In a move aimed at elevating its manufacturing capabilities, a leading jet engine manufacturer is gearing up to integrate two vapor phase aluminizing (VPA) coating furnaces during the first half of 2024.
These high-capacity, low-maintenance automated retort VPA furnaces from G-M Enterprises, a Nitrexcompany, are purposefully engineered with moving bases and a fixed heat chamber, enhancing operational efficiency. Each retort is sealed to the moving bases, allowing for concurrent handling of two loads, each containing three coating cans. The result is a streamlined process that runs two cycles back-to-back, completing the treatment in just over 24 hours. The automated furnace supports unattended start-ups, empowering operators to focus on preparing loads for the second system which facilitates concurrent operations for heightened productivity.
VPA furnace from G-M Enterprises, a Nitrex company
Source: Nitrex
Robert Huckins, national sales manager at G-M Enterprises, emphasized that the "VPA furnaces ensure seamless operations, providing our customer with a competitive edge in production capacity. This is crucial in meeting escalating demand while delivering high-performance and longer-lasting blades and vanes vital for high-temperature fired engines.”
A feature of the VPA design is the raised fixed heat chamber, effectively shielding operators and the furnace room against potential heat exposure. This innovation eliminates the need for cumbersome protective heat suits. The hot retort remains securely housed within the insulated furnace, prioritizing operator well-being. Furthermore, this safety measure confines the load base and retort/coating load within the SAR/VPA furnace housing until the retort temperature drops below 150°C (300°F).
This strategic investment not only underscores the manufacturer’s commitment to staying at the forefront of technological advancements but also solidifies a lasting partnership.
This press release is available in its original form here.
Sometimes our editors find items that are not exactly “heat treat” but do deal with interesting developments in one of our key markets: aerospace, automotive, medical, energy, or general manufacturing.
To celebrate getting to the “fringe” of the weekend, Heat Treat Today presents today’s Heat Treat Fringe Friday: an exciting development in metal 3D printing that one might even say is "out of this world."
Rob Postema Technical Officer ESA
Metal 3D printing will soon take place in orbit for the first time. A pioneering European-made metal 3D printer is on its way to the International Space Station on the Cygnus NG-20 resupply mission which launched January 30, 2024.
“This new 3D printer printing metal parts represents a world first, at a time of growing interest in in-space manufacturing,” explains ESA technical officer Rob Postema. “Polymer-based 3D printers have already been launched to, and used aboard the ISS, using plastic material that is heated at the printer’s head, then deposited to build up the desired object, one layer at a time.
“Metal 3D printing represents a greater technical challenge, involving much higher temperatures and metal being melted using a laser. With this, the safety of the crew and the Station itself have to be ensured – while maintenance possibilities are also very limited. If successful though, the strength, conductivity and rigidity of metal would take the potential of in-space 3D printing to new heights.”
Once arrived at the International Space Station, ESA astronaut Andreas Mogensen will prepare and install the approximately 180 kg Metal 3D printer in the European Draw Rack Mark II in ESA’s Columbus module. After installation, the printer will be controlled and monitored from Earth, so the printing can take place without Andreas’s oversight.
Metal 3D printer in operation on Earth
Source: ESA
The Metal 3D Printer technology demonstrator has been developed by an industrial team led by Airbus Defence and Space SAS – also co-funding the project – under contract to ESA’s Directorate of Human and Robotic Exploration.
“This in-orbit demonstration is the result of close collaboration between ESA and Airbus' small, dynamic team of engineers,” comments Patrick Crescence, project manager at Airbus. “But this is not just a step into the future; it's a leap for innovation in space exploration. It paves the way for manufacturing more complex metallic structures in space. That is a key asset for securing exploration of Moon and Mars.”
The printer will be printing using a type of stainless-steel commonly used in medical implants and water treatment due to its good resistance to corrosion.
The stainless-steel wire is fed into the printing area, which is heated by a high-power laser, about a million times time more powerful than your average laser pointer. As the wire dips into the melt pool, the end of the wire melts and metal is then added to the print.
ESA materials engineer Advenit Makaya from the ESA’s Directorate of Technology, Engineering and Quality, provided technical support to the project: “The melt pool of the print process is very small, in the order of a millimetre across, so that the liquid metal’s surface tension holds it securely in place in weightlessness. Even so, the melting point of stainless steel is about 1400 °C so the printer operates within a fully sealed box, preventing excess heat or fumes from reaching the crew of the Space Station. And before the print process begins the printer’s internal oxygen atmosphere has to be vented to space, replaced by nitrogen – the hot stainless steel would oxidise if it became exposed to the oxygen.”
