Nucor wins GM Supplier of the Year Award, and announces bar mill investment
May 24, 2019
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Nucor Corp., Charlotte, N.C., was recognized as a General Motors Supplier of the Year for Non-Fabricated Steel at the automotive company's 27th annual Supplier of the Year awards ceremony held on May 15 in Detroit.
"This is a tremendous accomplishment for our team, as we are the first electric arc furnace steelmaker to receive this recognition," says John Ferriola, Chairman, CEO, and President of Nucor Corporation. "We have made significant investments to expand our automotive product portfolio and are focused on providing exceptional customer service. As a result, we continue to gain share in this important market. We are honored to be recognized by GM, and we value the business they do with us."
Nucor also announces a capital investment that will add vacuum degassing to its engineered bar capabilities at its bar mill in Darlington, South Carolina. Adding this capability will enable the mill to produce engineered bar products meeting some of the most stringent quality specifications in the industry. The vacuum degassing system is expected to begin operations in late 2020.
"This strategic investment complements our existing bar mills that primarily produce engineered bar products in Norfolk, Nebraska, Memphis, Tennessee, and Wallingford, Connecticut. It will position us to better serve our customers in the Southeastern United States and support the growing demand in the region for higher quality automotive and other specialty steel applications," says Mr. Ferriola.
Nucor Steel South Carolina is the first steel mill Nucor built. Producing steel by means of melting recycled scrap in an electric arc furnace (EAF), the mill started a revolution in the way steel is made in the United States. Today, approximately 70 percent of the steel made in this country is produced using EAFs. Next month, the Darlington facility will hold an event to celebrate its 50th anniversary.
www.nucor.com
Nucor Corp., Charlotte, N.C., was recognized as a General Motors Supplier of the Year for Non-Fabricated Steel at the automotive company’s 27th annual Supplier of the Year awards ceremony held on May 15 in Detroit.
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Sandvik 3D prints diamond composite with high hardness and high heat conductivity
May 23, 2019
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Sandvik Additive Manufacturing, Sweden, announces that it has developed a technology for producing a 3D-printed diamond composite part with a complex shape, extremely high hardness, and exceptional heat conductivity. The diamond composite also provides low density, very good thermal expansion, and “fantastic†corrosion resistance. According to Sandvik, the diamond composite is three times stiffer than steel, with heat conductivity higher than copper, thermal expansion close to Invar, and density close to aluminum.
The process involves additive manufacturing and a proprietary post-processing method that enables fabrication of composites that can be formed into almost any shape, even those that are highly complex. Most of the composite is diamond, but to make it printable and dense, it is cemented into a very hard matrix material (which Sandvik has not revealed), keeping the most important physical properties of pure diamond.
“Our additive manufacturing process is highly advanced,†says Mikael Schuisky, Head of R&D and Operations at Sandvik Additive Manufacturing. “We are printing in a slurry consisting of diamond powder and polymer using a method called stereolithography, in which complex parts are produced, layer by layer, using ultraviolet light.
“The step after the 3D-printing is even more demanding. This is where Sandvik has developed a tailor-made, proprietary post processing method making it possible to achieve the exact properties of the super-hard diamond composite. This step was extremely complicated. However, after extensive R&D efforts and several trials, we managed to take control of the process and made the first 3D printed diamond composite.â€
www.sandvik.com
Sandvik Additive Manufacturing, Sweden, announces that it has developed a technology for producing a 3D-printed diamond composite part with a complex shape, extremely high hardness, and exceptional heat conductivity.
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Protolabs manufacturing facility features 3D printing, CNC machining, injection molding
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Protolabs, Maple Plain, Minn., celebrates its 20-year anniversary with a grand opening of its state-of-the-art advanced manufacturing facility in Brooklyn Park, Minn. The 215,000 sq.-ft. CNC machining facility, which currently houses nearly 300 mills and lathes, is Protolabs’ eighth manufacturing plant in the United States, and twelfth around the globe.
The company says that its digital approach to manufacturing enables accelerated time to market, reduces development and production costs, and minimizes risk throughout the product life cycle. It produces custom parts and assemblies in as little as one day using automated 3D printing, CNC machining, sheet metal fabrication, and injection molding processes. Its manufacturing model couples digital front-end part analysis with automated toolpathing to produce some custom machined components in only 24 hours.
It now serves more than 45,000 unique product developers each year, across three continents and 60 countries. Over the past 20 years, Protolabs has grown in capabilities with four flagship services and 11 manufacturing technologies, and has added capacity with more than a million square feet of manufacturing space that houses over 1000 machines producing nearly four million parts each month.
“Protolabs has exceeded my wildest dreams,†says Larry Lukis, Protolabs’ founder. “The company was born out of personal frustration that manufacturing parts took months, when it could take days or even minutes. There needed to be a way to make it easier and faster for product developers to get prototype parts and accelerate development cycles. Protolabs has achieved that goal and made advanced manufacturing technologies accessible for everyone, from makers to startups to Fortune 500 companies.â€
www.protolabs.com
Protolabs, Maple Plain, Minn., celebrates its 20-year anniversary with a grand opening of its state-of-the-art advanced manufacturing facility in Brooklyn Park, Minn.
