HEAT TREAT NEWS INDUSTRIES

TITAN® Vacuum Furnaces Take a Journey

Ipsen’s TITAN® product line has had quite the journey over the past few years. Found in facilities around the world, these vacuum furnaces can operate in most languages, feature several sizes and configurations and have a small footprint. Now, the PdMetrics® software platform for predictive maintenance also comes standard on TITAN heat-treating systems.

Most recently, Ipsen delivered two TITAN H2-size vacuum furnaces with 1.9-bar gas quenching and the PdMetrics platform to Japan. Shipped within three weeks of each other, these furnaces will be used by separate commercial heat treaters and feature 18” x 24” x 18” (455 mm x 610 mm x 455 mm) graphite hot zones with a 1,000-pound (450 kg) load capacity. They operate at temperatures up to 2,400 °F (1,320 °C) with ±10 °F (±6 °C) uniformity, and are capable of meeting applicable AMS 2750E and Nadcap requirements.

Through the PdMetrics platform – which securely connects to a network of integrated sensors on the furnace to gather and analyze data, run algorithms and provide real-time diagnostics – these TITAN furnaces provide sophisticated monitoring of critical systems and key parameters that improve the health and integrity of the equipment. Both companies also took a proactive approach to preventative maintenance by ordering one of Ipsen’s many spare parts kits. These kits consist of consumable and preventative maintenance items to help ensure equipment uptime and keep the furnace running smoothly.

Ipsen’s TITAN vacuum heat-treating systems provide an advanced solution in the form of speed, reliability and versatility of process capabilities. However, Ipsen is more than just an equipment manufacturer. They also offer expert-driven solutions for customers’ needs through all stages of the system’s life cycle, no matter the location – whether it is facilitating on-site installation, providing expert training and start-up assistance or delivering responsive field support and spare parts.

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RHI, Magnesita Combine Creating a Leading Refractory Company

RHI and the controlling shareholders of Magnesita, GP and Rhône (“Magnesita’s Controlling Shareholders”), have reached an agreement to combine the operations of RHI and Magnesita to create a leading refractory company. The combined company, to be named RHI Magnesita, will be established in the Netherlands and listed in London.

Accordingly, RHI’s Management Board has agreed to sign a share purchase agreement with Magnesita’s Controlling Shareholders regarding the acquisition of a controlling stake of at least 46%, but no more than 50% plus one share of the entire share capital in Magnesita, pending RHI’s Supervisory Board approval.

The consideration for the 46% stake will consist of cash amounting to € 118 million and 4.6 million new shares to be issued by RHI Magnesita.

A subsequent mandatory tender offer will be launched as a result of which a maximum number of 5.4 million RHI Magnesita shares will be issued, bringing the total number of newly issued RHI Magnesita shares to up to 10.0 million. The offer will also include a cash-only alternative amounting to € 8.19 per Magnesita share.

As a result of the transaction, GP, Magnesita’s largest shareholder, will become a relevant shareholder of RHI Magnesita and will be represented on its board of directors.

Following registration of the corporate restructurings, RHI’s shares will cease to be listed on the Vienna Stock Exchange. RHI’s migration from Austria and listing in London are subject to approval by RHI’s shareholders’ meeting. The transaction is also subject to approvals by relevant competition authorities. The place of effective management will be Austria.

The transaction is expected to complete in 2017. Both companies will remain completely separate and independent until then RHI Magnesita will be a leading refractory company with an enhanced growth profile due to improved regional presence and complementary asset portfolios. RHI, based in Austria, is a global supplier of high-grade refractory products, with 2015 revenues of € 1,753 million Brazil-based Magnesita is a global provider of integrated refractory solutions, services and industrial minerals, with revenues of US$ 1,013 million (€ 914 million) in 2015

Transaction Overview
RHI AG (“RHI”) and the controlling shareholders of Magnesita Refratários S.A. (“Magnesita”), investment vehicles affiliated with GP Investments (“GP”) and Rhône Capital (“Rhône”, and together with GP, “Magnesita’s Controlling Shareholders”), announce that they have reached an agreement to combine the operations of RHI and Magnesita to create a leading refractory company to be named RHI Magnesita.

