AEROSPACE HEAT TREAT NEWS

Global Aerospace Manufacturer Contracts with Aircraft Components Supplier

Boeing 787 Dreamliner

A global aerospace company that provides complex assemblies and systems solutions to aircraft and engine manufacturers and defense and space agencies worldwide recently announced that a number of major contract extensions and new awards have been made by world’s largest aerospace company and leading manufacturer of commercial jetliners and defense, space and security systems.

Magellan Aerospace, based in Toronto, Ontario, reported that multi-year contract renewals were agreed to for the manufacture of titanium wing fittings for the Boeing 787 Dreamliner and the detail manufacture and assembly of the tanker door for the Boeing 767-2C aircraft. In addition, Magellan was also awarded a new multi-year contract to manufacture winglet components for the Boeing 737 MAX.

The components and assemblies associated with these multiple contracts will be delivered from Magellan’s facilities in New York, New York, and Middletown, Ohio.

Haydn Martin, vice president New Business Development for Magellan

“These awards reflect Magellan’s commitment to continue to provide value solutions to Boeing in meeting their market challenges. Magellan will continue to innovate and optimize its performance to meet the expectations of Boeing and our customer base,” said Haydn Martin, vice president New Business Development for Magellan.

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Heat Treatment Processes Vary for Alloy Type, End Use

 

Source: AVWeb

 

Here’s a great article by Bob Hadley at AVWeb that explains the differences between aluminum alloys and how heat treating can make a crucial difference in the final properties.

Aluminum is usually marked by the manufacturer to indicate the alloy and temper. The markings may also include the lot number and the born-on date. (PC and caption: AVWeb)

An excerpt: 

“Heat treatment can dramatically alter the working characteristics of an alloy. 6061 is a great example. In the non-heat-treated state (6061-TO), it is quite bendable. But it is so soft, if you try to machine it, it will gum up the gullets of your saw and clog the flutes of your drill bits and end mills. It’s like trying to drill taffy. But when heat-treated to T4 or higher (such as 6061-T6 or 6061-T651…T651 being T6 temper plus stress-relived), it responds fine to any machining operation.”

Plus more, including

  • the range of temper/heat-treat designations denoting the specific process used to treat the material
  • the higher the number of alloy doesn’t necessarily indicate a stronger and harder alloy
  • which aluminum stock ought to be considered “mystery” material

Whether the OEM manufactures truck frames, aircraft components, or soda cans, applying the right heat treatment process to the right alloy produces the just the right weldability, machinability, and bendability.

 

Read more: “Home Shop Machinist: Material Matters—Aluminum”

Photo credit: Ichudov – Own work, CC BY-SA 3.0

 

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Heat Treat Industry Supplier Seeks Metrology Software Offerings to Broaden Capabilities

A Swedish high-tech engineering company that supplies to the heat treat industry, offering tooling systems, advanced stainless steels and special alloys, recently announced intentions to broaden its reach in digital manufacturing through the planned acquisition of French software company, Metrologic Group, headquartered in Meylan.

Björn Rosengren, president and CEO of Sandvik Group

Björn Rosengren, president and CEO of Sandvik Group, based in Sandviken, Sweden, noted that this announcement is a “first material step towards an increased offering in digital manufacturing in Sandvik Machining Solutions.”

A market leader in agnostic metrology software, Metrologic Group would form a new business unit within a new product area in Sandvik Machining Solutions and would maintain brand independence, in line with Sandvik’s decentralized business model.

Klas Forsström, president of Sandvik Machining Solutions

Metrologic Group develops 3D inspection software and electronics which run measurement machines used for dimensional control notably in the automotive, aeronautics, transport, and medical sectors. The company’s offering includes agnostic software for metrology, automation and robotics control as well as services for calibration and 3D-measuring. Products are used globally in most industries, including automotive, aerospace, energy, general engineering and consumer goods, all similar to that of Sandvik Machining Solutions.

“By merging Sandvik Machining Solutions’ know-how about materials, customer applications and machining processes with Metrologic’s deep understanding of measurement technology, we would be able to further expand the offering of increased productivity. I am convinced that this step towards increased digital manufacturing will be key for continued success for Sandvik Machining Solutions,” said Klas Forsström, president of Sandvik Machining Solutions.

