AEROSPACE HEAT TREAT NEWS

AM Solutions Supplier Plans EBAM® System for Aerospace Applications

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A leading metal additive manufacturing (AM) group based in Chicago recently announced that it will deliver large-scale metal 3D printing system to a supplier of highly engineered AM solutions.

Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI)  will deliver an industry-leading Electron Beam Additive Manufacturing (EBAM®) 110 System to Burloak Technologies, a division of Samuel, Son and Co., Limited, which delivers high quality, lightweight, fully functional additive manufactured parts for a range of industries including space, aerospace, defense, energy, medical, automotive, and transportation.

Peter Adams, co-founder and president of Burloak Technologies.

“Using traditional subtractive processes, such as forging and machining, the production of titanium parts of this size could take one year while generating a significant amount of waste,” said Peter Adams, co-founder and president of Burloak Technologies. “Our EBAM 110 system will allow us to manufacture the same large-scale titanium structural parts in a matter of days. We are already engaged with several aerospace end-users who have started the qualification process with us.”

Scott Phillips, president and CEO of Sciaky, Inc.

“Sciaky’s EBAM systems are the most widely sold large-scale metal 3D printing system in the world, having qualified parts on land, sea, air, and space applications,” said Scott Phillips, president and CEO of Sciaky, Inc. “The innovators at Burloak Technologies will leverage the numerous benefits of EBAM to produce faster and cheaper parts for their customers all across the globe.”

A July 2019 delivery is scheduled for this EBAM system.

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Iron Foundry Expanding into Aluminum at Ohio Facility

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Source: Business Journal Daily

 

An iron casting foundry located in Hubbard, Ohio, is expanding into aluminum casting with an aluminum slab and billet plant at its current site.

Ellwood Engineered Castings is investing $60 million to house its new Ellwood Aluminum division to serve customers in the aerospace and other industries.

 

Read more: “Ellwood Group Diversifies with $60M Aluminum Plant”

 

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Hot Zone Insulation Materials Critical in Preventing Heat Loss

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Source: Solar Atmospheres of Western PA

 

With electricity costs increasing, heat treat facilities are looking for ways to harness energy and minimize heat loss through a variety of insulating methods and applications. Heat Treat Today‘s Technical Tuesday feature comes from Reál J. Fradette of Solar Atmospheres Inc of Souderton, PA (with Nicholas R. Cordisco of Solar Manufacturing Inc. contributing), analyzing the different types of furnace hot zone insulation materials with the following points taken into consideration:

A) Hot Zone Designs

  • All-Metal Designs
  • Ceramic Fiber Included Designs
  • Graphite Type Insulated Hot Zones

B) Defining Hot Zone Losses For Different Hot Zone Configurations

  • Calculating Power Losses For A Given Size Furnace
  • Effect Of Hot Zone Losses On Heating Rates and Peak Power

C) Effect on Power Losses With Various Insulation Layers and Thicknesses

  • Projecting Relative Losses Versus Felt Thicknesses

D) Equating Insulation Designs To Actual Power Usage

  • Projecting Cycle Costs For Different Areas Of Operation
  • Impact of Hot Zone Type on Total Cycle Cost

E) Summary And Conclusions

An excerpt:

The heating rate of a load will dictate the total energy required to heat that load at that heating rate. Heating as fast as possible is not often the best solution to the application.

 

Read more: “Understanding Power Losses In Vacuum Furnaces”

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Process Control Methods Standard Debuted for Aerospace Applications

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A global association committed to providing and monitoring standards for the engineering profession recently published a new standard with guidance material to support specific aerospace engine applications, with a focus on the practical application of control methods for many different situations.

Dan Eigenbrode, vice president of module centers & supplier quality at Pratt & Whitney and AESQ Executive Sponsor for AS13006

SAE International in Warrendale, PA, released AS13006: Process Control Methods, which AESQ Strategy Group members will accept the immediate use of AS13006 within their respective supply chains. In addition, organizations are strongly encouraged to begin using this latest standard before it becomes a contractual requirement.

