MANUFACTURING HEAT TREAT NEWS

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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Record Gas Quenching Speeds Achieved in Ipsen’s ARGOS Heat Treating System

KLEVE, GERMANY – Ipsen’s Global Development Team recently celebrated the first build and testing of the ARGOS heat-treating system. The ARGOS uses low-pressure carburizing (AvaC®) in combination with 20-bar nitrogen quenching to provide metallurgical properties never before seen in gas quenching systems – even those utilizing 20-bar helium quenching. One industry visitor who witnessed the test run commented, “The ARGOS is likely the fastest inert gas quench furnace in the world.”

This initial test was performed on one of the most difficult to quench vacuum carburized components: layshafts for large gears. Until now, helium gas, which is both expensive and declining in availability, was required to fully transform parts with very high cross-sectional thicknesses.

Test outcomes showed that the shafts processed in the ARGOS system with 20-bar nitrogen quenching achieved higher surface hardness and core hardness values than shafts processed in the existing vacuum heat-treating furnaces that use 20-bar helium quenching. The ARGOS heat-treating system also offers several benefits, including:

  • Flexible installation with a selectable number of carburizing, nitriding, subzero and high vacuum process chambers with a nitrogen gas and/or oil quench module
  • Excellent temperature uniformity during heating and cooling
  • Minimal and controllable distortion due to temperature homogeneity throughout the entire load and the reversible gas flow during cooling
  • Extremely high gas velocity and volume due to Ipsen’s unique cooling system design

Overall, the ARGOS furnace line represents a significant milestone in the growing trend to operate low-pressure carburizing (LPC) lines in combination with inert gas quenching.

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Improved Materials and Enhanced Fatigue Resistance for Gear Components

BOTW-50w Source:  Thermal Processing for Gear Solutions

“When trying to improve fatigue properties, two important areas need to be addressed: improvements of material and improvements in heat treatment technology.”

Read More: Improved Materials and Enhanced Fatigue Resistance for Gear Components

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2200°F Conveyor Oven Supplied for Aquatic Heating Systems

Baker Furnace, Inc. shipped a custom-built, high-temperature conveyor oven designed to heat treat rods used to manufacture commercial heating elements.  The process also requires a nitrogen purge to create a specific atmosphere.

At 35 ft long with an operating temperature of 1900°F, the engineering challenges for this unique application were a combination of the size and high temperature coupled with the fact that the application required four different heating zones with a nitrogen injection in every zone.

The electrically-powered conveyor oven was constructed as a modular system which allowed Baker Furnace to conduct a complete test on site and then break it down to ship and install in the most cost-effective manner.   The first two zones for heating measure 24”w x 16”h x 12’L while the two cooling sections measure 24”w x 16”h x 20’L, both with nitrogen injection supply lines to create an inert atmosphere. The oven is equipped with a 24” wide inconel wire woven belt supported by an internal inconel slider bed, which is driven with a gear reduction motor (speed controlled by Allen Bradley drives).  Using formed rod-style, Kanthal elements rated at 60kW for heating, the entire system is controlled with an Allen Bradley touch screen HMI and Allen Bradley PLC software.

“Designing a conveyor oven of this size and temperature is a challenge in itself, but our biggest hurdle came when we had to achieve a plus or minus 25°F heat uniformity within the multiple zones.  Each zone required different temperatures with a nitrogen injection.  We leaned on our past experience as well as testing several scenarios to come up with a design that the customer loves.”   Tim Bacon, Lead Project Manager at Baker Furnace.

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Commercial Metals Company Celebrates the Groundbreaking of New Micro Mill

On April 29, 2016, Commercial Metals Company (NYSE: CMC), state, federal and local officials and their honored guests gathered for a groundbreaking ceremony marking the start of construction of CMC’s second technologically advanced micro mill which will be located in Durant, OK.

Joe Alvarado, Chairman of the Board, President and CEO of CMC, said, “This event marks another historic day for CMC, the State of Oklahoma, and the City of Durant.  We believe the addition of a second micro mill to CMC’s portfolio of highly efficient and customer focused production facilities will open new market opportunities and enhance CMC’s position as a leading supplier of long products in the U.S. market. Today would not have been possible without the support of the State of Oklahoma and the City of Durant and we look forward to many years of a very successful relationship.”