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Axial Suspension Plasma Sprayed Ceramic Coatings for Semiconductor Applications
May 17, 2019
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This ITSC 2019 presentation discusses the plasma treatment of large-scale substrates. The size of semiconductor and flat-panel-display (FPD) production equipment for dry etching and sputtering has been increasing due to the increased size of both silicon wafers and displays.
Plasma treatment is used for micro~nano fabrication, especially in dry etching, and a higher plasma power is needed to fabricate the large-scale substrates with high etching rates. This trend presents higher requirements on the plasma erosion-resistant coatings on the inside wall of the chamber. High-purity oxide ceramics such as alumina (Al2O3) and yttria (Y2O3) are good coating materials against plasma erosion.
These coatings have been used primarily applied with plasma spraying agglomerated-and-sintered powders. In this study, Al2O3 and Y2O3 coatings were sprayed using axial suspension plasma spraying with fine powders. The resulting coatings were harder, denser and smoother with improved plasma erosion resistance and dielectric properties compared to traditional plasma coatings. The effect of the powder properties on the coating structure were investigated, and their erosion resistance and dielectric properties are discussed.
www.mettech.com
Dr. Zhaolin Tang, Gaspar Masindo, Mr. Neil Young, Northwest Mettech Corp., Surrey, BC, Canada
Wednesday, May 29, 2019: 11:40
Annex Hall/F201 (Pacifico Yokohama)
This ITSC 2019 presentation discusses the plasma treatment of large-scale substrates, because the size of semiconductor and flat-panel-display (FPD) production equipment for dry etching and sputtering has been increasing due to the increased size of both silicon wafers and displays.
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Erosive Wear Testing of Laser Clad and HVOF Coatings for Drilling in Mining
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This ITSC presentation focuses on the fact that drilling is a major cost factor to mining operations (exploration, drill and blast operations), and wear of components is a significant driver of drilling costs. For drilling, especially in hard rocks, rotary drills do not deliver satisfactory results. Instead, down-the-Hole (DTH) hammers or Reverse Circulation (RC) hammers are used. These drills break the rock through repetitive impact. Cuttings are removed via a high velocity air stream. The main wear mechanism for these hammers was found to be erosion.
To combat erosive wear laser clad coatings with a Ni-matrix and different sized fused tungsten carbides FTC (WC/W2C) (angular and spherical) and monocrystalline WC were developed. Moreover, hard Fe-based HVOF coatings were investigated and a wear-resistant steel served as a reference.
An erosion testing apparatus which follows ASTM G76 was developed. Testing was carried out at 15 to 90 degree angles in 15-degree steps for all materials. Coating performance was assessed via volume loss, obtained using 3D profilometry. At low angles, the more brittle materials lost significantly less volume, but at a 90-degree angle the wear resistant steel performs almost as well as a hard phase loaded coating. Laser clad coatings with spherical FTC showed overall a better performance than coatings with angular FTC.
Dr. Thomas Schlaefer, LaserBond Ltd, Cavan, Australia
Dr. Christiane Schulz , Dr. Eric Charrault , Dr. Colin Hall , University of South Australia, Mawson Lakes, Australia
Tuesday, May 28, 2019: 15:30
Annex Hall/F203 (Pacifico Yokohama)
This ITSC presentation focuses on the fact that drilling is a major cost factor to mining operations (exploration, drill and blast operations), and wear of components is a significant driver of drilling costs.
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The Effect of Rapid Heat Treatment on the Mechanical Properties of Cold Spray Coatings
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This ITSC 2019 paper details the mechanical testing of Al 6061 cold spray coatings before and after a rapid heat treatment with a novel focused IR device. The focused IR device was used to heat treat the cold spray coatings in-process with the aim of improving ductility and substrate-coating bond strength, and reducing residual stresses.
The treated samples were compared to a controlled annealing process, which was carried out in a furnace after cold spray. The power output of the IR device was set to the maximum level of 220 W/cm2, which was focused over a 10 mm diameter outlet area. The number of passes and traverse speed of the heat treatment process were varied in order to optimize the effect of the heat treatment.
The mechanical properties of the coating were tested by tensile testing of dog-bone samples and by performing pull off tests. Residual stresses were evaluated using strain measurement changes, before cold spray and after heat treatment. It was found that the rapid IR heat treatment process delivered advantages with regard to mechanical properties when compared to the untreated state.
Mr. Richard Jenkins, Dr. Barry Aldwell, Mr. Jonathan Cassidy, Prof. Rocco Lupoi, Trinity College Dublin, Ireland
Tuesday, May 28, 2019: 11:00
Annex Hall/F202 (Pacifico Yokohama)
www.tcd.ie
This ITSC 2019 paper details the mechanical testing of Al 6061 cold spray coatings before and after a rapid heat treatment with a novel focused IR device.
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GKN Powder Metallurgy opens new headquarters in Michigan for additive manufacturing
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GKN Powder Metallurgy announces that it has opened its new North American Powder Metallurgy Headquarters and Additive Manufacturing Customer Center in Auburn Hills, Michigan, USA. The new facility will reportedly house over eighty employees from the three divisions of GKN Powder Metallurgy; GKN Hoeganaes, GKN Sinter Metals and GKN Additive, in a space the company states is designed to inspire teamwork and enhance customer experience.