Aerospace engine manufacturers and their suppliers currently have differing requirements for process control that have similar intent. This new SAE standard establishes a common practice and methodology, defining the requirements for ongoing process control to improve quality performance through optimized process variation management beyond customer-defined key characteristics.

“The release of AS13006 is a big step forward in harmonizing requirements in the Aero-Engine supply chain,” said Dan Eigenbrode, vice president of module centers & supplier quality at Pratt & Whitney and AESQ Executive Sponsor for AS13006. Aerospace Engine Supplier Quality (AESQ), an SAE ITC program, was founded and formed by major aerospace engine companies to standardize quality requirements across the supply chain.

“Process Control is the key ingredient for sustained product quality and AS13006 provides the means for all suppliers to implement robust systems to ensure consistent quality regardless of product type,” added Eigenbrode.

AS13006, the previously released AS13003, Measurement Systems Analysis Requirements for the Aero Engine Supply Chain, and AS13004, Process Failure Mode and Effects Analysis (PFMEA) and Control Plans align and support the SAE standard AS9145, Requirements for Advance Product Quality Planning and Production Part Approval Process, developed by the International Aerospace Quality Group (IAQG)/SAE G-14 AAQSC Committee. The SAE G-22 AESQ Committee and the IAQG/SAE G-14 AAQSC Committee worked together cooperatively to ensure proper alignment of these standards.This standard also aligns and collaborates with the requirements of AS9103, Quality Management Systems – Variation Management of Key Characteristics.

Although designed for the aerospace engine supply chain, AS13003, AS13004, and AS13006 may be applied effectively by other segments of the aviation, space, and defense industries.

The Aerospace Engine Supplier Quality (AESQ) Strategy Group, a program of the SAE ITC, was established to develop, specify, maintain, promote, and deploy quality standards specific to the aerospace engine supply chain. AESQ member companies include Arconic, GE Aviation, GKN Aerospace, Honeywell Aerospace, MTU Aero Engines, PCC, Pratt & Whitney, Rolls-Royce, and Safran.

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Aerospace Services Provider Cuts Ribbon on Component Repair Facility

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An Arizona-based aerospace service provider recently opened a new 206,000-sq. ft. repair facility in Cincinnati, Ohio, directly adjacent to its current 236,000 sq. ft. component repair facility, nearly doubling its capacity.

Rick Stine, president of StandardAero Components, Helicopters & Accessories

StandardAero Component Services hosted a ribbon-cutting ceremony attended by city and state of Ohio officials, local economic development executives, customers, company officials, and other guests.

The facility will accommodate component repair growth on new and legacy platforms, aero-derivative, military and commercial aircraft engine component repair, as well as larger components. Once fully operational, StandardAero expects to employ 200-300 new technicians to continue to meet the growing demands of customers over the next 12-18 months.

“As new engine platforms are launched and legacy fleets are still maintained, the entire industry is seeing tremendous growth. Demand for component repair has increased so we are stepping up to directly support our customers and address the continued and rapid need for more component repair capacity,” said Rick Stine, president of StandardAero Components, Helicopters & Accessories.

During 2018, StandardAero also increased shop capacity by an additional 60,000 sq. ft. with expansions of its facilities in Hillsboro, Ohio and Miami locations.

 

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Agreement Reached to Initiate Titanium 3D Printing for Boeing 787

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A Wichita, Kansas-based, manufacturer of fabricated parts for the aerospace industry recently announced its partnership with the world’s pioneering supplier of aerospace-grade, additive-manufactured, structural titanium components to initiate qualification of parts for the Boeing 787.

Spirit AeroSystems and Norsk Titanium US Inc. have reached an agreement to initiate qualification of Spirit’s first additive-manufactured, titanium, structural component for the Boeing aircraft.

Ron Rabe, Spirit AeroSystems Senior Vice President of Fabrication and Supply Chain Management

This qualification will validate NTi’s production and industrialization processes, integrate Spirit’s work scope of machining final parts from additively manufactured near-net shapes, and verify material and final part conformity to requirements.

