3rd Quarter – Vol. 23, No. 3

32 Pages·2016·39.72 MB·English

INDUSTRY NEWS
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SPRAYTIME: TABLE OF CONTENTS
l INDUSTRY NEWS .............................................................................4
l PRODUCT SPOTLIGHT .....................................................................8
l ITSA MEMBERSHIP ........................................................................10
l ITSA MEMBER NEWS .....................................................................12
Conference Review
l PEOPLE IN THE NEWS ...................................................................16
l FEATURES ....................................................................................18
*Cold Joining of Dissimilar Metals
Process Simulation and Modeling in HVOF Qualification and Optimization
l TECHNOLOGY .............................................................................28
l CALENDAR ..................................................................................30
Where is your article? We encourage you to send articles,
news, announcements and information to
[email protected]
On the cover: An arcbeam spray for dense coatings is in use. (Photo courtesy of Metallisation)
Published by International Thermal Spray Association SPRAYTIME® (ISSN 1532-9585) is a quarterly publication of the
A Standing Committee of the American Welding Society International Thermal Spray Association. Printed on Recycled Paper.
Copyright© 2016 by the International Thermal Spray Association. Starred
Mission: To be the flagship thermal spray industry publication providing
(*) items excluded from copyright.
company, event, people, product, research, and membership news of
interest to industrial leaders, engineers, researchers, scholars, policy- The International Thermal Spray Association is not responsible for the
makers, and the public thermal spray community. accuracy of information in the editorial, articles, and advertising sections
of this publication. Readers should independently evaluate the accuracy
OFFICERS of any statement in the editorial, articles, and advertising sections of this
Chairman: Jim Ryan, Carpenter Powder Products publication which are important to him/her and rely on his/her independent
Vice-Chairman: David Lee, Kennametal Stellite Company evaluation.
Article submissions (subject to acceptance and edit), advertising
EXECUTIVE COMMITTEE (above officers plus the following)
insertions, address correspondence, subscription request, back issue
Dan Hayden, Hayden Corporation
copies, and changes of address should be sent to:
Bill Mosier, Polymet Corporation
Peter Ruggiero, Curtiss-Wright Surface Technologies
David Wright, Accuwright Industries, Inc. American Welding Society
Att: SPRAYTIME
SPRAYTIME® 8669 NW 36 Street, #130, Miami, Florida 33166-6672
Phone: [phone] or 305-443-9353 | www.spraytime.org
Editor Cindy Weihl
Technical Editor Joe Stricker
A subscription to SPRAYTIME® is free for individuals interested in
Designer Willie Chinn
the thermal spray and coatings industry. Visit www.spraytime.org to
subscribe.
www.thermalspray.org 3
INDUSTRY NEWS
l
NORSK TITANIUM TO BUILD AEROSPACE ADDITIVE MANUFACTURING PLANT
Norsk Titanium AS, Norway, recently announced the State of New York, in partnership with SUNY Polytechnic Institute, has placed an
order for an initial lot containing 20 of the company’s patented MERKE IV™ Rapid Plasma Deposition™ machines. This is in accordance
with an approved state budget allocation to facilitate Norsk Titanium’s U.S. subsidiary building and operating what’s claimed to be the
world’s first industrial-scale metal additive manufacturing plant in New York.
The factory will be in Plattsburgh, N.Y., and is expected to be operational by the end of 2017. The first 20 machines will establish a baseline
production level of 400 metric tons/year of aerospace-grade, structural titanium components. The New York program also envisions a
capacity ramp-up to a total of 40 machines capable of up to 800 metric tons/year. New York has released an additional $4 million in planning
funds for the company’s U.S. factory.
“Today marks the beginning of a new era in the way aircraft, marine vessels, automobiles, spacecraft, and many industrial products are
designed and built,” said Norsk Titanium President and CEO Warren M. Boley Jr.
Norsk Titanium US will provide additional investment into the Plattsburgh operation that is expected to bring the total program commitment
to the $1 billion level over the initial ten-year period of operations. The company is also partnering with the North County Chamber of
Commerce in Plattsburgh to support the launch and growth of its factory, including workforce training.
l
HOLSTER ENGINEERING CELEBRATES
50-YEAR ANNIVERSARY
Holster Engineering Co., Ltd., celebrated 50 years in engineering
and 46 years in the thermal spray field this last October. Located
in Tokoroa, New Zealand, it is a medium-to-heavy precision
engineering repair service company that offers specialized
services in thermal spray and machinery repair. Operating under
the guidance of Directors Marty Camenzind (director/operations
manager) and Bruce Martin (director/works manager/senior thermal
spray engineer) is a staff of 27, many of whom have had a long
period of service with the company. Martin and Camenzind have a
combined 70 years’ experience in the industry.
