INSIDE THIS ISSUE 11 Wire Products Connecting with Customers 10 Safety First: Sales Manager Gains Support and Insight ATI WAH CHANG PO BOX 460 ALBANY, OREGON 97321 USA W W W . A L L E G H E N Y T E C H N O L O G I E S . C O M 9 Online Quoting and Inventory Portal Launched 3 Laboratory Services Testing for Chloride, Fluoride, and Other Impurities V O L U M E 2 5 N U M B E R 2 S E C O N D Q U A R T E R 2 0 0 4 A W A H C H A N G / A T I P U B L I C A T I O N PRODUCERS AND FABRICATORS OF REACTIVE AND REFRACTORY METALS AND CHEMICALS Corrosion Laboratory Manager Steve Sparkowich and his team unravel the mysteries of corrosion. Sparkowich holds a five-neck corrosion testing flask used for electrochemical analysis. The lab is currently testing zirconium in sulfuric acid pickling solutions along with many other customer-focused projects. Wah Chang’s Corrosion Page 2 Lab Lab Answers Pickling Questions
Transcript
24168-Outlook V25N2_X 6/17/04 8:28 AM Page 2
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INSIDE THIS ISSUE
11 Wire ProductsConnecting withCustomers
10 Safety First:Sales Manager GainsSupport and Insight
ATI WAH CHANGPO BOX 460ALBANY, OREGON 97321 USA
W W W . A L L E G H E N Y T E C H N O L O G I E S . C O M
9 Online Quotingand Inventory Portal Launched
3 Laboratory ServicesTesting for Chloride, Fluoride,and Other Impurities
V O L U M E 2 5 N U M B E R 2S E C O N D Q U A R T E R 2 0 0 4A W A H C H A N G / A T I P U B L I C A T I O N
P R O D U C E R S A N D F A B R I C A T O R S O F R E A C T I V E A N D R E F R A C T O R Y M E T A L S A N D C H E M I C A L S
Corrosion Laboratory Manager Steve Sparkowichand his team unravel the mysteries of corrosion.Sparkowich holds a five-neck corrosion testingflask used for electrochemical analysis. The labis currently testing zirconium in sulfuricacid pickling solutions along with manyother customer-focused projects.
Wah Chang’s Corrosion
Page 2
LabLabAnswers Pickling
Questions
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Tips for Success: Zirconium HeaBY: STEVE SPARKOWICH — Wah Chang
Tips for Success: Zirconium Heat Exchangersin Sulfuric Acid Pickling Processes
OUTLOOK2 SECOND QUARTER 2004
[ continued on page 4 ]
T E C H N I C A L L Y S P E A K I N G
Figure 1. Sulfuric acid pickling bath.
Advantages of Metallic Heat ExchangersPickling is an economical method of using acidto remove impurties and scale from metals foretching surfaces in preparation for galvanizing,painting, etc. (see Figure 1). Wide variationsare possible in the type, strength, andtemperature of the acid solutions used. Sulfuricacid in the 5 to 40% concentration range is acommon pickling acid for iron and steel.Sulfuric acid pickling tanks are typically heatedto a temperature between 140˚F (60˚C) and200˚F (93˚C) using steam or hot watercirculating through a heat exchanger.
Compared with non-metallic alternatives,metal heat exchangers, sometimes referredto as steam coils are generally preferred for
heating sulfuric acid pickling solutionsbecause they are:
a) Smaller: For the equivalent heattransfer capability, a metallic immersionheat exchanger will typically be 3-4times smaller than a thermoplastic(e.g. PTFE) heat exchanger. The smallerprofile of metallic heat exchangersallows more obstruction-free room inthe tank for pickling and helps tominimize the potential for damage dueto mishandled work.
b) More efficient heat transfer: Metalheat exchangers have substantiallyhigher thermal conductivity than dothermoplastics. This allows for more
efficient heat transfer and faster heat-up time for comparable surface area.Also, every square inch of a metallicheat exchanger is available for activeheat transfer.
