FEATURED NEWS

Callies Precision Engine Components Improves Process

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

Callies Precision Engine Components of Fostoria, OH has installed an automated nitriding process control system from Super Systems Inc (SSi).  Callies, a leading supplier to the high performance engine market for 28 years, is always looking at opportunities to invest in technologies that improve quality, reduce cost and collapse delivery time to the customer – and the SSI Nitriding system was a perfect fit.  “Our goal has been to outfit all equipment with the latest technological controls to assure complete accountability with our in-house operations.  This was the main reason we teamed up with Super Systems.”

The engineered control system from SSi provides Callies with the ability to perform tight nitriding process control using an easy-to-use recipe system that maintains tight tolerances on temperature(s), gas flows and nitriding potential.  The relatively shallow nitride case delivers a tremendous improvement to fatigue life of every Callies crankshaft.  The extremely hard nitrided surface also gives the crankshaft excellent wear resistance.   The SSi control system provides the latest in sensor and flow technology for measuring the nitrding atmosphere and an operator-friendly interface to provide complete traceability to the process and load data.

The SSi control panel was retrofitted on an existing a Lindberg pit furnace previously used for nitriding.  Delivering proper surface and case properties requires in-situ control of the nitriding potential (Kn) and control of the ammonia, dissociated ammonia and nitrogen gases.  The system delivered by SSi also included the control of the Dissociated Ammonia (DA) generator.  The controls for the DA generator provided gas flow monitoring and temperature control to ensure the ammonia is fully cracked prior to being used as process gas in the furnace.

Callies takes their heat treating seriously as illustrated by their investment in SSi which is just part of the million dollar plus investment in the department.  Carefully controlled heat treating can be found throughout their manufacturing process which includes induction, neutral hardening, and carburizing.

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Heat Treated Rolled Rings Used in Energy Industry

/ ENERGY HEAT TREAT, FEATURED NEWS

  Source:  Euskalforging

Five large rolled rings ranging from 6.500 mm of outer diameter up to 10.000 mm of outer diameter and input weights from 24t up to 80t have been ring rolled, heat treated, machined and delivered by Euskalforging.  The rings will be used in the manufacturing of the Blue 25M hammer from Fistuca. The hammer will be able to drive the largest offshore wind monopiles in the industry.

Read more: Euskalforging Breaks a World Record

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Hardening and Tempering Line Receives Upgrade

/ FEATURED NEWS, HARDENING NEWS, HEAT TREAT NEWS INDUSTRIES, TEMPERING NEWS

The Ohio-based Engineering Division of Conrad Kacsik Instrument Systems completed a full system upgrade of an automated hardening and tempering line for Nelson Fastening Systems, also located in Ohio. The project involved the removal of the existing control system, VFD drives, limits, and control wiring for Nelson, and included the installation of a new system that features safety controls.

A Honeywell HC900 with a 15-inch operator interface terminal integrated with a computer running Specview HMI software controls a 2-zone hardening furnace, generator, quench tank, water cooling tank, washer, 2-zone tempering furnace, and a blackening unit. The equipment was linked with six conveyors and wired into the four control panels completed by Kacsik’s engineering team.

The old conveyor system had VFD drives that did not communicate with a PLC. The new system was programmed with safety features: in the event of a chain break or a conveyor jam, the system will alarm and automatically shut other conveyors off.

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Metal Magnesium Ingots Produced in Quebec

/ AUTOMOTIVE HEAT TREAT, FEATURED NEWS

The  first metal magnesium ingots have been produced at the Danville demonstration plant in Quebec by Alliance Magnesium Inc. . This achievement comes after four years of technological development, design and construction of a pilot plant.The ingots, which are now produced on a regular basis, are used to validate the manufacturing process developed by AMI and to collect the technical and economic information necessary for the subsequent phases of magnesium production.

“This is a crucial step in the development of AMI that has just been completed. It depends on the hard work of all our staff, as well as our financial, technical and government partners who share our ambition to become the greenest magnesium producer on the planet. “Said Dr. Joël Fournier, Chief Executive Officer of AMI.

AMI is also announcing a $ 4.1 million loan from the Fonds de diversification économique de la MRC des Sources, a fund created by the Government of Québec. The proceeds of this funding will go toward the operations of its pilot plant and the preparation of its $ 100 million commercial demonstration plant, which will take shape during the year and create more than 70 jobs.

“We are delighted to count the Regional Fund as one of our strategic partners in the evolution of our company,” said Dr. Fournier. “This financial contribution demonstrates the recognition of AMI’s business model as a key driver of the region’s economic recovery and its positive impact on the community. ” he added.

AMI has invested more than $ 12 million in the region over the past three years and directly and subcontracts more than 20 professionals and operators.

About Alliance Magnesium Inc.

Alliance Magnesium is a privately-owned Canadian company engaged in the production of magnesium metal and other valuable minerals from serpentine. AMI has developed an innovative technology and process that gives it a cleaner and less expensive approach than those currently used worldwide by magnesium producers. The new AMI process is an alternative to the thermal process, which is one of the most important sources of CO2 emissions in the world. AMI has developed a three-stage development program that will lead to an annual production of 50,000 tons in 2019 and the creation of more than 350 jobs.

