliminates the need for press quenching systems and the problems associated with their operation. First, no more finishing treatment is needed to remove the oxidized layer. Second, it provides parts with higher surface quality and savings due to eliminating the need for heat treatment fixtures and material logistics. Third, it eliminates oil and oil vapor contamination, ensuring personnel safety and reduced environmental impact in addition to eliminating washers and chemicals.
Seco Warwick, Meadville, Pa., introduces its Super IQ integral quench furnace and UCM 4D Quench system.
Continue readingSolar Atmospheres 14-foot car-bottom air furnace can treat loads up to 30,000 pounds
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Solar Atmospheres of Western PA, Hermitage, recently installed a 14-foot long car bottom air furnace for the tempering of large tool steel components, as well as the age hardening processes of nickel-based alloys and precipitation hardenable stainless steels.
The furnace was surveyed in accordance with AMS2750 Rev E and is uniform within ±10°F (Class 2). With a working zone measuring 60 x 54 x 168 inches, the furnace is capable of handling workloads up to 30,000 pounds and feataures maximum operating temperature of 1400°F.
According to Bob Hill, President of Solar Atmospheres of Western PA, “This new air tempering furnace will be a good complement its larger counterpart, a recently installed 20-foot car bottom furnace. Expanding our large air furnace capability will enhance the turnaround for our ’raw material’ customers, and is more cost-effective than processing in a vacuum environment.â€
Solar Atmospheres of Western PA, Hermitage, recently installed a 14-foot long car bottom air furnace for the tempering of large tool steel components, as well as the age hardening processes of nickel-based alloys and precipitation hardenable stainless steels.
Continue readingOne Minute Mentor: Martensitic heat treating
June 12, 2019 Source:
The graph shows the tempering response of hardened 52100 bearing steel. In North America, the 1C-1.5Cr through-hardening steel was given the designation of 52100. One of the main reasons this steel became popular as a bearing steel is its consistent response to salt-bath and furnace heat treatment and oil quenching (assuming the incoming raw material conditions met hardness, microstructure, and grain size specifications).
The standard heat treating cycle for martensitic hardening of 52100 bearing steel is:
Austenitize 815–855C (1500–1570F) 15–40 min + 30 min for each additional inch of thickness, endo or neutral atm with 0.9–1 C potential;
Quench ≤150C (300F) agitated oil (martensitic hardening); ≥230C (445F) molten salt (bainitic hardening)
Temper 150–230C (300–445F) 2–4 h (58–64 HRC).
As-quenched hardness after heat treating is typically 64–67 HRC. Figure 1 shows hardness as a function of tempering temperature.
The goal of tempering 52100 bearing steel is to achieve a measure of toughness in the steel while maintaining high as-tempered hardness. A bearing must have a minimum hardness of 58 HRC to achieve the expected rolling contact fatigue performance in service. This requirement dictates a maximum tempering temperature of 260°C (500°F).
Another goal of tempering bearing steels is to achieve the required level of dimensional stability as described in specification DIN-623. This topic is discussed more thoroughly in an upcoming section.
For more information, click on the link below (subscription required), then scroll down the Chapter Contents on the left of the page, and click on Martensitic Heat Treating.
https://dl.asminternational.org/handbooks/book/9/chapter/110017/Heat-Treatment-of-Bearings
The graph shows the tempering response of hardened 52100 bearing steel.
Continue readingArcast produces titanium powder with zero risk of ceramic/oxide contamination
June 11, 2019 Source:
Arcast Inc., Oxford, Maine, reports that it has successfully produced a titanium superalloy powder with an as-atomized D50 of 20 µm, with narrow size distribution and with little-to-no oxygen pickup.
The alloy was produced using Arcast’s proprietary atomizing process. This process consumes relatively little gas, and has zero risk of ceramic/oxide contamination, the company states, making it possible to process metal alloys which other methods cannot.
Arcast stated that the new alloy is now being produced in significant quantities. With its growing capacity to produce as-atomized, advanced titanium alloys (along with other challenging metal alloys) from a range of low-cost feedstock, Arcast states that it can offer a complete solution for additive manufacturing, metal injection moulding and other powder metallurgy markets.
Arcast Inc., Oxford, Maine, reports that it has successfully produced a titanium superalloy powder with an as-atomized D50 of 20 µm, with narrow size distribution and with little-to-no oxygen pickup.
Continue readingITSC 2019 presentation: Solid-State Additive Manufacturing
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Inovati, Santa Barbara, Calif., presented a discussion about the application of its impact consolidation Kinetic Metallization (KM) process to an advanced and superior 3D manufacturing technology.
When integrated with CAD/CAM, Inovati characterizes this new technology as Solid-State Additive Manufacturing (SSAM). This innovative spray deposition process provides unique opportunities for development of a 3D fabrication technique with material properties not currently feasible with conventional fusion-based AM processes.
