AEROSPACE HEAT TREAT

Safran Celebrates the Completion of 500th Landing Gear for Boeing 787 Dreamliner

Ajax, Ont, 12 September 2016

Safran Landing Systems announces the completion of the 500th landing gear set (nose and main landing gear) for Boeing 787 Dreamliner in its Canadian facility located in Ajax, Ontario.

Since being awarded with the contract in 2006, Safran Landing Systems has been responsible for the design, development, qualification, testing, manufacture and support of the Boeing 787 Dreamliner main and nose landing gear.

“This milestone is a testament to our commitment to technology and research,” said Deane Weatherby, VP, North American Programs at Safran Landing Systems. “Our Boeing 787 landinggear features a number of innovations in material technology aimed at reducing landing gear weight, corrosion and providing higher resistance to fatigue.”

Production activities for the 787 program are shared across Safran Landing Systems facilities in Canada, USA, China, France, Mexico and the UK. Final integration takes place at the company’s Everett, Wash. and Ajax facilities as well as its sister company Safran Electrical and Power site in Charleston, S.C., where the system components are integrated with the landing gear structure prior to delivery to Boeing’s final assembly lines in Seattle and Charleston. The 500th landing gear set is scheduled to be shipped to Boeing’s final assembly line in Seattle.

“This is a significant landmark for Safran Landing Systems,” said Deane Weatherby. “Since the launch of this program, more than 113 million passengers have flown on the 787 Dreamliner equipped with our landing gear. We are pleased to be a part of the Boeing 787 family and we look forward to our continued partnership.”

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WHI Announces Strategic Combination Including Heat Treating

Albert Altieri, Aerospace Heat Treating, WHI Global
Albert Altieri, CEO of WHI Global

Sept. 12, 2016 –  WHI Global, LLC  announced that it has effected the strategic combination of three companies, Crow Precision Components, LLC, M&M Precision Components, LLC and Arlington Precision Components, LLC to create a vertically integrated manufacturer of complex metal parts and assemblies for the aerospace, defense and industrial markets.

With 65 years of operating history and a manufacturing footprint of over 200,000 square feet, WHI serves a diverse customer base. Utilizing a broad range of state-of-the-art equipment and support systems, WHI delivers enhanced capabilities and superior value to its customers. With industry-leading 3-, 4- and 5-axis CNC machining, closed-die forging, heat treating, assembly, testing and inspection capabilities, WHI produces complex components from virtually any metal.  WHI was formed through a series of acquisitions led by Rift Valley Equity Partners, LLC (“Rift Valley”), a private investment firm based in New York.

To lead this new entity, WHI is pleased to announce that Albert Altieri has joined the Company and will serve as its President and CEO.  Mr. Altieri is a 35-year veteran of the Aerospace & Defense industry and previously served as Vice President and Chief Operating Officer with Sikorsky Aerospace Services.

“The WHI platform allows us to deliver a significantly expanded suite of capabilities, while maintaining the highest standards of quality and service,” said David Caputo, Managing Partner of Rift Valley. “We are pleased to welcome Al to the WHI team, and are confident he will drive this new chapter of growth.”

“I am excited to join such a dynamic and high growth platform,” said Mr. Altieri.  “WHI’s industry leading capabilities in complex machined parts, forgings and assemblies offer tremendous potential.  Our focus will be to continue to provide high quality products and outstanding service to our global base of customers while delivering the enhanced benefits of the WHI platform to support their growth and capabilities.”

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Can-Eng Manufactures Rotary Furnace for Weber

Can-Eng Furnaces International Limited has been contracted to design, manufacture and commission a rotary furnace system for the heating and hot working of titanium and alloy billets and preformed shapes for Weber Metals Inc. of Paramount, California – Long Beach Facility. Weber Metals is a subsidiary of Otto Fuchs KG of Meinerzhagen, Germany, and an operating unit of the Otto Fuchs Aerospace Group.
This large diameter rotary furnace is a part of Weber Metals’ 60,000-t press expansion project. The 60,000-t press will allow Weber Metals to manufacture larger and lighter forgings utilizing more advanced materials and will incorporate the latest in green technology to reduce waste, energy consumption and increase efficiency. The new facility will house the largest aerospace forging press in the Americas making some of the world’s largest monolithic forging components.

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Schafer Gear Works Transfers its Fort Wayne, Ind., Commercial Aviation Shafts and Small Gear Capabilities to South Bend, Ind.