Accordingly, RHI’s Management Board has agreed to sign a share purchase agreement (“SPA”) with Magnesita’s Controlling Shareholders regarding the acquisition of a controlling stake of at least 46%, but no more than 50% plus one share of the total share capital in Magnesita (the “Transaction”), pending RHI’s Supervisory Board approval. The purchase price for the 46% stake will be paid in cash amounting to € 118 million and 4.6 million new shares to be issued by RHI Magnesita, a new RHI entity to be established in the Netherlands and listed in London. Based on RHI’s six-month volume-weighted average price (“VWAP”) of € 19.52, the implied value of the 46% stake amounts to € 208 million.

As a result of the transaction, GP will become a relevant shareholder of RHI Magnesita. The combined company’s corporate governance will be constituted on a one-tier board structure while GP will be represented on the board of directors. All RHI Magnesita shares issued as a result of the Transaction and subsequent mandatory tender offer will be subject to a minimum 12-month lock-up period.

The resulting combination will be a leading refractory company. Refractories are materials that retain their strength at high temperatures and are used in various industrial processes in the steel, cement, nonferrous metals, glass and chemicals industries. The combination will bring under one roof two complementary businesses, both in terms of products and geographical footprint. RHI, based in Austria, is a global supplier of high-grade refractory products, with 2015 revenues of € 1,753 million and adjusted EBITDA of € 198 million. Brazil-based Magnesita is a global provider of integrated refractory solutions, services and industrial minerals, with revenues of US$ 1,013 million (€ 914 million) and adjusted EBITDA of US$ 145 million (€ 131 million) in 2015.1

The completion of the transaction is amongst others subject to

(i) approvals by the relevant competition authorities,

(ii) the migration of RHI to the Netherlands,

(iii) the listing of RHI Magnesita’s shares in the premium segment of the Official List on the Main Market of the London Stock Exchange and

(iv) RHI’s shareholders not having exceeded statutory withdrawal rights in an amount of more than € 70 million in connection with organizational changes preceding RHI’s migration from Austria.

The migration and the preceding organizational changes in Austria require qualified approval by RHI’s shareholders’ meeting. If the transaction is terminated for reasons not under the control of Magnesita’s Controlling Shareholders, an aggregate break fee of up to € 20 million is payable by RHI to Magnesita’s Controlling Shareholders.

The migration of RHI to the Netherlands and the subsequent listing on the London Stock Exchange have the objective of reinforcing and underlining the truly international scope of the enlarged combined company, enhancing its capital markets presence and maximizing value potential for the company’s shareholders. The migration of RHI will be effected by RHI Magnesita becoming the ultimate holding company of RHI Group and the shareholders of RHI will cease to hold shares in RHI and instead hold RHI Magnesita shares. Following registration of the corporate restructurings, RHI’s shares cease to be listed on the Vienna Stock Exchange. The place of effective management of RHI Magnesita will be Austria.

The transaction is expected to complete in 2017. Until then, the two companies will remain completely separate and independent. Therefore customers, suppliers, employees and other stakeholders should expect no change in management teams, commercial relationships, supply chains and product offerings during this period.

Mandatory Tender Offer
Following completion of the transaction, a mandatory tender offer will be launched by RHI Magnesita or one of its affiliates (“Offer”) for the remaining shares in Magnesita. As part of the Offer, a maximum number of 5.4 million RHI Magnesita shares will be issued, resulting in an aggregate number of no more than 10.0 million newly issued shares to finance the acquisition. The Offer will include the option to sell shares on the same payment terms as the transaction as well as a cash-only alternative amounting to € 8.19 per Magnesita share (subject to certain adjustments according to the SPA). If some or all of Magnesita’s other shareholders elect not to receive RHI Magnesita shares in the Offer, Magnesita’s Controlling Shareholders have committed to purchase additionally at least 1.9 million and at most 3.4 million of the remaining new RHI Magnesita shares, thereby increasing their total number of RHI Magnesita shares to a maximum of 8.0 million. RHI may decide to combine the Offer with a delisting offer and/or a voluntary offer to exit Magnesita from the “Novo Mercado” listing segment. The Offer will follow applicable Brazilian laws and regulations. Any RHI Magnesita shares that are not taken up in the Offer by Magnesita’s shareholders may be either placed into the market or with institutional investors.

