IperionX, a producer of high-quality titanium alloys, has commissioned a titanium production facility in Virginia.
Anastasios (Taso) Arima, CEO of IperionX, commented in a letter to the company’s shareholders: “Our Virginia titanium facility is designed to apply our HAMR [Hydrogen Assisted Metallothermic Reduction] and HSPT [Hydrogen Sintering & Phase Transformation] technologies to produce sustainable, high-quality and high strength titanium metal products at low cost.”
Full capacity is scheduled for 2026, with more than 1,000 metric tons of titanium produced per year. Using titanium powder produced on site, IperionX plans to employ unique forging technologies to produce titanium mill products and near net shape titanium products and to apply AM to produce 3D printed titanium products.
Arima also added, “We engaged with Lockheed Martin, GKN Aerospace, and the U.S. Army to replace traditional titanium mill products, in this case titanium plate, providing a new domestic and sustainable source to enhance their critical supply chains.” To aid these goals, Iperion is installing a large-scale, industrial furnace at their Virginia facility.
This letter to IperionX’s shareholders can be found here.
Cemented carbide is often used interchangeably with other terms in the industry to describe a popular material for tool production. However, the specifics of what makes up a cemented carbide, and how this material can be processed, are not so widely discussed.
In this best of the web article, discover the composition, applications, and processes involved in sintering cemented carbide, as well as how vacuum furnaces play an essential role for this material. You will encounter helpful diagrams and resourceful images depicting each step of the process.
An Excerpt:
“Hard metal, or cemented carbide, refers to a class of materials consisting in carbide particles dispersed inside a metal matrix. In most cases, the carbide of choice is tungsten carbide but others carbide forming element can be added, such as tantalum (in the form of TaC) or titanium (in the form of TiC). The metal matrix, often referred as ‘binder’ (not to be confused with wax and polymers typically used in powder metallurgy) is usually cobalt, but nickel and chromium are also used. This matrix is acting as a ‘cement,’ keeping together the carbide particles (hence the ‘cemented carbide’ definition).”
Welcome to Heat Treat Today’sThis Week in Heat Treat Social Media. As you know, there is so much content available on the web that it’s next to impossible to sift through all of the articles and posts that flood our inboxes and notifications on a daily basis. So, Heat Treat Today is here to bring you the latest in compelling, inspiring, and entertaining heat treat news from the different social media venues that you’ve just got to see and read!
This week, we dive into innovations in several heat treat processes, take a look at some fascinating technological applications for heat treaters, tune into a conversation on batch vs. continuous furnaces, and explore an unexpectedly beautiful result of AM.
If you have content that everyone has to see, please send the link to editor@heattreattoday.com.
1. Bikes of the Future: the titanium revolution
Titanium has historically been limited as a material for bikes, despite its excellence as a material, due to its high cost and difficulty to process. Check out this post by IperionX on LinkedIn, sharing the revolutionary innovations they intend to bring to titanium processing, with applications for biking.
2. Metallurgical Moments: from Medicine, to rust removal, to atomic structure
As all heat treaters know, the world of metals is a vast one. Here are a few fascinating metallurgical moments to inform you and hopefully put a smile on your face.
The Power of Metals in MRI
Laser Cleaning: Heat Treat Potential Of The Future (Or Past?)
Did you know that the first lasers were created in 1960? They may have a futuristic look, but these devices have been around for quite a while, and their potential applications in the heat treating industry continue to grow. Check out this fascinating video from @Metallurgical Engineering on LinkedIn to get an up-close look at how lasers can be used to clean rust and perhaps streamline your heat treating maintenance in the future.
Metallurgical Art: The Structure of Metals
3. Continued Learning
Each of these posts brings an educational aspect of part of the heat treat world you may or may not be familiar with.