The transaction is expected to close mid-2018.

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U.S. Army Lakota Program Expands Under New Contract

A contract valued at approximately $116 million to deliver 16 additional UH-72A Lakotas for the United States Army has been received by a leading aeronautics, space, and related services provider, the company’s second request this year to supply the U.S. Army’s Lakota program.

Chris Emerson, president and CEO of Airbus Helicopters, Inc. and head of the North America Region

Airbus Helicopters Inc announces the new contract includes the UH-72A production aircraft, associated technical and flight operator manuals and program management in training configuration for the Initial Entry Rotary Wing mission at Ft. Rucker. The UH-72A is a twin-engine utility helicopter used for a wide range of military operations including troop and light cargo transport, MEDEVAC, VIP transport, border security, and Homeland Defense.

“We are proud of our partnership with the U.S. Army. As the world’s best Helicopter Trainer provider, we recognize how important an asset the Lakota is for Army Aviation and our nation. Our employees at Airbus are committed to delivering every aircraft on-cost and on-schedule, without exception,” said Chris Emerson, president and CEO of Airbus Helicopters, Inc. and head of the North America Region. “Our mission of providing this vital national asset is crucial to the protection of our country and the closure of the pilot shortage gap.”

The Lakota is a key component of the Army’s Aviation Restructuring Initiative (ARI) and the primary rotary-wing trainer for the U.S. Army Aviation Center of Excellence at Fort Rucker, Ala. The UH 72A Lakota is fielded in and out of the Continental United States in several different configurations, performing a number of essential missions for the U.S. Army, U.S. Navy, and the National Guard.

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High-Tensile, Shock-Resistant Hybrid Prepreg Launched for Aerospace Applications

 A new high-tensile, highly shock-resistant prepreg that incorporates carbon fiber has recently been developed by a high-performance fiber company in Germany for aerospace applications and specialized carbon nanotubes (CNT).

Toho Tenax Co., Lt., the core company of the Teijin Group, announced the hybrid prepreg has been adopted by Mizuno Corporation in a new golf club shaft that weighs nearly 30 percent less than conventional shafts of the same thickness. A prepreg is a carbon fiber sheet pre-impregnated with matrix resin and used as an intermediate material for carbon fiber reinforced plastics (CFRP). The high-tensile prepreg enables the shaft to bend suitably as the ball is impacted and then cuts the shock of impact by more than 10 percent to reduce club movement on the follow-through swing.

The surface of the CNT is specially treated and its structural elements disperse equally when Toho Tenax’s carbon fiber is impregnated with matrix resin containing the CNT. The hybrid combination of carbon fiber and CNT realizes a superior CFRP that offers improved tensile strength and shock resistance. The CFRP is more durable because the carbon fiber and matrix resin do not peel away from each other thanks to the CNT’s balanced dispersion.

The Teijin Group is accelerating its development of its new high-tensile, highly shock-resistant prepreg for high-end applications in the sports and leisure fields, then eventually in aircraft fields, where weight reduction and high functionality are especially critical. Teijin also is strengthening its capabilities to provide solutions for diverse global businesses, from upstream to downstream.

 

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Aerospace Heat Treating Could Be Disrupted by Additive Manufacturing

 

Source: Aviation Week

 

Mark Meyer of GEAdditive

Henry Canady of Aviation Week interviews Mark Meyer of GEAdditive to gain insight on how additive metal manufacturing will disrupt the manufacturing landscape, particularly the aerospace sector, as techniques are refined for metal additive. Meyer speculates that additive will compete with metal forging and further enhance forging processes.

An excerpt:

“Just as taxi service often improves when Uber and Lyft move into town, metal casting is being enhanced as additive competes with casting.”

 

Read more: “Additive Manufacturing Could Disrupt A Lot of Aerospace Markets”

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Midwest Heat Treat Expansion to Meet Nadcap and Medical Industry Requirements

A commercial heat treater specializing in low-pressure vacuum carburizing recently expanded its processing capacity with a 12-bar gas quenching vacuum furnace.

