Mary Glenn

IBC Advanced Alloys Supplies Newport News Shipbuilding

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

IBC Advance Alloys announces that it is now an “Approved Forging Supplier” with Newport News Shipbuilding, a division of Huntington Ingalls Industries.  Newport News is the largest shipbuilding company in the U.S. and is the sole designer, builder, and re-fueler of U.S. Navy aircraft carriers and one of two providers of U.S. Navy submarines.

The announcement marks the second such attainment by IBC of approved forging supplier status with a world-class shipbuilder in as many weeks.  On September 13, IBC announced that it received “Approved Forging Supplier” status with General Dynamics’ Electric Boat Division (see that press release here).

“Achieving approved forging supplier status with Newport News is another significant advance for IBC, and positions us to grow our forged products business,” said Major General Duncan Heinz (USMC, ret.), President and CEO of IBC.

IBC’s qualification with Newport News positions the Company to provide forged product to Newport News through approved suppliers.  The qualification was awarded after Newport News conducted due diligence of IBC’s Copper Alloys Division facility in Franklin, Indiana.

Newport News builds the most advanced ships in the world using its expertise in nuclear propulsion, naval design, and manufacturing, and it is currently building the new Ford-class aircraft carriers and Virginia-class fast-attack submarines, and performing Refueling and Complex Overhaul (RCOH) on Nimitz-class aircraft carriers. With approximately $4 billion in revenues and more than 20,000 employees, Newport News has built more than 800 ships, including both naval and commercial ships.

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Weldaloy’s Aluminum Heat-treating Capacity Increased

/ AEROSPACE HEAT TREAT NEWS, ALUMINUM PROCESSING NEWS, ENERGY HEAT TREAT, FEATURED NEWS

On the heels of a recent expansion of their seamless rolled ring capabilities, Weldaloy continues to grow with the addition of a new low temperature aluminum aging oven. The new oven will increase Weldaloy’s aluminum heat-treating capacity.

Ovens created specifically for aluminum can reduce cycle times and increase productivity by optimizing temperature uniformity through adequate airflow. This translates to a better product that can be made in a repeatable recipe.

“We’re receiving more and more requests for large aluminum work, so we needed to add this low temperature aluminum aging oven to be able to increase our capacity and meet production needs. This addition will allow us to produce more parts in the same amount of time for our customers while maintaining quality,” said Kurt Ruppenthal, Vice President & General Manager at Weldaloy.

Many of the new opportunities for aluminum work have come from the oil and gas industry and the aerospace industry, as well as from the private space sector. Weldaloy recently achieved the AS9100C certification for their Quality Management System, which has opened the door for them to work with more aerospace companies that require certification of their suppliers.

“We look forward to continuing to grow our aluminum capabilities to meet the increase in demand,” said Ruppenthal.

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Carbon Sensor Troubleshooting

/ CARBURIZING, FEATURED NEWS, HARDENING, HEAT TREAT NEWS INDUSTRIES

Jim Oakes, Super Systems, Carbon Sensor Troubleshooting, Stephen Thompson

by Stephen Thompson – President – Super Systems, Inc.

There are several key components in all atmosphere control systems. When a difficulty arises, it is important to identify the cause with minimum effort and expended time. The procedure that follows is designed to aid in that process.

INTRODUCTION

The starting point for any troubleshooting procedure is to properly identify the symptom that necessitates it. The cause of the symptom can often be elicited by answering some preliminary questions. Is this a startup problem, or has the system been operating under control? If this is a startup problem, it is necessary to establish that all system components have been properly connected and configured for the application. If the system has been operating properly and there has been either a gradual or sudden change in the control performance, it may conceivably be a problem with the probe. In order to establish the correct performance of the carbon sensor, resist the temptation to remove the sensor from the furnace. All of the tests outlined here must be done while the sensor is located in the furnace, at temperature, and exposed to a reducing atmosphere. This procedure can be performed on the SSi Gold Probe and on most other manufacturers’ sensors. We strongly recommend that you call us at 800-666-4330 before you remove the probe.

NOTE: IF YOU HAVE ALREADY REPLACED THE PROBE AND THE PROBLEM PERSISTS…..THE PROBE MAY NOT BE THE PROBLEM!