Four interesting shapes have been chosen to test the performance of the Metal 3D printer. These first objects will be compared to the same shapes printed on ground, called reference prints, to see how the space environment affects the printing process. The four prints are all smaller than a soda can in size, weigh less than 250 g per print, and takes about two to four weeks to print. The scheduled print time is limited to four hours daily, due to noise regulations on the Space Station – the printer’s fans and motor of the printer are relatively noisy.
Once a shape has been printed, Andreas will remove it from the printer and pack it for safe travels back to Earth for processing and analysis, to understand the differences in printing quality and performance in space, as opposed to Earth.
Metal 3D printer test print
Source: ESA
One reference and 0xg print, which is a part of a dedicated tool, will go to the European Astronaut Centre (EAC) in Cologne, Germany. Another two will be headed to the technical heart of ESA, the European Space Research and Technology Centre (ESTEC), where a team at the Materials and Electrical Components Laboratory awaits the samples for macro and micro analysis of the printed parts. The final print will go to the Technical University of Denmark (DTU), who proposed its shape, and will investigate its thermal properties in support of e.g. future antenna alignment.
“As a technology demonstration project, our aim is to prove the potential of metal 3D printing in space,” adds Rob. “We’ve already learned a lot getting to this point and hope to learn a lot more, on the way to making in-space manufacturing and assembly a practical proposition.”
One of ESA’s goals for future development is to create a circular space economy and recycle materials in orbit to allow for a better use of resources. One way would be to repurpose bits from old satellites into new tools or structures. The 3D printer would eliminate the need to send a tool up with a rocket and allow the astronauts to print the needed parts in orbit.
Tommaso Ghidini, head of the mechanical department at ESA, notes: “Metal 3D in space printing is a promising capability to support future exploration activities, but also beyond, to contribute to more sustainable space activities, through in-situ manufacturing, repair and perhaps recycling of space structures, for a wide range of applications. This includes in-orbit large infrastructure manufacturing and assembly as well as planetary long-term human settlement. These aspects are key focuses in ESA's upcoming technology cross-cutting initiatives.”
Thomas Rohr, overseeing ESA's Materials and Processes Section, adds: “This technology demonstration, showcasing the processing of metallic materials in microgravity, paves the way for future endeavours to manufacture infrastructure beyond the confines of Earth.”
This press release from The European Space Agency can be found in its original form here.
Norsk Titanium, a global additive manufacturing supplier for aerospace-grade structural titanium components, announces delivery of flight critical aircraft structure to General Atomics Aeronautical Systems, Inc. (GA-ASI), a leading developer of unmanned aircraft systems and prime contractor to the US Department of Defense.
Under a development contract with GA-ASI’s Additive Design & Manufacturing Center of Excellence, Norsk Titanium has delivered RPD® final machined components for test and evaluation. GA-ASI will conduct destructive testing in support of specification and part development.
Said Nicholas Mayer, president of commercial at Norsk, “After an extensive collaborative qualification effort over the past few years with Norsk Titanium, GA-ASI plans to apply the qualified process to structural components within their next generation platforms currently under development, and is planning on their first flight of a critical, structurally loaded component, within the 2024-2025 timeframe.”
Norsk Titanium has recently announced qualification and production milestones in their core commercial aerospace titanium market.
This press release can be found in its original form here.
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Stephen Harris
Group Chief Executive
Bodycote
Source: LinkedIn
Bodycote has announced its acquisition of Lake City Heat Treating, based in Warsaw, Indiana, which was successfully completed on January 19, 2024. The midwestern heat treater is a leading medical market provider of hot isostatic pressing (HIP) and vacuum heat treatment services, primarily supplying the orthopedic implant market as well as civil aerospace.
Stephen Harris, group chief executive of Bodycote plc, commented: "This acquisition is an excellent fit, and it allows us to better address the growth opportunities in the medical and aerospace markets." With this acquisition, the heat treater will increase their range of specialist thermal processing and heat treatment solutions available to these industries.
Lake City Heat Treating is forecast to have achieved 2023 full year revenues of around $14m (£11m). The business revenue grew 30% in 2023 and looking ahead is expected to continue to deliver good progress.
