One of the leading global power, aviation and renewable energy providers has selected a vacuum furnace hot zone replacement. The replacement and modernization of this hot zone is to be updated in a 20+ year old furnace. Once the furnace is updated, it will be installed at the client's facility in Hungary, Europe.
The supplier, SECO/WARWICK, replaced the hot zone of a horizontal vacuum furnace so that it could be integrated with the new, technologically advanced materials in the industry.
Peters’ Heat Treating, Inc., a 40-year-old heat treating company that specializes in a variety of high tech heat treating processes, moved its headquarters into a newly expanded Meadville, Pennsylvania facility located in the western part of the state.
Ribbon Cutting with the Owners: Doug and Jackie Peters (founders), Diana Wilkosz (VP), and Andy Wilkosz (President) (photo source: Peters' Heat Treating, Inc.)
Additionally, Peters' Heat Treating also announced two new lines of business: aluminum alloy processing and stainless steel black oxide.Vice President Diana Wilkosz shared in a recent interview, "We added these two new lines because of the growing demands from the automotive, aerospace, energy, and defense industries. We are also working on Nadcap certifications."
The company specializes in vacuum processing, atmosphere heat treating/integral batch quench processing, laser heat treating, aluminum alloy processing, carburizing, scale free aging/stress relieving, cryogenics, black oxide coating, induction processing, nitriding/FNC and the proprietary Nitreg nitriding processes.
After being in their original facility for 40 years, this expansion, that covers 32,000 square foot of manufacturing space, has provided them the opportunity to expand and update their vacuum line, provide room to add new vacuum furnaces, as well as increase their product offerings and continue to grow the now 60-employee business.
“We are excited to consolidate our services and knowledge in a way that maintains our history and dedication to the local community and industry while providing us the runway for a successful future,” said Andy Wilkosz, newly named president in 2019 and son-in-law of founders Doug and Jackie Peters. “These current times are challenging, but we know our business and the country will persevere.”
In addition to Peters' Heat Treating, the family also co-ownsLaser Hard, a robotic laser heat treating company.
“It’s been a pleasure to be a part of the local community and to help companies grow,” Doug Peters said. “Probably the thing I’m most proud of is the great people I’ve had the opportunity to work with. I’ve watched them buy houses and have children, and now their kids are having children.”
In today’s Heat Treat TodayTechnical Tuesday feature, learn more about how a temperature control system can improve the performance of heat treat equipment.
A century-old producer of die forgings recently needed to improve the process controls on its heat treating furnaces.
With process controls well over 10 years old, Clifford-Jacobs turned to Conrad Kacsik to improve its temperature process control system. The company, which serves a number of industries, including energy, aerospace, construction, mining, forestry, and rail, was eager to upgrade, particularly because the incumbent system was producing inconsistent work.
(source: Conard Kacsik)
The Challenge
Clifford-Jacobs was not getting consistent, repeatable results from its furnaces. The company also wanted more efficient and automated processes with data acquisition and electronic operating capability.
“We looked at a number of controls companies throughout the Midwest and interviewed them to learn about their experience with system controls and data acquisition,” said Bud Kinney, vice president of Innovation and Technology at IMT Corporation, the parent of Clifford-Jacobs. “We knew we wanted an integrated system so we started looking at companies that did that as a matter of course. Most companies are limited to traditional controls, but Conrad Kacsik has a lot of experience doing the exact type of job we needed.”
Increasing Demands
Clifford-Jacobs makes forged parts for a variety of clients. Although forging does not generally require as much precision as other types of processes, customers are increasingly demanding, said Kinney.
“We believe that sooner rather than later things like Nadcap will come into forging, and our customers are very interested in us being able to demonstrate that our processes are always in control, even forge heating,” Kinney said. “This project helps ensure that we meet those needs. We couldn’t track things like set-point input values before. That’s another element we wanted to manage.”