Shafer Gear Works, Aerospace Heat Treat, Automotive Heat Treat, Medical Heat Treat, Manufacturing Heat TreatTo meet Schafer Gear Works’ growing demand for high-precision commercial aviation shafts and gears, the company recently moved its Fort Wayne, Ind., operations to its larger production facility in South Bend, Ind. “Acquisition of new, state-of-the-art equipment at our South Bend plant and the ability to better leverage our gear manufacturing expertise led to the transfer,” said Paresh Shah, operations manager for the South Bend facility. The transition was seamless and the plant now produces precision-critical shafts and small-diameter gears with tolerances to 0.0004” and microfinishes to 16 RMS.

Shah said moving the small-diameter gear production 90 miles west to Schafer Gear Works South Bend will improve design and manufacturing efficiencies as well as customer support. By centralizing the facility’s small- and medium-diameter gear engineering, production and quality control expertise, the company is expanding its presence in the aerospace and automotive industries as well as with medical instruments, light and heavy industrial products, recreation vehicles, and material handling companies. Its efforts to reduce tool costs and downtime keep pricing competitive and delivery among the fastest in the gear-making industry. Because of the South Bend facility’s continuous equipment improvements and stringent quality standards, it has earned ISO 9001-2008 and AS9100 certification.

Schafer Gear Works manufactures one of the widest ranges of custom-engineered, precision-cut gears for off-highway markets. In addition to the small-diameter gears and precision components, the South Bend plant produces 1.5- to 10-inch diameter spur, internal and helical gears as well as shafts.

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Aleris To Be Acquired By Zhongwang USA LLC

Aleris Corporation, a global aluminum rolled products producer, announced today that it has entered into a definitive agreement to be acquired by Zhongwang USA LLC, a company majority-owned and led by Mr. Liu Zhongtian, founder of China Zhongwang Holdings Limited (“China Zhongwang”, HKEX code: 01333).  The aggregate value of Aleris amounts to $2.33 billion, comprising $1.11 billion in cash for the equity to be paid by Zhongwang USA, plus $1.22 billion in net debt.

Aleris will continue to be headquartered in Cleveland, Ohio, and will be operated as an independent entity. The Aleris management team will remain in place, providing continuity for Aleris employees and customers and supporting the continued implementation of the Aleris strategy.

Aleris will retain its name and continue to serve its customers with no changes to current operations, contracts or commitments.  It will continue with the implementation of all strategic growth projects, including its major expansion project in Lewisport, Kentucky, which will enable Aleris to meet the North American automotive industry’s growing demand for aluminum auto body sheet.

“We are excited about this transition to strategic ownership as it will allow us to accelerate our strategy to expand our capabilities to support the production of high-value advanced materials for the global automotive and aerospace markets, while maintaining our position as a leading supplier to critical regional markets like building and construction,” said Sean Stack, President and CEO of Aleris.  “We expect the transition to be seamless for our employees and customers, and that the new strategic shareholder will provide us with greater financial flexibility to continue to anticipate and meet the needs of our customers well into the future.”

The acquisition of Aleris reflects Mr. Liu’s commitment to disciplined operating investments over the long-term in an industry to which he has been committed for two decades.  In addition to his role at Zhongwang USA, Mr. Liu is also the chairman and founder of China Zhongwang, the second largest aluminum extrusions product developer and manufacturer in the world and the largest in Asia.  With the acquisition of Aleris, Mr. Liu will now oversee companies that have complementary geographic footprints and capabilities.

“This acquisition is an international expansion to establish a complementary business foothold, as I strongly believe in the potential and prospects of Aleris and the aluminum industry as a whole,” Mr. Liu said.  “Aleris has a strong management team, talented employees and industry-leading capabilities with a complementary geographic footprint.  As the company enters the final phase of its Lewisport automotive project, I believe Aleris is well-positioned to capitalize on the positive demand trends we see globally, and I look forward to supporting the Aleris management team in implementing their growth strategies and pursuing continued success with expanded resources and financial and operational flexibility.”

Since 2010, Aleris has been owned and controlled by a group led by certain investment funds of Oaktree Capital Management, L.P., with affiliates of Apollo Management, L.P., and Sankaty Advisors, LLC owning minority interests.

The transaction is expected to close in the first quarter of 2017 following the customary regulatory approvals and closing conditions.

