Mary Glenn

2200°F Conveyor Oven Supplied for Aquatic Heating Systems

Baker Furnace, Inc. shipped a custom-built, high-temperature conveyor oven designed to heat treat rods used to manufacture commercial heating elements.  The process also requires a nitrogen purge to create a specific atmosphere.

At 35 ft long with an operating temperature of 1900°F, the engineering challenges for this unique application were a combination of the size and high temperature coupled with the fact that the application required four different heating zones with a nitrogen injection in every zone.

The electrically-powered conveyor oven was constructed as a modular system which allowed Baker Furnace to conduct a complete test on site and then break it down to ship and install in the most cost-effective manner.   The first two zones for heating measure 24”w x 16”h x 12’L while the two cooling sections measure 24”w x 16”h x 20’L, both with nitrogen injection supply lines to create an inert atmosphere. The oven is equipped with a 24” wide inconel wire woven belt supported by an internal inconel slider bed, which is driven with a gear reduction motor (speed controlled by Allen Bradley drives).  Using formed rod-style, Kanthal elements rated at 60kW for heating, the entire system is controlled with an Allen Bradley touch screen HMI and Allen Bradley PLC software.

“Designing a conveyor oven of this size and temperature is a challenge in itself, but our biggest hurdle came when we had to achieve a plus or minus 25°F heat uniformity within the multiple zones.  Each zone required different temperatures with a nitrogen injection.  We leaned on our past experience as well as testing several scenarios to come up with a design that the customer loves.”   Tim Bacon, Lead Project Manager at Baker Furnace.

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Commercial Metals Company Celebrates the Groundbreaking of New Micro Mill

On April 29, 2016, Commercial Metals Company (NYSE: CMC), state, federal and local officials and their honored guests gathered for a groundbreaking ceremony marking the start of construction of CMC’s second technologically advanced micro mill which will be located in Durant, OK.

Joe Alvarado, Chairman of the Board, President and CEO of CMC, said, “This event marks another historic day for CMC, the State of Oklahoma, and the City of Durant.  We believe the addition of a second micro mill to CMC’s portfolio of highly efficient and customer focused production facilities will open new market opportunities and enhance CMC’s position as a leading supplier of long products in the U.S. market. Today would not have been possible without the support of the State of Oklahoma and the City of Durant and we look forward to many years of a very successful relationship.”

“This groundbreaking represents how local, state and tribal partnerships can bring together various entities to achieve great things for the State of Oklahoma,” said Governor Mary Fallin. “Not only will this mill produce high quality steel products that can be used by many Oklahoma industries, it will bring quality jobs to the Durant area, providing great opportunities for Oklahomans and further diversifying our economy.”

CMC’s innovative micro mill technology uses a continuous-continuous manufacturing process that melts, casts and rolls steel from a single uninterrupted strand, producing higher yields and lower energy consumption than the traditional minimill process.  The Oklahoma micro mill is expected to create approximately 300 jobs in the Durant area.

CMC expects the new Durant micro mill to be commissioned in the fall of 2017.

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How Will We Design, Manufacture and Test 900 Satellites?

OneWeb Satellites, a joint venture between Airbus Defence and Space and OneWeb, has chosen Florida in the United States as the site for its final assembly line, completing the last step in its industrial organisation. This facility, located at Florida’s Exploration Park, near the Kennedy Space Center, will carry out the series production of nearly 900 satellites for the OneWeb constellation.

“In June 2015, we started from scratch to create a new satellite design and manufacturing company,” stated François Auque, Head of Space Systems. “In both Florida and Europe, we are now embarking on the next stage of an unprecedented venture in the space industry: a site that can mass-produce dozens of satellites every month. All this, of course, without affecting the levels of quality and technology that are essential when it comes to spacecraft – complex machines that need to operate for several years in space.”

The choice of Florida for the final assembly line follows the announcement of the creation of OneWeb Satellites in January 2016. The production site will cover an area of 100,000+ square feet and will create nearly 250 direct jobs.

A prototype production line at Airbus Defence and Space in Toulouse (France) will assemble and test the first 10 satellites, and check and validate industrial solutions for the series production. The design of the satellites is currently under way in the company’s design offices in Toulouse.

The space segment of OneWeb will comprise initially a constellation of 648 operational satellites and replacement satellites, all of which will be identical. Each satellite will weigh approximately 150 kg and will operate in low Earth orbit. Arianespace and Virgin Galactic will begin launching the spacecraft in 2018 and the satellites will be placed in orbit using electrical propulsion.

This joint venture, equally owned by Airbus Defence and Space and OneWeb, has been set up following the selection in June 2015 of Airbus Defence and Space as the industrial partner of OneWeb to design and build its satellites. The constellation to be operated by OneWeb will provide high-speed internet services with global coverage. OneWeb Satellites will also be able to produce satellites, platforms or equipment to be marketed by Airbus Defence and Space for the benefit of other operators of future constellations.