The System
Conrad Kacsik built a full process temperature control system that includes SCADA software from SpecView. They were able to retrofit the system on Clifford-Jacobs’ existing 16 furnaces, saving the company considerable expense and time. The temperature process control system uses Watlow F4T controllers paired with SpecView SCADA software, which allows for programming jobs/recipes, remote operation, secure (password protected) operation of furnaces, and accurate automatic temperature recording. Conrad Kacsik also added alert lights that allow the operators to quickly see the status of each furnace from the shop floor.
(source: Conrad Kacsik)
H2: Benefits of Temperature Control System Integration
Clifford-Jacobs has noted several beneficial results from the new temperature control system. These include:
• Increased accuracy. The new system runs each recipe exactly and records the results. The company can also control which employees can adjust temperature settings, preventing operators from rushing jobs with a higher temperature or inadvertently setting the furnace incorrectly.
• Higher efficiency. With preprogramming, each furnace is always at the exact temperature it needs to be for the given task. An automatic preheat setting also safely prepares the furnace for the workday—eliminating downtime or the need to send an employee in early to start the furnaces.
• More speed. Clifford-Jacobs can preprogram any recipe it needs, allowing for highly accurate and fast running of complex processes.
• More convenience. Clifford-Jacobs can operate their furnaces from anywhere with an internet connection, or via an iPad used by an approved employee.
• Precision for the future. The new system can be part of a Nadcap-approved process should the need arise. The SpecView software and advanced controllers automatically record each job and retain all data for verification.
The Results
“We used to have to use all kinds of resources to provide oversight on temperature control,” said Kinney. “This has given us a heating strategy. We write the recipes we want and just select from
those. In addition to that, we know exactly what every furnace is doing at all times.”
The company is also pleased with the increased efficiency. They only heat product when they are ready to run production, and the furnace only uses the exact energy needed for each recipe. They are also saving on staffing, as they used to have to schedule people to ensure the furnace was at the right temperature.
“With this system, we can develop recipes for each part we make, which is both convenient and precise. It’s doing exactly what we expected it to do,” said Kinney.
inTEST Corporation, a global supplier of precision-engineered solutions for use in manufacturing and testing across a wide range of markets including automotive, defense/aerospace, and energy, announced today that its thermal segment subsidiary, Ambrell Corporation, is expanding its applications laboratory capabilities in the United States and Europe.
Ambrell’s applications laboratory, known in the industry as THE LAB at Ambrell (THE LAB), is well known in the induction heating market. With applications laboratory facilities in Rochester, NY, and Hengelo, the Netherlands, Ambrell is expanding its laboratory capabilities to a third location on the west coast. The new lab facility will be located in Fremont, California, specifically to serve customers in the western United States and will include hands-on demonstrations and parts testing of a variety of induction heating applications.
(source: the Wall Street Transcript)
“Customers turn to THE LAB at Ambrell to explore the precision induction heating solutions required to solve their unique heating challenges,” said Jim Pelrin, President and CEO of inTEST. “Our applications laboratory expansion project in Hengelo and California embodies the partnership, collaboration and continued commitment to strengthen the support we provide to our global customer base.”
Scott Nolen, Ambrell’s Vice President and General Manager, added, “Under the direction of Dr. Girish Dahake in the United States and Frank Kuster in Europe, THE LAB at Ambrell now offers an expanded geographical reach and provides state-of-the-art laboratory equipment to deliver innovative and effective heating solutions for the most challenging applications. As a leader in the industry, we’re very excited to announce these important, value-added capabilities to existing and prospective customers worldwide.”
An electrically heated homocarb pit furnace was recently shipped to a manufacturer in the power industry. It is designed to work with a protective carbonaceous atmosphere. The top loading furnace, from Lindberg/MPH, is ideal for case carburizing, hardening, annealing, and carbon restoration at temperatures up to 1750°F. Gross workload is 1600 pounds, with temperature uniformity of +/-25°F at 1650°F.
The furnace can accommodate a work basket with a 25-inch diameter that is 48 inches deep, providing a clear work volume of 13.64 cubic feet. A retort minimizes atmosphere consumption and furnace-conditioning time between loads. The cover lid utilizes an electrically operated boom lift, which provides ease of loading and unloading.
