MANUFACTURING HEAT TREAT

Direct-Chill Casting

BOTW-50w  Source:  Total Materia

Direct-chill (DC) casting is currently the most common semi-continuous casting practice in non-ferrous metallurgy. The process is characterized by molten metal being fed through a bottomless water cooled mould where it is sufficiently solidified around the outer surface that it takes the shape of the mould and acquires sufficient mechanical strength to contain the molten core at the centre. As the ingot emerges from the mould, water impinges directly from the mould to the ingot surface (direct chill), falls over the cast surface and completes the solidification.

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Pulsed Electric Current Sintering

BOTW-50w  Source:  Total Materia

Pulsed electric current sintering (PECS) also known as spark plasma sintering (SPS) or field assisted sintering (FAST) is a relatively new innovative technique for the consolidation of fine or nanocrystalline powders and has received much attention in the recent years because of its many advantages compared with other sintering/bonding methods such as the hot pressing and hot isostatic pressing (HIP) processes.

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Making Metal Wires – No Heating Required

BOTW-50w  Source:  Materials Today

“A team of engineers from North Carolina State University looked to eutectic gallium indium (EGaIn) – a metal with a melting point of ∼15.5 °C – to produce thin wires at room temperature. Conventional electrical wires are fabricated by using large forces to repeatedly pull and elongate a metal rod that had been produced at high temperatures. The approach taken by Prof. Michael Dickey and his team is rather different.”

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New Boride Material Forms Own Protective Coating

BOTW-50w  Source:  Materials Today

“This resistance to oxidation is possible because of the presence of aluminum in layers between molybdenum and boron layers,” Barsoum said. “When heated to high temperatures in air the aluminum atoms selectively diffuse to the surface and react with oxygen – forming a surface aluminum oxide, or alumina, protective layer that slows down further oxidation considerably. So the material forms its own protective coating.”

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The FINEX Process

BOTW-50w  Source:  Total Materia

Molten Iron is produced directly using iron ore fines and non-coking coal rather than processing through a sinter plant and coke ovens as traditional blast furnace route. In the Finex process, iron ore fines are charged into a series of fluidized-bed reactors. The fines pass in a downward direction where they are heated and reduced to direct-reduced iron (DRI) by means of a reduction gas – derived from the gasification of the coal – that flows in the counter – current direction to the ore. The DRI fines are then hot-compacted to hot-compacted iron, transferred to a charging bin positioned above a melter gasifier where smelting take place. The tapped product, liquid hot metal, is equivalent in quality to the hot metal produced in a blast furnace ore Corex plant.

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Analysis of Heat Treat on Carburized Ring Gear and Multivariate Regression Model Development

BOTW-50w  Source:  Thermal Processing for Gear Solutions

Like most other heat treatments, the carburizing and hardening process is known to introduce dimensional changes and gear distortion [4]. If these size and shape changes can be anticipated and controlled, it is possible to eliminate post–heat treatment machining by designing ring gears that would allow for the heat treat change. Such gear manufacturing would significantly reduce cost and machining-to-assembly time, both of which are critical in a commercial environment and large-scale production.

Read More:  Analysis of Heat Treat Growth on Carburized Ring Gear and Multivariate Regression Model Development

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Vermont Precision Tools Selects Lucifer Furnaces

Vermont Custom Gage LLC. a subsidiary of Vermont Precision Tools Inc., Swanton VT, selected Lucifer Furnaces to create manufacturing capability with the addition of an air recirculating oven, a salt bath pot furnace and a quench tank. The new equipment will be used in the production of small steel component parts of their measuring (gage) equipment. The oven, a 4000 series, model 48-R36 with working dimensions of 24”Hx24”Wx36”L, heats to 800°F and will be used for Tempering. Insulated with 6.5” multi-layered lightweight firebrick and block insulation with a roof lined with ceramic fiber modules, the oven features a stainless steel liner which isolates the workload from the heating elements and directs airflow in a horizontal pattern. A high CFM fan assembly mounted through the oven rear wall circulates air over heating elements and back through the work chamber. The horizontal swing door is mounted with heavy duty hinges, 6” of insulation and two cam latches for a secure seal. After pre-heating, parts will be loaded into the salt pot furnace, model 2055-1624 and then oil quenched in a Lucifer Quench Tank, QT-2020, complete with air mixer, heater and soak timer. Next, the tools will be loaded into the 4000 series, model 48-R36 oven to be held at a constant temperature over a period of time to stabilize the structure of the steel. Vermont Precision Tools dba Vermont Gage manufactures a wide range of fixed limit gages including both threaded and cylindrical. Vermont Gage manufactures high quality gages with tolerances ranging from .00020” – .00002”.  Vermont Precision Tools Inc. chose Lucifer Furnaces for the equipment based on its robustness and value.

