EU-project Z-Ultra develops new chromium steels for high-temperature applications (US)

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In the project Z-Ultra, a 12-ton forging was produced as a demonstrator. (Credit Photo © Saarschmiede)

As the most important industrial construction material, with more than 2,500 grades, steel is highly specialized for diverse applications. Even the smallest changes of the composition can modify the material structure on an atomic scale and improve material properties on the macroscale. The consortium of the EU-project Z-Ultra, led by the Fraunhofer Institute for Mechanics of Materials IWM, has developed new 12% chromium alloys for high-temperature applications that are up to 30% stronger than traditional 9% chromium steels and withstand higher temperatures and pressures for a longer period of time. Atomistic simulations supported the development of the new steel alloys in a targeted manner.

Higher operating temperatures in gas and coal power plants mean higher efficiencies and, therefore, less CO2 emissions per kilowatt-hour of electricity. However, the temperature capacity of real materials is naturally limited. The materials used in power plants (usually steels) Read more

Engineers Demonstrate Value of Cold Spray additive Repairs to Naval Aviation (US)

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Naval Air Station North Island, Calif. (January 23, 2017) Matthew Minnick (left center), a materials engineer at Fleet Readiness Center Southwest (FRCSW), explains how the center is using Cold Spray Additive Technology to Marine Corps Assistant Deputy Commandant for Aviation (Sustainment), William E. Taylor. Taylor, a member of the Senior Executive Service, visited FRCSW to learn about the Cold Spray process to repair aircraft components. The additive, solid-state thermal spray can restore components’ critical dimensional features that have been lost due to corrosion, wear or mechanical damage. Listening behind them are (l to r) Chris Root, FRSCW advanced technologies lead, Tim Woods, FRCSW materials laboratory supervisor, and Gabe Draguicevich, FRCSW manufacturing department head. U.S. Navy (Credit Photo @ US Navy )

SAN DIEGO (NNS) — The Marine Corps Assistant Deputy Commandant for Aviation (Sustainment), William E. Taylor, visited Fleet Readiness Center Southwest (FRCSW) Jan. 23 to learn more about cold spray additive technology. Engineers and artisans from FRCSW didRead more

10 millions d’euros vont être investis pour développer la Métallurgie des poudres au Creusot (FR)

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Un centre d’excellence va être monté, sans doute, dans le prolongement du centre technique d’AREVA. «Un programme d’investissement d’avenir, pour faire du Creusot la capitale du développement de la Métallurgie des Poudres, avec le projet EXACALIBURE», souligne Jean-Claude Lagrange. (Credit Photo @ Creusot Infos)

7 millions vont être mobilisés pour la seule machine fabriquée en Suède. Elle sera installée dans un bâtiment tout neuf où on fera monter la pression à 2000 bars et jusqu’à 2000 degrés.

Berceau de la révolution industrielle en Europe continentale avec une première foulée de fonte au coke en décembre 1785, Le Creusot va devenir une des capitales d’une nouvelle technologie, celle de la métallurgie des poudres. Pour l’occasion, l’Université de Bourgogne, le PNB – Pôle de l’Industrie Nucléaire et l’agence Ecosphère, l’agence de développement économique de la Communauté Urbaine, créeront officiellement l’agence Excalibure. Ce sera très officiellement le lundi 20 février prochain. La métallurgie des poudres est uneRead more

Carpenter Technology to Acquire Assets of Puris LLC (US)

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Carpenter Technology Corporation  announced the  purchase of substantially all of the assets and business of Puris LLC (“Puris”), a producer of titanium powder for additive manufacturing and advanced technology applications, for $35 million. The assets and business to be acquired include Puris’ titanium powder operations and business, additive manufacturing assets, patents and related intellectual property. “This acquisition will provide Carpenter with immediate entry into the rapidly expanding titanium powder market and is consistent with our strategic focus on strengthening our leadership position in important growth areas,” said Tony Thene, Carpenter’sRead more