A Brief Overview of Quenching
HIP: What the Cool Heat Treaters Are Up To
4. Reading (and Podcast!) Corner
You can’t read everything, we get it. Heat Treat Today is here to recommend one informative podcast to enjoy on your daily commute, suggest a quick video on laser heat treating, and put a comprehensive article on surface treatments for automotive on your radar!
The Highly-Anticipated Sequel is Here! Tune in to Listen to Heat Treat Radio #105: Batch IQ Vs. Continuous Pusher Part 2, with Michael Mouilleseaux.
Interested in Surface Treatment? This Article from Race Engine Technology/Race Engine Suppliers magazine is for you!
In case you missed it: An overview of laser heat treating with Aravind Jonnalagadda (AJ), CTO and Co-founder at Synergy Additive Manufacturing LLC
5. AM is the Name of the Game
Additive Manufacturing (AM) is taking the heat treating world by storm, but it’s not often we get to sit back and appreciate the beauty that this technology is capable of creating. Check out this amazing gothic cathedral creating using LMM technology. Be sure to click below to see the full post.
Have a great weekend!
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Bringing forward plans by two years, Wallwork Group have signed for a second hot isostatic press. Following hot on the heels of opening their £10 million Wallwork HIP Centre, Wallwork Group is installing this HIP to meet and serve increasing demand from various manufacturers.
David Loughlin Business Manager Wallwork HIP Centre
This second HIP from Quintus Technologies, a high pressure manufacturer with North American locations, has been contracted following Quintus completing the commissioning of the first HIP in the third quarter of 2023.
“We expected strong demand from UK castings, 3D printing, powder fabrication, and near-net-shape manufacturers. Especially, as the UK is currently under-served with hot isostatic pressing capacity,” says Wallwork HIP Centre, business manager, David Loughlin.
Adds Simeon Collins, group director of Wallwork, “Demand from customers for processing components in our first hot isostatic press has been astonishing. It is prudent to bring forward planned investment for the next HIP, knowing it will take most of 2024 to build and install. We hope to have it up and running by early 2025. Deciding to prepare pits for expansion during the first installation has proved right.”
The second HIP will be identical to the first, operating at pressures from 40 to 207 MPa (5,800 to 30,000 psi) and temperatures up to 2282°F (1250°C). It will also have the latest rapid cooling technology, as well as the capability to offer increased cycle pressures at elevated temperatures, complements engineering advances in metal 3D printing and more.
This press release from Wallwork Group can be found in its original form here.
ECOACERO, an ESTRELLA Group company, has placed an order for a new rebar mill with a heat treater with North American locations. It will be located nearby Santo Domingo, in Dominican Republic, for serving the growing local and regional construction industry.
The upcoming ECOACERO facility with a rebar mill from SMS group will introduce a versatile range of rebar to the market, tailored to meet the demands of different construction industry segments, manufactured with state-of-the-art technology from SMS, and adhering to rigorous international quality standards.
The complete project, conceptualized with a sustainability philosophy, consists of two phases, with the forthcoming integration of a steel production, involving a melt shop with a continuous casting machine, from the scrap processing.
The scope of delivery of the SMS includes a reheating furnace for billets, feeding a continuous single-strand rolling mill. Products are finished on a MEERdrive® finishing block, a machine that reduces CO₂ emissions and boots plant efficiency. Water boxes in the production process enable steel with improved mechanical properties through quenching and self-tempering of the bars, minimizing the use of expensive alloying elements in the melt shop.
From left to right: Pedro Estrella, Director of ECOACERO; Giuseppe Maniscalco, CEO of industrial division Grupo Estrella; Filippo Verlezza, SMS group and Nicola Redolfi, SMS group (Source: SMS group)
The second phase involves a modern electric arc furnace (EAF), high electrical efficient and designed with burner and oxygen injector technology to reduce CO₂ emissions and operating costs.
The scrap charging-based electric arc furnace will be equipped with the latest SMS technologies for safe and automatic operation aimed at reducing the carbon footprint. The entire melting-refining-casting process line is monitored by X-Pact® Level 2 system.
