Rolls Royce

Purdue Heat Treating Consortium

Heat Treat Today publishes eight print magazines a year and included in each is a letter from the editor, Bethany Leone. In this letter, Bethany reports on her visit to the September meeting of Purdue Heat Treating Consortium where industry leaders presented key technical and operations decisions in heat treating. The academic partnership encourages research into topics such as sustainability and technology alternatives. Read more of what Bethany learned from her attendance at this dynamic and forward-looking consortium in this letter, which first appeared in the November 2024 Vacuum print edition.

Feel free to contact Bethany at bethany@heattreattoday.com if you have a question or comment. 


What heat treat issue do you need fixed? At Purdue Heat Treating Consortium’s (PHTC’s) September meeting, I witnessed industrial manufacturers targeting key technical and operations decisions in heat treat through an academic partnership.

Since summer of 2022, the research driven School of Materials Engineering at Purdue has positioned itself as a partner to industrial leaders in the Midwest. Their main goal: advance research of precompetitive projects.

I spoke with one member who commented on the beginnings of PHTC: “Some of the Midwest, I’d say, user companies . . . wanted a Midwest school and more research-oriented university. To have Purdue be able to fill that was perfect; that’s some place that we recruit from, where we know has a lot of depth of professors that would be able to contribute, and which has facilities that would be able to be a part of. So, it was a really good partner to make that change with.”

At the recent quarterly meeting, I sat amongst several dozen representatives from Amsted Rail, Caterpillar, Cummins, Rolls Royce, ECM USA, and other member companies as we settled in for a day of research presentations. Foremost in members’ minds was feasibility in real world application.

Topics included developing sustainable quenchant alternatives and identifying a method for greenhouse footprint analysis that would meet standards. The presentations of ongoing research were each met with intent nods of satisfaction, questions scrutinizing the data, and proposals on what specific direction industry players wanted to see examined.

Purdue Heat Treating Consortium’s (PHTC’s) September meeting where projects about developing sustainable technology were presented, as well as research topic findings

A mix of faculty and graduate students presented the five research topic findings. Guided by professors, the young people develop and execute research plans to address objectives determined by member voting at previous sessions. When I inquired what type of value this research held and the quality of the presenters, industry members were quick to speak highly of their abilities and the actionable research results.

Specifically, one member commented to me that the lifecycle work was proving to be helpful. Explorations like this give a “gauge of what we are able to meter on some of our own furnaces . . . and to have some common ways of describing emissions.” He continued, “that leads to either confirmation that we’re doing things right or to adjusting what we’re doing.”

Other topics that have been of interest address property variations when austempering certain materials and the quench oil work. Even when members may not apply all research results gained from the studies, ancillary work being done within a study — such as machine learning — offers additional value.

The group’s strength is collaborative action: as research objectives evolve, the academic contingent adapts. One paper was met with a peppering of cross-examination questions, the result being a large consensus as to the end value of this research. A plan to reconvene outside of regular sessions to provide industry testing data was determined, and industry members eagerly voiced their desire to contribute to this special moment.

Following presentations, the meeting came to a close. Voting members first determined which research to continue. Then, we toured the Manufacturing and Materials Research Laboratories at Purdue. The members witnessed various methods of metal 3D printing materials in action and handled printed parts of different alloy compositions.

Rounding out the day was an optional networking reception at a local pub and grill, Walt’s, where conversations around personal interests bled into reflections on research at PHTC.

My special thanks to Mark Gruninger, Managing Director for Industrial Consortia and Centers, and Mike Titus, Associate Professor of Materials Engineering and Technical Director of PHTC, for their invitation and warm welcome.

Contact Bethany at bethany@heattreattoday.com.


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Aluminum Alloy Achieves Ultimate Tensile Strength in Heat Treating

An aluminum alloy developed and patented five years ago has been identified as one of the strongest aluminum additive manufacturing powders commercially available.

Mike Bond, Director of Advanced Material Technology at Aeromet
Mike Bond, Director of Advanced Material Technology at Aeromet

Aeromet’s A20X™ surpassed the key 500 MPa UTS mark following a recent research project involving aero-engine giant Rolls-Royce and additive manufacturing equipment specialist Renishaw. Heat-treated parts produced using A20X™ Powder have achieved an Ultimate Tensile Strength (UTS) of 511 MPa, a Yield Strength of 440 MPa and Elongation of 13%. Crucially, parts additively manufactured with A20X™ Powder maintain high-strength and fatigue properties even at elevated temperatures, outperforming other leading aluminum powders.

