Titanium carbide nanoparticles infused into aluminum alloy 7075 enable strong welds
January 27, 2019
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Engineers at the UCLA Samueli School of Engineering announce that they have developed a way to weld aluminum alloy AA 7075 by infusing titanium carbide nanoparticles into welding wires, which results in welded joints with a tensile strength up to 392 MPa. (By comparison, AA 6061 has a tensile strength of 186 MPa in welded joints.) According to the study, post-welding heat treatments could further increase the strength of AA 7075 joints up to 551 MPa, which is comparable to steel.
"The new technique is just a simple twist, but it could allow widespread use of this high-strength aluminum alloy in mass-produced products such as cars or bicycles, where parts are often assembled together," said Xiaochun Li, UCLA's Raytheon Professor of Manufacturing and the study's principal investigator. "Companies could use the same processes and equipment they already have to incorporate this super-strong aluminum alloy into their manufacturing processes, and their products could be lighter and more energy efficient, while still retaining their strength."
The researchers already are working with a bicycle manufacturer on prototype bike frames that would use the alloy; and the new study suggests that nanoparticle-infused filler wires could also make it easier to join other hard-to-weld metals and metal alloys.
“Nanoparticle-enabled phase control for arc welding of unweldable aluminum alloy 7075,†was published in the January 9 issue of Nature Communications.
Engineers at the UCLA Samueli School of Engineering announce that they have developed a way to weld aluminum alloy AA 7075 by infusing titanium carbide nanoparticles into welding wires, which results in welded joints with a tensile strength up to 392 MPa.
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Desktop Metal’s single-pass jetting is four times faster than other binder jet 3D printers
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Desktop Metal, Burlington, Mass., announces several major advances and expanded capabilities to its Production System, the world’s fastest metal printer, delivering the lowest cost per part with the highest capacity of any metal 3D printing system available. Low-cost MIM powder, high throughput, and simple post-processing deliver per-part costs that are competitive with traditional manufacturing processes—and up to 20x lower than today’s metal 3D printing systems.
The installation of the first Production System is scheduled for Q1 2019 to a Fortune 500 company among Desktop Metal’s early Pioneer customers. Additional customer installations at major automotive, heavy duty, and leading metal parts manufacturers will follow throughout 2019, with broad availability in 2020.
Powered by Single Pass Jetting technology, the Production System is the first and only metal 3D printing system for mass production that delivers the speed, quality, and cost-per-part needed to compete with traditional manufacturing processes. It is more than four times faster than any binder jet competitor and offers a 100 times speed improvement over any laser-based system. Since it was first introduced, advancements to the technology and capacity of the Production System have expanded to include:
â–º Accelerated printing speeds to 12,000 cm3 per hour, making it the fastest metal 3D printer in the world with the highest capacity;
► The company’s flagship configuration now features an expanded build volume of 750 x 330 x 250 mm, a 225 percent improvement, designed for higher throughput and efficiency;
â–º Two full-width print bars, advanced powder spreaders, and anti-ballistic system that work to spread powder and print in a single quick pass across the build area - making it the most sophisticated single pass inkjet print head ever installed in a binder jet system;
â–º 32,768 piezo inkjet nozzles that enables the broadest range of binder chemistries to print an array of metals - including tool steels, low alloy steels, titanium, and aluminum - at a rate of 3 billion drops per second;
â–º First and only binder jet system with an industrial inert environment, including gas recycling and solvent recovery, to safely print reactive metals in mass production; and
â–º Capability to print more than 60 kilograms of metal parts per hour.
www.desktopmetal.com
Desktop Metal, Burlington, Mass., announces several major advances and expanded capabilities to its Production System, the world’s fastest metal printer, delivering the lowest cost per part with the highest capacity of any metal 3D printing system available.
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Wisconsin Oven dual-chamber heat treating furnace preheats up to 4000 pounds of steel
January 24, 2019
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Wisconsin Oven Corp., East Troy, has shipped a natural gas-fired Heavy Duty Batch Series furnace for preheating dies to a customer in the automotive industry. The dual-chamber die heating furnace has a maximum operating temperature of 1250°F and work chamber dimensions of 6 x 4 x 6 feet. Guaranteed temperature uniformity of ±15°F at 800°F and 1100°F was verified through a nine-point profile test conducted in an empty furnace chamber under static operating conditions.
The dual chamber furnace has sufficient capability to heat 4000 pounds of steel from 70°F to 1100°F within four hours when loaded into a preheated furnace, with guaranteed temperature uniformity of ±15°F at 800°F and 1100°F. Each chamber features a carbon steel die support structural frame to accommodate two dies, one above the other. Each structural frame is designed to support a 2000-pound load.
“This furnace was sold to a repeat customer in the automotive industry,†says Jim Lucas, Senior Sales Engineer. “A majority of the equipment we ship is to our repeat customer base, which is a testament to our customer service. We look forward to continuing to do business with this customer for years to come.â€
www.wisoven.com
Wisconsin Oven Corp., East Troy, has shipped a natural gas-fired Heavy Duty Batch Series furnace for preheating dies to a customer in the automotive industry.