Credit Suisse acted as financial advisor to Aleris.  Fried, Frank, Harris, Shriver and Jacobson, LLP acted as legal advisors.  Moelis & Co. advised the Aleris Board on certain aspects of this transaction. Paul, Weiss, Wharton & Garrison LLP acted as legal advisors to Oaktree Capital Management.

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Advanced Heat Treat Receives Nadcap Merit Status

Advanced Heat Treat Corp. announces that it has been awarded Nadcap Merit status for Heat Treating (Ion Nitriding) at the MidPort location in Waterloo, IA.

“Achieving Merit status for the second time in a row is a huge accomplishment for us. Our team works hard each day to ensure the highest quality is given not only to our aerospace and defense customers, but every customer that sends parts to AHT! We are proud to offer the Nadcap certification for our ion (or plasma) nitriding services and hope our customers take pride in the fact they send their parts to AHT.” Stated John Ludeman, Director of Metallurgy and Quality Excellence.

Advanced Heat Treat Corp. has held Nadcap accreditation since 2013. Having demonstrated their ongoing commitment to quality by satisfying customer requirements and industry specifications, the Nadcap Task Group has determined that Advanced Heat Treat Corp. has earned special recognition. This means that, instead of having their next Nadcap audit in twelve months, Advanced Heat Treat Corp. has been granted an accreditation that lasts 18 months!

“Achieving Nadcap accreditation is not easy: it is one of the ways in which the aerospace industry identifies those who excel at manufacturing quality product through superior special processes. Companies such as Advanced Heat Treat Corp. go above and beyond achieving Nadcap accreditation to obtain Merit status and they should be justifiably proud of it,” said Joe Pinto, Executive Vice President and Chief Operating Officer at the Performance Review Institute. “Benefitting from a less frequent audit schedule reduces audit costs and associated pressures and demonstrates the trust that the aerospace industry has in Advanced Heat Treat Corp., based on their past performance in Nadcap audits. PRI is proud to support continual improvement in the aerospace industry by helping companies such as Advanced Heat Treat Corp. be successful and we look forward to continuing to assist the industry moving forward.”

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Heat Treat TV: 48′ Vacuum Furnace Installed in Western Pennsylvania

Take a look at this fascinating time-lapse video of a 48 foot vacuum furnace being installed at a leading commercial heat treat shop in western Pennsylvania. The furnace was manufactured by Solar Manufacturing and will be used for vacuum processing very large, long, and/or heavy aerospace, automotive and energy sector parts. Watch it now by clicking here or on the image below.

Solar Atmospheres' 48' Vacuum Furnace 2

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Norsk Titanium to Build World’s First Industrial-Scale Aerospace Additive Manufacturing Plant in New York

State Releases First Funds for Signature Economic Development Project for Initial Lot of 20 Norsk Titanium MERKE IV™ Rapid Plasma Deposition™ Machines to Launch Aerospace Factory of the Future

Norsk Titanium AS, the world’s pioneering supplier of aerospace-grade, additive manufactured, structural titanium components announced today the State of New York, in partnership with SUNY Polytechnic Institute, has placed an order for an initial lot of 20 of Norsk Titanium’s patented MERKE IV™ Rapid Plasma Deposition™ (“RPD™”) machines.  The order is in accordance with an approved state budget allocation to facilitate Norsk Titanium’s US subsidiary building and operating the world’s first industrial-scale metal additive manufacturing plant in New York with the following details:

  • Plattsburgh, New York selected as the location for the world’s first Rapid Plasma Deposition™ factory
  • Facility to be operational by the end of 2017
  • The first 20 MERKE IV™ RPD™ machines establish a baseline production level of 400 metric tons per year of aerospace-grade, structural titanium components
  • The New York program envisions a capacity ramp-up to a total of 40 MERKE IV™ RPD™ machines capable of up to 800 metric tons per year, which will be consumed to meet increasing demand from the aviation industry
  • New York State investment advances Norsk Titanium’s production of the first 20 machines
  • New York has released an additional $4.0 million in planning funds for the Norsk Titanium US industrial-scale Plattsburgh factory

“We are proud to be a part of the unwavering vision and leadership of Governor Cuomo and are moving forward in support of his efforts to revitalize upstate New York with jobs, technology and community pride,” said Norsk Titanium Chairman of the Board John Andersen, Jr. “Our researchers have spent ten years pioneering the Rapid Plasma Deposition™ process that is now ready to cut millions of dollars in cost from the world’s premier commercial and military aircraft, and with the foresight displayed in other sectors, the State of New York is the ideal place to launch this manufacturing revolution.”

