AEROSPACE HEAT TREAT

Advanced Heat Treat Receives Nadcap Merit Status

Advanced Heat Treat Corp. announces that it has been awarded Nadcap Merit status for Heat Treating (Ion Nitriding) at the MidPort location in Waterloo, IA.

“Achieving Merit status for the second time in a row is a huge accomplishment for us. Our team works hard each day to ensure the highest quality is given not only to our aerospace and defense customers, but every customer that sends parts to AHT! We are proud to offer the Nadcap certification for our ion (or plasma) nitriding services and hope our customers take pride in the fact they send their parts to AHT.” Stated John Ludeman, Director of Metallurgy and Quality Excellence.

Advanced Heat Treat Corp. has held Nadcap accreditation since 2013. Having demonstrated their ongoing commitment to quality by satisfying customer requirements and industry specifications, the Nadcap Task Group has determined that Advanced Heat Treat Corp. has earned special recognition. This means that, instead of having their next Nadcap audit in twelve months, Advanced Heat Treat Corp. has been granted an accreditation that lasts 18 months!

“Achieving Nadcap accreditation is not easy: it is one of the ways in which the aerospace industry identifies those who excel at manufacturing quality product through superior special processes. Companies such as Advanced Heat Treat Corp. go above and beyond achieving Nadcap accreditation to obtain Merit status and they should be justifiably proud of it,” said Joe Pinto, Executive Vice President and Chief Operating Officer at the Performance Review Institute. “Benefitting from a less frequent audit schedule reduces audit costs and associated pressures and demonstrates the trust that the aerospace industry has in Advanced Heat Treat Corp., based on their past performance in Nadcap audits. PRI is proud to support continual improvement in the aerospace industry by helping companies such as Advanced Heat Treat Corp. be successful and we look forward to continuing to assist the industry moving forward.”

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Heat Treat TV: 48′ Vacuum Furnace Installed in Western Pennsylvania

Take a look at this fascinating time-lapse video of a 48 foot vacuum furnace being installed at a leading commercial heat treat shop in western Pennsylvania. The furnace was manufactured by Solar Manufacturing and will be used for vacuum processing very large, long, and/or heavy aerospace, automotive and energy sector parts. Watch it now by clicking here or on the image below.

Solar Atmospheres' 48' Vacuum Furnace 2

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Norsk Titanium to Build World’s First Industrial-Scale Aerospace Additive Manufacturing Plant in New York

State Releases First Funds for Signature Economic Development Project for Initial Lot of 20 Norsk Titanium MERKE IV™ Rapid Plasma Deposition™ Machines to Launch Aerospace Factory of the Future

Norsk Titanium AS, the world’s pioneering supplier of aerospace-grade, additive manufactured, structural titanium components announced today the State of New York, in partnership with SUNY Polytechnic Institute, has placed an order for an initial lot of 20 of Norsk Titanium’s patented MERKE IV™ Rapid Plasma Deposition™ (“RPD™”) machines.  The order is in accordance with an approved state budget allocation to facilitate Norsk Titanium’s US subsidiary building and operating the world’s first industrial-scale metal additive manufacturing plant in New York with the following details:

  • Plattsburgh, New York selected as the location for the world’s first Rapid Plasma Deposition™ factory
  • Facility to be operational by the end of 2017
  • The first 20 MERKE IV™ RPD™ machines establish a baseline production level of 400 metric tons per year of aerospace-grade, structural titanium components
  • The New York program envisions a capacity ramp-up to a total of 40 MERKE IV™ RPD™ machines capable of up to 800 metric tons per year, which will be consumed to meet increasing demand from the aviation industry
  • New York State investment advances Norsk Titanium’s production of the first 20 machines
  • New York has released an additional $4.0 million in planning funds for the Norsk Titanium US industrial-scale Plattsburgh factory

“We are proud to be a part of the unwavering vision and leadership of Governor Cuomo and are moving forward in support of his efforts to revitalize upstate New York with jobs, technology and community pride,” said Norsk Titanium Chairman of the Board John Andersen, Jr. “Our researchers have spent ten years pioneering the Rapid Plasma Deposition™ process that is now ready to cut millions of dollars in cost from the world’s premier commercial and military aircraft, and with the foresight displayed in other sectors, the State of New York is the ideal place to launch this manufacturing revolution.”

“Today marks the beginning of a new era in the way aircraft, marine vessels, automobiles, spacecraft and many industrial products are designed and built,” said Norsk Titanium President & Chief Executive Officer Warren M. Boley, Jr. “Not only are we creating jobs, huge economic impact and great visibility for the wider Plattsburgh community, we are also making history by kicking off a new phase of on-demand, near-net-shape manufacturing that sets a new benchmark of efficiency and customer responsiveness.”