Their constant growth reflects the high-quality business that has successfully gained share among distinguished medical and aerospace OEMs. The acquisition fits with Bodycote’s strategy to grow its Specialist Technologies businesses.
This Bodycote press release can be found in its original form here.
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Effective November 30, 2023, Joe A. Powell has sold his remaining shares in Akron Steel Treating Company, his family’s commercial heat treating business for over 80 years in Akron, Ohio, USA, to a fourth generation of new “family” ownership.
The team at AST will continue to deliver ISO and Nadcap aerospace heat treating and related metallurgical services to part making customers.
Joe A. Powell, AST’s Chairman of the Board, will remain active in the heat treating and metallurgical services community as president ofIntegrated Heat Treating Solutions, LLC. (IHTS). IHTS is a “heat transfer” consulting company for product development teams to enable more sustainable heat treating equipment and practices to be integrated into their new product designs. IHTS and its team of part making consultants enable their part making clients to deliver more “total added value” from heat treating and forging per BTU expended in making their products for their end users; including the design of the associated heating and quench cooling equipment for "leaner + greener, more sustainable, manufacturing" and for greater recyclability of metal alloys.
Pictured in the image above: AST’s new shareholder team, and Joe A. Powell, Chairman of the Board, are pictured from left to right: Matt Moldvay, President; Steve Powell, Vice President of Quality, Christina Powell Somogye, Vice President of Administration; Joe A. Powell, Chairman; and Joe N. Powell, Vice President of Sales. (Source: AST)
A precision heat treatment company Vacu Braze recently partnered with a U.S. furnace manufacturer to procure new equipment to expand its processing capabilities.
The TM8 is the first high-pressure gas quenching furnace to be installed in Vacu Braze’s clean processing room. This high-purity furnace from TM Vacuum Productsexpands the heat treater’s high-pressure gas quenching capacity for large and small jobs, while offering increased processing cleanliness.
The TM8 is equipped with a molybdenum all-metal hot zone and a cryogenic pump capable of helping the furnace reach the 10-7 vacuum scale. With a qualified work zone of 12” x 12” x 24”, small batches of parts made from a wider array of materials can be processed more quickly than with traditional atmospheric methods.
The new furnace is fully compliant with AMS 2750 class 2 pyrometry and fit for processing critical parts for aerospace applications. As clean processing capabilities expand, Vacu Braze is proud to provide innovative solutions to industries requiring precision, purity, and cleanliness from their heat treatment provider.
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Sławomir Tomaszewski Vacuum Melting Team Director SECO/WARWICK Source: LinkedIn
One of the world’s largest producers of jet engines has modernized their casting furnace, which was last updated two decades ago.
This company has two casting units supplied two decades ago by RETECH, a North America-based company belonging to the SECO/WARWICK Group. The modernization project was for the VIM EQ furnace - a system for the production of castings in equiaxed crystallization. It will involve replacing almost all the furnace components except the power supply, melting chambers and mold. The platforms will also remain unchanged. The remaining components will be replaced with more modern, ergonomic, and user-friendly parts and assemblies.
Says Sławomir Tomaszewski, vacuum melting team director at SECO/WARWICK, “This order includes the complete elimination of hydraulic components by replacing them with electrical components such as an elevator drive or crucible rotation drive. In addition, two old feeders: one for loading crucibles, the other for removing disposable crucibles, will be replaced with a modern system that can perform both activities."
He added, "An additional advantage of the operation will be the fact that the furnace operator will not have to come into physical contact with hot used crucibles, because they will be removed automatically without human intervention."
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Richard B. Conway
Founder/Director/ CTO
DELTA H® Technologies, LLC
Source: DELTA H
Three heat treat systems have recently been delivered and commissioned to joint base San Antonio-Randolph for maintaining the T-38 Talon Trainer aircraft.
These systems are a dual chamber model DCAHT®-181248-1200/500-MIL, a DCAHT®-241672-1200/500-MIL, and a large single chamber SCAHT®-303048-1200-MIL.
USAF depot level heat treating requires full compliance to AMS2750G. The heat treating systems provided by DELTA H were for replacing existing systems which were too troublesome or costly to try to qualify and were never designed for modern pyrometry standards. The furnace systems were placed into production service the week following qualifying and training.