c) More durable: Metallic heatexchangers have inherently higherstrength and toughness than non-metallic materials, such as graphite andthermoplastics, and are less prone todamage during handling and in theharsh conditions of a pickling tank.
d) Easier to work with: Metallic heatexchangers are generally easier tofabricate or repair than alternativematerials such as graphite orthermoplastics. Good ductility andworkability allow for standard methodsand equipment to be used infabrication and repair.
e) Compatible with pressurized steam:Metallic heat exchangers are the mostpractical choice for use with pressuredsteam. Thermoplastic heat exchangersare generally not rated for higher than35 psi steam pressure.
Please note that at a steam pressure of 100 psi,the surface temperature on the heat exchangercan be nearly 338˚F (170˚C). A common erroris to select heat exchanger materials based onthe solution temperature, which can be as muchas 200˚F (93˚C) lower than the skin temperatureon the heat exchanger. We recommend thatmaterial selection decisions for heat exchangersbe based on the maximum temperature of theheating medium.
Advantages of ZirconiumOver Other MetalsThe conditions in sulfuric acid pickling tankscan be very corrosive to most available metallicheat exchanger materials. Stainless steels andother heat exchanger metals generally do nothave adequate corrosion resistance in thesulfuric acid ranges used in steel pickling asshown in Table 1. Zirconium, however, shows
Table 1.
Corrosion Rate (mils/yr) of Zirconium vs. Other Alloys in Sulfuric Acid Solutions.
Concentration Temperature
10%
20% + 8% Fe+3
30%
40%
55%
216˚F (102˚C)*
176˚F (80˚C)
226˚F (108˚C)*
176˚F (80˚C)
270˚F (132˚C)*
Zr702
< 0.1
< 0.1
< 0.1
< 0.1
0.1
310L SS
45
--
1,137
> 28,000
> 100,000
316L SS
574
--
> 500
--
> 10,000
Alloy B-2
< 1
--
2
--
1.89
Alloy C276
7.0
> 20
55
--
295
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Wah Chang’s Laboratory & Technical Services Group
Wah Chang’s Laboratory & Technical Services Group
The Wah Chang Analytical Laboratory offersa complete range of inorganic analyticaltesting services. With industry qualifications andan experienced staff of more than 40 chemistsand technicians, we can support our customerswith accurate, rapid and economical service. Ourareas of expertise include the analysis of inorganics,metals, oxides, ores, and in particular, the alloysof the reactive and refractory metals.
Over 40 years experience in analyzingprocess streams from our own chlorine-basedextractive metallurgy process, makes us a highlyreliable source for accurate results in the analysisof halides such as the chlorides found in thepickling baths of the metal finishing industry.The Wah Chang Analytical Lab also has extensiveexperience developing testing methods fordiffering matrices.
We have developed the following discussionof the various testing methods available toanalyze your pickling solutions for chlorides andfluorides, including the advantages anddisadvantages of each, to help you understandwhich tests are best suited to your needs.
Based on experience analyzing samples ofcomplex or variable compositions, Wah Changpersonnel will select the technique that has thehighest probability to provide accurate results.This means selecting the simplest method thatwill allow us to maximize the sample size whileminimizing interferences. Galvanizing baths havethe potential for containing a variety of elementsthat might interfere with obtaining a correctanalytical result. Due to the fact that everygalvanizing bath may vary in composition andcontain the potential to produce inaccurateresults, the laboratory staff would recommendanalyzing for fluoride utilizing the distillationtechnique and chloride utilizing the ICP technique.
If you have a sample you need analyzed,you may send a properly packagedrepresentative sample directly to the Wah Chang
OUTLOOK 3SECOND QUARTER 2004
Chemical Analysis of Galvanizing Solutions
* Analytical technique will be selected basedon the matrix of the sample to provide aquality result consistent with customerrequirements.