“This unparalleled investment by Governor Andrew Cuomo in the North Country’s aerospace sector brings together a leading-edge global company in Norsk Titanium with an established high-tech aviation ecosystem in the region and the state, a perfect match that will create good paying advanced manufacturing jobs in Plattsburgh while advancing New York’s leadership in this dynamic and growing industry,” said SUNY Polytechnic Institute Vice President Christopher Walsh. “SUNY Poly is proud to partner with Norsk Titanium to bring this revolutionary technology to market and to continue to drive cutting edge research in all of the state’s nanotechnology-enabled industries.”

Under the terms of the deal, Norsk Titanium US will provide additional investment into the Plattsburgh operation that is expected to bring the total program commitment to the $1 billion dollar level over the initial 10-year period of operations. A $125 million New York investment in the Norsk Titanium US Plattsburgh factory was approved in the 2016-2017 State budget and first highlighted by Governor Cuomo on April 1, 2016 during the North County Highlights budget address in Albany.

Norsk Titanium US is also partnering with the North County Chamber of Commerce in Plattsburgh to support and promote the successful launch and growth of Norsk’s industrial-scale factory including workforce training, economic development and STEM outreach including specific educational programs for SUNY Plattsburgh, local community colleges and other schools in the region.

Norsk Titanium’s proprietary RPD™ process works by feeding titanium wire into a set of plasma torches protected by a cool argon environment that has made it possible to replace legacy forged parts, which take months and even years to develop and produce, with precision, additive manufactured components. The company has signed numerous contracts with the top echelon of aerospace manufacturers and tier-1 suppliers interested in leveraging RPD™ to cut cost and lead time from airframe and engine programs.

Norsk Titanium RPD™ components have equivalent strength to forgings, but are delivered inexpensively and efficiently, with unprecedented part cost and design-to-market speeds.

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Ellwood Texas Forge Navasota Completes Forgings for Boeing

gI_164487_July2016On July 19, 2016, Ellwood Texas Forge Navasota, LLC (ETFN) made its first production shipment of 15-5PH flap-track forgings for the 737 program to the Boeing Portland (Oregon) fabrication facility. Ellwood and Boeing had concluded negotiations on a new multi-year contract in May of 2015, and shortly thereafter began the qualification processes and testing required, ultimately resulting in the successful production of the flap track forgings. ETFN looks forward to a long term relationship with Boeing, exploring new opportunities across all airplane programs.

About Ellwood Texas Forge Navasota, LLC

ETFN is one of two closed die forging companies owned by Ellwood Group Inc., headquartered in Ellwood City, PA.  Located in southeast Texas, ETFN uses conventional hammers, computer controlled counter blow hammers and computer controlled presses to manufacture near net closed die forgings out of carbon, alloy, stainless and titanium.  ETFN also has in-house die sinking, cutting, heat treatment, testing and machining capabilities.

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Ion Nitriding of Titanium Alloys for Gear Applications

BOTW-50w  Source:  Thermal Processing for Gear Solutions
The advantages of ion nitriding heat treatments in many low-alloy steels and titanium alloy gears used in high-performance applications include resisting wear and fatigue.

Thermochemical surface engineer heat treatments are effective in improving the performance of various gears made of ferrous alloys. The cost of machining typical gears during the manufacturing process often exceeds 55 percent of total cost, especially when there is significant grinding after carburizing the gears. Therefore, improvements in the manufacturing of gears that can lead to a reduction in machining are valuable.

Nitriding produces high hardness and compressive stresses in many low-alloy steels used for gears. It is a nearly distortion-free process, which allows for the treating of finished components, thus minimizing costs. The complex nature of the stresses at the contact area of rotating gears leads to contact fatigue and sliding friction. Nitriding is superior to other surface engineering techniques in resisting wear at gear f lanks. When a high-strength alloy steel suitable for nitriding is used, a nitrided surface layer withstands high contact Herztian stress (contact stress) at gear flanks better than a deeper carburized layer in many instances.

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Laser -Induced Breakdown Spectroscopy: A New Tool for Real Time Metal Quality Measurement

BOTW-50w  Source:  Die Casting Engineer

“Laser-induced breakdown spectroscopy (LIBS) has shown great potential for use in metal processing and can be performed directly in the molten metal, allowing for quick and representative measurements.”