The plant commissioning is scheduled for the beginning of 2025, pointing to ECOACERO as the one of the largest and modern steel companies in the Caribbean and Central America.
This SMS group press release can be found in its original form here.
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An Ultra Low NOx HPH®-flameless bell-type annealing plant at thyssenkrupp Hohenlimburg has achieved CO2-neutral heat treatment of precision strip.
Tenova LOI Thermprocess, a company which is part of Tenova, continues to prove that CO2-neutral heat treatment can go together with low nitrogen oxide (NOx) emissions in a cooperation project with thyssenkrupp Hohenlimburg GmbH. Tenova LOI Thermprocess is part of Tenova and is one of the leading companies supplying industrial furnace systems for the heat treatment of metals. Tenova, a Techint Group company, is as a worldwide partner for sustainable, innovative, and reliable solutions in the metals and the mining industries.
In bell-type annealing plants, which have so far been mainly operated with natural gas, precipitation and spheroidizing annealing of steel coils is carried out to specifically adjust the mechanical properties for subsequent rolling processes or the required product properties at the end customer.
At thyssenkrupp’s Hagen-Hohenlimburg site, Tenova LOI Thermprocess’s heating hoods with LOI’s patented Ultra low NOx HPH®-flameless concept has been used for around 12 years. By increasing air preheating temperatures to 1112°F (600°C), this technology has led to energy and therefore CO2 savings of up to 12%.
Dr. Gökhan Gula Project Manager and Process Engineer Tenova LOI Thermprocess.
In a campaign involving several annealing cycles, a further step has been taken towards decarbonizing steel production as part of the joint project. In production trials, the fuel gas supply for the heat treatment of hot-rolled narrow strip was gradually converted from natural gas to up to 100% hydrogen. Tenova indicates that, for the first time in the world, 70 t of steel strip were heat treated in a bell-type annealing plant in a locally CO2‑neutral process. The flameless concept demonstrates its advantages here because despite the higher combustion temperature compared to natural gas and thus a tendency towards higher nitrogen oxide emissions, it results in remarkably low NOx emissions.
Using the bell-type annealing plant, up to 2600 kg of CO2 can be saved per annealing cycle by using regenerative produced hydrogen, while maintaining productivity and product properties.
“The combustion of hydrogen is technically more complex than the direct use of electricity or the combustion of natural gas. This project has provided us with further insights into the decarbonization of the bell-type annealing process and is helping us on our joint path towards the transformation to climate-neutral steel production,” says Dr. Gökhan Gula, project manager and process engineer at Tenova LOI Thermprocess.
Artificial intelligence remains a hot topic for every industry, not least heat treating. Understanding the how and why of AI’s potential impacts on the industry, however, is not so easily apparent.
Today’s article, written by Joe Coleman, cybersecurity officer at Bluestreak Consulting, breaks down the pros and cons of implementing AI, to help you decide if artificial intelligence might be a beneficial addition to your heat treat operations.
Joe Coleman, cyber security officer, Bluestreak Consulting
As all of you are aware, artificial intelligence (AI) is getting more and more attention, and companies are beginning to use AI to help with many aspects of running their businesses. I’m sure you’ve heard of ChatGPT and other intelligent user interfaces (IUI). You may be one of those businesses considering the idea or experimenting with it to access its potential benefits for your business.
Like any industry, there are quite a few pros and cons associated with using AI to improve the heat treating processes. This article will outline some of these advantages and disadvantages. Always make sure you do your own research before jumping into the AI world because it’s not always what it seems.
What Is Artificial Intelligence (AI)?
