Search Results for: 3d

Titanium Producer Boosts Melt Capabilities with New Furnaces

Frank Perryman, president and chief executive officer of Perryman Company

Perryman Company, a metal fabricator headquartered in Houston, Pennsylvania, recently announced it will more than double its current titanium melting capacity through the addition of two new furnaces, one electron beam (EB) and one vacuum arc remelt (VAR).

The integrated titanium producer from melting of ingot to finished products has existing melting facilities at its western Pennsylvania location which are utilized for projects in the commercial aircraft and medical sectors. The company expects the new furnaces to alleviate backlog and support demand for titanium products in these as well as other industrial, recreation, and infrastructure industries.

“Our aerospace forecast model indicates there will be a need for additional melting capacity. With the increased capacity we will be in position to pursue segments of the aerospace market where we have not yet been a participant. We believe there’s more opportunity for us to leverage our fully integrated capabilities,” stated Frank Perryman, president and chief executive officer of Perryman Company.

The added capacity will also support planned growth in medical, additive/3D and other emerging markets.

Installation of the new furnaces will begin in late 2018 and are expected to be fully operational by mid-2019. Once complete, the company’s total melt capacity will exceed 26 million pounds, placing Perryman among the world’s largest melters of aerospace quality titanium.

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Kanfit Achieves Nadcap Accreditation for Composites, Renews Heat Treatment Certificate

Aerospace engineering company Kanfit Ltd announced recently that it has successfully completed its Nadcap audit for composites as well as a renewed certificate for heat treatment.

Shai Fine, Founder and General Manager of Kanfit

Successful accreditations include core processing (CP) and liquid resin processing (LRP). In addition, Kanfit received recertification for prepreg/adhesive bonding/resin film infusion and process control testing. Accreditations for LRP authorizes Kanfit’s resin transfer mold (RTM) process according to the requirements of Israel Aerospace Industries (IAI).

“We are extremely proud of our Composites and QA teams for bringing the company to the next level of Nadcap certification,” said Shai Fine, general manager of Kanfit. “Obtaining such a prestigious certification demonstrates our continued commitment to achieving our goal of providing top quality innovative solutions so that our customers continue to trust and depend on our products and services.”

Additionally, Kanfit reports that the new RTM process and specification for complex aerospace products that it created and developed has been adopted without changes by a prominent aerospace industry leader and has already been incorporated into its process specification library.

 

The company recently added 3D additive manufacturing to its autoclave manufacturing capabilities, and it is also developing other production technologies, including automated fiber placement (AFP) and robotic filament winding of closed frames.

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More Accessible Design-to-Launch Services Unveiled with IT, AM Technologies Partnership

Sudip Singh, Global Head, Engineering Service at Infosys Ltd

An end-to-end product development service using metal additive manufacturing (AM) technology was announced last month by two leading companies partnering to help customers accelerate their deployment of AM, also known as 3D printing, for volume production of end-use metal components.

Engineering and IT services company Infosys will apply its engineering processes and design for AM knowledge to manage product development projects from concept through to launch. Renishaw, a leader in metrology and additive manufacturing technologies, will support Infosys through its global network of Additive Manufacturing Solutions Centres, which provide access to Renishaw’s metal AM technology, which is used in series production of high-performance parts for aerospace, medical, automotive, oil and gas, mould and die, and consumer products.

“Additive manufacturing enables us to design and make innovative products with spectacular gains in performance and efficiency,” said Sudip Singh, Global Head, Engineering Service at Infosys Ltd. “Infosys has developed a rich knowledge base of AM design best practices, coupled with powerful design tools to analyze and optimise product designs, so that we can take full advantage of the flexibility that AM offers.”

Marc Saunders, Director – Global Solutions Centres at Renishaw

“Whilst additive manufacturing can create complex geometries in a single process step, some level of finishing is generally required to produce functional products,” said Marc Saunders, Director – Global Solutions Centres at Renishaw. “Renishaw’s knowledge of metrology, machining and finishing processes can help customers to develop an integrated manufacturing solution for their innovative new product.”

The two companies are currently working together on projects for customers located in Europe, Asia, and North America.

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Japan-Based Foundry Builds First U.S. Manufacturing Facility

Global manufacturer of alloy castings for the automotive and industrial sectors, Kimura Foundry America, has announced plans to locate its first U.S.-based manufacturing facility in Shelbyville, Indiana. The 35,200-square-foot plant, built on 10 acres of property, will house 3D-printing equipment which will facilitate the production of complex castings and molds for its U.S. clients. Planning to break ground in October 2017, the subsidiary of Japan’s Kimura Group targets a December 2018 opening and plans to create 20 new jobs by 2020.