Read More:  Laser-Induced Breakdown Spectroscopy:  A New Tool for Real Time Metal Quality Measurement by Shaymus Hudson, Joseph Craparo, Robert De Saro, Diran Apelian

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Alcoa Awarded Multi-year, $470 Million Contract with Embraer

“Lightweight metals leader Alcoa (NYSE:AA) today announced a long-term contract with Embraer – the leading manufacturer of commercial jets up to 130 seats – valued at approximately $470 million. Under the multiyear agreement, Alcoa will supply aluminum sheet and plate for Embraer’s new E2s, the second generation of its E-Jets family of commercial aircraft, a narrow-body medium-range jet airliner. The Embraer E-Jets E2 were launched at the Paris Airshow in 2013 and are scheduled to enter into service in 2018.

“Our partnership with Embraer is rooted in constant innovation and this contract is further proof of that strength,” said Mark Vrablec, President of Alcoa’s Aerospace & Automotive Products business. “Our patented alloys enable us to support our customer’s game-changing E2 program, and we’re proud that Alcoa will fly with Embraer.”

Embraer chose Alcoa’s proprietary alloys for the E2 due to the combination of strength, corrosion resistance and fatigue resistance that they offer.

“Alcoa offers a good combination of technical expertise and industry leading material and capabilities,” said Fernando Queiroz, Embraer Vice President, Supply Chain. “Embraer designed the E-Jets E2 commercial aircraft to be the best in its segment and to do that, we needed the best material in the business, and Alcoa offers the best solution.”

According to Embraer, the market segment that the new E2 program was designed to serve is projected to require 6,350 new aircraft over the next 20 years. In addition, Embraer also stated that it has more than 50 percent market share by orders with the current E-Jet and expects to maintain similar levels with the new E-Jets E2 aircraft.

The long-term agreement makes Alcoa sole supplier to Embraer for proprietary wing skins and fuselage sheet on the E2 line of jets. Other Alcoa plate products, used in key applications such as wing ribs, fuselage frames and other structural parts of the aircraft, are also part of the contract and will be featured on the E2 as well as Embraer’s KC-390 military transport aircraft and executive jets.

Alcoa has developed most of the aluminum aerospace alloys to ever take flight, and every major new aircraft program incorporates Alcoa’s product innovations. The Alcoa/Embraer partnership draws on the aerospace manufacturing capabilities of Alcoa’s Global Rolled Products business, supplying Embraer from its plants in Davenport, Iowa, and Kitts Green, United Kingdom.

Alcoa products can also be found on other parts of the E2 aircraft: the state-of-the-art Pratt & Whitney PurePower® engine. Alcoa already supplies key parts for the PurePower® engines, including the forging for the first ever aluminum fan blade.”

Alcoa Awarded Multi-year, $470 Million Contract with Embraer Read More »

Foundry Sector’s Expectations

BOTW-50w  Source:  Foundry Gate

“India is the third largest manufacturer of metal castings globally, producing approx 10 million tonnes of castings in various metals.

The Institute of Indian Foundrymen (IIF) is the apex industry body promoting the competitiveness of India’s foundry industry. There are about 5,000 foundries in India largely in the MSME category.

The foundry or metal casting industry is a key component feeder for the various sectors such as auto, auto components, railways, agro, tractors, textile, cement making, electrical machinery, earthmoving machinery, power equipment, defence equipment, and aero and space industry its sustainable growth has become more important today than ever before given the emphasis of the government on “Make in India”.

Read More:  Foundry Sector’s Expectations

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New High Temp Al-Ti Coating Protects Flight Decks

BOTW-50w  Source:  Engineering 360

“Specialist teams from across the Aircraft Carrier Alliance—a UK government/industry partnership—have developed a thermal coating from aluminum and titanium that can withstand temperatures of up to 1,500°C. The coating, developed in partnership with Monitor Coatings, is expected to provide protection throughout the life of the carriers and forms an important part of the work under way to prepare the HMS Queen Elizabeth for sea trials in 2017 and flight trials in 2018.”

Read More:  New Thermal Coating Protects Flight Deck

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Pratt & Whitney Searching for Products, Services to Ramp Up Monthly Engine Production

BOTW-50w  Source:  Manufacturing Engineering

“In 2010 P&W delivered about 55 engines a month. In 2017, that number grows to about 100 engines a month. And in 2024, it continues to climb to about 158 engine deliveries a month, she said.

“And I’m doing that with 20-year-old technology and 20-year-old manufacturing processes and a very well-seasoned workforce” that adds significant complexity to the digital manufacturing transformation of the East Hartford, CT-based firm, Hagerty  said during a panel talk on best practices.

“So the challenges ahead of me are steep.”

In an interview with Smart Manufacturing magazine after the panel discussion, Hagerty said she is “fresh into the exploratory phase” to find products and services her firm needs. She has mapped out her requirements.

“Now, I’m reaching out to the service providers” and scheduling visits to firms using products and services that might well work for Pratt & Whitney.”

Read More:  Pratt &Whitney Searching for Products, Services to Ramp UP Monthly Engine Production

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