Artificial Intelligence is the simulation of human intelligence in machines that are programmed to think and learn like humans. It includes a wide range of techniques and approaches, including machine learning, allowing computers to perform tasks that typically require human intelligence, such as understanding natural language, recognizing patterns, solving problems, and making decisions. AI systems are designed to learn from data, improving their performance over time without direct programming. These technologies find applications in many areas, from virtual assistants and language translation services to autonomous vehicles and industrial diagnostics, revolutionizing industries and helping to shape the future of technology
Pros of AI in Heat Treating
Quality Improvement:
AI systems can monitor and help control the heat treatment process in real time, ensuring you have consistent quality and to minimize defects.
Predictive analytics in AI can anticipate potential defects, allowing for corrective actions before they occur.
Increased Efficiency:
AI algorithms can optimize processing parameters and reduce bottlenecks, leading to faster and more efficient heat treating processes.
AI-driven automation can improve employee labor throughput and increase overall production speed.
Cost Reduction:
By optimizing utilities usage and resources, AI can help reduce the plethora of operational costs within heat treating facilities.
Predictive maintenance generated by AI can prevent costly equipment breakdowns and production downtime.
Customization and Personalization:
AI algorithms can analyze customer requirements and tailor heat treating processes to their specific needs.
Improved data analysis can lead to the development of new and specialized heat treatments for different metals and alloys.
Data Analysis and Information:
AI systems can process enormous amounts of data generated during heat treatment, collecting valuable information that can be used for process improvements and better-quality management.
Pattern recognition and statistical process control (SPC) analysis by AI can identify trends and correlations that could normally be overlooked.
Click image to download a list of cybersecurity acronyms and definitions.
Cons of AI in Heat Treating
Initial Investment:
Implementing an AI system requires a significant initial investment in the technology, training, and infrastructure, which may be a showstopper for smaller businesses.
Dependency on Technology:
Dependencies on AI systems can be a problem if there are technical glitches or breakdowns, disrupting the entire heat treating process.
Data Security and Privacy:
AI systems rely heavily on data. Ensuring the security and privacy of sensitive data is critical, especially when dealing with Controlled Unclassified Information (CUI), your proprietary heat treating processes, and sensitive customer information.
Ethical Concerns:
AI decision-making processes raise ethical questions, especially if the technology is used in critical applications, ensuring fairness, transparency, and accountability in AI decision-making is essential.
Skilled Workers Replaced:
Automation using AI might reduce the need for certain manual tasks, potentially leading to skilled workers losing their jobs without the necessary skills to operate or maintain AI systems.
Here’s the bottom line: You should always do your own research to see if AI is a good fit for your business. AI is not always better. There are upsides of using it, and there are definitely downsides to using it. You can’t always trust AI to give you the best information, so always make sure you confirm the information it is giving you through V&V (verification and validation).
At the Metal Treating Institute’s (MTI) national fall meeting, held October 9–11 in Tucson, AZ, Jay Owen gave an excellent presentation entitled, “Artificial Intelligence: Be Afraid or Be Excited.” Contact MTI by visiting www.heattreat.net.
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 for 5G’s applications in the metallurgical industry, allowing for the development of new materials and the reduction of energy consumption and emissions.
Jens Petri Head of Technologies and Partnerships SMS digital Source: LinkedIn
SMSGroup, a metallurgical company with North American locations, is building its own “private 5G Campus network” for research and development at its Hilchenbach location in the Siegerland. Together with Mugler and Ericsson, a private 5G infrastructure was set up here that enables not only the testing of the highest mobile communications standard currently available, but also the advancement of new developments for the metallurgical industry.
The use of a private 5G network offers a whole array of approaches to solutions, which SMS is now testing for the first time on an industrial scale and developing for customers in the metallurgical industry around the world.
The private 5G standalone Campus network used at SMS provides the basis for an initial test environment for the implementation of various 5G use cases. The network based on Ericsson Private 5G Technology (EP5G) was implemented by Mugler. Thanks to the efficient collaboration of all project partners, the system went live just four weeks after the project was launched.