The building includes a 3,200 ft2 Additive Manufacturing Customer Center, equipped with two EOS M290 metal Laser Powder Bed Fusion (L-PBF) systems. EOS’s systems are capable of manufacturing functional metal prototypes within a two-week lead time and allow customers to test factors such as usability, ergonomics, manufacturability and materials in the early stages of the development process. It is expected that the full 38,260 ft2 combined facility will expand the company’s global Additive Manufacturing network and the scope of its in-house Powder Metallurgy capabilities.
Reid Southby, President of GKN Sinter Metals Large Segment, stated, “We are excited to start a new journey in Auburn Hills with a space that is dedicated to our team, our community and the advanced technology we create for our customers. This building reinforces our commitment to the North American market and continued global growth.â€
www.gknpm.com
GKN Powder Metallurgy announces that it has opened its new North American Powder Metallurgy Headquarters and Additive Manufacturing Customer Center in Auburn Hills, Michigan.
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Spray Tips: Sources of coating porosity
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The most common source of coating porosity is trapped, unmelted, or resolidified particles. The figure shows particle impact states that create structural features. Depending on the particle temperatures, the arriving droplets may cover the full range of liquid to solid states.
The liquid-state particles flow easily and fill most voids, as illustrated in Fig. 7 shown. Solid particles, some of which are reflected from the solid surface, may adhere locally to, or become trapped in, the rough finish of the coatings. These “overspray†particles are not well bonded, nor are they in intimate contact with the underlying splat, which creates voids that are not open to direct line-of-sight.
As stated before, thermal spray is a line-of-sight process; hence, the next arriving particles cannot fill voids adjacent to trapped solid particles. This is shown in Fig. 7. In other cases, even in the same instant, some solid + liquid (i.e., partially molten) particles may deform and be completely densified, provided sufficient liquid is available to fill any voids that form around the small amount of existing solid core. It is also possible that partially melted particles act similarly to solid particles, leaving trapped voids around their solid portions.
This information is from ASM Handbooks Online, Vol. 5A Thermal Spray Technology, Coating Structures, Properties, and Materials. To find this information, click on the link below and scroll down to Fig. 7.
https://dl.asminternational.org/books/book/12/chapter/132400/Coating-Structures-Properties-and-Materials
The most common source of coating porosity is trapped, unmelted, or resolidified particles. The figure shows particle impact states that create structural features.
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Leco metallographic mounting press offers simple operation, touchscreen interface
May 13, 2019
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Leco, Saint Joseph, Mich., introduces the MX400 mounting press, which offers dual mount capability, a slim eight-inch design, a simple steel closure, low thermal mass, and energy-efficient heating with substantially faster cooling than previous generations of mounting presses. Its convenient standby option with selectable temperature keeps the mold cylinder warm between uses, allowing for increased throughput. An optional ventilation system also helps to keep the work area clean and safe from harmful fumes.
A seven-inch touchscreen interface with simple swipe-and-touch operation makes the MX400 easy to use. It is simple to select all parameters, such as heat, pressure, and cure time, for unparalleled versatility. These parameters can then be used to create customizable methods for optimized repeatability.
Leco-developed methods are also available to help the user get started. The MX400 offers three fixed common mold sizes, enabling users to choose the one that best fits their needs: a 1.25 inch, 1.50 inch, and 30 millimeters. The MX400 is ideal in sample preparation for a wide range of applications, including, but not limited, to metal such as steel, iron, and nickel; heat treatment or coatings; and most manufacturing quality control and research and developmental needs.
www.leco.com
Leco, Saint Joseph, Mich., introduces the MX400 mounting press, which offers dual mount capability, a slim eight-inch design, a simple steel closure, low thermal mass, and energy-efficient heating with substantially faster cooling than previous generations of mounting presses.
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One Minute Mentor: Ductile iron austempering temperature and time
May 9, 2019
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The austempering temperature is the primary determinant of the final microstructure and therefore the hardness and strength of the austempered ductile iron product. As the austempering temperature increases, the strength varies, as shown in Fig. 19 for irons with two levels of manganese.
The attainment of maximum ductility at any given austempering temperature is a sensitive function of time. The initial increase in elongation occurs as stage I, and elongation progresses to completion, at which point the fraction of austenite is a maximum.
Further austempering merely serves to reduce ductility, as the stage II reaction causes decomposition to the equilibrium bainite product. Typical austempering times vary from one to four hours.
Adapted from: K. Hayrynen, Heat Treating and Properties of Ductile Iron, Heat Treating of Irons and Steels, Vol 4D, ASM Handbook, ASM International, 2014, p 508–521. https://doi.org/10.31399/asm.hb.v04d.a0005937
For more information on this topic, visit the article (subscription required), scroll down the Chapter Contents column on the left, and click on Austempering Ductile Iron.
The austempering temperature is the primary determinant of the final microstructure and therefore the hardness and strength of the austempered ductile iron product.
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