ENERGY HEAT TREAT Archives - Page 4 of 12

Clifford-Jacobs Receives Improved Temperature Control System on Heat Treat Equipment

May 12, 2020 / ENERGY HEAT TREAT, FEATURED NEWS

In today’s Heat Treat Today Technical 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.

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.

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.

This article first appeared in December’s Heat Treat Today‘s Medical and Energy Heat Treating magazine.

Clifford-Jacobs Receives Improved Temperature Control System on Heat Treat Equipment Read More »

inTEST’s Induction Heating Lab Expands To the West Coast

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.

“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.”

inTEST’s Induction Heating Lab Expands To the West Coast Read More »

Homocarb Pit Furnace Dispatched to Power Industry

March 16, 2020 / ENERGY HEAT TREAT, FEATURED NEWS

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.

Homocarb Pit Furnace Dispatched to Power Industry Read More »

Heat Treat Provider Expands HIP Capabilities to Serve Quality-Critical Industries

December 12, 2019 / ENERGY HEAT TREAT, FEATURED NEWS, HIPING NEWS

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.”

Heat Treat Provider Expands HIP Capabilities to Serve Quality-Critical Industries Read More »

Magnesium Extrusion Press Expands Heat Treating Capabilities

November 25, 2019 / ENERGY HEAT TREAT

Source: Light Metal Age

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.

Magnesium Extrusion Press Expands Heat Treating Capabilities Read More »

Tungsten Metal 3D Printing Focus of Collaboration

November 20, 2019 / ENERGY HEAT TREAT, FEATURED NEWS

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.”

Tungsten Metal 3D Printing Focus of Collaboration Read More »

Innovation Center to Pair Design, Metal AM for Rapid Problem Solving

November 18, 2019 / ENERGY HEAT TREAT

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.

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.

Innovation Center to Pair Design, Metal AM for Rapid Problem Solving Read More »

Smart Materials, Magnesium Alloys Manufacturer Breaks Ground on Expanded Foundry

November 14, 2019 / ENERGY HEAT TREAT, FOUNDRY CASTING NEWS

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.

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.”

Smart Materials, Magnesium Alloys Manufacturer Breaks Ground on Expanded Foundry Read More »

Pennsylvania Steel Producer Transfers Specialty Steel, Cast Roll Subsidiaries

October 14, 2019 / ENERGY HEAT TREAT, FEATURED NEWS

A Pittsburgh-based steel and aluminum producer for multiple industries, including oil and gas, sold its Canadian specialty steel subsidiary to a global manufacturer of stainless steel and nickel alloys bars and wires.

Valbruna Canada Ltd., a subsidiary of Acciaierie Valbruna S.p.A., of Vicenza, Italy, purchased ASW Steel Inc, a steel fabricator in Welland, Ontario, from Ampco-Pittsburgh, which operates through its operating subsidiary Union Electric Steel which produces forged and cast rolls for the worldwide steel and aluminum industries.

The new company will now be known as Valbruna ASW.

In a related transaction, Ampco-Pittsburgh, which also manufactures ingot and open die forged products, air and liquid processing equipment, primarily custom-engineered finned tube heat exchange coils, large custom air handling systems, and centrifugal pumps, announced it completed the sale of its Avonmore, Pennsylvania, cast roll manufacturing facility, Akers National Roll, to an affiliate of WHEMCO, Inc., also located in Pittsburgh, which uses heat treating and other metal-forming capabilities in the manufacture of heavy industrial components for the metals, power generation, mining, and shipbuilding industries.

“As previously discussed, excess capacity and high operating costs in our cast roll system have made the operation of the Avonmore facility unsustainable,” said Brett McBrayer, Ampco-Pittsburgh’s CEO. “With the closing of this transaction, the divestiture of our Canadian specialty steel operations, as announced yesterday, and further improvement initiatives being implemented in our businesses, we expect a significant impact on our future financial results moving forward. The Corporation remains focused and committed to building a sustainable and profitable future for our core businesses.”

Photo image credit: Akers National Roll

Pennsylvania Steel Producer Transfers Specialty Steel, Cast Roll Subsidiaries Read More »

U.S. Steel Acquires Interest in Arkansas Steel Company, First Step Toward Consolidation

October 3, 2019 / ENERGY HEAT TREAT, FEATURED NEWS

A leading integrated steel producer headquartered in Pittsburgh, Pennsylvania, announced a joint venture partnership agreement under which it has taken the first step toward acquiring an Arkansas-based steel manufacturer.

Big River Steel, which operates a LEED-certified Flex Mill™ in northeast Arkansas, will expand U.S. Steel’s technological capability and geographic presence through this agreement. U.S. Steel has purchased 49.9% ownership interest with a call option to acquire the remaining 50.1% over the next four years.

David B. Burritt, president and CEO of U. S. Steel

The Big River flat-rolled mill has advanced technology that allows it to produce a wide product spectrum, including advanced automotive steels and electrical steels, and provide high-quality products and services to customers in the automotive, energy, construction and agricultural industries. Big River’s recently announced Phase II-A expansion is expected to double the mill’s hot-rolled steel production capacity to 3.3 million tons annually.

“Our new partnership with Big River is designed to accelerate our strategy to offer our customers the ‘best of both’ by bringing together the capabilities of integrated and mini-mill steel production,” said David B. Burritt, president and CEO of U.S. Steel. “Big River operates the most advanced, state-of-the-art and sustainable mill in North America, and our investment would ultimately strengthen our competitive positioning in highly strategic steel-end markets, creating an unmatched value proposition for our stakeholders.”

“We have been investing in leading technology and advanced manufacturing so that we can assemble a portfolio of competitive assets with distinct advantages to serve strategic markets to better position U.S. Steel to be an industry leader in delivering high-quality, value-added products,” added Burritt. “The investment in Big River, coupled with our announced investments at Mon Valley Works and Gary Works, would ultimately position U.S. Steel with three core market-leading, differentiated and technologically advanced assets that will enable us to compete with anyone, anywhere, for generations to come. Each of these locations would be able to focus on the products that each facility is best designed to produce. As an organization, we will be nimbler, more resilient and our teams will be more efficient. Collectively, these actions will help us continue to create long-term value for our stockholders, customers, employees and the communities in which we live and work.”

“U. S. Steel’s decision to partner with us through this investment in Big River is a decisive vote of confidence in our company, our vision and our people,” said Dave Stickler, CEO of Big River. “After just over two years of operations, we have built a unique platform that features the most advanced technology in our industry, and the very finest steel technicians in the business. We have always called ourselves a ‘technology company that just happens to make steel.’ In U. S. Steel, we have a likeminded technology-focused partner with an enduring tradition of excellence and a commitment to innovation. We are very excited about the possibility for what we can do together. As the newest steel production facility in North America, I could not be more proud to be partnering with a company started by Andrew Carnegie more than 118 years ago.”

Closing of the transaction is anticipated on October 31, 2019.

U.S. Steel Acquires Interest in Arkansas Steel Company, First Step Toward Consolidation Read More »

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