A heat treating and metal processing services provider in the Pacific Northwest recently increased its hot isostatic pressing (HIP) capabilities with the purchase of new equipment to enable the company to process a broad range of materials and lot sizes for quality-critical industries, such as energy, aerospace, and medical.
Doug Puerta, CEO, Stack Metallurgical Group
Stack Metallurgical Group has doubled its HIP processing with the addition of a model QIH 122 M URC® from Quintus Technologies following the recent installation of a high-capacity Mega-HIP, the QIH286 M URC®; both combine HIP and heat treatment in a single process and are located at Stack’s recently completed facility in Albany, Oregon.
“We’ve been extremely happy with the market response as we have expanded our service offerings to include HIP,” said Doug Puerta, CEO, Stack Metallurgical Group. “The massive size of our first unit enables us to process larger castings and/or powder metal components. The new unit now allows us to process all ranges of materials and lot sizes and is ideal for moderately sized components. The capabilities and capacity offered by these two units further strengthen the value proposition that Stack facilities provide their clients.”
Jan Söderström, CEO of Quintus Technologies
“We see opportunities not only in traditional markets such as castings but also in emerging markets, with additive manufacturing being the most notable,” added Puerta.
“Stack’s decision to invest in a second Quintus HIP is a tribute to our leadership position in the industry,” said Jan Söderström, CEO of Quintus Technologies. “As the need for hot isostatic pressing steadily increases, we are very pleased with this next step in our relationship.”
A manufacturer of engineered response materials for the oil and gas industry expects to expand its heat treating capability with the recent installation of a new 3,500 MT extrusion press.
The installation of the state-of-the-art press at Terves Inc. in Euclid, Ohio, was completed by Extral Technology SRL, an aluminum extrusion manufacturer based in Italy. Housed within the company’s new 11,000 sq ft H3-classified magnesium metal processing facility, the press will also expand Terves’s magnesium molten metal processing, machining, and storage capabilities.
Extral Technology designed the press to accommodate Terves’s internal production of TervAlloy (a family of patented dissolvable magnesium alloys that provide reliable dissolution rate at a variety of temperatures), as well as for full-scale development services for new alloys.
A 3D equipment and materials supplier recently announced a collaboration agreement to develop advanced tungsten-based metal 3D printing using binder jetting that focuses on two metal matrix composites.
Deborah West, vice-president of Business Unit Refractory & Specialty Powders, GTP
Global Tungsten & Powders Corp, a global manufacturer of tungsten and metal powders, and The ExOne Company, which manufactures industrial sand and metal 3D printers using binder jetting technology, have entered into this collaborative partnership to focus on tungsten-copper (W-Cu), used in high-voltage electrical applications, and cemented carbide (WC-Co), used in cutting tools and wear-resistant parts.
GTP uses the ExOne® Innovent®, an advanced and compact binder jet 3D printer, to manufacture parts in tungsten carbide and other tungsten composites. Binder jetting is a 3D printing process that uses a digital file to inkjet a bonding agent into a bed of powder particles, creating a solid part one layer at a time. Compared to other 3D printing processes, binder jetting delivers precision parts at a high rate of speed, making it an ideal approach for serial production.
The new ExOne-GTP collaboration focuses on the development of two metal matrix composites:
cemented carbide (WC-Co), a material with very high hardness and toughness that is widely used for the production of cutting tools and wear-resistant parts
Tim Pierce, ExOne Vice President of Metal Commercial Products
copper-tungsten (CuW), which is used in applications where high heat resistance, high electrical and thermal conductivity, and low thermal expansion are needed
“Binder jetting is the 3D printing method of choice for serial production of hard metal parts,” said Deborah West, vice-president of Business Unit Refractory & Specialty Powders, GTP. “Traditionally, tungsten carbide powder is pressed into the desired shape and then sintered to give it strength and density. Instead of costly and timely mold construction, the parts now can be printed directly in the desired shape, still using sintering technology to achieve the final strength. As a market leader in the development and production of high-quality tungsten powders, GTP always stays on top of the latest technology. We are excited to work with ExOne in the development of cutting-edge technology for the additive manufacturing industry.”