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UPS Launching On-Demand 3D Printing Manufacturing Network

UPS will launch a distributed, on-demand manufacturing network that links its global logistics network with 3D printers at The UPS Store in more than 60 locations around the U.S. and Fast Radius’ On Demand Production Platform and 3D printing factory in Louisville, Kentucky. The integration into one additive manufacturing and logistics solution this summer will make 3D printing accessible to more potential users, enabling them to realize the convenience and cost-savings this technology offers.

Further strengthening UPS’s distributed, on-demand manufacturing offering, SAP today announced an agreement with UPS to create an end-to-end industrial solution. SAP’s extended supply chain solutions will be integrated with UPS’s on-demand manufacturing solution and global logistics network to simplify the industrial manufacturing process from digitization, certification, order-to-manufacturing and delivery.SAP made its announcement at the SAPPHIRE NOW conference.

“UPS is a leader in bringing industrial-strength 3D printing to reality. By building this disruptive technology into our supply chain models, we also bring new value to our manufacturing customers of all sizes,” said Stan Deans, president, UPS Global Distribution & Logistics. “Additive manufacturing technology is still developing rapidly so ‘manufacturing as a service’ is a smart approach for many companies.”

Customers will visit the Fast Radius website (formerly CloudDDM) to place their 3D printing orders, which will be directed to the optimal manufacturing or The UPS Store location based on speed, geography, and the product quality the customer requires. Orders can be shipped as early as same day. While participating The UPS Store locations are all in the U.S., companies globally could utilize the network and place orders.

By integrating SAP’s extended supply chain software with the UPS additive manufacturing solution and logistics network, manufacturing companies of all sizes will be able to access on-demand industrial manufacturing with the touch of a button. SAP customers will be able to digitize and simplify the production part approval process through SAP and their orders can be seamlessly routed to UPS for production and delivery.

The on-demand network created will benefit customers of all sizes:

  • Manufacturers wanting to reduce inventory for slow-moving parts
  • Manufacturers with short production runs where the cost to create the mold or tooling could make these orders too expensive for traditional manufacturing
  • Manufacturers and retailers of custom/semi-custom goods as additive manufacturing allows cost-effective customization of goods
  • Industrial designers and engineers who want high quality rapid prototypes delivered as fast as one day
  • Entrepreneurs, start-ups and manufacturers who don’t currently have access to 3D printers or have limited capital and time and will use 3D printing for rapid prototyping and manufacturing of initial production runs

“Fast Radius plans to continue enhancing its production platform and to globally expand its manufacturing capabilities in 3D printing (plastics and metals), CNC machining and rapid injection molding,”said Rick Smith, co-founder and CEO of Fast Radius.  “With this distributed, on-demand manufacturing network, UPS customers will be able to get their products to market faster and more cost-effectively because parts can be produced exactly in the quantity they need and when they need them. The potential of on-demand manufacturing is here today.”

The UPS Store was the the first nationwide retailer to offer 3D printing services in-store. “Connecting all The UPS Store locations into a larger network provides more opportunity for new customers to access our printers and gives customers added flexibility to match their requirements with the appropriate UPS location,” said Daniel Remba, Small Business Technology Leader for The UPS Store, Inc.

For more information about 3D printing at UPS, please visit www.ups.com/3Dprinting.  UPS is a minority investor in Fast Radius through the UPS Strategic Enterprise Fund (SEF).  The UPS SEF is a corporate venture capital group that focuses on developing critical partnerships and acquiring knowledge returns from its investments in information technology companies and emerging market-spaces.

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Saudi Aramco Signs to Set Up High-End Forging & Casting Manufacturing Facility

Saudi Aramco has signed a Memorandum of Understanding (MoU) with GE (NYSE: GE) and Cividale SpA of Italy to build the Middle East and North Africa’s first-of-its-kind high-end forging & casting manufacturing facility that will serve the region’s maritime and energy industries.

Marking a joint investment of over US$400 million (SAR1.5 billion), the new facility, to be located in Ras Al-Khair under the Royal Commission of Jubail and Yanbu industrial area, aims to establish a high-value supply chain that boosts exports and economic competitiveness. Set to be operational in 2020, the plant will create 2,000 quality jobs in the Kingdom and catalyze the growth of Saudi small and medium enterprises (SMEs).