Financial Terms of the Transaction
Based on RHI’s six-month VWAP of € 19.52, the implied value for the entire share capital of Magnesita will be € 451 million, 45% above Magnesita’s market capitalization as of October 4, 2016.2 The transaction will be financed by additional debt and the issuance of 4.6 million RHI Magnesita shares to Magnesita’s Controlling Shareholders. The transaction will increase RHI’s current financial leverage, measured as net debt to EBITDA, to 4.0x at closing of the transaction when assuming an acquisition of Magnesita’s entire share capital. RHI expects, however, that leverage will decline to below 2.0x by 2020 as a result of the strong cash generation profile of the newly combined company. Magnesita will continue to finance itself on a standalone basis without credit support from RHI Group. Before or at completion of the transaction, Magnesita is expected to adopt RHI’s accounting practices, which, according to RHI, could lead to significant, however substantially non-cash adjustments in Magnesita’s book equity value.

Enhanced Growth Profile and Global Footprint
The combination of RHI and Magnesita represents a unique opportunity to accelerate growth in certain regions, resulting from the high complementary of the businesses both in terms of geographic footprint and products.

Magnesita’s presence in South America and the United States fits well with RHI’s presence in Europe and Asia. It results in strengthened geographic clusters of the combined company by adding production facilities in several markets in which RHI and Magnesita are lacking capacity on their own. This combination will also strengthen the competitive position against the Chinese refractory industry, which is expected to consolidate in the coming years as announced by the Chinese government. Moreover, Magnesita’s position in dolomite-based products is highly complementary to RHI’s asset portfolio, which traditionally has a strong focus and an excellent market reputation for high-quality magnesite products.

The combination of RHI and Magnesita will enable the combined company to offer its customers an even broader product and service portfolio thereby delivering enhanced value-add. Additional potential for value creation will be realized through synergies and the implementation of common proven standards of operational and commercial excellence.

Significant Value Creation and Synergy Potential
The Transaction will result in meaningful synergies in the following key areas, amongst others:

(i)      a highly complementary offering of value-added products and services as a result of the combination of both product portfolios;

(ii)     a more efficient cost structure, benefitting from economies of scale in important operational areas such as raw materials supply, freight, marketing and administration, as well as an optimized operational set-up leading to enhanced flexibility in production and an improved cost basis;

(iii)    an optimized working capital structure, especially given Magnesita’s presence in the Americas, by means of improved inventory management and related costs, resulting from the complementary regional footprint of RHI and Magnesita’s operations and customer base; and

(iv)   a relevant reduction in capital expenditure requirements and maintenance costs.

As a result of the transaction, RHI expects minimum net run-rate synergies on EBIT level of approx. € 36 million by 2020. However, RHI is optimistic that as a result of the Offer, RHI Magnesita’s stake in Magnesita will significantly exceed 46%. In this case, RHI expects substantially higher synergies of approx. € 72 million, especially in the areas of enhanced production efficiency and cost benefits in research and development, marketing and administrative functions. In addition, capital expenditure synergies are expected to amount to between € 2 million and € 7 million annually, while aggregate working capital savings of € 40 million are expected in the coming years.

Cash integration costs as a result of the transaction are expected by RHI to be of the magnitude of € 50 million to € 90 million, while non-cash integration costs, effectively write-offs, should vary between € 20 million and € 35 million, depending on the amount of Magnesita shares acquired pursuant to the Transaction and subsequent Offer. Both cash and non-cash integration costs will mainly crystallize in 2017 and 2018.

Increased Financial Targets
As a result of the transaction, RHI’s mid-term financial targets will surpass RHI’s current targets. RHI expects the combined company to generate fully consolidated revenues of € 2.6 billion to € 2.8 billion (previously € 2.0 to € 2.2 billion) with an operating EBIT margin of more than 12% (previously more than 10%) by 2020. It projects a cumulative operating cash flow of approx. € 1.1 billion for the period from 2017 to 2020 for the combined business, assuming an acquisition of Magnesita’s entire share capital.