“Spirit has had a comprehensive and long relationship with Norsk Titanium, and this part will be our first additive structural titanium component incorporated into a commercial airplane program,” said Ron Rabe, Spirit AeroSystems Senior Vice President of Fabrication and Supply Chain Management.

NTi is the world’s first FAA-approved, OEM qualified, supplier of additive-manufactured, structural titanium components.  NTi’s proprietary Rapid Plasma Deposition™ (RPD™) process has been in serial production of Boeing 787 titanium components since April 2017.

“I am very proud of the Norsk Titanium team and this accomplishment. It represents years of technology development,” said Mike Canario, CEO of Norsk Titanium. “I also would also like to thank Spirit for this vote of confidence in the Norsk RPD™ process and capability.”

Mike Canario, CEO of Norsk Titanium

NTi’s Plattsburgh, N.Y., facility was recently added to Spirit’s Approved Supplier List (ASL) and Boeing’s Qualified Producer’s List (QPL).  Spirit and NTi have had an ongoing technology collaboration for more than nine years. In 2017, both companies signed a Master Procurement Agreement (MPA) for qualification and production activities.  The first commercial aircraft part will begin serial production later this year.

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UK MRO to Open Component Maintenance Center with Heat Treating, Hardness Testing

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A leading independent Maintenance Repair & Overhaul (MRO) provider in the U.K. prepares to open a new Component Maintenance Centre in Northampton, England, with operations planned to start this month.

Monarch Aircraft Engineering (MAEL) has invested approximately £2 million in this new center, which will include heat treating lines compliant to industry standard for standard processing and detail fabrication requirements, as well as hardness testing.

Chris Dare, Managing Director at Monarch Aircraft Engineering

“Our new Northampton facility will enable us to more effectively and efficiently support our burgeoning line and base maintenance facilities across the UK,” said Chris Dare, Managing Director at Monarch Aircraft Engineering. “This multi-million-pound investment in new facilities, equipment and, most importantly, skilled engineering talent, is an integral part of our long-term growth plan and will play a vital role in our success in the years ahead.”

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Aerospace Giant Signs Multi-Year Contract for Aluminum Solutions

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Ingrid Joerg, President of Constellium’s Aerospace and Transportation

A European provider of aluminum products and solutions announced recently that it has signed a multi-year agreement with The Boeing Company to support its leading commercial airplane programs. With this agreement, Constellium, based in The Netherlands, will supply Boeing with a broad range of advanced aluminum-rolled products coming mostly from its plant in Ravenswood, West Virginia.

“This new contract reflects the strong relationship established over the years with Boeing,” said Ingrid Joerg, President of Constellium’s Aerospace and Transportation business unit. “We look forward to continuing to support Boeing in its commercial airplane programs.”

 

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Electric Airplane Pioneer Establishes U.S. Headquarters in Arizona

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An Israel-based manufacturer of all-electric air mobility solutions recently announced it has selected Prescott, Arizona, for its U.S. headquarters, which will include the manufacture of the aircraft’s ultra-light all-composite frames.

EViation Aircraft will establish operations for its electric commuter aircraft, Alice, at a site located adjacent to the Prescott Municipal Airport. The facility will serve as EViation’s base of operations for its expansion from Israel into the U.S. market. EViation selected Prescott as an optimal location for its U.S. headquarters given the area’s skilled workforce and high-density altitude, an ideal environment for test flights.

Omer Bar-Yohay, CEO of EViation

With the goal of making clean regional air travel accessible for all, EViation is tackling one of the world’s dirtiest industries — aviation. Its zero-emission, 100% electric solution, the Alice Commuter, which will be test flown at the 53rd Paris Air Show in June 2019, leverages an IP portfolio that includes thermal management and autonomous landing, as well as distributed electric propulsion, industry-leading battery technology, and cutting-edge composite body frames capable of carrying up to nine passengers on a single charge for 650 miles. EViation will certify and commercialize the Alice aircraft while partnering with leading industry suppliers to bring its prototypes to scale and to the global market.

“As we develop our regional electric aircraft, the U.S. represents a high-growth, near-term target market for us, given its many regional transit corridors and abundance of approved airstrips,” said Omer Bar-Yohay, CEO of EViation.

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