PROCEDURE

Does a shim stock analysis, a 3-gas analysis (SSi PGA3000) or a dew point analysis (SSi DP2000) verify the indicated value from the probe? If the values are close to the same, the problem is not likely the Gold Probe. If the values are not similar, continue with the following steps:

  1. Verify that both mV and t/c cables between the sensor and the controller are clean and connected firmly to the Gold Probe and controller terminals. Verify polarity.
  2. Verify that the reference air supply is connected to the reference air fitting. This will be the fitting closest to you when you face the probe. It has been found that on occasion the reference air has been connected in error to the burn off fitting, causing low readings.
  3. Check that the reference air is flowing. Disconnect the air supply at the probe and submerge it in a cup of water. Bubbles verify the flow.
  4. Verify that no air is flowing into the burn off fitting by submerging the burn off tubing in a cup of water. (Flow can occur if the burn off air pump is subject to external vibration.)
  5. Leak test- this test can detect a cracked or broken substrate in your Gold Probe. Verify that reference air is flowing at 0.5 to 2.0 scfh. Turn off the reference air for one minute and read the Gold Probe output millivolts. Turn the reference air back on and note the change in mV. It should not display more than a 5 mV increase.
  6. Is the controller COF set to the proper value? This factor is referred to by other descriptions such as Process Factor, Furnace Factor, CO Factor, Circulation Factor, Calibration Factor, etc. The factor may require adjustment to eliminate any offset or discrepancy between the indicated carbon potential and the actual achieved result in the work pieces or shim stock.
  7. Do the sensor temperature and MV output as measured by an independent digital calibrator agree with the indicated values on the controller with one sensor and one t/c lead disconnected? If not, there is most likely a controller calibration problem or a cable problem.
  8. Does the Gold Probe mV signal return to within 1mV of it’s original value in 1 minute as measured by a digital VOM after it has been shorted for 5 seconds? If it does not, go to step 10.
  9. Probe impedance (resistance) test-this is one of several electrical tests that determine the electrical integrity and reliability of the Gold Probe. Some contemporary controllers can perform it. If yours does not, conduct this simple test: at process temperature, disconnect the controller cable at the Gold Probe mV output and measure the mV value with a VOM. Then shunt the signal with a 100 kilohm resistor. After 10 seconds, read the new mV value, divide the original value by the new value, subtract 1 from the result and multiply by the value of the shunt resistor (=100K). The calculated value is the sensor resistance in kilohms, which should be less than 25 kilohms.
  10. If the problem is not corrected by probe and/or furnace burnout as described in the Gold Probe Manual and your system manual, and the problem is a faulty probe, contact SSi at (800)666-4330 and describe your problem to our technician. You may then request a Returned Material Authorization for repair or replacement of your Gold Probe.
  11. WARNING- even though you suspect a faulty sensor, DO NOT remove your Gold Probe from a hot furnace at a rate faster than 2 inches per minute. Cool the sensor on an insulating medium to avoid thermal shock. This will prevent damage that is expensive to repair.

Author information:
Stephen Thompson
Super Systems Inc.
7205 Edington Drive, Cincinnati,  OH 45249
Phone: 513-772-0060
Fax: 513-772-9466
www.supersystems.com

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New Brazing Audit Criteria Released by MedAccred

/ BRAZING TECHNICAL CONTENT, FEATURED NEWS, MEDICAL HEAT TREAT

In response to industry demand, the MedAccred program has recently released new audit criteria for brazing. AC8102/1 MedAccred Audit Criteria for Heat Treating – Brazing will be used during MedAccred audits conducted at companies performing brazing in an atmosphere or vacuum furnace or  in a dip salt bath.

The new audit criteria were developed by the MedAccred Heat Treating Task Group which is comprised of technical experts from Johnson & Johnson, Stryker, GE Healthcare, Medtronic, Applied Thermal Technologies, Bodycote, Harterei Gerster, Hansen Balk, Lake City Heat Treating, Paulo Products and Solar Atmospheres. To date the Task Group is one of the most successful within the MedAccred program. It has released six audit criteria in total and has several companies who have already achieved accreditation; these include Solar Atmospheres, Hansen Balk and Bodycote.