Tests are carried out on applications from the fields of mobility and automated guided vehicles (AGV), the Industrial Internet of Things (IIoT), and lone worker applications. These are integrated and comprehensively tested at SMS’s Hilchenbach site, with the aim of optimizing their practical implementation. Moreover, the new private 5G network location serves as a platform for putting into practice the findings gained within the framework of the 5G-Furios research projects being run and funded by the state of North Rhine-Westphalia, the European Union’s Horizon 2020 project Zero-SWARM, and the CLOUD56 research project of the Federal Ministry for Digital and Transport (BMDV).
The SMS test environment offers a unique opportunity to test use cases internally and to present them to potential customers in a clear and illustrative way. The 5G Campus network represents an important step in the evaluation of advanced digitalization technologies and their applications in the steel industry.
Says Jens Petri, head of Technologies and Partnerships at SMS digital, “We serve the market with a sensor solution for production companies that is scalable and easy to integrate. Thanks to the 5G connectivity, it enables the transmission and processing of data to gain insights into the process that were jointly developed and tested at SMS group in Hilchenbach. SMS group is closing the gap between physics, sensor technology, OT, and IT.”
Heat Treat Today is partnering with two international publications:heat processing, a Vulkan-Verlag GmbH publication that serves mostly the European and Asian heat treat markets, and Furnaces International, a Quartz Business Media publication that primarily serves the English-speaking globe. Through these partnerships, we are sharing the latest news, tech tips, and cutting-edge articles that will serve our audience — manufacturers with in-house heat treat.
In this installment, explore important company partnerships with wide-spread industry effects as well as innovative new technologies from abroad.
TECHMO CAR Welcomes Anthony Tropeano as New Senior Advisor
Founded in 1961, TECHMO CAR drives innovation in the engineering and manufacturing of mobile and stationary equipment for the aluminum and metal production sector. (Source: Furnaces International)
"Anthony Tropeano of TT CONSULTING INC. has joined TECHMO CAR as a Senior Advisor for the US and Mexico market. Mr. Tropeano has spent over 40 years in the primary, secondary and downstream aluminum and metals worldwide market.”
New Tin Plate Complex from Partnership Between Danieli and Habaş Group
Caption: Situated in Aliağa near Izmir, the new facility will serve the needs of the packaging industry and the increasing need for cold-rolled and annealed thin sheets. (Source: heat processing)
"The facility, with a capacity of 900,000 tons per year, will produce a diverse range of steel grades, including T1 to T4 and DR7 to DR10. Among its offerings are 250,000 tons of tinplate, 150,000 tons of thin, continuous annealed cold-rolled coil, and 500,000 tons of semi-finished products. The complex comprises four crucial process areas: electrolytic cleaning, cold rolling and tempering, electrolytic tinning, and continuous annealing.”
SMS Group Partners with Turkish Plant Operator Kardemir to Digitize Blast Furnace 5
Using BFXpert solution from Paul Wurth, SMS Group has digitized a blast furnace belonging to Kardemir, Türkiye’s oldest blast furnace operator. (Source: Furnaces International)
"The Paul Wurth BFXpert system is a comprehensive package of systems for the chemical and thermal control of blast furnaces. It is an integrated level-2 process control and operator guidance system for superior blast furnace operation, utilizing the benefits of artificial intelligence to take process optimization to the next level and towards a fully autonomous blast furnace."
Karlsruhe Institute of Technology (KIT) Develops New Process for Sustainable Pig Iron Production
“By integrating the blast furnace and coking plant as well as the consistent recycling of process gases and heat, CO₂ emissions in steel production can be reduced.” (Source: heat processing.com)
"Around eight percent of global CO₂ emissions are caused by the steel industry. Professor Olaf Deutschmann from the Institute for Technical Chemistry and Polymer Chemistry (ITCP) at KIT is of the opinion that this must change quickly. In the long term, thanks to new hydrogen technologies, there is a climate-neutral perspective, but it will still be a few years before sufficient green hydrogen is available worldwide and newly built plants go into operation.”
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)
