An iron casting foundry located in Hubbard, Ohio, is expanding into aluminum casting with an aluminum slab and billet plant at its current site.
Ellwood Engineered Castings is investing $60 million to house its new Ellwood Aluminum division to serve customers in the aerospace and other industries.
With electricity costs increasing, heat treat facilities are looking for ways to harness energy and minimize heat loss through a variety of insulating methods and applications. Heat Treat Today‘s Technical Tuesday feature comes from Reál J. Fradette of Solar Atmospheres Inc of Souderton, PA (with Nicholas R. Cordisco of Solar Manufacturing Inc. contributing), analyzing the different types of furnace hot zone insulation materials with the following points taken into consideration:
A) Hot Zone Designs
All-Metal Designs
Ceramic Fiber Included Designs
Graphite Type Insulated Hot Zones
B) Defining Hot Zone Losses For Different Hot Zone Configurations
Calculating Power Losses For A Given Size Furnace
Effect Of Hot Zone Losses On Heating Rates and Peak Power
C) Effect on Power Losses With Various Insulation Layers and Thicknesses
Projecting Relative Losses Versus Felt Thicknesses
D) Equating Insulation Designs To Actual Power Usage
Projecting Cycle Costs For Different Areas Of Operation
Impact of Hot Zone Type on Total Cycle Cost
E) Summary And Conclusions
An excerpt:
The heating rate of a load will dictate the total energy required to heat that load at that heating rate. Heating as fast as possible is not often the best solution to the application.
A global association committed to providing and monitoring standards for the engineering profession recently published a new standard with guidance material to support specific aerospace engine applications, with a focus on the practical application of control methods for many different situations.
Dan Eigenbrode, vice president of module centers & supplier quality at Pratt & Whitney and AESQ Executive Sponsor for AS13006
SAE International in Warrendale, PA, released AS13006: Process Control Methods, which AESQ Strategy Group members will accept the immediate use of AS13006 within their respective supply chains. In addition, organizations are strongly encouraged to begin using this latest standard before it becomes a contractual requirement.
Aerospace engine manufacturers and their suppliers currently have differing requirements for process control that have similar intent. This new SAE standard establishes a common practice and methodology, defining the requirements for ongoing process control to improve quality performance through optimized process variation management beyond customer-defined key characteristics.
“The release of AS13006 is a big step forward in harmonizing requirements in the Aero-Engine supply chain,” said Dan Eigenbrode, vice president of module centers & supplier quality at Pratt & Whitney and AESQ Executive Sponsor for AS13006. Aerospace Engine Supplier Quality (AESQ), an SAE ITC program, was founded and formed by major aerospace engine companies to standardize quality requirements across the supply chain.
“Process Control is the key ingredient for sustained product quality and AS13006 provides the means for all suppliers to implement robust systems to ensure consistent quality regardless of product type,” added Eigenbrode.
AS13006, the previously released AS13003, Measurement Systems Analysis Requirements for the Aero Engine Supply Chain, and AS13004, Process Failure Mode and Effects Analysis (PFMEA) and Control Plans align and support the SAE standard AS9145, Requirements for Advance Product Quality Planning and Production Part Approval Process, developed by the International Aerospace Quality Group (IAQG)/SAE G-14 AAQSC Committee. The SAE G-22 AESQ Committee and the IAQG/SAE G-14 AAQSC Committee worked together cooperatively to ensure proper alignment of these standards.This standard also aligns and collaborates with the requirements of AS9103, Quality Management Systems – Variation Management of Key Characteristics.
Although designed for the aerospace engine supply chain, AS13003, AS13004, and AS13006 may be applied effectively by other segments of the aviation, space, and defense industries.
The Aerospace Engine Supplier Quality (AESQ) Strategy Group, a program of the SAE ITC, was established to develop, specify, maintain, promote, and deploy quality standards specific to the aerospace engine supply chain. AESQ member companies include Arconic, GE Aviation, GKN Aerospace, Honeywell Aerospace, MTU Aero Engines, PCC, Pratt & Whitney, Rolls-Royce, and Safran.
An Arizona-based aerospace service provider recently opened a new 206,000-sq. ft. repair facility in Cincinnati, Ohio, directly adjacent to its current 236,000 sq. ft. component repair facility, nearly doubling its capacity.