Russian rocket builder may have replaced special alloys with cheap metals (US)

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“The failure of the engine was reportedly traced to illegal replacement of precious heat-resistant alloys within the engine’s components with less expensive but failure-prone materials,”

In recent years, the Russian space program has had a series of problems with its flagship rockets, the heavy-lift Proton booster and the smaller Soyuz rocket used to launch crews and cargo to the International Space Station. The Proton rocket has been grounded since last summer, and the Soyuz has not flown since December, when its third stage engine failed and a Progress cargo spacecraft was lost. Most of these problems have been traced to engines that power the second and third stages of the Proton and Soyuz rockets. The majority of these engines are built at the Voronezh Manufacturing Plant in southwestern Russia, near the Ukrainian border. Russian Space Web reports thatRead more

Former Tata Steel produces ultra-clean steels with its new VIM furnace (US)

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Production of speciality steels and super alloys at Tata Steel in Stocksbridge, using the new VIM X-eed® unit supplied by SMS group.

At its Stocksbridge site, Tata Steel´s Speciality Steels, UK, has successfully commissioned the VIM X-eed® vacuum induction melting furnace supplied by SMS Mevac. This new tertiary metallurgy facility produces high-purity steels and specialty alloys for the aerospace industry. The VIM unit at Tata Steel comprises an eight-ton vacuum induction melting crucible and the associated vacuum pumping, material charging and process control equipment. All core components supplied by SMS Mevac have been designed to allow Tata Steel toRead more

Tata Steel UK agrees to $125m sale of speciality steel unit to Liberty House (US)

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Sanjeev Gupta, the head of the Liberty Group 

Tata Steel UK has concluded the £100m sale of its Specialty Steels business to Sanjeev Gupta’s Liberty House in a deal that should guarantee some 1,700 jobs in northern England. Tata’s specialty division makes high-end alloy metals for the aerospace and energy industries. Bimlendra Jha of Tata said the sale would help secure the future of the threatened Port Talbot plant in South Wales. which makes slab steel, and employs 8,500 people. “This is good news for Speciality Steels and for Tata Steel’s core business in the UK,” he said. Global steel pricesRead more

Boeing to buy $18 billion of titanium from Russia in the next 10 years (Russian)

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В следующем десятилетии сумма закупок авиастроительного концерна Boeing изделий из российского титана достигнет 18 млрд долларов, заявил в интервью «Ведомостям» президент Boeing в России и СНГ Сергей Кравченко, сообщает Ростех.   На сегодняшний день Boeing получает около 35% титана для гражданских самолетов от корпорации ВСМПО-АВИСМА. Это Read more

Disruptive Metallurgy: How Big Data, Machine Learning and Genetic Algorithms will revolutionize the metallurgy industry in the next 100 years (US)

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The metallurgy disruption is coming and it will revolutionize how materials are designed, manufactured and controlled during the entire life cycle. This revolution is based on three science fields :  Big Data, Machine Learning, and Genetic Algorithms. After the Medtech,  the Biotech, the Cleantech, the Finetech industries,   now its up to “Metaltech” to take the lead  for the next 100 years. Read the futuristic paper published by NATURE magazine entitled ” Can Artificial Intelligence Create the Next Wonder Material ?

AA 

It’s a strong contender for the geekiest video ever made: a close-up of a smartphone with line upon line of numbers and symbols scrolling down the screen. But when visitors stop by Nicola Marzari’s office, which overlooks Lake Geneva, he can hardly wait to show it off. “It’s from 2010,” he says, “and this is my cellphone calculating the electronic structure of silicon in real time!” Even back then, explains Marzari, a physicist at the Swiss Federal Institute of Technology in Lausanne (EPFL), Switzerland, his now-ancient handset took just 40 seconds to Read more

Machine Learning Method Accurately Predicts Metallic Defects (US)

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Dominant defect type predictions from r-MART model for 946 B2-type intermetallics. Colors indicates the relationship between prediction and calculations as shown in the legend