* dl (ppm) = typical detection limit in parts per millionor mg/l for liquids
Analyte Method* Detection Limit Price Tests
Fluoride
Fluoride
Fluoride
Chloride
Chloride
Chloride
Matrix Suitability
SIE
Pyro F
Dist
Titr
Pyro Cl
ICP
10 ppm
5 ppm
1 ppm
10 ppm
1 ppm
5 ppm
$30
$75
$80
$25
$50
$30
Free Ion
Total
Total
Free Ion
Total
Total
Simple
Solids/liquids/mixtures
Complex
Simple
Solids/liquids/mixtures
Complex
Advantages: Lower Cost; Rapid; Minimal equipment required.Disadvantages: Questionable accuracy — subject to many interferences which maynot be discernable; Higher detection minimums.
Advantages: Mixtures of solid and liquid can be analyzed; Most interferences eliminated.Disadvantages: More costly; Not applicable to solutions containing organics; Incompletecombustion produces potentially false low results.
Advantages: Complex matrix be simplified; Electrode is selective for fluoride; Lowdetection levels. Disadvantages: Time intensive; More costly; Organic materials willnot be separated, potentially interfering with detection; High levels of low boiling acidspotentially interfere with detection.
Advantages: Lower cost; Low testing material costs; Automated equipment.Disadvantages: Sample with silver insoluble species would cause erroneous highresults; Some metals and acids interfere, detrimental to accuracy.
Advantages: Most interferences eliminated; Very sensitive; Small amount of sample needed.Disadvantages: Halides other than fluoride measured as chloride giving erroneous highresult; Dilution factor decreases accuracy; Some volatile unknowns prevent detection.
Advantages: Few interferences; Very sensitive for chloride; Potential to do multiplemetal elements; Relatively low cost. Disadvantages: Large dilution decreases accuracy.
KEY TERMS:SIE: Selective Ion Electrode - F ion in buffer solutionTitr: Potentiometric Titration - AgNO3 titrationDist: Distillation/SIE - boil from sulfuric acidPyro: Pyrohydrolysis/SIE - combust in airPyro Cl: Pyrohydrolisys/Titr - combust in 02; titrate coulometricallyICP: Inductively Coupled Plasma Emission Spectroscopy
Analytical Laboratory. To request a test, pleasecontact Bill Beasley, our laboratory servicescoordinator, or visit our website atwww.wahchanglabs.com to order online.
Mr. Beasley can be reached on 541.967.6913,or by email at [email protected] Chang’s shipping address: 1600 Old SalemRoad NE, Albany, OR 97321. A
Tests for Chloride, Fluoride, and Other Impurities
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OUTLOOK4 SECOND QUARTER 2004
Tips for Success: Zirconium HeaTips for Success: Zirconium Heat Exchangersin Sulfuric Acid Pickling Processes[ continued from page 2 ]
FIGURE 2. Corrosion Rate Zr 702 in Sulfuric Acid (mils/yr).
0 20 40 60 80 100
300
260
220
180
140
100
60
20
Concentration of H2SO4 %
Tem
pe
ratu
re (
C)
Boiling Point Curve
Tem
pe
ratu
re (
F)
500
400
300
200
100
5
5-20 mils/yr
20-200 mils/yr
<5 mils/yr
20
200>200 mils/yr
superior corrosion resistance in theseconcentrations and temperatures. The presenceof oxidizing ferric ion in the pickling solutiondoes not significantly diminish the corrosionresistance of zirconium when the sulfuric acidconcentration is less than 50%. For example,when zirconium was tested in 20% H2SO4
contaminated with 8% ferric ion (Fe+3) ferricion at 175ºF (80ºC), the results showed nilcorrosion of the zirconium samples.
Zirconium 702 exhibits excellent corrosionresistance in 5 to 65% sulfuric acid up toboiling temperature and beyond as shownon the iso-corrosion curve in Figure 2.Zirconium heat transfer coils, similar to the
one in Figure 3, have become widely acceptedamong metal finishers for over 30 yearsbecause they provide an efficient andeconomical means to heat sulfuric acid.Zirconium heat exchangers can be fabricatedin virtually any size or configuration, dependingupon space limitations and the amount ofheat transfer required.