Rick Stine, president of StandardAero Components, Helicopters & Accessories
StandardAero Component Services hosted a ribbon-cutting ceremony attended by city and state of Ohio officials, local economic development executives, customers, company officials, and other guests.
The facility will accommodate component repair growth on new and legacy platforms, aero-derivative, military and commercial aircraft engine component repair, as well as larger components. Once fully operational, StandardAero expects to employ 200-300 new technicians to continue to meet the growing demands of customers over the next 12-18 months.
“As new engine platforms are launched and legacy fleets are still maintained, the entire industry is seeing tremendous growth. Demand for component repair has increased so we are stepping up to directly support our customers and address the continued and rapid need for more component repair capacity,” said Rick Stine, president of StandardAero Components, Helicopters & Accessories.
During 2018, StandardAero also increased shop capacity by an additional 60,000 sq. ft. with expansions of its facilities in Hillsboro, Ohio and Miami locations.
A Wichita, Kansas-based, manufacturer of fabricated parts for the aerospace industry recently announced its partnership with the world’s pioneering supplier of aerospace-grade, additive-manufactured, structural titanium components to initiate qualification of parts for the Boeing 787.
Spirit AeroSystems and Norsk Titanium US Inc. have reached an agreement to initiate qualification of Spirit’s first additive-manufactured, titanium, structural component for the Boeing aircraft.
Ron Rabe, Spirit AeroSystems Senior Vice President of Fabrication and Supply Chain Management
This qualification will validate NTi’s production and industrialization processes, integrate Spirit’s work scope of machining final parts from additively manufactured near-net shapes, and verify material and final part conformity to requirements.
“Spirit has had a comprehensive and long relationship with Norsk Titanium, and this part will be our first additive structural titanium component incorporated into a commercial airplane program,” said Ron Rabe, Spirit AeroSystems Senior Vice President of Fabrication and Supply Chain Management.
NTi is the world’s first FAA-approved, OEM qualified, supplier of additive-manufactured, structural titanium components. NTi’s proprietary Rapid Plasma Deposition™ (RPD™) process has been in serial production of Boeing 787 titanium components since April 2017.
“I am very proud of the Norsk Titanium team and this accomplishment. It represents years of technology development,” said Mike Canario, CEO of Norsk Titanium. “I also would also like to thank Spirit for this vote of confidence in the Norsk RPD™ process and capability.”
Mike Canario, CEO of Norsk Titanium
NTi’s Plattsburgh, N.Y., facility was recently added to Spirit’s Approved Supplier List (ASL) and Boeing’s Qualified Producer’s List (QPL). Spirit and NTi have had an ongoing technology collaboration for more than nine years. In 2017, both companies signed a Master Procurement Agreement (MPA) for qualification and production activities. The first commercial aircraft part will begin serial production later this year.
A leading independent Maintenance Repair & Overhaul (MRO) provider in the U.K. prepares to open a new Component Maintenance Centre in Northampton, England, with operations planned to start this month.
Monarch Aircraft Engineering (MAEL) has invested approximately £2 million in this new center, which will include heat treating lines compliant to industry standard for standard processing and detail fabrication requirements, as well as hardness testing.
Chris Dare, Managing Director at Monarch Aircraft Engineering
“Our new Northampton facility will enable us to more effectively and efficiently support our burgeoning line and base maintenance facilities across the UK,” said Chris Dare, Managing Director at Monarch Aircraft Engineering. “This multi-million-pound investment in new facilities, equipment and, most importantly, skilled engineering talent, is an integral part of our long-term growth plan and will play a vital role in our success in the years ahead.”
Ingrid Joerg, President of Constellium’s Aerospace and Transportation
A European provider of aluminum products and solutions announced recently that it has signed a multi-year agreement with The Boeing Company to support its leading commercial airplane programs. With this agreement, Constellium, based in The Netherlands, will supply Boeing with a broad range of advanced aluminum-rolled products coming mostly from its plant in Ravenswood, West Virginia.
“This new contract reflects the strong relationship established over the years with Boeing,” said Ingrid Joerg, President of Constellium’s Aerospace and Transportation business unit. “We look forward to continuing to support Boeing in its commercial airplane programs.”
A global aerospace and defense corporation recently announced an agreement to purchase a developer of small-satellite systems for military and national security projects.
An Israel-based manufacturer of all-electric air mobility solutions recently announced it has selected Prescott, Arizona, for its U.S. headquarters, which will include the manufacture of the aircraft’s ultra-light all-composite frames.