“Metal 3D printing using our exclusive approach to binder jetting has exciting and significant consequences for a variety of manufacturers, including those who make parts with cemented carbide and other tungsten composites,” said Tim Pierce, ExOne Vice President of Metal Commercial Products. “Our latest development collaboration with GTP will help advance the materials necessary to deliver on the vision of producing these parts faster, with less waste and more geometric design freedom.”
A new, highly advanced innovation center was recently opened in Orlando, Florida, pairing design with manufacturing, implementing robotics, rapid prototyping, scanning, digital tools, and on-site metal additive manufacturing.
Tim Holt, COO of Siemens Gas and Power
Siemens and Materials Solutions, a Siemens Business, have equipped the 17,000 sq. ft. center with the latest manufacturing and inspection technologies, enabling faster solutions for industry opportunities and encouraging innovation for the creation of advanced components and digital solutions, using automation tools such as robotic machines, 3D printer, and 3D scanners. The Siemens innovation center will focus on rapid problem solving supporting the company’s energy businesses, while Materials Solutions will offer additive services to support the innovation center and external customers. According to Siemens, this center is the first of its kind in the U.S.
“This center is unique, bringing together a multitude of our innovative processes under one roof,” said Tim Holt, COO of Siemens Gas and Power. “The combination of these competencies, with the 12 years of experience in metal additive that Materials Solutions brings, provides us with a distinctive capability to support the development of holistic additive solutions/services to our customers in our energy business, as well as in high-performance industries such as aerospace, automotive and others.”
Main Photo Credit / Caption: Siemens / Vinod Philip, CEO Service Power Generation for Siemens Gas & Power, officially opens the Siemens Innovation Center in Orlando, Florida.
A manufacturer of smart materials for the oil and gas industry and advanced magnesium alloys for lightweighting recently broke ground on its expanded magnesium foundry for manufacturing dissolvable metals.
Andrew Sherman, CEO of Terves
Terves Inc launched the 12,000 sq. ft. expansion to its Magnesium Foundry, an H3-classified magnesium metal processing facility expansion which enables the company to further expand its metal processing, heat treatment, machining, and storage capabilities. The expansion plans include additional permanent mold and materials handling and storage space, and the addition of sand casting, squeeze casting, and diecasting capabilities for custom magnesium and magnesium alloys and composites, in addition to further expansion of build-to-print component CNC machining services. These additions enable the company to support aerospace and defense magnesium applications in addition to Terves’ leading position in the dissolvable oilfield tool market.
“Dissolvable Metals are the New Composites as far as oilfield tools are concerned,” said Andrew Sherman, CEO of Terves. “Oilfield tools made from composite materials were adopted in the industry about two decades ago and today occupy a sizable market share. We are seeing a major adoption and growth trajectory for oilfield tools made from dissolvable magnesium materials. At the end of 2017, roughly 2% of all frac plugs deployed in the field were being made using dissolvable metals and the market is expected to grow to 5% of all frac plugs deployed in the field by the end of 2018 – a 250% growth in one year, with adoption and use increasing through 2025. We are seeing tremendous innovation as the industry gains extensive field experience with these new Engineered Response multifunctional materials, including several new staging and completion tools engineered using dissolvable materials. Given the massive value-add of dissolvable tools, primarily eliminating post-completion drill-outs coupled with the ability to do longer laterals, we expect that dissolvable tools would replace over 30% of drillable tools used in well completion over the next 3-5 years. Terves is investing in a further doubling of production capacity for cast and wrought magnesium products, and the expansion frees up space in existing facilities for initial production of new Engineered Response products, including revolutionary expandable structural materials and gas-generating reactive materials.”
One of the leading global power, aviation and renewable energy providers has selected a vacuum furnace hot zone replacement. The replacement and modernization of this hot zone is to be updated in a 20+ year old furnace. Once the furnace is updated, it will be installed at the client's facility in Hungary, Europe.