The MoU follows a preliminary partnership between Saudi Aramco and Cividale, a leading European producer in the steel and cast iron sector, to conduct feasibility studies for forging and casting manufacturing services in the Kingdom. GE has come on board to extend its expertise and investment in developing the world-class manufacturing plant through a joint venture between the three entities.

The Forging & Casting Manufacturing Facility complements plans by Saudi Aramco to develop several industrial projects in the Kingdom including a maritime project focused on building, maintenance, repair and overhaul (MRO) of offshore platforms, jack-ups, offshore service vessels and commercial tankers.

Saudi Aramco is also working with its partners to develop an onshore rig manufacturing facility for providing new build and MRO services to onshore rigs and systems; an engine manufacturing project for the manufacturing, maintenance and repair of diesel engines, manufacturing and repair of marine pumps; and an Energy Industrial City to accelerate manufacturing industries in the oil and gas sector.

The Forging & Casting Manufacturing Facility will serve all these projects in addition to providing the best-in-class services and technologies to downstream & other industries across the region and global markets. It will also support the ongoing emphasis of the government, under Saudi Vision 2030, to develop the mining sector of the Kingdom by creating a domestic source-market for various raw materials & supplies that go into the production line.

Abdallah I. Al-Saadan, Senior Vice President, Finance, Strategy & Development, Saudi Aramco, said: “The MoU reflects our ambition to create a robust supply chain that builds positive synergies in the oil and gas manufacturing sector. This builds on our deep commitment to support the goals of Saudi Vision 2030 to promote economic and industrial diversification in the Kingdom and boost localized manufacturing.”

Rami Qasem, President & CEO, GE Oil & Gas, Middle East, North Africa & Turkey said: “For the Forging & Casting Manufacturing Facility, we will leverage our already strong expertise in ‘Made in Saudi’ manufacturing. Together with our partners, we will actively engage Saudi SMEs to support the plant’s operations, and train & hire Saudi professionals, adding further value to the economy. By building a domestic forging and casting production unit, Saudi and regional customers can achieve greater operational efficiencies in product procurement, repair and service support.”

Antonio Valduga, President of Cividale, added: “The feasibility assessment study underlines the strong potential for a world-class manufacturing facility for forging and casting services in the Kingdom. Developing a full-fledged facility through the joint partnership will position Saudi Arabia as a technology and services hub for specialized equipment and services.”

The collaboration is a strong example of the public-private partnerships that the government fosters under Saudi Vision 2030 to develop local manufacturing capabilities that add significant value to the economy.

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NASA Releases Dozens of Patents into the Public Domain

Washington – NASA has released 56 formerly-patented agency technologies into the public domain, making its government-developed technologies freely available for unrestricted commercial use. In addition to the release of these technologies, a searchable database now is available that catalogs thousands of expired NASA patents already in the public domain.
These technologies were developed to advance NASA missions but may have non-aerospace applications and be used by commercial space ventures and other companies free of charge, eliminating the time, expense, and paperwork often associated with licensing intellectual property. The technologies include advanced manufacturing processes, sensors, propulsion methods, rocket nozzles, thrusters, aircraft wing designs, and improved rocket safety and performance concepts.
“By making these technologies available in the public domain, we are helping foster a new era of entrepreneurship that will again place America at the forefront of high-tech manufacturing and economic competitiveness,” said Daniel Lockney, NASA’s Technology Transfer program executive. “By releasing this collection into the public domain, we are encouraging entrepreneurs to explore new ways to commercialize NASA technologies.”
This patents release is the latest in NASA’s long tradition of extending the benefits of its research and development into the public sector, where it may enhance the economy and quality of life for more Americans. The release also may help familiarize commercial space companies with NASA capabilities and result in new collaborations with private industry.
The innovations included in this transfer were selected by NASA officials using a rigorous review process, during which decision-makers looked for technologies that offer the potential for high unit values but are less likely to be licensed by outside companies because of low demand for resulting products (for example, spacecraft), or the technology still requires significant development before it is marketable.
A few examples include:
  • Inventions related to rocket nozzles, injection systems, and propellants that might help launch a new generation of commercial spacecraft
  • Methods for controlling airflow around vehicles in hypersonic flight
  • Technologies designed to mitigate the dangerous gases created as humans live and work in space
NASA’s patent portfolio, managed by the agency’s Technology Transfer Program, includes more than 1,000 technologies in categories such as manufacturing, optics and sensors, and is available for industry use through licensing agreements.

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