 

 

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Alcoa Unveils Four New Specialty Alloys

BOTW-50w Source: Alcoa

Lightweight, high-performance metals leader Alcoa (NYSE:AA) today launched a family of innovative foundry alloys designed to meet the growing need for both part performance and lightweighting in the automotive industry and beyond.”

Read More: Alcoa Launches Four New Specialty Alloys that Deliver Lightweight, High-performance Solutions to Meet Growing Automotive Demand

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Buehler Consolidates European Metallography and Hardness Testing Business

Buehler (http://www.buehler.com), a leading manufacturer of equipment, consumables and accessories for metallography and hardness testing, has combined its business sectors Metallography, formerly based in Düsseldorf/Germany, and Hardness Testing, still widely known under its previous name, Wilson Hardness, and traditionally based in Esslingen am Neckar in Germany. After the formal consolidation of both core activities in 2009 under the name of Buehler ITW Test & Measurement GmbH, this site in Southern Germany now takes on the function of European Headquarters. In Düsseldorf, the company is currently establishing a new, central laboratory in close cooperation with partners in industry, universities and research institutes, for handling international research projects covering the full span from sample preparation in the laboratory right up to fully automatic in-process hardness testing.

The facilities at the new ‘Buehler Solutions Centre’ in Esslingen offer Buehler ITW Test & Measurement adequate space for development, training, production, sales and warehousing. They even allow for a future expansion of these activities, providing customers from the German-speaking region, France and the UK with direct access to a team of highly qualified professionals in all matters of the procurement, operation and servicing of equipment and systems, as well as a central warehouse for spare parts and consumables. In addition, Buehler is represented in 50 countries worldwide through distributors.

European Commercial Director Roland Prauss said: “The physical consolidation of our Metallography and Hardness Testing operations at a single site will produce synergistic effects, which will enable us to respond to the future demands of a Europe-wide market. We are proactively meeting the needs of our customers, who are increasingly active in multiple countries, and require the same level of service to be available from a single source throughout these countries, so that they, in turn, can optimize their own processes. Buehler can now create new opportunities by pooling our resources, upgrading existing products and developing new products ideally suited to the requirements of our international customers. This consistent focus on the ‘Voice of the Customer’ is an approach already successfully adopted by ITW Test & Measurement in the US and Chinese markets.”

As a concrete example, Prauss cited the growing trend towards ITW Test & Measurement products being used in demanding industrial environments and in multi-shift operation. “We are seeing an increasing trend for measurement and testing activities to move from the laboratory onto the production floor. This implies an increasing level of training on the part of operating staff and places higher demands on the equipment itself and its suitability for continuous round-the-clock operation. It necessitates an appropriate approach to the design of hardware and software, including ergonomics, and a consistent adaptation of our inventory with a view to satisfying rapidly changing demand and high volumes. At our new Esslingen headquarters, we are now eminently well set up to assist our customers on their chosen paths“.

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CT Scanners for Industrial Jobs

BOTW-50w Source:  Today’s Energy Solutions

“These 3D imaging devices and long-range scanners serve a wide range of industries, and help assure that they are performing the highest level of testing and accuracy possible. A few of the diverse industries currently using this technology and the goals sought are:

Manufacturing – for internal inspection of components and to ensure that a part meets specifications; this includes injection molded, cast, forged or fabricated parts made from metal, plastic, polymers, composites and even 3D printed products.”

Read more: CT Scanners for Industrial Jobs

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Solar Atmospheres Receives First Reaccreditation from MedAccred

Solar Atmospheres, Inc. has announced that it has become the first company to receive MedAccred critical process reaccreditation.  Furthermore, Solar Atmospheres, Inc. successfully expanded its scope of accreditation to include Hardness Testing and Metallography & Microindentation Hardness.  MedAccred is an industry-managed critical process supply chain oversight program which was developed by leading medical device companies to improve device quality and most importantly enhance patient safety.

The effort to establish MedAccred began in 2010 when the Performance Review Institute (PRI) was asked to consider the development of a Nadcap-style special process supplier accreditation program for the medical device industry.  An industry roundtable was organized and convened in 2012 among interested medical device companies and PRI.  Following this roundtable meeting, briefings were held with the FDA Center for Devices and Radiological Health’s (CDRH) Office of Compliance and the FDA’s Office of Global Operations within the Office of the Commissioner. The program purpose and scope was discussed, along with the results of proof of concept audits which were conducted to demonstrate the program’s viability. The FDA provided positive feedback and strong encouragement to pursue the development of the program.

By 2014, several critical process Task Groups were operating on a formal basis, program documents were drafted, circulated and approved by the executives of the participating companies and audit criteria had been published in several critical process areas.  Solar Atmospheres, Inc. committed to hosting the first MedAccred audit.

In early 2015 the first MedAccred critical process accreditation was issued to Solar Atmospheres Inc. for Heat Treating.