The thermal spray division was set up in 1969 and today is at the
forefront using equipment such as plasma, flame spray, arc spray,
high-velocity oxyfuel (HVOF), and high-velocity air fuel (HVAF)
along with robotic automated traverses. It is the only thermal spray
company to currently hold Lloyds Register approval for flame, arc,
plasma, and HVOF spraying of engineering components in New
Zealand.
Holster was the first New Zealand engineering company to realize
the benefits of thermal spray technologies reclaiming damaged parts
at a fraction of the cost of new replacements and as an alternative to
traditional welding process repairs.
Holster has worked on some of the largest and most challenging
thermal spray coating projects in the country. In 1984, one such
project dealt with corrosion inside a local kraft pulp digester. A
nickel-based alloy powder was plasma sprayed to approximately
800 sq ft of the digester with a fully automated system believed to be
the first in the world at that time. The company now has equipment
that gives the flexibility to apply coatings in-house as well as in-
situ. The company also purchased the first HVAF aero-spray (by
Browning) in the world.
In 1996, Holster Engineering acquired the franchise to be the
sole applicators in New Zealand to apply the full range of release
coatings developed by Plasma Coatings, Inc., based in Connecticut,
which is now a subsidiary company of American Roller. This
agreement is still in place. The company has a wide customer base
and has assisted with more than 90 hydro and 20 thermal station
overhauls, most having metallized coatings designed by Holster
Engineering to help with erosion, corrosion, and cavitation.
More than 200 past and present employees, suppliers, and friends
For 50 years, Holster Engineering has been in business. enjoyed the festivities of the special event held to celebrate the 50th
Its staff is shown on the newly installed Berthiez vertical lathe. anniversary.
SPRAYTIME | THIRD QUARTER 2016 4 www.thermalspray.org
INDUSTRY NEWS
l STATE OF THE POWDER METALLURGY market; all powder-related applications account for an estimated
20–25% of hot isostatic pressing business; an estimated 50 to less
INDUSTRY IN NORTH AMERICA GETS than 100 companies and organizations are actively pursuing metal
additive manufacturing and development programs using metal
ANALYZED powders; and while the tungsten market continues to experience
difficult times, nonmining and energy-related demand continues at a
steady pace.
The State of the PM Industry in North America — 2016 was Most Metal Powder Industries Federation members also forecast
recently presented at POWDERMET2016. This study showed that sales increases this year. The powder metallurgy parts makers,
the entrepreneurial spirit still rings true in the powder metallurgy depending upon what markets they serve, see business increasing
industry, and confidence remains strong in the majority of powder in the mid- to upper-single digits.
metallurgy industry companies. Following a prosperous 2015, the
year opened on a positive trend with a modest growth forecast by
most observers. Press-and-sinter companies and metal powder
producers report good business levels as well as companies
involved with metal injection molding, metal additive manufacturing,
and hot isostatic pressing. However, demand for refractory metals
has continued to decline.
The total North American iron powder shipments increased by
1.73% to 423,565 short tons with the powder metallurgy sector
reflecting 91% and growing by 2.3% to 385,559 short tons (see
graph). Other sectors representing welding, cutting, scarfing,
and lancing dropped off. Developing metal powders for metal
additive manufacturing via gas atomization is a new trend set for
acceleration by most leading powder makers.
Overall, powder metallurgy parts makers fared well in 2015,
especially firms selling heavily into the automotive market. Western
Pennsylvania powder metallurgy parts makers saw moderately busy
production levels, yet continued facing skilled-labor shortages.
Highlights for specialty powder metallurgy products were as This graph, reflecting North American iron powder shipments,
follows: Slower growth impacted the U.S. metal injection molding not only shows short tons and years but is also color coded for
industry in 2015, mainly due to a decline in the domestic firearms powder metallurgy parts, welding, and other uses
www.thermalspray.org 5 THIRD QUARTER 2016 | SPRAYTIME
INDUSTRY NEWS
l
ALCOA OPENS 3D PRINTING METAL
POWDER PLANT
Alcoa has opened its 3D printing metal powder production facility.
Located at the Alcoa Technology Center in Pennsylvania, the
company will produce proprietary titanium, nickel, and aluminum
powders optimized for 3D printed aerospace parts. The lightweight
metals provider has also invested in technologies to further develop
additive processes, product design, and qualification.