The industry chairperson of the Heat Treating Task Group is Bruce Dall, Senior Staff Quality Engineer – Metal Injection Molding of Stryker. He is very proud of the achievements of the program to date:  “I would like to thank my fellow members of the Heat Treating Task Group for their hard work and the commitment they have shown in the development of these new audit criteria for brazing. In most other environments we are competing organizations but when we come together as a MedAccred Task Group, we are able to put aside our rivalries in the interest of quality and working towards consistently safer products for our patients. The fact that we are now seeing suppliers stepping forward to pro-actively gain a Heat Treating accreditation MedAccred is a strong indication of how important this program will be to the future of the industry and I am proud to be at the forefront of this effort.”

Companies interested in gaining accreditation for Heat Treating are encouraged to contact Justin McCabe, MedAccred Co-Lead (jmccabe@p-r-i.org) for more information. Companies achieving accreditation will be listed on MedAccred’s Qualified Manufacturers List (located at www.eAuditNet.com).

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Understanding the Short Circuit Current Rating

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

BOTW-50w Source: Ceramic Industry

by Dan Bender – Director of Sales for Control Concepts, Inc.

In this article, Dan Bender discusses Short Circuit Current Ratings, how to determine it, examples, and suggested solutions for keeping workers and workplaces safe.

Click here to read the entire article.

Click on the video below to watch a video about this same subject featuring Dan Bender.

dan-bender-video

Source: Ceramic Industry

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Linde Improves Additive Manufacturing

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

Pierre Forêt

Pierre Forêt – GDC Additive Manufacturing bei The Linde Group

Linde Gases, a division of The Linde Group, today announced the launch of ADDvance™ O precision, the first-of- its-kind measuring and analysis unit which will enable metal additive manufacturers to analyse and control more precisely the level of oxygen (O) and humidity present in the printer chamber.

The new technology, developed in response to a need identified by aerospace company Airbus Group Innovations, can detect O levels up to 10 parts per million (ppm) within the printer chamber and then modify the gas atmosphere by adjusting the level of argon or nitrogen. The presence of too much oxygen or humidity can present a challenge to additive manufacturers as it can negatively impact the quality and performance of the item being printed. In addition to ADDvanceTM O precision allowing for more accurate levels of oxygen and humidity, it does so without cross-sensitivity effects and ensures a constant level of oxygen during the process.

The launch of ADDvance™ O precision comes on the back of Linde’s recent opening of a dedicated industrial gases laboratory for additive manufacturing in Unterschleissheim, near Munich, Germany. The focus of the laboratory is to research the effect of different atmospheric gases and gas mixtures on the different metal powders used in additive manufacturing in order to optimise the various layering processes. Reproducibility is one of the most important parameters for industries requiring strict consistency in end product, such as the aerospace and automotive industries. ADDvanceTM O precision is an effective solution to improve reproducibility and through its new research facility Linde will continue to lead research into how oxygen and humidity impact the additive manufacturing process.

“Linde has always played a leading role in developing new technologies for our customers in order to improve the efficiency of their production processes and quality of output,” said Pierre Forêt, responsible for additive manufacturing R&D at Linde.

The additive manufacturing process operates within a closed chamber filled with high purity inert gas such as argon or nitrogen. However, impurities due to incomplete purging, small machine leakages and metal powder can have an influence on the oxygen level. A variation in oxygen content in the chamber can result in differences in mechanical properties or chemical composition of the end product – for example a decrease in fatigue resistance.

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Solar Atmospheres in South Carolina Now Nadcap Approved

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

Solar Atmospheres Southeast has successfully completed its first round of surveillance audits for maintaining its AS9100 and Nadcap accreditations.  Solar also expanded its scope of Nadcap approval to include Low Pressure Vacuum Carburizing to meet growing aerospace carburizing needs in the Southeast US.

Steve Prout, President of Solar Atmospheres Southeast states: “We are proud to be taking this next step in our start up plan to be able to offer Low Pressure Vacuum Carburizing services alongside the rest of our Nadcap approved scope of thermal processing capabilities.  We are excited that once again we are able to offer the Southeast US another regional option for aerospace processing that did not exist previously.”