Berkeley Lab Research Could Accelerate Development of New Metallic Materials for the Aerospace Industry

For the first time, researchers at the Lawrence Berkeley National Laboratory (Berkeley Lab) have built and trained machine learning algorithms to predict defect behavior in certain intermetallic compounds with high accuracy. This method will accelerate research of new advanced alloys and lightweight new materials for applications spanning automotive to aerospace and much more. Their results were published in the December 2016 issue of Nature Computational Materials. Materials are never chemically pure and structurally flawless. They almost always contain defects, which play an important role in dictating properties. These defects may appear as vacancies, which are Read more

Larsen & Toubro aims to conclude some asset sales (US)

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A major point of pain has been the forging shop as it has not delivered the expected returns. The company has spent close to Rs 3,000 crore in building a nuclear forge shop to become the super hi-tech company of India. However, the tsunami in Japan in 2011 changed the outlook for nuclear power plants. that things could improve from 2018 because many nuclear reactors are coming and some forging will be made here. So from virtually 20% proper utilisation, it will go to 70 %. On photo India’s biggest open die hydraulic press (9000 MT) with 150 MT manipulator (Credit Photo @ LT Heavy Engineering)

Over the last couple of decades, L&T has entered several new businesses and geographies to grow topline. But not all these business lines have delivered the kind of growth anticipated. While some legacy businesses date back to the pre-liberalisation days, some later-day investments like the forging shop too have not delivered returns. Outgoing boss AM Naik is doing his best to resolve these issues before heRead more

ArcelorMittal, the Walloon government and Sogepa celebrate world-first for steel industry, developed in Liège (US)

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ArcelorMittal has opened a new, €63m production line – the Jet Vapor Deposition (JVD) line – at its facilities in Kessales, Belgium. His Majesty King Philippe of Belgium officially inaugurated the line at an event, held today. The opening is the culmination of years of scientific investigation by ArcelorMittal’s research and development teams in collaboration with the Metallurgical Research Centre, CRM group, to create a new, breakthrough technology for the metallic coating of steel. The invention continues the Walloon tradition of stretching theRead more

Indian forgings auto parts marker to invest €56 million in the next three to five years (US)

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Auto component manufacturer Sona BLW Precision Forgings Ltd on Thursday said it would invest ₹300-400 crore in the next three to five years on capacity expansion and to develop new products for the global market. It aims to achieve a revenue of ₹2,000 crore by then. The company will also hire around 200 people for its Indian operations, which has around 990 people at present, Sunjay Kapur, ManagingRead more

UCLA physicists map the atomic structure of an alloy (US)

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Identification of the 3-D coordinates of 6,569 iron and 16,627 platinum atoms in an iron-platinum nanoparticle to correlate 3-D atomic arrangements with material properties at the single-atom level. In the world of the very tiny, perfection is rare: virtually all materials have defects on the atomic level. These imperfections — missing atoms, atoms of one type swapped for another, and misaligned atoms — can uniquely determine a material’s properties and function. Now, UCLA physicists and collaborators have mapped the coordinates of more than 23,000 individual atoms in a tiny iron-platinum nanoparticle to reveal the material’s defects. The results demonstrate that the Read more

KTH Develops a new Fe-10Cr-4Al-Zr steel grade for the Swedish Advanced Lead Reactor (US)

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The technological breakthrough developed by KTH in cooperation with the Swedish steel industry is a new aluminum and zirconium alloyed steel (Fe-10Cr-4Al-Zr) that provides adequate long-term performance in hot lead. After 19,000 hours of exposure at 550 C, the material appears to be in like new condition. By limiting operating temperature to 450 C the designers are confident that SEALERs using the new alloy will be able to operate reliably for as long as 30 years. That confidence, of course, will be something that LeadCold will have to demonstrate to the satisfaction of the regulatory agency. On photo  Lead corrosion laboratory: >19000 hour exposure of Fe-10Cr-4Al-Zr alloys at 550°C completed. Optimised alloys in perfect condition after exposure.