“Alcoa is forging a leadership path in additive manufacturing with
a sharp focus on the critical input material — metal powders,” said
Chairman and CEO Klaus Kleinfeld.
Metal powders used for 3D printing durable aerospace parts are
available in limited quantities. Through this expansion, announced
in September 2015, Alcoa will develop materials with the specific
properties needed to 3D print high-performance components.
In addition, the facility will form part of Arconic following separation
from Alcoa’s traditional commodity business in the second half of
2016. The plant is part of a $60-million investment in advanced 3D
printing materials and processes that builds on the company’s 3D
The company has launched its 3D printing metal powder production facility printing capabilities in California, Georgia, Michigan, Pennsylvania,
at the Alcoa Technology Center (shown here from an aerial perspective).
and Texas.
l l
H.C. STARCK POWDER DIVISIONS WATSON VALVE UPGRADES OXYGEN
ADOPT NEW CORPORATE LEGAL CLEAN ROOM
STRUCTURE
Watson Valve Services, Inc., has upgraded its O2 clean room at
its Houston, Tex., facility to ensure proper cleaning procedures are
H.C. Starck, Munich, Germany, a manufacturer of customer- performed on valves for oxygen service.
specific powders and components made from technology metals Operated by trained technicians, the room has been constructed
and advanced ceramics, is optimizing the corporate legal structure with positive pressure ventilation to limit airborne particles and
of its powder divisions (tungsten, tantalum/niobium, plus surface environmental contamination. Mechanical and solvent cleaning
technology and ceramic powders). methods are used. The company also maintains separate tools,
Employees assigned to the three powder divisions were benches, and equipment.
transferred to the new companies as of August 1. Employees who Procedures are followed to maintain and keep all O2 clean room
work in technical/administrative services and group functions will equipment clean and free of contaminants. After each valve is
remain at H.C. Starck GmbH. H.C. Starck Infrastructure GmbH & thoroughly cleaned and reassembled, it is given a seat and shell
Co. KG will have no staff for the time being. The new companies test; once inspected, all cleaned valves are labeled and sealed to
began operating as independent enterprises on August 1. protect them during storage and shipment.
The new structure will allow the business segments to operate
with greater autonomy and individual responsibility.
“We are giving the new companies the capabilities and leeway
they need in order to position themselves optimally on the market,” l
INNOVNANO LAUNCHES NEW WEBSITE
said Dr. Engelbert Heimes, chairman of the executive board of H.C.
Starck.
Innovnano, Coimbra, Portugal, has launched a new website at
innovnano-materials.com to highlight its zirconia powder range.
PRINT OR ONLINE OR BOTH?
These powders have applications across many industries, such
YOUR CHOICE. as structural ceramics, refractories, energy materials, and thermal
barrier coatings.
If you would rather receive SPRAYTIME The website has been designed so technical content and product/
online or receive both the print and online application information is accessible via tablets and smartphones.
The resource area includes articles and technical papers written
version, please send an email to spraytime@
by company scientists to explain its proprietary manufacturing
thermalspray.org with your preference and
technology, Emulsion Detonation Synthesis.
you will receive an email automatically when
“To celebrate the launch, we are offering new customers the
the next issue is available at spraytime.org. chance to receive a trial sample of the powder of their choice,”
added Paul Newbatt, sales and marketing director at Innovnano.
SPRAYTIME | THIRD QUARTER 2016 6 www.thermalspray.org
What: Why:
Thermal spray coating equipment
• -brand • Services:
and consumables from Praxair
coating equipment installations and
training, calibrations
and repairs
• Half a century
of leadership
Thermal spray powder and wire Replacement parts HP/HVOF , arc spray, plasma systems and more
www.praxairsurfacetechnologies.com
Copyright © 2012 Praxair S.T. Technology, Inc. All rights reserved.