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One Minute Mentor: Tensile properties of austempered ductile iron
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It is obvious from the graph that austempered ductile iron (ADI) is a unique cast iron material with tensile properties attributable to γH with the fine dispersion of ferrite.
Austempering is accomplished by first heating the casting to a temperature in the austenite-phase range (usually 815 to 925°C, or 1500 to 1700°F). The next step is holding for the time required to saturate the austenite with carbon, then cooling to a temperature above the Ms temperature at a rate sufficient to avoid the formation of pearlite or other mixed structures. The final step is holding at that austempering temperature for the time required to produce the optimal structure of acicular ferrite and carbon-enriched austenite. In some instances, austenitizing is completed in an intercritical region.
Austempered ductile iron is a unique cast iron material with tensile properties attributable to ?H with the fine dispersion of ferrite.
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Solar Atmospheres’ Roger Jones to semi-retire after 45 years in heat treating industry
January 23, 2019
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Solar Atmospheres, Souderton, Pa., recently awarded the title of CEO Emeritus to Roger A. Jones, a Fellow of ASM International. The honorary title was conferred by the company, which also announces his semi-retirement as Solar Atmospheres’ CEO, the culmination of 45 years of leadership and service to the vacuum heat treating industry.
A 1974 graduate of Hocking Technical College (Nelsonville, Ohio), Mr. Jones began his professional career in the heat treating industry at Abar Corporation. He left Abar in 1978 to join the newly formed Vacuum Furnace Systems Corporation (VFS), working with his father and VFS founder, William R. Jones FASM.
In 1983, Roger assisted in the founding of Solar Atmospheres Inc., serving as Vice President until 1993. He was promoted to President in 2001, and eventually to CEO in June 2017, overseeing operations of all four heat treating facilities.
As a member of several professional societies, Mr. Jones has provided leadership and has received numerous industry awards, primarily from the American Society for Metals (now ASM International) and the Metal Treating Institute (MTI). He has been recognized many times for his outstanding commitment and service to the vacuum heat treating industry.
www.solaratm.com
Solar Atmospheres, Souderton, Pa., recently awarded the title of CEO Emeritus to Roger A. Jones, FASM, and announces his semi-retirement as Solar Atmospheres’ CEO, the culmination of 45 years of leadership and service to the vacuum heat treating industry.
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Stack Metallurgical installs Quintus Mega HIP for heat treating aerospace, medical products
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Stack Metallurgical Group, Albany, Ore., announces that it has installed a Quintus Mega-HIP hot isostatic press for heat treating and processing of aerospace, power generation, medical implant, and other products. The model QIH 286 M URC is equipped with proprietary uniform rapid cooling and features a work zone of 63 in. dia. by 102 in. tall, allowing densification of large batches at 29,000 psi and a maximum operating temperature of 2280°F.
The URC design enables all casting areas to cool uniformly, minimizing thermal distortion and non-uniform grain growth. Heating and cooling the workload only once, in a single cycle, enhances efficiency and dramatically reduces per-unit processing costs. In addition, the press offers significant savings in space, energy, and infrastructure investment.
With its new HIP facility coming on-line in 2019, Stack will offer four Nadcap-accredited locations with a focus on the aerospace, power generation, medical implant, and high-end knife and cutlery markets. The company’s modern and extensive equipment line-up offers a comprehensive portfolio of services for demanding clients throughout North America. With a range of aerospace OEM approvals for heat treatment, Stack has built trusted relationships with aerospace titans Boeing, General Electric, Sikorsky, and PCC Aerostructures.
“As a new entrant into the HIP market, it was critical that we continue to have the ability to offer a premium combination of quality and delivery to our clients,†says Doug Puerta, CEO, Stack Metallurgical Group.
http://www.stackmet.com
Stack Metallurgical Group, Albany, Ore., announces that it has installed a Quintus Mega-HIP hot isostatic press for heat treating and processing of aerospace, power generation, medical implant, and other products.
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Boston Metal raises $20M to scale up molten oxide electrolysis production of ferroalloys
January 17, 2019
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Boston Metal announces that it has raised $20 million in a Series A funding round to accelerate the first industrial-scale deployments of its molten oxide electrolysis (MOE) technology for the production of ferroalloys. The new funding also supports the continued scale-up of MOE for the production of emissions-free steel.
Molten oxide electrolysis is a process in which electricity transforms metal from its raw oxide form into molten metal products. The MOE process was invented on the lab-scale at MIT, and Boston Metal has since scaled up the technology by a factor of over 1000.
At the heart of the MOE cell is a soup of molten oxides tailored for each specific feedstock and product. Electrons act to melt this soup and selectively reduce the targeted oxide. The resulting metal gathers in pools at the bottom of the cell and is tapped by drilling into the cell in a process adapted from the blast furnace. The tap hole is then plugged and the process continues. The inherent modularity of these MOE cells provides the metal industry with a capital-efficient means of adding production capacity.