With thermal processing in furnaces ranging from those suited for small lots and development cycles to a 6-1/2 foot diameter by 24 foot long vacuum chamber capable of processing up to 50,000 lbs at 2400°F, Solar Atmospheres is backed by AS9100 and Nadcap quality systems to provide our customers the confidence that their product is being processed appropriately.

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New MB Aerospace Technologies (Poland) to Focus on Heat Treating Processes

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, FEATURED NEWS

International aerospace engineering group MB Aerospace has completed the acquisition of Vac Aero (Poland) from its Canadian parent company Vac Aero International.

The business, which employs over 100 employees at two sites in Kalisz (central Poland) and Rzeszow (south-east Poland), specializes in providing protective and performance enhancing coatings for aero-engine and industrial gas turbine components. These OEM licensed and proprietary coatings provide wear, corrosion and heat resistance properties across performance critical compressor, combustor and turbine components. Since the company was founded in 2003, it has developed an extensive range of special process capabilities including heat treatment and vacuum brazing, vacuum carburizing, air plasma spray (APS) and high-velocity oxygen fuel (HVOF) protective coatings, as well as corrosion and oxidation resistant paint coatings. The former Vac Aero subsidiary will continue to serve key customers in Europe including UTC, Pratt & Whitney and Siemens.

The business will remain at its two current sites and will be immediately rebranded as MB Aerospace Technologies (Poland). In order to support the existing customer base and growing aerospace market in Eastern Europe, MB Aerospace is planning to invest across the business with particular focus on its surface coating services, including thermal and plasma coatings and a range of paint capabilities, as well as heat treatment and brazing processes.

Craig Gallagher, MB Aerospace chief executive officer, said: “We are delighted to acquire the Polish operations of Vac-Aero – now trading as MB Aerospace Technologies (Poland) – as its extensive range of capabilities and skilled employees will help us broaden our offering to existing customers and the expanding aerospace market in Poland and the surrounding industrial areas of Western and Eastern Europe.

“With thermal and plasma coating capabilities now available to us in the region, we can provide customers with fast, responsive lead times for aero-engine and industrial gas turbine component treatments, whilst mitigating the logistics, and cost, of shipping products long distances to have such critical work done.”

Dave Farmery, managing director of MB Aerospace Poland, added: “We have inherited a well-established and respected business in Poland with highly skilled employees and a wide range of customer approvals. Working closely with the existing team, we will invest heavily to provide the local market with the capabilities and capacity required to ensure customers continue to receive a world-class service.”

Tomasz Krążyński, General Manager, of MB Aerospace Technologies (Poland) said: “After more than a decade of growth and success under Vac-Aero we look forward to starting a new chapter within the MB Aerospace family of companies. The acquisition offers a fantastic opportunity for the business and the planned investment will help us establish ourselves as one of the premier providers of thermal processes and surface coating services in Europe.”

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Lindberg/MPH Ships Tube Furnaces

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

Lindberg/MPH announced the shipment of four (4) heavy duty tube furnaces to a leading manufacturer of thermocouples for use in a laboratory to heat treat parts inside tubes. The tube furnaces are easy to operate, utilize an energy efficient design, and provide rapid heat-up rates along with fast cooling and response time. They offer superior radial and linear temperature uniformity and require little or no maintenance.

The four (4) heavy duty tube furnaces have a maximum temperature rating of 1500°C and work chamber of 3” in diameter and 34” in length with removable side panels. Double-end silicon carbide heating elements are mounted above and below the furnace chamber for uniform heating. The chambers are constructed of high-temperature graded insulation. The insulating vestibules at the ends of the heated chambers keep the heat loss to a minimum ensuring even greater temperature uniformity. These tube furnaces provide easy element installation, electrical hook-up, and adjustment.

“These compact tube furnaces offer customers a number of benefits. With a design that is easy to operate while at the same time provides energy efficiency and premium performance, they are the ideal solution for many customers.” –Jason Dobberstein, Inside Sales Manager

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