The company uses a proprietary process for casting molds using 3D printing technology, allowing it to manufacture products including stamping die castings and machine and industrial tool castings. These products are used in automotive engine parts, pumps, compressors and energy components. “Kimura has established a Development Department and is engaged in thoroughly researching improvements in quality and in developments of new products. This approach has enabled us to introduce positive techniques in the casting industry, which used to depend only on workers’ experience and good sense. The results of these research outcomes are fed back to our foundries,” reads the company’s website.

“When we were searching for our first U.S. manufacturing partner, Indiana offered exactly what we were seeking,” said Yoya Fukuda, Ph.D., president of Kimura Foundry America. “That is because Indiana is strategically located in the epicenter of the industries we serve. The state’s highly-developed transportation networks and its highly-skilled manufacturing workforce were an excellent match. Indiana has a long history of welcoming Japanese companies to the state, and we are looking forward to joining the many other Japanese companies in Shelby County.” Kimura Group employs more than 830 associates at its 10 facilities across three locations in Japan and at its North American sales office in Schaumburg, Illinois.

“Shelbyville is a great community in a prime location for industry growth with capable Hoosiers ready to get to work,” stated State Representative Sean Eberhart (R-Shelbyville). “Kimura Foundry America is a perfect fit as they join other global manufacturing companies that already call Shelbyville home.”

Kimura Group employs more than 830 associates at 10 facilities across three sites in Japan and at its North American sales office near Chicago. The company uses a proprietary process for casting molds using 3D-printing technology, allowing it to manufacture products including stamping die castings and machine and industrial tool castings used in automotive engine parts, pumps, compressors, and energy components.

Sources: Business Facilities, Foundry MagazineIndustrial Heating, Indiana House Republicans

 

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TMK IPSCO restarts operations at Tulsa Port of Catoosa

Source:  Tulsa World

Keith Marquart leads a tour of the control room of the TMK IPSCO facility at the Tulsa Port of Catoosa. Photo Credit: Cory Young/Tulsa World

When the price of oil nosedived, one of this area’s casualties was TMK IPSCO, which idled its plant in September 2015.

“There was really no business for us,” said Joel Mastervich, vice president and chief operating officer of the company, which does welding, heat-treating, and threading on pipes used in drilling operations. “We had to make tough decisions back then. So we did.”

TMK IPSCO celebrated the restart of operations—and the creation of 168 jobs by year’s end—at a news conference August 8, 2017, at the Tulsa Port of Catoosa.

Read more: “Manufacturer restarts operations at Tulsa Port of Catoosa

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BAE Systems Begins Production on First Royal Navy Type 26 Global Combat Ship

Production on the first of the new Type 26 Global Combat Ships for the UK Royal Navy began with the push of a button last month at the BAE Systems shipyard in Glasgow, Scotland.

BAE Systems welcomed Sir Michael Fallon MP, Secretary of State for Defense, to its Glasgow facility to signal the start of production following the UK Government’s recent award of a contract for the first three ships to be built in this series. This advances the work already underway to construct five River Class Offshore Patrol Vessels and provides a strong foundation for the next two decades of shipbuilding in Scotland. During his speech, the Defense Secretary unveiled the name of the first ship as Glasgow.

The Type 26 Global Combat Ship will be a world-class anti-submarine warfare vessel, replacing the Type 23 anti-submarine variant frigates, with the premier ship due to be delivered to the Royal Navy in the mid-2020s. Globally deployable, the flexible mission bay, aviation facilities, and combat systems ensure it will be capable of undertaking a wide range of roles from high-intensity warfare to humanitarian assistance, either operating independently or as part of a task group.

The ship benefits from the latest advances in digital technologies, including 3D and virtual reality, to ensure that the ship’s design is refined earlier in the process.  This has enabled BAE Systems to work in collaboration with the Ministry of Defense and the Royal Navy to ensure every zone of the ship has the requirements of its crew at the heart of the design.

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ATI and GE Aviation Announce Titanium JV

Allegheny Technologies Incorporated, a global leader in the production of technically advanced specialty materials and components, announced a joint venture (JV) with GE Aviation for the development of a new meltless titanium alloy powder manufacturing technology. The JV will construct a new R&D pilot production facility. The titanium alloy powders are being developed for use in additive manufacturing applications, including 3D printing.