EViation Aircraft will establish operations for its electric commuter aircraft, Alice, at a site located adjacent to the Prescott Municipal Airport. The facility will serve as EViation’s base of operations for its expansion from Israel into the U.S. market. EViation selected Prescott as an optimal location for its U.S. headquarters given the area’s skilled workforce and high-density altitude, an ideal environment for test flights.
Omer Bar-Yohay, CEO of EViation
With the goal of making clean regional air travel accessible for all, EViation is tackling one of the world’s dirtiest industries — aviation. Its zero-emission, 100% electric solution, the Alice Commuter, which will be test flown at the 53rd Paris Air Show in June 2019, leverages an IP portfolio that includes thermal management and autonomous landing, as well as distributed electric propulsion, industry-leading battery technology, and cutting-edge composite body frames capable of carrying up to nine passengers on a single charge for 650 miles. EViation will certify and commercialize the Alice aircraft while partnering with leading industry suppliers to bring its prototypes to scale and to the global market.
“As we develop our regional electric aircraft, the U.S. represents a high-growth, near-term target market for us, given its many regional transit corridors and abundance of approved airstrips,” said Omer Bar-Yohay, CEO of EViation.
A Cleveland-based heat treatment software and engineering firm, specializing in metallurgical process engineering and thermal/stress analysis of metal parts, recently announced that mechanical and fatigue testing is underway on an innovative gas quenching unit designed to minimize component distortion during the hardening process.
The DANTE Controlled Gas Quenching (DCGQ) unit is capable of quenching single components following a time-temperature schedule designed for a specific component and steel alloy using the DANTE software.
DANTE Solutions proposed the concept of the process and the DANTE Controlled Gas Quench (DCGQ) unit and collaborated with Milwaukee-based Atmosphere Engineering (now part of United Process Controls), which built the unit, and Akron Steel Treating. The project is funded by the US Army Defense Directorate (ADD), and the aim market is aerospace, where high hardenability steels are used for gears, bearings, and shafts.
Front view of DANTE Controlled Gas Quench (DCGQ) unit
Back view of DANTE Controlled Gas Quench (DCGQ) unit, showing the HMI in process
Test coupons in the unit after the run.
Justin Sims, mechanical engineer, DANTE Solutions
According to Justin Sims, a mechanical engineer with DANTE Solutions, the project began with Phase 1, wherein the team had to “make sure that a relatively slow cooling rate through the martensite transformation did not degrade material properties.”
“Phase 1 showed that we had comparable results for hardness, tensile properties, Charpy impact properties, and bending fatigue to the standard quenching practice for Ferrium C64,” said Sims. “We then initiated Phase 2 and had a unit built that was capable of controlling the temperature of the incoming quench gas to within +/- 5°C.” Phase 2 will end December 2018 after two years. The Phase 1 process currently has a patent pending.
Mechanical & Fatigue testing is currently underway at Akron Steel Treating Company where the unit is installed, and samples have been processed to compare the DCGQ process to standard HPGQ of high alloy steels. The current steel under investigation is Ferrium C64. Sims noted that DANTE is overseeing the processing of the test materials, and commercial metallurgical testing companies are performing the tests.
Tensile Testing Metallurgical Laboratory completed the hardness, tensile and Charpy impact testing, and the results are similar for conventionally hardened C64 samples and DCGQ processed samples. IMR Test Labs is conducting the bending fatigue tests. The US Army at Fort Eustis will conduct the rolling contact fatigue tests.
“We have hardness, tensile, and Charpy impact results from the unit we can share with anyone who is interested,” said Sims. “Distortion, bending fatigue, and rolling contact fatigue are currently being evaluated and the results will be available before the end of 2018.”
“We believe that the DANTE Controlled Gas Quench (DCGQ) process, patent pending, has the potential to change the way heat treating is performed on high hardenability steels,” added Sims. “By controlling the temperature of the incoming quench gas, components experience a near uniform transformation to martensite. This near-uniform transformation has the potential to eliminate post-heat treatment correction operations by minimizing part distortion and allowing designers to account for the size change distortion in the initial design of a component. To date, mechanical and dynamic properties for Ferrium C64 processed using the standard hardening process and the DCGQ process has been identical. Bend fatigue and rolling contact fatigue are currently being evaluated.”