In particular, the low temperature attribute of the process enables fabrication of metallic and composite parts with metallurgically uniform properties, while fusion-based processes tend to be unstable or degrade at high melting temperatures. The SSAM deposition rates associated with Kinetic Metallization permit an order of magnitude faster fabrication rate of parts when compared to many conventional AM methods. The paper presented the developments of the technology to date and the potential applications.
Dr. Ralph Tapphorn , Mr. Howard Gabel , Mr. Travis Crowe , Inovati, Santa Barbara, California
www.inovati.com
Inovati, Santa Barbara, Calif., presented a discussion about the application of its impact consolidation Kinetic Metallization (KM) process to an advanced and superior 3D manufacturing technology.
Continue readingSintavia opens additive manufacturing facility for large-scale aerospace production
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Sintavia LLC, Hollywood, Fla., has opened the doors to its new 55,000-square-foot advanced manufacturing facility, which is said to be the first of its kind in North America to offer large-scale AM production coupled with a robust aerospace quality management system.
The facility houses over $25 million of advanced manufacturing equipment, including medium and large scale metal printers, EDMs, post-processing machines, wet-booths, and multiple furnaces. Some of the industrial engineering improvements of the building include separate manufacturing rooms segregated by alloy, a large-scale powder management system, an uninterruptable power supply, an inert gas farm, and a final production acceptance quality-control room.
The new facility is capable of producing tens of thousands of parts representing in excess of $100mm of AM revenue annually. The expansion is anticipated to bring more than 130 new jobs for skilled employees and support staff to South Florida.
“As we grow, it will serve as a template for future vertically aligned advanced manufacturing facilities around the United Staets and the world,†said Brian Neff, Sintavia’s Chairman and Chief Executive Officer.
The grand opening was attended by over 150 customers and industry partners, including Sumitomo Corporation, a growth equity investment partner of Sintavia and one of the largest international trading companies in the world. “Sintavia has again proven itself as a leader in the industrialization of AM production,†said Mr. Masaki Nakajima, CEO and President of Sumitomo Corporation of Americas.
Sintavia LLC, Hollywood, Fla., has opened the doors to its new 55,000-square-foot advanced manufacturing facility, which is said to be the first of its kind in North America to offer large-scale AM production coupled with a robust aerospace quality management system.
Continue readingSpray Tips: Porosity created by shadowing resulting from off-axis spraying
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The angle of impingement of the spray stream is another source of porosity. The diagram shows porosity caused by shadowing. Figure 8 illustrates the type of shadowing generally associated with coatings sprayed at angles below 45 degrees from the optimal normal angle of incidence.
Coating porosity decreases (i.e., density increases) as the angle of spray approaches 90 degrees; that is, normal to the surface being coated. It follows that more advanced coating systems are sprayed with tighter tolerances on fixture alignment. Plasma coatings may be sprayed at ±15 degrees, whereas low-end coatings may be sprayed at ±30 degrees.
Figure 8 shows how surface protrusions build up and then shadow interstices or voids adjacent to the protrusions and behind them. These protrusions produce even more shadowing, particularly as the angle of incidence is lower relative to the surface, that is, <90 degrees.
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. 8.
The angle of impingement of the spray stream is another source of porosity:The diagram shows porosity caused by shadowing.
Continue readingKeyence VHX 7000 digital microscope features expanded memory, one-click focus
June 10, 2019 Source:
Keyence, Itasca, Ill., introduces the VHX-7000 Series digital microscope, the first model to feature the Focus View function, which enables simultaneous viewing of the lens and the target. Thanks to the intuitive software interface, focusing can be carried out easily with just a click.
Even when the target has an uneven surface, a fully-focused image is obtained instantly, composed of multiple images with varying focus positions. Additionally, 3D display can be used to observe surface contours.
The Auto-Measurement Teaching function enables repeated measurements to be made automatically on identically-shaped samples. Not only XYZ coordinates, but also magnification and light settings are reproduced automatically. The user simply places the target on the stage, and everything else – including alignment, focus adjustment, magnification switching and so on – is fully automatic.
The VHX Series offers observation that exceeds conventional imaging tools. With advanced measurement capabilities, this system enables a variety of analyses. Expanded memory capacity allows for storage of millions of images. Its easy-to-use interface can be used effectively by expert and novice users. The VHX Series is equipped with all of the features needed to enhance your analysis.
https://www.keyence.com/ss/products/microscope/vhx-7000
Keyence, Itasca, Ill., introduces the VHX-7000 Series digital microscope, the first model to feature the Focus View function, which enables simultaneous viewing of the lens and the target
Continue readingBuehler AabrasiMet XL Pro simplifies cutting of metal samples up to 7 inches in diameter
June 7, 2019 Source: ASM International
Buehler, an ITW Company, Lake Bluff, Ill., has launched the AbrasiMet XL Pro large abrasive cutter to provide consistency and repeatability in cutting large samples for production environments.
Continue reading