Praxair, the Flowing Airstream design, the TAFA logo and the FLAME design are trademarks of Praxair S.T. Technologies,
Inc. TAFA Incorporated is a wholly owned subsidiary of Praxair Surface Technologies.
www.thermalspray.org 7 THIRD QUARTER 2016 | SPRAYTIME
PRODUCT SPOTLIGHT
THERMAL SPRAY SYSTEMS AWS RELEASES NEW FEEDER FEATURES TWO
CAPABLE OF REMOTE SPECIFICATION FOR THERMAL POWDER HOPPERS
DIAGNOSTICS SPRAYING ZINC ANODES ON
The Twin 150,
STEEL REINFORCED CONCRETE
The 25 Series single- a multiprocess
process thermal spray powder feeder, can
The American
systems have been An AmeArWicaSn C N2a.2ti0o/Cna2l. 2S0tMan:2d0a1rd6 Welding Society be integrated into a
introduced. The AP-25 thermal spray, laser
(AWS) has released
plasma and HV-25 HVOF cladding, or powder
C2.20/C2.20M:2016,
products utilize stainless Specification for additive manufacturing
steel plumbing and fittings Thermal Spraying Specification for system. The unit can
Zinc Anodes on Thermal Spraying
throughout, a Siemens Steel Reinforced Zinc Anodes on be operated in full
12-in. color touch screen, Concrete remote mode, where its
Steel Reinforced
and Horizon-S software. functions are controlled
Concrete. This
They are capable of by the user’s external
technical standard covers the application
remote diagnostics through control system, such as a robot or process
of zinc thermal spray coatings to steel-
eWon technology. This series, capable of controller, using UDP/IP or PROFIBUS
reinforced concrete using arc and flame
interfacing with most plasma and HVOF protocols. The product can be used in stand-
spray equipment. It is formatted for
systems, is also manufactured to CE and alone (manual operation) or remote on/off
industrial process instructions and includes
UL standards. Additional features include mode, where an external mechanism turns
information on job descriptions, safety,
ergonomically comfortable process control powder feeding on or off. In addition, this
equipment, surface preparation, thermal
knobs and being compact with a small model has two powder hoppers.
spraying, and quality control. The publication
footprint.
is $68 for non AWS members and $51 for Oerlikon Metco
Flame Spray Technologies AWS members. oerlikon.com / [phone]
fst.nl / +31 [0]26 3190140
AWS Book Store
pubs.aws.org / [phone]
BOOK ON HIGH-PRESSURE REPORTS DETAIL GLOBAL
COLD SPRAY DESCRIBES THERMAL SPRAY MATERIALS
APPLICATIONS IN MANY AND EQUIPMENT MARKETS WHERE IS YOUR
INDUSTRIES
Two thermal spray reports have recently ADVERTISEMENT?
been released by Research and Markets.
High Pressure Cold Spray: Principles and
The Global Thermal Spray Materials Market
Applications presents baseline information
– Trends and Forecasts (2015–2020) valued
on design and modeling, materials science
this market at $1.40 million in 2015, but that’s From classified to
of engineered coatings, and specific
expected to grow over the forecast period.
applications in various high-tech industries.
This division is driven by growing thermal business-card size
Published by ASM International, the 300-
spray applications in the aerospace and
page book is authored by a group of global
automotive sectors, increased use of thermal to full-page sizes,
cold spray experts, and edited by Charles M.
spray in medical devices, and reduced
Kay and J. Karthikeyan of ASB Industries,
Barberton, Ohio, with an introduction technology transfer time. In terms of con- we can work
sumption last year, North America led the
by Dr. Mark Smith of Sandia National
Labs. Various applications of cold spray market. Additionally, the Global Thermal with your format.
Spray Equipment Market – Segmented by
processes, including protective coating
Product Type, by End-User Industry, by
production, development of performance- Please visit
Thermal Spray Process, and Geography
enhancing layers, repair and refurbishing of
– Trends and Forecasts (2015–2020)
parts, plus NNS fabrication, are elaborated www.spraytime.org
indicates this market size includes only the
in each industry with illustrative case
revenues being generated through the sales
studies by cold sprayers actively involved for rate information,
and repair of equipment being used in
in the field. The price is $199, but for ASM
thermal spray. Key deliverables consist of
members, it is $149. region-specific assessments and compet- email the SPRAYTIME
ASM International ition analysis on global and regional scales,
asminternational.org / [phone] plus macro and micro factors that affect this publishing office via
market on global and regional scales.
[email protected]
Research and Markets
researchandmarkets.com / [phone]
SPRAYTIME | THIRD QUARTER 2016 8 www.thermalspray.org
WIRE FOR THE WORLD
STANDING COMMITTEE
Whatever your needs, wherever you are
– We’ll get you wired.
SCHOLARSHIP OPPORTUNITIES
International Thermal Spray Association
Up to three (3) Graduate scholarships worth
$2,000.00 each to be awarded each
calendar year.
Since 1991, the ITSA Scholarship Program has contributed
to the growth of the Thermal Spray Community, especially
the development of new technologists and engineers. The
International Thermal Spray Association is very proud of
Manufacturer of
this education partnership and encourages all eligible
High Performance Wire for Hardfacing,
participants to apply.