“This groundbreaking represents how local, state and tribal partnerships can bring together various entities to achieve great things for the State of Oklahoma,” said Governor Mary Fallin. “Not only will this mill produce high quality steel products that can be used by many Oklahoma industries, it will bring quality jobs to the Durant area, providing great opportunities for Oklahomans and further diversifying our economy.”

CMC’s innovative micro mill technology uses a continuous-continuous manufacturing process that melts, casts and rolls steel from a single uninterrupted strand, producing higher yields and lower energy consumption than the traditional minimill process.  The Oklahoma micro mill is expected to create approximately 300 jobs in the Durant area.

CMC expects the new Durant micro mill to be commissioned in the fall of 2017.

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Solar Manufacturing’s Vacuum Furnace Reference Series

 

 

BOTW-50w Source:  Solar Manufacturing’s Vacuum Furnace Reference Series

This series includes eight releases with the following titles.

Release 1:  Critical Melting Points and Reference Data for Vacuum Heat Treating

Release 2:  Optimizing Procedures for Temperature Uniformity Surveying of Vacuum Furnaces

Release 3:  Operating a Vacuum Furnace Under Humid Conditions

Release 4:  Understanding PID Temperature Control as Applied to Vacuum Furnace     Performance

Release 5:  Understanding Power Losses in Vacuum Furnaces

Release 6:  Important Considerations when Purchasing a Vacuum Furnace

Release 7:  Important Considerations when Selecting a Vacuum Furnace Water Cooling System

Release 9:  Understanding Vacuum and Vacuum Measurement

Read More:  Solar Manufacturing’s Resources for Vacuum Heat Treating Releases 1 – 9

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Heat Treating Oven Part of Norsk Titanium’s Ultra Lean Manufacturing Line

Norsk Titanium AS, the world’s leading provider of aerospace-grade, titanium additive manufacturing technology, today announced the groundbreaking of a new European assembly and test center outside Oslo, Norway.

Norsk Titanium Chief Commercial Officer Chet Fuller, Chief Executive Officer Warren M. Boley Jr., and Senior Vice President of Operations Chris Bohlmann were on hand to kick off construction of the new facility, which is scheduled to be completed October 2016.

“Customer demand for our additive manufacturing technology is growing to the point where we need significantly more space to assemble and test our MERKE IV™ RPD™ machines prior to worldwide shipment,” said Senior Vice President of Operations Chris Bohlmann. “This new factory will enable us to better serve our manufacturing partners and aerospace customers while expanding our footprint in this innovative region of Norway.”

Norsk Titanium also plans to install the world’s first end-to-end aerospace Ultra Lean Manufacturing line in the facility. A MERKE IV™ Rapid Plasma Deposition™ machine paired with a heat treating oven and a multi-axis CNC machining center will demonstrate the conversion of titanium wire into finished aerospace parts in a production line length of approximately 30 meters.

“The new Ultra Lean Manufacturing line allows our customers to do hands-on development of new part programs on the same campus as our worldwide technology center,” said CEO Warren M. Boley Jr. “Titanium wire comes in one end, the CAD drawing is input, and finished aerospace parts that are fully tested, heat treated and ready for installation are produced in a matter of days. RPD™ truly is a game-changer in terms of cost reduction, speed to market and production line efficiency.”

About Norsk Titanium AS

Norsk Titanium AS is the world’s pioneering supplier of aerospace-grade, additive manufactured, structural titanium components. The company is distinguished in the aviation industry by its patented Rapid Plasma Deposition™ (RPD™) process that transforms titanium wire into complex components suitable for structural and safety-critical applications. The Norsk Titanium research and development team is committed to displacing the inefficient forging process with a precision wire deposition technology embodying substantial savings for aerospace, defense and commercial applications. www.norsktitanium.com

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Economist: Manufacturing Revives in 2016’s Second Half

BOTW-50w Source:  SME Manufacturing Engineering

“We’re about out of the woods,” Alan Beaulieu, president of ITR Economics, said during a presentation at the MFG Meeting in Palm Desert, CA. “We are not looking at a recession in manufacturing in the United States.”

 

Read more:  Economist: Manufacturing Revives in 2016’s Second Half

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