Today’s functioning critical process Task Groups include Cable & Wire Harnesses, Heat Treating, Plastics Injection Molding, Printed Circuit Board Assemblies, Sterilization and Welding.  The industry managed task groups develop audit criteria, conduct audits, and award MedAccred Critical Process Accreditations to leading suppliers at all tiers in the Medical Device Supply Chain.  Many companies are seeking MedAccred Accreditation to demonstrate their commitment to quality and patient safety. Future MedAccred Task Groups under consideration for development include Material Testing Laboratories, Assemblies, PCBs, Batteries, Chemical Processing, NDT, Cleaning, Coating, Optics, Packaging, etc.  Active OEM and Contract Manufacturer participants include: Johnson & Johnson, Philips, Stryker, GE Healthcare, Medtronic, NYPRO Jabil, Steris, etc.  The list of participating suppliers is growing steadily.

Joe Pinto, Executive Vice President and Chief Operating Officer of PRI explained the significance of Solar Atmospheres’ accomplishment: “Gaining a critical process accreditation from MedAccred is recognition of a company’s commitment to quality and the high standards of critical process manufacturing which they maintain.  The successful completion of a reaccreditation audit is a clear indication that a company is able to consistently uphold those extremely high standards over an extended period of time.   I would like to congratulate the whole team at Solar Atmospheres on this important achievement.”

Solar Atmospheres Receives First Reaccreditation from MedAccred Read More »

Alcoa to Supply 3D-Printed Metal Parts for Airbus

Lightweight metals leader Alcoa (NYSE:AA) has entered into an agreement with Airbus to supply 3D-printed titanium fuselage and engine pylon components for Airbus commercial aircraft. Alcoa expects to deliver the first additive manufactured parts to Airbus in mid-2016.

“We are proud to partner with Airbus to help pave the way to the future of aerospace development and manufacturing,” said Alcoa Chairman and Chief Executive Officer Klaus Kleinfeld. “The unique combination of our multi-material alloy development expertise, powder production capabilities, aerospace manufacturing strength and product qualification know-how position us to lead in this exciting, emerging space.”

Airbus chose to work with Alcoa because of its comprehensive capabilities, from materials science leadership to additive manufacturing and aerospace parts qualification. The agreement will draw on Alcoa’s decades of aerospace experience and new technologies gained through the recent acquisition of RTI and organic expansion in Whitehall, Michigan. Alcoa also recently invested in 3D-printing and metallic powder production capabilities at its technical center outside of Pittsburgh, Pennsylvania.

Last year, Alcoa acquired RTI International Metals (RTI)—now known as Alcoa Titanium & Engineered Products (ATEP)—which grew Alcoa’s additive manufacturing capabilities to include 3D-printed titanium and specialty metals parts produced at ATEP’s Austin, Texas facility. The Airbus agreement will draw on these capabilities as well as ATEP’s titanium ingot melting and billetizing, machining, finishing and inspection technologies.

Alcoa will employ advanced CT scan and hot isostatic pressing (HIP) capabilities at its advanced aerospace facility in Whitehall, Michigan. HIP is a technology that strengthens the metallic structures of traditional and additive manufactured parts made of titanium and nickel based superalloys. Through a $22 million investment in the technology in Whitehall, Michigan, Alcoa today owns and operates one of the largest aerospace HIP technology complexes in the world.

Additionally, Alcoa is bolstering its additive manufacturing capabilities through a $60 million expansion in advanced 3D-printing materials and processes, including metallic powders. The expansion is located at the Alcoa Technical Center near Pittsburgh, Pennsylvania, the world’s largest light metals research center.

 

 

 

Post updated Thursday 4/29/2021 at 3:37pm.

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Temperature Uniformity Surveying for Vacuum Furnaces

BOTW-50w Source:  Solar Atmosphere’s Vacuum Reference Series Number 2

A Temperature Uniformity Survey ( TUS ) for a vacuum furnace to satisfy AMS 2750D must be performed using established procedures and methods that fully meet the requirements of the specification and allows for consistent and more accurate results of actual furnace capabilities.

Read More: Optimizing Procedures for Temperature Uniformity Surveying of Vacuum Furnaces

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Solar Manufacturing’s Vacuum Furnace Reference Series

 

 

BOTW-50w Source:  Solar Manufacturing’s Vacuum Furnace Reference Series

This series includes eight releases with the following titles.

Release 1:  Critical Melting Points and Reference Data for Vacuum Heat Treating

Release 2:  Optimizing Procedures for Temperature Uniformity Surveying of Vacuum Furnaces

Release 3:  Operating a Vacuum Furnace Under Humid Conditions

Release 4:  Understanding PID Temperature Control as Applied to Vacuum Furnace     Performance

Release 5:  Understanding Power Losses in Vacuum Furnaces

Release 6:  Important Considerations when Purchasing a Vacuum Furnace

Release 7:  Important Considerations when Selecting a Vacuum Furnace Water Cooling System

Release 9:  Understanding Vacuum and Vacuum Measurement

Read More:  Solar Manufacturing’s Resources for Vacuum Heat Treating Releases 1 – 9

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