“Since bringing the A20X™ alloy to market for additive manufacturing 5 years ago we have seen significant adoption for high-strength, design-critical applications,” said Mike Bond, Director of Advanced Material Technology at Aeromet. “By working with Rolls-Royce, Renishaw, and PSI, we have optimized processing parameters that led to record-breaking results, opening up new design possibilities for aerospace and advanced engineering applications.”

The HighSAP project was backed by the UK’s National Aerospace Technology Exploitation Programme (NATEP).  A20X™ Powder for additive manufacturing is derived from the MMPDS-approved A20X™ Casting alloy, the world’s strongest aluminum casting alloy, which is in use by a global network of leading aerospace casting suppliers.

Aluminum Alloy Achieves Ultimate Tensile Strength in Heat Treating Read More »

Aviation Systems Manufacturer, PA Specialty Metals Group Extend Purchase Agreement

A manufacturer of power systems for aviation and other industries recently announced that it has extended its Long-Term Purchase Agreement (LTPA) with a global specialty metals company headquartered in Pittsburgh, Pennsylvania.

Warrick Matthews, Executive Vice President, Procurement and Installations Supply Chain, Rolls-Royce

Rotating disc quality specialty materials will be supplied to Rolls-Royce for their Trent engine family by Allegheny Technologies Incorporated (ATI). The LTPA extends Rolls-Royce and ATI’s agreement through 2029.

“We are very pleased to have signed another long-term agreement with ATI for disc quality nickel alloys,” said Warrick Matthews, Executive Vice President, Procurement and Installations Supply Chain, Rolls-Royce. “Rolls-Royce’s supply chain requires on-time delivery of the highest quality materials. ATI’s track record of cost, quality and delivery performance has been a key consideration in award of this contract. This new contract provides an opportunity for Rolls-Royce and ATI to further develop their relationship and to enjoy engine production and services volume growth.”

Robert S. Wetherbee, ATI’s President and Chief Executive Officer

“We are pleased to extend our long-standing relationship with Rolls-Royce, partnering with them on the development of next-generation jet engines and supporting their legacy jet engine supply chain,” said Robert S. Wetherbee, ATI’s President and Chief Executive Officer. “This agreement reliably secures Rolls-Royce’s supply of critical materials for their innovative engine portfolio for the next ten years.”

John Sims, Executive Vice President, High-Performance Materials and Components Segment

“This agreement covers the production of a wide range of critical products used to make Rolls-Royce’s next-generation jet engines as well as spare parts for in-service engines. It supports ATI’s market-leading alloy development and broad production capabilities, including our iso-thermal forging operations,” said John Sims, Executive Vice President, High-Performance Materials and Components Segment. “In recognition of ATI’s commitment to innovation, quality and operational reliability, Rolls-Royce awarded ATI a majority share of all materials covered under this LTPA. We are honored to support Rolls-Royce as they work to confidently deliver on this unprecedented aerospace ramp.”

 

 

Aviation Systems Manufacturer, PA Specialty Metals Group Extend Purchase Agreement Read More »

10 Quick Heat Treat News Items to Keep You Current

10 Quick Heat Treat News Items to Keep You Current

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry.

Personnel and Company Chatter

  • A Berwick, Pennsylvania, machining company which offers heat treating among its services was recently acquired by precision machining provider DPMS, based in Santa Clara, California. K-Fab Inc. operates a 22,000-sq.-ft. precision machine shop that manufactures parts for the aerospace, defense, and semiconductor sectors.
  • GKN Powder Metallurgy recently announced a strategic collaboration with HP Inc, becoming the first to deploy the just-launched HP Metal Jet, a groundbreaking binder jetting technology, into its factories to produce functional metal parts for auto and industrial leaders, including Volkswagen and Wilo, and for companies around the world.
  • Joshua Farrell recently took over the Operations Manager position at Mid-South Metallurgical, based in Murfreesboro, Tennessee.