RHI expects RHI Magnesita to pay stable dividends in 2017 and 2018, in line with RHI’s previous years’ payment levels. In the mid- to long-term, however, RHI Magnesita aims to increase its dividend payments, as a result of stronger cash flow generation resulting from synergies, organic growth and de-leveraging of the company’s capital structure.

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Remix S.A. Commissions Gas Fired Rotary Hearth Furnace

REMIX S.A., Poland, commission a 4,500 kg/h gas-fired rotary hearth furnace for preheating titanium alloys used in the aerospace/aircraft industry. The furnace, with a working temperature of 1,300°C, was commissioned at a leading Central European forging company who supplies critical forged parts to a variety of industries worldwide.

The furnace utilizes high-efficiency recuperative burners and the entire system complies with AMS 2750E standards.

In late 2015, Remix also supplied this same company with a 3,000 kg maximum capacity washing-drying unit for removing oil from oil-quenched parts.

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IBC Advanced Alloys Supplies Newport News Shipbuilding

IBC Advance Alloys announces that it is now an “Approved Forging Supplier” with Newport News Shipbuilding, a division of Huntington Ingalls Industries.  Newport News is the largest shipbuilding company in the U.S. and is the sole designer, builder, and re-fueler of U.S. Navy aircraft carriers and one of two providers of U.S. Navy submarines.

The announcement marks the second such attainment by IBC of approved forging supplier status with a world-class shipbuilder in as many weeks.  On September 13, IBC announced that it received “Approved Forging Supplier” status with General Dynamics’ Electric Boat Division (see that press release here).

“Achieving approved forging supplier status with Newport News is another significant advance for IBC, and positions us to grow our forged products business,” said Major General Duncan Heinz (USMC, ret.), President and CEO of IBC.

IBC’s qualification with Newport News positions the Company to provide forged product to Newport News through approved suppliers.  The qualification was awarded after Newport News conducted due diligence of IBC’s Copper Alloys Division facility in Franklin, Indiana.

Newport News builds the most advanced ships in the world using its expertise in nuclear propulsion, naval design, and manufacturing, and it is currently building the new Ford-class aircraft carriers and Virginia-class fast-attack submarines, and performing Refueling and Complex Overhaul (RCOH) on Nimitz-class aircraft carriers. With approximately $4 billion in revenues and more than 20,000 employees, Newport News has built more than 800 ships, including both naval and commercial ships.

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Carbon Sensor Troubleshooting

Jim Oakes, Super Systems, Carbon Sensor Troubleshooting, Stephen Thompson

by Stephen Thompson – President – Super Systems, Inc.

There are several key components in all atmosphere control systems. When a difficulty arises, it is important to identify the cause with minimum effort and expended time. The procedure that follows is designed to aid in that process.

INTRODUCTION

The starting point for any troubleshooting procedure is to properly identify the symptom that necessitates it. The cause of the symptom can often be elicited by answering some preliminary questions. Is this a startup problem, or has the system been operating under control? If this is a startup problem, it is necessary to establish that all system components have been properly connected and configured for the application. If the system has been operating properly and there has been either a gradual or sudden change in the control performance, it may conceivably be a problem with the probe. In order to establish the correct performance of the carbon sensor, resist the temptation to remove the sensor from the furnace. All of the tests outlined here must be done while the sensor is located in the furnace, at temperature, and exposed to a reducing atmosphere. This procedure can be performed on the SSi Gold Probe and on most other manufacturers’ sensors. We strongly recommend that you call us at 800-666-4330 before you remove the probe.

NOTE: IF YOU HAVE ALREADY REPLACED THE PROBE AND THE PROBLEM PERSISTS…..THE PROBE MAY NOT BE THE PROBLEM!