ATI will provide operational, technical, and project support to the joint venture. The joint venture will leverage ATI’s technology, manufacturing, and quality leadership in the production of specialty metal powders and premium-quality titanium and nickel-based alloys for critical and technically advanced applications. The JV will also draw upon GE Aviation’s engineering and development capabilities and technical knowledge of the use of alloyed titanium powders.

“We are pleased to join with GE Aviation to create this innovative next-generation technology joint venture,” said Rich Harshman, ATI’s Chairman, President and Chief Executive Officer. “The science of specialty metal powders is a transformative technology and we intend to maintain and enhance our industry-leading position.”

“Developing new materials is an important part of our vision for our business,” said David Joyce, vice chairman of GE and president and CEO of GE Aviation. “ATI is a recognized leader in advanced specialty materials, and we are excited about the collaboration this new joint venture enables.”

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Heat Treat Radio #6: Peter Hushek on Reducing TUS Failures

Welcome to another episode of Heat Treat Radio, a periodic podcast where Heat Treat Radio host, Doug Glenn, discusses cutting-edge topics with industry-leading personalities. Below, you can either listen to the podcast by clicking on the audio play button, or you can read an edited version of the transcript. To see a complete list of other Heat Treat Radio episodes, click here.


Audio: Heat Treat Radio: Peter Hushek on Reducing TUS Failures

In this conversation, Heat Treat Radio host, Doug Glenn, interviews Peter Hushek about Virtual Visual Surveys, a new 3D software that will help minimize temperature uniformity survey failures. Listen to Peter’s description of how this innovative new tool can help aerospace heat treaters know what’s going on inside the furnace during a TUS.

Click the play button below to listen.

 

Doug Glenn, Publisher, Heat Treat Today
Doug Glenn, Heat Treat Today publisher and Heat Treat Radio host.

To find other Heat Treat Radio episodes, go to www.heattreattoday.com/radio and look in the list of Heat Treat Radio episodes listed.

 

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Brazilian Steel Producer Purchased Continuous Slab Caster

A two-strand continuous slab caster supplied by Primetals Technologies has gone on stream at Companhia Siderúrgica do Pecém (CSP), a Brazilian steel producer. The plant has a capacity of 3 million t of slabs per annum. The continuous slab caster is part of a new steel works in the Pecém Industrial and Port Complex in São Gonçalo do Amarante in the state of Ceará. Primetals received the order in 2012 from Posco E&C, a company based in South Korea.
The continuous slab caster has a machine radius of 9.5 m and a metallurgical length of 39.8 m. It produces slabs in thicknesses of 220, 250 and 300 mm, and in widths ranging from 1,100–2,300 mm. A wide range of steel grades are cast, from low-carbon structural steels to peritectic and micro-alloyed medium and high-carbon steels, such as ULC, LC, MC, HSLA and HC. The slabs are then rolled into plate and sheet metal for use in mechanical engineering, shipbuilding, boiler and pipeline construction. The maximum casting speed is 1.8 m/min. Primetals engineered the entire plant and supplied core components, the fluid systems, the basic and process automation, and technology packages. The project also included training the operator’s personnel, and supervising the construction and commissioning work.The scope of supply from Primetals included straight Smart Mold molds plus the DynaWidth technology package for dynamic width adjustment during casting. LevCon mold level control and an electromagnetic, multi-mode mold-stirring system were installed to ensure an optimum bath level in the mold. The DynaFlex mold oscillation provides flexible adaptation of the oscillation parameters. The caster’s strand-guide system has a remotely adjustable Smart Bender and Smart Segments which, together with DynaGap Soft Reduction 3D, means that slab thickness can be changed quickly and automatically. I-Star strand-guide rollers support the strand.The Dynacs 3D secondary cooling process model dynamically calculates a three-dimensional temperature profile along the whole length of the strand. This helps to determine precisely the working points of the secondary cooling and the final strand solidification in response to the casting speed, slab format and steel grade. The internal quality of the slabs is improved by using DynaGap Soft Reduction 3D. The roller gap is dynamically adjusted during final solidification based on the working points calculated by Dynacs 3D. DynaJet spray cooling with movable nozzles in the segments ensures uniform, optimum cooling of the slabs, and consequently a high quality surface.

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