Equipment Chatter

  • California-based Delta H Technologies, LLC, recently delivered a commissioned dual chamber aerospace heat treating system — the largest and most advanced to date — to a leading U.S. military aircraft manufacturer. Both chambers are certified for heating parts up to 1200°F and capable of solution heat treating, aging, annealing aluminum, stress relieving titanium and ferrous castings, weldments, and aging of PH stainless steel.
  • An auto parts manufacturer recently received shipment of a customized oxidation nitriding furnace, manufactured by JGEF Furnace, a vacuum heat treating  equipment supplier with U.S. offices in San Francisco, California. The pit furnace, which has useful dimensions of 43.3 inches (1,100 mm) in diameter x 70.9 inches (1,800 mm) high, has a maximum temperature rating of 1292°F (700°C). The goal for this project was to represent an advanced solution for metallic parts. The furnace includes an advanced oxidation system that ensures the workpieces are preheated in a controlled oxidizing atmosphere and guarantees corrosion resistance, which in turn facilitates nitrogen uptake and growth of the nitride compound layer.
  • A large capacity fastener hardening furnace system has been commissioned by a tier one automotive supplier based in Detroit, Michigan. CAN-ENG Furnaces International Ltd has been contracted to design and commission the system for the company, which offers heat treating among its services.
  • A large capacity SECO/Warwick vacuum furnace was delivered to U.K.-based Wallwork Heat Treatment company just before Christmas.

Kudos Chatter

  • America Makes recently announced the awardees of a Directed Project Opportunity on advancing additive manufacturing (AM) post-processing techniques (AAPT), funded by the Air Force Research Laboratory (AFRL), Materials and Manufacturing Directorate, Manufacturing and Industrial Base Technology Division. Awardee #1 is Arizona State University, in conjunction with Quintus Technologies; Phoenix Heat Treating, Inc.; and Phoenix Analysis & Design Technologies, Inc. Awardee #2 is ASTM International Additive Manufacturing Center of Excellence (AM CoE), a collaborative, which includes ASTM International, Auburn University, EWI, the National Aeronautics and Space Administration (NASA), Wichita State University – National Institute for Aviation Research (NIAR), in conjunction with Quintus Technologies, Carpenter Technologies Corporation, Aerojet Rocketdyne, Rolls Royce Corporation, Honeywell Aerospace, GE Aviation, and Raytheon.
  • Paulo recently announced the recent addition of the St. Louis Division to the approved heat treat sources list for General Motors High-Pressure Die Casting Die Insert Material. The approval list references AWQ49658 which includes the heat treatment specifications for Hot Work Tool Steels for GM High-Pressure Die Casting applications.  The St. Louis Division joins Paulo’s Nashville plant on the approval list, which includes only seven approved locations in the US. AWQ49657 covers approved material providers, heat treaters, and testing labs. Paulo is the only US source with two facilities on the list.
  • Nominations are open for the ASM HTS/Surface Combustion Emerging Leader Award, which recognizes an outstanding early-to-midcareer heat treating professional whose accomplishments exhibit exceptional achievements in the heat treating industry. The award was created in recognition of Surface Combustion’s 100-year anniversary in 2015. The winning young professional will best exemplify the ethics, education, ingenuity, and future leadership of our industry. Deadline for the nomination is February 1, 2019. Past winners include Olga Rowan of Caterpillar in 2015 and Lee Rothleutner of Timken in 2017. For nomination rules and forms, visit the Heat Treating Society website at hts.asminternational.org and click on Membership & Networking and Society Awards.

Heat Treat Today is pleased to join in the announcements of growth and achievement throughout the industry by highlighting them here on our News Chatter page. Please send any information you feel may be of interest to manufacturers with in-house heat treat departments especially in the aerospace, automotive, medical, and energy sectors to the editor at editor@heattreattoday.com.

10 Quick Heat Treat News Items to Keep You Current Read More »

Aerospace Services Provider Inducts New Engines for Defense Supplier

 

An aerospace maintenance and repair provider recently inducted two engines in the launch of a 20-year, multi-engine MRO agreement signed earlier this year with a major manufacturer of power systems for aviation and other industries.

StandardAero inducted its first Rolls-Royce AE 1107C engine at the company’s Maryville, Tennessee, facility, and its first Rolls-Royce T56-427 engine at its San Antonio, Texas, facility.