LeadCold and Essel Group ME have announced an agreement for a $200 million (USD) investment to build uranium-fueled power sources. Their systems, trademarked SEALER, are designed to compete with diesel generators to supply dependable power to communities and industries in remote areas of the world. SEALER (Swedish Advanced Lead Reactor) is a fast spectrum nuclear reactor that uses low enriched uranium oxide fuel (19.5%) cooled by molten lead. TheRead more

La Fédération Forge Fonderie (FR)

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Née de l’union de l’Association Française de Forge et des Fondeurs de France, la Fédération Forge Fonderie constitue aujourd’hui un acteur fort dont l’action rayonne sur l’ensemble du secteur industriel Français. Représenter, promouvoir, défendre et servir sont autant d’objectifs que la Fédération s’est engagée à remplir aux côtés de ses adhérents.

La Fédération Forge Fonderie représente les entreprises du secteur de la mise en forme des métaux par moulage et par forgeage. Les fondeurs et les forgerons fournissent des produits complexes, tels que des pièces de structure et de sécurité, avec un savoir-faire reconnu par leurs clients tant nationaux qu’internationaux. Les produits forgés et moulés sont présents dans tous les marchés : Automobile,Read more

Prismadd prévoit de livrer ses premieres pièces en titane issues de la fabrication additive pour Airbus en 2017 (FR)

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Prismadd a été créée en 2014 suite à une collaboration entre le fabricant aéronautique Farella, le fabricant Rhonatec et l’entreprise d’impression 3D Creatix3D. Dirigée par Philippe Rivière, Prismadd a connu une importante croissance ces dernières années et est désormais prête à commencer sa production industrielle grâce à la fabrication additive. De gauche à droite: Philippe Rivière, PDG de Prismadd, et Pascal Farella, Président de We are aerospace

La startup française Prismadd enclenche son activité dans son usine de Montauban équipée de 5 (et bientôt 7) imprimantes 3D industrielles. L’entreprise, qui a signé un contrat de 6 millions d’euros avec Airbus, prévoit de livrer ses premières pièces en titane Read more

Czapek’s secret stainless steel (US)

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One of the most versatile forms of stainless steel, which is also used in lower-priced watches, is SAE grade 304 (EN 1.4301), which comprises 18% chromium and 8% nickel. The most common grade used in luxury watches, however, is 316 or 316L, which in addition contains up to 2.5% molybdenum, giving it greater resistance to corrosion. As a notable exception, Rolex uses 904L stainless steel for its cases. This particular alloy also contains copper and has been favoured by Rolex since the 1980s because it takes a higher polish, even though it is more difficult to machine. 

To understand how special the stainless steel used in Czapek watches is, you first need a primer in the different types of stainless steel used in watches in general. First of all, let’s consider just what stainless steel is exactly. The term refers to a group of iron alloys that contain 10.5% chrome or more and 1.2% carbon or less. These alloys have a self-replenishing surface layer that gives a high level of protection Read more

Emmanuel VIELLARD, LISI’s CEO Strategy : Building the “Forge of the 21st century” (US)

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Emmanuel VIELLARD, LISI CEO, has been interviewed during a « Meeting with CEOs of listed companies » at Lyon the 5th and 6th January 2017.

Key moments of the interview for LISI AEROSPACE:

Results of 2016?  The results were in line the budget and included many successful projects and significant ramp-up in our customer’s production rates.

Aerospace market? It’s balanced between multiple programs and some exciting new ones. The aerospace industry is generally strong with a good outlook.