Welding and Thermal Spraying.
NEW APPLICATION DATES: Scholarship applications
are now accepted annually April 15 through July 15 ONLY
for the Graduate scholarships. polymet.us
[email protected]
Please visit the Scholarship area at +1.513.874.3586
WWW.THERMALSPRAY.ORG
www.thermalspray.org 9 THIRD QUARTER 2016 | SPRAYTIME
ITSA MEMBERSHIP
JOB SHOP MEMBER n EXLINE, INC. n SUPERIOR SHOT PEENING, INC.
Salina, KS Houston, TX
COMPANIES
Mr. Doug Porter Ms. Mollie Blasingame
[email protected] / 785.825.4683 [email protected]
n ACCUWRIGHT INDUSTRIES, INC. www.exline-inc.com 281.449.6559 / www.superiorshotpeening.com
Gilbert, AZ n F.W. GARTNER THERMAL SPRAYING n UNITED SURFACE TECHNOLOGIES
Mr. David Wright
Houston, TX Altona, Melbourne Australia
[email protected] / 480.892.9595
Richard McCullough Mr. Hugo Howse
www.accuwright.com
[email protected] / 713.225.0010 [email protected] / 61.393.98.5925
n ATLAS MACHINE & SUPPLY, INC. www.fwgts.com www.ust.com.au
Louisville, KY n FUSION, INC.
Mr. Richie Gimmel
[email protected] / 502.584.7262 Houston, TX SUPPLIER MEMBER
Mr. Jeff Fenner
www.atlasmachine.com
[email protected] / 713.691.6547 COMPANIES
n BENDER US www.fusionhouston.com
Vernon, CA n HAYDEN CORP. n AMETEK, INC.
Mr. Doug Martin Eighty-Four, PA
West Springfield, MA
[email protected] / 323.232.2371 Ms. Cindy Freeby
Mr. Dan Hayden
www.benderus.com [email protected] / 724-225-8400
[email protected]
www.ametekmetals.com
n BYRON PRODUCTS 413.734.4981 / www.haydencorp.com
Fairfield, OH n KERMETICO, INC. n ARDLEIGH MINERALS, INC.
Mr. Keith King Beachwood, OH 44122
Benicia, CA
[email protected] / 513.870.9111 Mr. Ernie Petrey
Mr. Andrew Verstak
www.byronproducts.com [email protected] / 216.464.2300
[email protected] / 707.745.3862
www.ardleigh.net
n CASTOLIN EUTECTIC www.kermetico.com
Lausanne, Switzerland n NATION COATING SYSTEMS n CAMFIL APC
Ms. Patricia Frund Jonesboro, AR
Franklin, OH
[email protected] / 0041.21.694.1132 Mr. Matt Caulfield
Mr. Larry Grimenstein
www.castolin.com [email protected] / 800.479.6801
[email protected] / 937.746.7632
www.farrapc.com
n CINCINNATI THERMAL SPRAY, INC. www.nationcoatingsystems.com
Cincinnati, OH n PLASMA COATINGS n CARPENTER POWDER PRODUCTS
Mr. Bill Menth Pittsburgh, PA
Union Grove, WI
[email protected] / 513.699.3992 Mr. Chip Arata
Mr. Daniel Cahalane
www.cts-inc.net [email protected] / 412.257.5102
[email protected] / 262.878.2445
www.carpenterpowder.com
n CURTISS-WRIGHT SURFACE www.plasmacoatings.com
TECHNOLOGIES n PLASMA TECHNOLOGY, INC. n CENTERLINE WINDSOR LTD.
Windsor, CT Torrance, CA Windsor, ON Canada
Mr. Peter Ruggiero Mr. Robert D. Dowell Mr. Julio Villafuerte
[email protected] [email protected] / 310.320.3373 [email protected] / 519.734.8464
860.623.9901 / www.cwst.com www.ptise.com www.supersonicspray.com
n ELLISON SURFACE n SPRAYMETAL, INC. n DEWAL INDUSTRIES, INC.
Narragansett, RI
TECHNOLOGIES, INC. Houston, TX Ms. Susan Dunn
Mason, OH Mr. Andrew Schumacher [email protected] / 401.789.9736
Mr. Eric Dolby [email protected] / 713.924.4200 www.dewal.com
[email protected] / 513.770.4928 www.schumachercoinc.com
www.ellisonsurfacetech.com
SPRAYTIME | THIRD QUARTER 2016 10 www.thermalspray.org