The new AE 1107C turboshaft engine powers the Bell-Boeing V-22 Osprey tiltrotor aircraft, delivering 7,000 lbs. shaft horsepower, and is in service with the U.S. Marine Corps and the U.S. Air Force.

Russell Ford, CEO of StandardAero

The T56-427/427A is also a new engine for StandardAero, powering the Northrop Grumman E-2 Hawkeye and Advanced Hawkeye, an all-weather, carrier-capable tactical airborne early warning aircraft in service with the U.S. Navy. The T56-427 delivers 5,250 lbs. shaft horsepower. The new contract expands the company’s exclusive 8-year agreement to support T56 engine MRO services in support of the U.S. Air Force fleet of C-130H aircraft at StandardAero’s San Antonio facility.

In addition, this new multi-engine agreement will significantly grow work currently conducted by StandardAero on the Rolls-Royce AE 2100 engines, serviced at the company’s Winnipeg, Manitoba, Canada facility with capacity also being added to StandardAero’s San Antonio facility within the United States.

“Our first induction of these new engine models represents a huge milestone for our company and for our customers,” said Russell Ford, CEO of StandardAero. “This is the beginning of a new and expanded long-term relationship with Rolls-Royce along with the privilege and honor of serving the mission-critical needs of our nation’s military forces.”

Aerospace Services Provider Inducts New Engines for Defense Supplier Read More »

Aerospace Giant Secures 15-year Agreement for Heat Treating Services

Engineering giant Rolls-Royce has entered into a 15-year contract with a UK-based thermal processing services specialist to secure specialized vacuum heat treatment and hot isostatic pressing (HIP) to support its civil aerospace production.

Bodycote, which provides heat treatment services that protect and improve the properties of metals and alloys, extending their operational life and making them safer, will work with Rolls-Royce’s turbine blade casting facilities in Derby and Rotherham.

The agreement, which is expected to be worth over £160 million ($227.3 million US) in incremental revenues over the 15-year period, ensures the provision of specialist thermal processing capacity utilizing Bodycote’s high performance, quality-focused approach to support the growth of Rolls-Royce’s large civil engine programs, including the Trent XWB, Trent 1000, Trent 7000, Trent 700 and Trent 900.

Aerospace Giant Secures 15-year Agreement for Heat Treating Services Read More »

10 Quick Heat Treat News Chatter Items to Keep You Current

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry.

Personnel and Company Chatter

Equipment Chatter

  • Solar Atmospheres, Inc., in Souderton, PA, recently installed a 74″ diameter by 72″ deep horizontal internal quench vacuum furnace, designed by Solar Manufacturing, Inc., to quench with argon at 10-bar while utilizing a 600 horsepower motor running at 460 volts from a variable speed drive, and rear head moveable gas baffle doors. The goal of the massive quench system is to be able to quench larger batches of power generation castings by increasing the cooling rate and eliminating the supplemental use of helium and operating in 100% argon.
  • An electrically heated cyclone pit furnace was recently delivered by Lindberg/MPH to a steel heat treater to be used for a heat treating process on aircraft components. The maximum temperature rating for this electric pit furnace is 1250ºF. The work chamber has a 38″ diameter x 48″ depth and is constructed with an alloy liner backed with 7″ of block insulation.
  • Spanish supplier of aluminum sheets and coils Aludium has announced that the company will install a multi-chamber furnace to reduce metal costs and improve the sustainability of its operations. The new furnace will be installed in the Amorebieta cast house and will increase Aludium’s ability to melt lacquered scrap and is due to come onstream during 2019. The multi-chamber furnace selected is a Hertwich Ecomelt PS275, a proven technology and one of the largest shaft furnaces in the world.

Kudos Chatter

Proudly presenting the certificates are (l-r) Director Georg Anzer, Managing Partner Renate Keinath and Head of Training Michael Vieth.