Investments of 2016? It has been a record year with new programs and new products. It’s necessary to protect what we have today andRead more

Vallourec and Asco Industries announce the creation of Ascoval (US)

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January 26, 2017  – Vallourec, the global leader in premium tubular solutions, and Asco Industries, a major European actor in the production of special steels (long products), today finalize the acquisition of a majority shareholding by Asco Industries in the Saint Saulve steel mill.  Ascoval S.A.S., 60% owned by Asco Industries and 40% by Vallourec, will own all the assets of the steel mill. The creation of Read more

PCC to acquire German Pipe Company Wilhelm Schulz (US)

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Precision Castparts Corporation, owned by Mr. Buffett, has reached a deal to acquire Wilhelm Schulz, the world leader in piping components. It’s the second acquisition by Mr. Buffett in Germany in the past two years. U.S. billionaire Warren Buffett has purchased another mid-sized German company through a subsidiary of his holding company Berkshire Hathaway, Handelsblatt has learned. Precision Castparts Corporation, or PCC, purchased by Mr. Buffett two years ago for $37 billion (€34 billion), has reached a deal to acquire Wilhelm Schulz, the world leader in piping components. Wilhelm Schulz has 450 employees and generated €172 million in 2014. Mark Donegan, the chief executive of PCC, confirmed the deal to Handelsblatt but declined to disclose the purchase price or provide specifics about the acquisition. Mr. Donegan said PCC is looking for additional acquisitions in the aviation and energy sectors.

“He is looking for companies that have proven themselves on the market over many decades and have developed a brand.”

Zypora Kupferberg,, Kupferberg Transactions

The acquisition of Wilhelm Schulz is part of Mr. Buffett’s growing interest in Germany’s mid-sized business segment. Mr. Buffett sent his portfolio manager, Ted Weschler, to Germany in December to look for potential acquisition candidates. Zypora Kupferberg, founder of Read more

Kobe Steel begins mass production of titanium alloy forged material for large jet engine made by GE (US)

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TOKYO, January 23, 2017 — Kobe Steel, Ltd. announces that it has begun supplying titanium alloy forged material for shafts to IHI Corporation. The forged material certified by IHI is used in a large commercial jet engine manufactured by General Electric (GE). IHI is one of the joint development partners of the engine. Rotating parts such as shafts and disks made of titanium alloy forged material must be of extremely high quality. These are some of the largest components used in aircraft jet engines. Kobe Steel launched development of theRead more

Investment in production line boosts Alloy Wire (US)

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Significant investment in a custom-built production line is helping a leading wire manufacturer prove that ‘size does matter’. Alloy Wire International (AWI), which employs 28 people across its two factories in the Black County and Yorkshire, has spent more than £150,000 on a host of new machinery that gives its customers access to wider and thinner or bigger cross-section profiles (up to 100mm2) in more than 60 different alloys. The decision comes after a major customer research exercise and is already proving a successful decision, withRead more

Boeing expands Forgings R&D centre in Bengaluru (US)

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BENGALURU: Boeing has expanded significantly its engineering and technology centre in Bengaluru and said the centre will play a crucial role in areas like materials science, flight science and data analytics as the aircraft maker moves towards using newer materials for building planes and using the increasing amounts of digital data being generated to make all operations more efficient. The 42,000-sqft Boeing India Engineering & Technology Centre (BIETC) will house about 300 engineers, and that capacity will expand to double that by the end ofRead more

Japanese steelmakers are looking to survive through sales of high-end steel used mostly in automobiles (US)

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Japanese steelmakers have focused on light, high-tension and high-grade steel used mostly in automobiles. A high degree of skill is required to produce high-grade steel, making it difficult for overseas companies to easily produce. In addition, steelmakers can expect stable demand for this type of steel from automakers that must maintain product quality in order to meet high safety standards.

Amid the current worldwide slump in the price of steel, Japanese steelmakers are looking to survive through sales of high-end steel that requires advanced technology to produce, as well as the demand for building material for the 2020 Olympic Games. Even so, prospects of China cutting back overproduction are bleak, while U.S. President Donald Trump’s “America first” policy is feared to generate harmful effects on the Japanese steel and iron industry. A series of risks regarding steel materials seem to be weighing down the domestic Read more

Accuride manufactures new advanced aluminum alloy (US)