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Heat Treating of Jaw Fixation Plates Provides Superelasticity

/ ANNEALING, FEATURED NEWS, MEDICAL HEAT TREAT

  Source:  Bioengineering

Process parameters and post-processing heat treatment techniques have been developed to produce both shape memory and superelastic NiTi using additive manufacturing. By introducing engineered porosity, the stiffness of NiTi can be tuned to the level closely matching cortical bone. Using additively manufactured porous superelastic NiTi, we have proposed the use of patient-specific, stiffness-matched fixation hardware, for mandible skeletal reconstructive surgery.
Read more:  Finite Element Simulation and Additive Manufacturing of Stiffness-Matched NiTi Fixation Hardware for Mandibular Reconstruction Surgery by Ahmadreza Jahadakbar , Narges Shayesteh Moghaddam , Amirhesam Amerinatanzi , David Dean , Haluk E. Karaca  and Mohammad Elahinia

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Melting Line, Casting Line and Two Forging Presses to be Installed

/ AUTOMOTIVE HEAT TREAT, FEATURED NEWS, FORGING NEWS

Production of aluminum forged suspension products will be expanded by Kobe Aluminum Automotive Products, LLC, to meet the rising demand in North America.

Based in Bowling Green, Kentucky, KAAP decided in November 2015 to install a melting and casting line and two forging presses. Mass production is scheduled to begin in summer 2017. When this capital investment is completed, KAAP will have three melting and casting lines and eight forging presses. Production capacity will increase from the current 540,000 pieces per month to 750,000 pieces per month.

In the latest expansion plan announced today, KAAP plans to invest approximately US$53 million (about 5.8 billion yen) to install an additional melting and casting line and two forging presses. Startup is to begin in stages starting from autumn 2018, with completion slated for early 2019. KAAP anticipates hiring 100 more people.

When the latest capital investment is completed, KAAP will have a total of four melting and casting lines and 10 forging presses. Production capacity will increase to 970,000 pieces per month, and employees are anticipated to total 600 people.

KAAP was established in 2003 as a joint venture by Kobe Steel, Mitsui & Co., Ltd. and Toyota Tsusho Corporation to produce aluminum forged suspension products in the United States. Ever since it began production in 2005, KAAP has maintained the top share of the North American market for aluminum forged suspension products.

The United States is the world’s second-largest automobile market, and car production is anticipated to continue growing. Production of approximately 17.5 million cars in 2016 is projected to increase to 19 million cars in 2020.

Owing to their light weight, aluminum forged suspensions contribute to improving the fuel economy of cars. Demand has been rising due to the increasing need to reduce the weight of car bodies in response to environmental regulations.

KAAP began by supplying mainly Japanese automakers in the United States. It now supplies U.S. automakers, too. KAAP anticipates that in the future automakers will use aluminum forged suspension products in a wider range of vehicles.

This latest expansion will further contribute to solidifying KAAP’s position in the North American market for aluminum forged suspension products.

Outline of Seventh Expansion

Extension of building:  About 13,000 sq m (140,000 sq ft)

Equipment:  1 melting and casting line, 2 forging presses, auxiliary equipment

Investment amount:  About $53 million

No. of employees to be hired:  About 100 (when in full operation)

Start-up of equipment:  To be in stages from autumn 2018

 

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PW4168 Nacelles Benefits from Supply Program

/ AEROSPACE HEAT TREAT, FEATURED NEWS

Triumph Group, Inc. is proud to join forces with VAS Aero Services, LLC to provide airline operators with PW4168 nacelles for the A330. The comprehensive supply program will be supported out of Triumph’s Hot Springs, Arkansas, or Chonburi, Thailand, facility.

The alliance will assist Triumph in providing best-quality, timely maintenance services for PW4168 nacelles for its airline customers. The cooperation helps facilitate exchanges or leases that guarantee availability of spares to Triumph’s customers while their components are undergoing maintenance.

“We are excited about this opportunity to work with VAS Aero Services, one of the premier aftermarket service providers in the aviation industry,” said Mike Abram, executive vice president of Triumph Product Support. “Together we think we can bring unique value to the A330/PW4168 operators.”

“VAS has enjoyed a close relationship with Triumph, and we are delighted to expand on that with this new program,” said Tommy Hughes, CEO of VAS Aero Services.

VAS Aero Services, LLC is a provider of aftermarket services in the aviation industry. VAS Aero Services sources, warehouses, and markets aftermarket components across a broad range of aircraft and engine platforms and provides related services to airlines, leasing companies, and MRO providers around the world.

Triumph Group, Inc., headquartered in Berwyn, Pennsylvania, designs, engineers, manufactures, repairs and overhauls a broad portfolio of aircraft structures, components, accessories, subassemblies and systems. The company serves a broad, worldwide spectrum of the aviation industry, including original equipment manufacturers of commercial, regional, business and military aircraft and aircraft components, as well as commercial and regional airlines and air cargo carriers.

 

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