PROCEDURE

Does a shim stock analysis, a 3-gas analysis (SSi PGA3000) or a dew point analysis (SSi DP2000) verify the indicated value from the probe? If the values are close to the same, the problem is not likely the Gold Probe. If the values are not similar, continue with the following steps:

  1. Verify that both mV and t/c cables between the sensor and the controller are clean and connected firmly to the Gold Probe and controller terminals. Verify polarity.
  2. Verify that the reference air supply is connected to the reference air fitting. This will be the fitting closest to you when you face the probe. It has been found that on occasion the reference air has been connected in error to the burn off fitting, causing low readings.
  3. Check that the reference air is flowing. Disconnect the air supply at the probe and submerge it in a cup of water. Bubbles verify the flow.
  4. Verify that no air is flowing into the burn off fitting by submerging the burn off tubing in a cup of water. (Flow can occur if the burn off air pump is subject to external vibration.)
  5. Leak test- this test can detect a cracked or broken substrate in your Gold Probe. Verify that reference air is flowing at 0.5 to 2.0 scfh. Turn off the reference air for one minute and read the Gold Probe output millivolts. Turn the reference air back on and note the change in mV. It should not display more than a 5 mV increase.
  6. Is the controller COF set to the proper value? This factor is referred to by other descriptions such as Process Factor, Furnace Factor, CO Factor, Circulation Factor, Calibration Factor, etc. The factor may require adjustment to eliminate any offset or discrepancy between the indicated carbon potential and the actual achieved result in the work pieces or shim stock.
  7. Do the sensor temperature and MV output as measured by an independent digital calibrator agree with the indicated values on the controller with one sensor and one t/c lead disconnected? If not, there is most likely a controller calibration problem or a cable problem.
  8. Does the Gold Probe mV signal return to within 1mV of it’s original value in 1 minute as measured by a digital VOM after it has been shorted for 5 seconds? If it does not, go to step 10.
  9. Probe impedance (resistance) test-this is one of several electrical tests that determine the electrical integrity and reliability of the Gold Probe. Some contemporary controllers can perform it. If yours does not, conduct this simple test: at process temperature, disconnect the controller cable at the Gold Probe mV output and measure the mV value with a VOM. Then shunt the signal with a 100 kilohm resistor. After 10 seconds, read the new mV value, divide the original value by the new value, subtract 1 from the result and multiply by the value of the shunt resistor (=100K). The calculated value is the sensor resistance in kilohms, which should be less than 25 kilohms.
  10. If the problem is not corrected by probe and/or furnace burnout as described in the Gold Probe Manual and your system manual, and the problem is a faulty probe, contact SSi at (800)666-4330 and describe your problem to our technician. You may then request a Returned Material Authorization for repair or replacement of your Gold Probe.
  11. WARNING- even though you suspect a faulty sensor, DO NOT remove your Gold Probe from a hot furnace at a rate faster than 2 inches per minute. Cool the sensor on an insulating medium to avoid thermal shock. This will prevent damage that is expensive to repair.

Author information:
Stephen Thompson
Super Systems Inc.
7205 Edington Drive, Cincinnati,  OH 45249
Phone: 513-772-0060
Fax: 513-772-9466
www.supersystems.com

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Understanding the Short Circuit Current Rating

BOTW-50w Source: Ceramic Industry

by Dan Bender – Director of Sales for Control Concepts, Inc.

In this article, Dan Bender discusses Short Circuit Current Ratings, how to determine it, examples, and suggested solutions for keeping workers and workplaces safe.

Click here to read the entire article.

Click on the video below to watch a video about this same subject featuring Dan Bender.

dan-bender-video

Source: Ceramic Industry

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Linde Improves Additive Manufacturing

Pierre Forêt

Pierre Forêt – GDC Additive Manufacturing bei The Linde Group

Linde Gases, a division of The Linde Group, today announced the launch of ADDvance™ O precision, the first-of- its-kind measuring and analysis unit which will enable metal additive manufacturers to analyse and control more precisely the level of oxygen (O) and humidity present in the printer chamber.

The new technology, developed in response to a need identified by aerospace company Airbus Group Innovations, can detect O levels up to 10 parts per million (ppm) within the printer chamber and then modify the gas atmosphere by adjusting the level of argon or nitrogen. The presence of too much oxygen or humidity can present a challenge to additive manufacturers as it can negatively impact the quality and performance of the item being printed. In addition to ADDvanceTM O precision allowing for more accurate levels of oxygen and humidity, it does so without cross-sensitivity effects and ensures a constant level of oxygen during the process.