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Accuride’s engineers developed the proprietary next-generation Quantum 99 alloy to be 20 percent stronger than the Company’s previous aluminum alloy. Its optimized microstructure enhances wheel performance, ensuring industry-leading strength and durability

  • Quantum 99™ aluminum alloy to lower weight, boost durability across wheel range
  • New 40 lb. wheel gives industry stronger solution for light-weighting drive

Accuride Corporation – a leading supplier of components to the North American and European commercial vehicle industries – today introduced its new Quantum 99™ aluminum alloy, the strongest, most advanced alloy for aluminum wheels in the commercial vehicleRead more

New study reveals solidification cracking during welding of steel (US)

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3D ex situ reconstruction and characterisation of weld solidification cracks, showing: a) macrograph of the sample and cracking topography, b) 3D image reconstruction showing the solid sample machined from the sample in Figure 3a. The weld and solidification crack are visible on the surface. The yellow arrows denote the Cartesian co-ordinates for view plane reference, c) view of y-z plane showing the air (filling the space of the solidification cracking network) inherent to the sample. The blue box represents a “mature” solidification crack that is fully grown. The red box represents “infant” solidification cracks that are primarily sub-surface and invisible from visual inspection of Figure 3(a), d) z-x plane view of the solidification cracks showing somewhat symmetric features in terms of the angle of cracking either side of the weld centreline

New research led by the University of Leicester has made a novel breakthrough in understanding how solidification cracking occurs during the welding of steel, an important engineering alloy. In a new study, which has been published in the journal Scientific Reports from Nature Research, the team from the University of Leicester Department of Engineering propose that solidification cracks grow by linking micro-porosities in the meshing zone in the solidifying weld pool. This is the first time that researchers have observed solidification cracking inRead more

Hydrogen turned into a metal for the first time (US)

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Scientists compressed hydrogen under vast amounts of pressure to turn the gas into a metallic state.

US scientists have succeeded in squeezing hydrogen so intensely that it has turned into a metal, creating an entirely new material that might be used as a highly efficient electricity conductor at room temperatures. The discovery, published in the journal Science on Thursday, provides the first confirmation of a theory proposed in 1935 by physicists Hillard Bell Huntington and Eugene Wigner that hydrogen, normally a gas, could occur in a metallic state if exposed to extreme pressure. Several teams have been racing to develop metallic hydrogen,Read more

GE is substituting nickel alloy in four parts, including turbine blades with innovative Japanese composites (US)

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Nickel alloy, a mainstay material in engine production, offers less heat resistance than silicon carbide fibers and requires air cooling. Silicon carbide fibers let planes use air more effectively for propulsion instead. The composite material costs more than nickel alloy, but producers hope that mass production will bring the cost down. Silicon carbide fibers weigh one-third that of nickel alloy and can withstand temperatures up to 2,000 C. On photo Bill Millhaem, general manager of the GE90/GE9X engine programs at GE Aviation, stands by a full-scale mock-up of the GE9X in 2015

TOKYO — Tough, lightweight silicon carbide fibers will help improve the fuel efficiency of General Electric’s aircraft engines and could spread to other uses, following in the footsteps of earlier Japanese innovations in materials engineering. Japan’s materials industry has had success with carbon fibers. Aircraft makers increasingly substitute carbon-fiber-reinforced plastics for aluminum alloys in wings andRead more

Ohio State scientists find a way to remove defects from alloys to enable jet engines to run hotter and cleaner (US)

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COLUMBUS, Ohio—Researchers here have made a discovery in materials science that sounds like something from the old Saturday morning cartoon Super Friends: They’ve found a way to deactivate “nano twins” to improve the high-temperature properties of superalloys that are used in jet engines. The advance could speed the development of powerful and environmentally friendly turbine engines of all sorts, including those used for transportation and power generation. The “nano twins” in question are microscopic defects that grow inside alloys and weaken them, allowing them to deform under heat and pressure. In the journal Nature Communications, engineers at The Ohio State University describe how tailoring an alloy’s composition and then exposing it to high heat and pressure can not only prevent nanoRead more