“Today marks the beginning of a new era in the way aircraft, marine vessels, automobiles, spacecraft and many industrial products are designed and built,” said Norsk Titanium President & Chief Executive Officer Warren M. Boley, Jr. “Not only are we creating jobs, huge economic impact and great visibility for the wider Plattsburgh community, we are also making history by kicking off a new phase of on-demand, near-net-shape manufacturing that sets a new benchmark of efficiency and customer responsiveness.”

“This unparalleled investment by Governor Andrew Cuomo in the North Country’s aerospace sector brings together a leading-edge global company in Norsk Titanium with an established high-tech aviation ecosystem in the region and the state, a perfect match that will create good paying advanced manufacturing jobs in Plattsburgh while advancing New York’s leadership in this dynamic and growing industry,” said SUNY Polytechnic Institute Vice President Christopher Walsh. “SUNY Poly is proud to partner with Norsk Titanium to bring this revolutionary technology to market and to continue to drive cutting edge research in all of the state’s nanotechnology-enabled industries.”

Under the terms of the deal, Norsk Titanium US will provide additional investment into the Plattsburgh operation that is expected to bring the total program commitment to the $1 billion dollar level over the initial 10-year period of operations. A $125 million New York investment in the Norsk Titanium US Plattsburgh factory was approved in the 2016-2017 State budget and first highlighted by Governor Cuomo on April 1, 2016 during the North County Highlights budget address in Albany.

Norsk Titanium US is also partnering with the North County Chamber of Commerce in Plattsburgh to support and promote the successful launch and growth of Norsk’s industrial-scale factory including workforce training, economic development and STEM outreach including specific educational programs for SUNY Plattsburgh, local community colleges and other schools in the region.

Norsk Titanium’s proprietary RPD™ process works by feeding titanium wire into a set of plasma torches protected by a cool argon environment that has made it possible to replace legacy forged parts, which take months and even years to develop and produce, with precision, additive manufactured components. The company has signed numerous contracts with the top echelon of aerospace manufacturers and tier-1 suppliers interested in leveraging RPD™ to cut cost and lead time from airframe and engine programs.

Norsk Titanium RPD™ components have equivalent strength to forgings, but are delivered inexpensively and efficiently, with unprecedented part cost and design-to-market speeds.

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Ellwood Texas Forge Navasota Completes Forgings for Boeing

gI_164487_July2016On July 19, 2016, Ellwood Texas Forge Navasota, LLC (ETFN) made its first production shipment of 15-5PH flap-track forgings for the 737 program to the Boeing Portland (Oregon) fabrication facility. Ellwood and Boeing had concluded negotiations on a new multi-year contract in May of 2015, and shortly thereafter began the qualification processes and testing required, ultimately resulting in the successful production of the flap track forgings. ETFN looks forward to a long term relationship with Boeing, exploring new opportunities across all airplane programs.

About Ellwood Texas Forge Navasota, LLC

ETFN is one of two closed die forging companies owned by Ellwood Group Inc., headquartered in Ellwood City, PA.  Located in southeast Texas, ETFN uses conventional hammers, computer controlled counter blow hammers and computer controlled presses to manufacture near net closed die forgings out of carbon, alloy, stainless and titanium.  ETFN also has in-house die sinking, cutting, heat treatment, testing and machining capabilities.

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Ion Nitriding of Titanium Alloys for Gear Applications

BOTW-50w  Source:  Thermal Processing for Gear Solutions
The advantages of ion nitriding heat treatments in many low-alloy steels and titanium alloy gears used in high-performance applications include resisting wear and fatigue.

Thermochemical surface engineer heat treatments are effective in improving the performance of various gears made of ferrous alloys. The cost of machining typical gears during the manufacturing process often exceeds 55 percent of total cost, especially when there is significant grinding after carburizing the gears. Therefore, improvements in the manufacturing of gears that can lead to a reduction in machining are valuable.

Nitriding produces high hardness and compressive stresses in many low-alloy steels used for gears. It is a nearly distortion-free process, which allows for the treating of finished components, thus minimizing costs. The complex nature of the stresses at the contact area of rotating gears leads to contact fatigue and sliding friction. Nitriding is superior to other surface engineering techniques in resisting wear at gear f lanks. When a high-strength alloy steel suitable for nitriding is used, a nitrided surface layer withstands high contact Herztian stress (contact stress) at gear flanks better than a deeper carburized layer in many instances.

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