  • PyroGenesis Canada Inc. has announced that it has received certification for the production of metal powders under a quality management system which complies with the requirements of ISO 9001:2008. This certification is an amendment to the company’s existing ISO certification, pertains specifically to metal powder production, and was received under the auspices of a major independent risk and standards company, SAI Global.
  • Family-owned global manufacturer of plastic processing machines Arburg, based in Loßburg, Germany, has recently been presented three certifications: LQW, ISO, and IHK recognition. The LQW certificate was presented to the machine manufacturer in January after the successful completion of the “Learner-oriented Quality Certification in Continuing Education and Training”. The company received the approval of DIN ISO 29990:2010 “Quality Management Systems for Learning services for Non-formal Education and Training” inspection in February. In late 2017, the manufacturer was recognized with the “1A Excellent Training Company” award presented by the Chamber of Industry and Commerce (IHK) – Northern Black Forest region.
  • Countyline Tool, a Komet Service Partner based in East Peoria, Illinois, has attained ISO 9001:2015 certification. All Komet partners are currently working to obtain the ISO 9001:2015 certification, and Countyline Tool is the eighth partner to have completed the certification.

Heat Treat Today is pleased to join in the announcements of growth and achievement throughout the industry by highlighting them here on our News Chatter page. Please send any information you feel may be of interest to manufacturers with in-house heat treat departments especially in the aerospace, automotive, medical, and energy sectors to the editor at editor@heattreattoday.com.

10 Quick Heat Treat News Chatter Items to Keep You Current Read More »

Rolls Royce Grants Approval

Rolls Royce has granted approval to Solar Atmospheres of Western Pennsylvania to conduct certain commercial aerospace heat treat processes. Rolls Royce requires strict specification requirements, strict process execution, and a daily commitment to quality processing from its suppliers in order for this to be granted.

Susan Generalovich, Quality Manager said: “The successful certification of our western Pennsylvania facility is a testament to our commitment to continual improvement, and to growing our business within the aerospace industry.  We are excited about the opportunities this certification will allow and the added confidence it provides to our customers.”

More information about Solar Atmosphere’s Quality Certifications: click here.

Rolls Royce Grants Approval Read More »

Rolls Royce, General Electric and Lufthansa Invest in Poland

  Source:  ETMM

In the recent weeks, two huge investments in Poland have been confirmed. Not only will they help create several thousand new jobs but they should also have a positive influence on the country’s economy.

Read more:  International Giants Invest by Robert Ocetkiewicz and Rosemarie Stahl

Rolls Royce, General Electric and Lufthansa Invest in Poland Read More »

Rolls-Royce to Invest $30 Million in New CMC R&D Facility

Rolls-Royce recently announced that it is growing its presence in Southern California with a $30 million expansion into a new 62,000-sq-ft facility that will be dedicated to the research and development of ceramic matrix composite (CMC) materials and processes for use in next-generation aerospace engine components. Rolls-Royce held a dedication ceremony with federal, state, and local officials; customers; and employees at the new facility. Rolls-Royce purchased Hyper-Therm High-Temperature Composites (HTC) in May 2013 and continues to grow and invest with this new “CMC technology hub” located in Cypress, Calif.

“The development of lighter, stronger, composite fiber components is just part of our commitment to continuously improve the performance of our products by focusing on lowering fuel consumption, emissions and noise,” said Marion Blakey, Rolls-Royce president and CEO of North America. “The team here in Cypress will be dedicated to seeing the commercial application of these technologies that will soon be adopted into advanced manufacturing production methods for gas turbine components.”

“I want to welcome Rolls-Royce to its new location in Cypress, and I applaud their commitment to bring jobs and grow their innovative R&D facility here in Southern California,” said Rep. Alan Lowenthal (D-Calif.). “Today’s official opening highlights yet again that Southern California has the tools, the skills, and the talent to grow our already established aerospace industry here.”

“The turbine sits at the heart of the engine. I am very excited about several technologies we are developing across Rolls-Royce that will contribute to a significant reduction in fuel consumption,” said Andy Greasley, executive vice president of turbines, civil aerospace. “Our HTC team in California is part of a global team working on high-temperature composites. This dedication ceremony represents the completion of another major milestone and the creation of a state-of-the art facility specifically purposed for the development of our next-generation turbine materials.”

The facility reportedly will develop production-ready manufacturing processes and produce components that will be used for engine test programs. From there, manufacturing processes refined in the Cypress facility will be applied to a future dedicated production facility for manufacturing of engine components. Since Rolls-Royce acquired Hyper-Therm in 2013, it has grown from 15 employees to nearly 50. The company expects to hire at least 10 more people this year, with the potential for 40 more positions as the production and product testing increase.

Rolls-Royce to Invest $30 Million in New CMC R&D Facility Read More »