Midwest Thermal-Vac (MTV), based in Kenosha, Wisconsin, which provides conventional heat treating, as well as solution, isothermal, spherodized or full annealing, homogenizing, normalizing, austenitizing, tool steel tempering and cryogenic treatments for the aerospace, defense, and general commercial industries, purchased the furnace to facilitate processing for companies needing to meet Nadcap and medical industry requirements such as MedAccred.

MTV’s capabilities will expand with a TITAN® vacuum furnace with 12-bar gas quenching from Ipsen USA. This furnace features a diffusion pump for high-vacuum levels and an all-metal hot zone to ensure part cleanliness, and an all-metal hot zone measuring 18″ x 24″ x 18″ (455 mm x 610 mm x 455 mm), with a 1,000-pound (450 kg) load capacity. It is capable of operating at temperatures ranging from 900 °F to 2,400 °F (482 °C to 1,316 °C) with ± 10 °F (±6 °C) temperature uniformity.

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Specialty Materials Invests in Aerospace Iso-Thermal Forging, Heat Treat Capacity

A global manufacturer of technically advanced specialty materials and complex components recently announced investment toward its iso-thermal forging and heat treating capacities to satisfy growing demand from the aerospace jet engine market.

CEO of Allegheny Technologies Inc. (ATI), Rich Harshman, CEO of Allegheny Technologies Inc. (ATI), announcing the expansion of ATI’s iso-thermal forging and heat treating capacities to satisfy growing demand from the aerospace jet engine market.  Photo credit: Tony Bettack, WTMJ, Twitter

Allegheny Technologies Incorporated (ATI), headquartered in Pittsburgh, Pennsylvania, will self-fund approximately $95 million, representing two projects: a fourth iso-thermal press and expansion of heat treat capacity. Both will take place at the company’s iso-thermal forging center in Cudahy, Wisconsin. ATI expects the projects to be completed in 2020 and fully qualify for aerospace-related production.

“We continue to invest in our advanced forging capabilities in support of our aerospace customer’s ramp-up of next-generation jet engine production. Once completed and fully qualified, this critical growth project will enable us to meet the increasing production requirements for existing long-term agreements with our engine OEM partners,” said Rich Harshman, ATI’s chairman, president, and CEO. “Iso-thermal is the most technologically advanced forging method available today and ATI’s ongoing leadership in this area is further solidified by this significant investment.”

“This investment, along with our recent nickel-based superalloy powder expansion in Monroe, NC, will enable the High-Performance Materials and Components (HPMC) segment to meet its longer-term financial goals by increasing our capacity to produce technologically advanced powder-to-iso-thermally-forged jet engine components,” said John Sims, Executive Vice President, HPMC Segment.

 

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Jason Schulze on AMS2750E: Understanding Key AMS2750E Definitions

This is the fifth in a series of articles by AMS2750 expert, Jason Schulze (Conrad Kacsik).  Click here to see a listing of all of Jason’s articles on Heat Treat TodayIn this article, Jason advances the discussion of TUSs with a lesson on the definitions of key AMS2750E terms. Please submit your AMS2750 questions for Jason to editor@heattreattoday.com.

Introduction

When executing a technical process, understanding the meaning and intent of certain definitions can clarify the interpretation of certain requirements, thereby, altering a specific course based on that interpretation.

In this article, we will focus on the primary definitions associated with temperature uniformity surveys as they apply to AMS2750E.

Control Zone vs Qualified Work Zone

Control Zone

AMS2750E, page 44, para 2.2.9: “A portion of the work zone in thermal processing equipment having a separate sensor/instrument/heat input or output mechanism to control its temperature. This portion of a furnace is independently controlled.”

Qualified Work Zone

AMS2750E, page 6, para 2.2.42: “The defined portion of a furnace volume where temperature variation conforms to the required uniformity tolerance.”

It’s important to understand the difference between the two definitions. Below is a figure which outlines the most basic idea behind each.

Figure 1

Failure of a Survey Thermocouple

AMS2750E, page 4, para 2.2.19: “Obviously incorrect or erratic activity of a survey thermocouple indicated by extreme high readings, extreme low readings, and/or erratic changes in readings not reflected by other sensors.”