JBSA-Randolph – SCAHT®-303048-1200-MIL & DCAHT®-241672-1200/500-MIL Includes Power Driven Quench Tank
Source: DELTA H
Richard Conway, director and CTO of DELTA H, states, "We are grateful and humbled to be recognized among the mission critical technology partners supporting this very important project, and pleased to play a part in extending the service life of the valuable T-38 airframe."
JBSA-Randolph, TX – DCAHT®-181248-1200/500-MIL Heat Treat Computer Work Station
Source: DELTA H
Third party compliance and initial qualifying certification of all 5 chambers were provided by Conrad Kacsik Instrument Systems of Solon, Ohio.
Jake Kacsik, president of Conrad Kacsik Instrument Systems, shares, “The results are always impressive when testing DELTA H furnaces. By far the most reliable and consistent systems for maintaining the strict standards of aerospace pyrometry. Richard and I not only have a career-long professional relationship, but also, we both served in the USAF.”
DELTA H is exclusively represented worldwide by PHILLIPS FEDERAL Division for all military and government sales.
JBSA-Randolph, TX – SCAHT®-303048-1200-MIL & DCAHT®-181248-1200/500-MIL
Source: DELTA H
John Murray, retired SMSgt of USAF and product manager of Phillips Corporation, Federal Division added, “DELTA H compliments our product offerings to Metals Tech facilities. Regardless of traditional machining or additive manufacturing, Phillips Corporation – Federal Division strives to meet the needs of the USAF Fabrication Flight Warfighter, providing the best solutions for their support of US power projection and strategic deterrence. Phillips Corporation – Federal Division stands beside USAF Fabrication Flights around the globe ready to cut, fabricate, manufacture, and metallurgically process any part-anytime-anywhere."
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Sometimes our editors find items that are not exactly “heat treat” but do deal with interesting developments in one of our key markets: aerospace, automotive, medical, energy, or general manufacturing.
To celebrate getting to the “fringe” of the weekend, Heat Treat Today presents today’sHeat Treat Fringe Friday: an exciting development in Additive Manufacturing with Airbus Helicopters using 3D printing.
Helmut Fárber Site Manager Airbus Helicopters in Donauwöth
Airbus Helicopters is to use 3D printing technology to produce components for its helicopter vehicles and the aircraft of parent company Airbus.
Airbus Helicopters will use TRUMPF‘s 3D printing technology to produce components for its electric-powered City Airbus experimental high-speed Racer helicopter, as well as the Airbus A350 and A320 passenger aircraft, with structural components made of titanium and high-strength aluminum believed to be the focus. The company is investing heavily in additive manufacturing technology because of its ability to reduce weight and, in turn, bring down fuel consumption and costs. It is said to be exploring the part consolidation of some systems, again to save weight, and values the capacity to reuse powder.
“With innovative manufacturing processes, we are working on the helicopters of the future in Donauwörth,” commented Helmut Fárber, site manager at Airbus Helicopters in Donauwöth. “Among other things, 3D printing helps reduce the weight of components.”
Said Richard Bannmueller, CEO of TRUMPF Laser and System Technology, “Additive manufacturing saves expensive raw material and can lower production costs in the aviation industry. 3D printers only use the material that designers actually need for their components and that ends up taking off in the aircraft.”
Airbus, like many other aerospace manufacturers, has had a keen interest in additive manufacturing technology for several years, with the company recently signing a 3.8 million EUR contract with Oerlikon for the additive manufacture of satellite antenna clusters.
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GKN Aerospace has expanded its capabilities with additive manufacturing (AM) machines, accelerating its industrialization of sustainable aero engine solutions. This new technology will offer more reliable and sustainable alternatives to traditional castings and forgings.
The supplier of these machines is Nikon SLM Solutions, whose NXG XII 600's printing area and 12 lasers align with GKN Aerospace's vision to produce large parts with high productivity. Two systems have been ordered, one to be used with In718 and another for Ti64.
In the words of Martin Thordén, VP of Permanova, the newly formed business unit for material solutions within GKN Aerospace, "Partnering with Nikon SLM Solutions is a key milestone in our journey to create better, more sustainable aerospace products. . . . This collaboration provides us access to cutting-edge additive manufacturing capabilities necessary to propel us towards our net zero ambition."
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Norsk Titanium, a global additive manufacturing supplier for aerospace-grade structural titanium components, announces delivery of flight critical aircraft structure to General Atomics Aeronautical Systems, Inc. (GA-ASI), a leading developer of unmanned aircraft systems and prime contractor to the US Department of Defense.