The launch of ADDvance™ O precision comes on the back of Linde’s recent opening of a dedicated industrial gases laboratory for additive manufacturing in Unterschleissheim, near Munich, Germany. The focus of the laboratory is to research the effect of different atmospheric gases and gas mixtures on the different metal powders used in additive manufacturing in order to optimise the various layering processes. Reproducibility is one of the most important parameters for industries requiring strict consistency in end product, such as the aerospace and automotive industries. ADDvanceTM O precision is an effective solution to improve reproducibility and through its new research facility Linde will continue to lead research into how oxygen and humidity impact the additive manufacturing process.

“Linde has always played a leading role in developing new technologies for our customers in order to improve the efficiency of their production processes and quality of output,” said Pierre Forêt, responsible for additive manufacturing R&D at Linde.

The additive manufacturing process operates within a closed chamber filled with high purity inert gas such as argon or nitrogen. However, impurities due to incomplete purging, small machine leakages and metal powder can have an influence on the oxygen level. A variation in oxygen content in the chamber can result in differences in mechanical properties or chemical composition of the end product – for example a decrease in fatigue resistance.

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Solar Atmospheres in South Carolina Now Nadcap Approved

Solar Atmospheres Southeast has successfully completed its first round of surveillance audits for maintaining its AS9100 and Nadcap accreditations.  Solar also expanded its scope of Nadcap approval to include Low Pressure Vacuum Carburizing to meet growing aerospace carburizing needs in the Southeast US.

Steve Prout, President of Solar Atmospheres Southeast states: “We are proud to be taking this next step in our start up plan to be able to offer Low Pressure Vacuum Carburizing services alongside the rest of our Nadcap approved scope of thermal processing capabilities.  We are excited that once again we are able to offer the Southeast US another regional option for aerospace processing that did not exist previously.”

With thermal processing in furnaces ranging from those suited for small lots and development cycles to a 6-1/2 foot diameter by 24 foot long vacuum chamber capable of processing up to 50,000 lbs at 2400°F, Solar Atmospheres is backed by AS9100 and Nadcap quality systems to provide our customers the confidence that their product is being processed appropriately.

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Lindberg/MPH Ships Tube Furnaces

Lindberg/MPH announced the shipment of four (4) heavy duty tube furnaces to a leading manufacturer of thermocouples for use in a laboratory to heat treat parts inside tubes. The tube furnaces are easy to operate, utilize an energy efficient design, and provide rapid heat-up rates along with fast cooling and response time. They offer superior radial and linear temperature uniformity and require little or no maintenance.

The four (4) heavy duty tube furnaces have a maximum temperature rating of 1500°C and work chamber of 3” in diameter and 34” in length with removable side panels. Double-end silicon carbide heating elements are mounted above and below the furnace chamber for uniform heating. The chambers are constructed of high-temperature graded insulation. The insulating vestibules at the ends of the heated chambers keep the heat loss to a minimum ensuring even greater temperature uniformity. These tube furnaces provide easy element installation, electrical hook-up, and adjustment.

“These compact tube furnaces offer customers a number of benefits. With a design that is easy to operate while at the same time provides energy efficiency and premium performance, they are the ideal solution for many customers.” –Jason Dobberstein, Inside Sales Manager

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World’s Largest Commercial Vacuum Furnace Completes Successful First Run

Solar Atmospheres of Western PA, launched into operation its newest and largest vacuum furnace.  In its inaugural cycle, the 48-foot furnace successfully vacuum heat treated nickel alloy components while preserving the crucial elements of brightness and cleanliness. The state of the art vacuum furnace has the ability to apply tight pyrometric controls to ± 10° F.  The innovative, U.S. patented load car design prevented distortion of the more than 40-foot long tubes. Due to the furnace’s increased efficiency, the total cycle time for this thermal process will be reduced by two days compared to traditional furnace designs. Solar Atmospheres of Western PA is absolutely confident their brand new 48-foot vacuum furnace will consistently surpass customers’ expectations.

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