“Molten oxide electrolysis is a platform technology that can produce a wide array of metals and alloys,†says Tadeu Carneiro, CEO of Boston Metal, “but our first industrial deployments will target the ferroalloys on the path to our ultimate goal of steel. Boston Metal’s MOE technology will offer the steel industry a modular, low-cost, and zero-emissions solution for the production of high-tonnage steel.â€
Boston Metal operates a fleet of semi-industrial MOE systems at its headquarters outside of Boston, and will be commissioning its first industrial systems at this same facility. Boston Metal works closely with customers and partners to tailor the MOE platform for pecific feedstocks and products.
www.bostonmetal.com
Boston Metal announces that it has raised $20 million in a Series A funding round to accelerate the first industrial-scale deployments of its molten oxide electrolysis (MOE) technology for the production of ferroalloys.
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Optomec partners with Phillips Federal to bring 3D printing to US government agencies
Source: ASM International
Optomec, Albuquerque, N.M., has signed a partnership agreement with Phillips Federal that will enable Phillips to resell the Optomec Laser Engineered Net Shaping (LENS) systems to U.S. government facilities.
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Nucor to invest $1.35 billion to build state-of-the-art steel plate mill in the Midwest
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Nucor Corp., Charlotte, N.C., announces plans to invest $1.35 billion to build a state-of-the-art plate mill in the United States Midwest that will be capable of producing 1.2 million tons per year of steel plate products. The mill is expected to be fully operational in 2022, and is expected to create approximately 400 full-time jobs.
The new plate mill will produce cut-to-length, coiled, heat-treated, and discrete plate ranging from 60 to 160 inches wide, and in gauges from 3/16 of an inch to 14 inches in thickness, enabling Nucor to supply plate products that the company does not currently offer. Nucor currently operates plate mills in North Carolina, Alabama, and Texas.
"This investment is consistent with our drive to continue delivering sustainable, profitable growth and superior returns for shareholders," said John Ferriola, Chairman, CEO & President of Nucor. "Together with the significant share repurchases completed in 2018, the Board's decision to fund this high-return opportunity demonstrates our commitment to balanced capital allocation. We have a strong foundation to build upon as we advance our goal of leading in every market in which we compete."
According to Leon Topalian, Executive Vice President of Beam and Plate products, "By building this state-of-the-art plate mill in the Midwest – the largest plate-consuming area in the United States – we will enhance our ability to serve our customers in the region while also furthering our goal of meeting all the steel needs of our customers around the country. We expect to select a site for the new mill early this year. Our team is poised and ready to take the next step in advancing our position in steel plate products."
"This administration is taking the decisive and meaningful actions that American manufacturers need to compete on a level playing field," Mr. Ferriola said. "Tax reform, continued improvements to our regulatory approach, and strong trade enforcement are giving businesses like ours the confidence to make long-term capital investments here in the United States that create jobs and ensure our success for decades to come."
www.nucor.com
Nucor Corp., Charlotte, N.C., announces plans to invest $1.35 billion to build a state-of-the-art plate mill in the United States Midwest that will be capable of producing 1.2 million tons per year of steel plate products.
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One-Minute Mentor: Processing sequence for austempered ductile iron
January 10, 2019
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The figure shows an isothermal transformation (IT) diagram for a ductile cast iron, together with a processing sequence depicting the production of ADI. In this process, austenitizing is followed by rapid quenching (usually in molten salt) to an intermediate temperature range for a time that allows the unique metastable carbon-rich (~2% C) austenitic matrix (γH) to evolve simultaneously with nucleation and growth of a platelike ferrite (α) or of ferrite plus carbide, depending on the austempering temperature and time at temperature.
This austempering reaction progresses to a point at which the entire matrix has been transformed to the metastable product (stage I in the figure). Then that product is “frozen in†by cooling to room temperature before the true bainitic ferrite plus carbide phases can appear (stage II).
In ductile cast irons the presence of 2 to 3 wt% Si prevents the rapid formation of iron carbide (Fe3C). Hence the carbon rejected during ferrite formation in the first stage of the reaction (stage I) enters the matrix austenite, enriching it and stabilizing it thermally to prevent martensite formation upon subsequent cooling.
Thus the processing sequence shows that the austempering reaction is terminated before stage II begins, and illustrates the decrease in the martensite start (Ms) and martensite finish (Mf) temperatures as γH forms in stage I. The kinetics of stages I and II have been described in detail in the literature.
Typical austempering times range from 1 to 4 hours. If the part is austempered too long, undesirable bainite will form. Unlike steel, bainite in cast iron microstructures exhibits lower toughness and ductility.
Volume 4D, Heat Treating of Irons and Steels -> Heat Treatiment of Cast Irons -> -> Heat Treating and Properties of Ductile Iron -> General Characteristics
The figure shows an isothermal transformation (IT) diagram for a ductile cast iron, together with a processing sequence depicting the production of ADI.
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