This situation can be observed by pyrometry technicians in real time as the survey is running. Possible reasons for this may be:

  • a loss in chrome due to vapor pressure (vacuum furnaces only),
  • movement of the thermocouple during the test from the documented position,
  • Polarity reversal during test thermocouple assembly.

Note that AMS2750E allows only a specific number of thermocouples to fail during a TUS (see AMS2750E, page 30, para 3.5.16).

Heat Sink

AMS2750E, page 5, para 2.2.24: “A mass of material equivalent to the heat transfer characteristics of the thinnest section of the part being heat-treated. Heat sinks may be used during TUS (3.5.10.1) and during production (3.3.5).”

The use of heat sinks during a TUS is optional. Operators are permitted to utilize heat sinks on both TUS test thermocouples and the load thermocouple being used. The key is to document the initial TUS load condition, including the use of heat sinks, and utilize this configuration on subsequent tests.

If heat sinks are utilized on either the TUS test thermocouples, or the load thermocouples, the heat sink must comply with AMS2750E, page 26, para 3.5.10. Additional requirements and clarification regarding heat sink requirements can be found in the Nadcap Pyrometry Guide on page 47, question #43 and Heat Treat Auditor Advisory 17-007.

Figure 2

Qualified Operating Temperature Range

AMS2750E, page 6, para 2.2.41: “The temperature range of thermal processing equipment where temperature uniformity has been tested and found to be within required tolerances as specified in 3.3”

This temperature range affects multiple aspects of pyrometry, including the instrument calibration setpoints of both furnace instruments (AMS2750E page 14, para 3.2.5.5.1) as well as field test instruments (AMS2750E, page 14, para 3.2.5.4) used on that particular equipment. It also affects what product can be heat treated in the particular furnace.

Field Test Instrument

AMS2750E, page 4, para 2.2.20: “An instrument that is portable, that meets the requirements of Table 3, has calibration traceable to secondary equipment or better and is used to conduct on-site tests of thermal processing equipment.”

One of the key points in this definition is the term “portable”. This implies that furnace instruments cannot be used as field test instruments. For those new to pyrometry, this may cause confusion as a single instrument make and model could be designated as a field test instrument or a furnace instrument. As an example, consider a Yokogawa DX model electronic recorder. A supplier could buy two of the same model and use one as a furnace recorder and the other as a TUS recorder (making it a field test instrument). The only differences are its designated use, calibration points, and the fact that is independent from the furnace (portable).

Field test instruments must be calibrated using a standard instrument or better at 6 points per AMS2750E, page 14, para 3.2.5 and have an accuracy of ±1°F or 0.1%, whichever is greater.

Temperature Uniformity

AMS2750E, page 7, para 2.2.66: “The temperature variation (usually expressed as ± degrees) within the qualified furnace work zone with respect to set point temperature. For retort furnaces where a sensor in the retort is used to control temperature, the temperature variation is with respect to the sensor in the retort and not to the furnace set temperature.”

This relates directly to the furnace class designation per Figure 2 of AMS2750E. It’s important to keep in mind question #21 of the Hwhen designating furnace class.

Temperature Uniformity Survey

AMS2750E, page 7, para 2.2.68: “A test or series of tests where calibrated field test instrumentation and sensors are used to measure temperature variation within the qualified furnace work zone prior to and after thermal stabilization.”

As any pyrometry technician knows, one of the main issues to watch for is thermal inertia, or overshoot. Any overshoot will be cause for immediate failure and initiation of an internal RCCA per AMS2750E, page 34, para 4.2.

Conclusion

Understanding AMS2750E definitions will be advantageous to readers of the remaining articles in this TUS series.

We will next discuss the differences between periodic surveys, initials surveys and more.

Submit Your Questions

Please feel free to submit your questions and I will answer appropriately in future articles. Send your questions to editor@heattreattoday.com.

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Metal AM Manufacturer Dedicates Heat Treatment Department, Adds Furnaces

 

Source: Metal AM

An Italian metal additive manufacturer recently installed two furnaces and dedicated a new department exclusively to heat treating in a bid to expand its heat treatment capability and maximize the performance of aluminum alloys.

Read more: “BEAMIT Strengthens Investment in Heat Treatment for Metal Additive Manufacturing”

 

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