Use of Zirconium Heat Exchangers withAcid Recovery Systems (ARS)While zirconium does exhibit superior corrosionresistance in most sulfuric acid steel picklingenvironments, there are a few factors that canlimit its effectiveness. The use of sulfuric Acid
Recovery Systems (ARS), also known ascrystallizers, in metal finishing processes (seeFigure 4) has required some precautions be takenwhen using zirconium heat exchangers. Whenusing an acid recovery system, spent pickle acidis recycled rather than being discharged, whichcan cause a build-up of chloride, fluoride, andother solution contaminants.
The presence of chlorides may have adetrimental effect on the corrosion resistanceof zirconium, particularly when ferric ions arealso present. The effect of chlorides onzirconium corrosion in sulfuric acid is seen inFigure 5. For example, in 15 wt% acid,chlorides should be maintained below 4500ppm with <1800 ppm being preferred.
Figure 6 shows how the presence of smallamounts of fluoride ion can dramaticallyincrease the corrosion rate of zirconium. Forthis reason, it is recommended that the fluorideconcentration level be maintained below 10ppm when using zirconium with levels below5 ppm being preferred.
High chloride and fluoride levels are knownto cause corrosion, not only to zirconium, butalso to metallic components in contact withthe pickle solution, especially the sulfuric acidrecovery systems centrifuge parts (e.g. screens,scrolls, baskets, clamping rings, etc.). Elevatedchloride levels can cause a localized pitting.Elevated fluoride levels cause general surfacecorrosion which may cause a gradual thinningof tube diameters. In extreme cases, elevatedfluoride levels may cause both generalcorrosion and pitting. Keeping chloride andfluoride concentrations low is important toavoid costy replacements.
There are several major sources forchlorides and fluorides:
• From the caustic: The most commonlyused caustic, diaphragm cell grade, canhave up to 10,500 ppm chloride. Thesechlorides are dragged into the pickletank with caustic residues.
• From pumping containment pitwater into the acid tanks: The choiceto pump containment pit water intothe acid tank causes high-chloride
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eat Exchangers in Sulfuric Acid
[ continued on page 6 ]
OUTLOOK 5SECOND QUARTER 2004
PHOTO COURTESY OF VULCANIUM
PHOTO COURTESY OF TITAN METAL FABRICATORS
PHOTO COURTESY OF ASTROCOSMOS
FIGURE 3. Examples of Zr 702 gridcoil heat exchangers (Figure 3C shows gridcoil with solution level protectors).
FIGURE 4. Example of Sulfuric Acid Recovery Stystem.
Pickling Tank
Pre-filter
PrimaryExchanger
ReactorCrystalSettler
Centrifuge
PumpBack
Crystal CollectorARTWORK COURTESY OF BETA CONTROL SYSTEMS
A
B
Cspillage from the flux and caustic tanksto be put into the acid tanks. The pitmust be divided so that the caustic andthe caustic rinse will drain into onesection, acids and acid rinses intoanother section, and flux into yetanother section. Thus, drainage fromthese tanks is pumped directly backinto the tanks from which it came.
• From chemicals added to thepickling bath: Inhibitors, accelerators,or fume-control agents may be a sourceof fluorides and chlorides as well ascorrosive bromides and iodides. Somebatches of raw sulfuric acid have beenfound to contain elevated levels ofchlorides and fluorides.
• From chlorinated and/orfluorinated tap water: Evaporationof water from the heated pickle bathcauses chlorides and fluorides toconcentrate over time.
Ten Tips for Successful Use ofZirconium Heat ExchangersTo reduce the potential for corrosion onzirconium heat exchangers or on othermetallic components when using an acidrecovery system, consider these tenpreventative measures:1) Use a low chloride grade of caustic:
The cost low chloride or low salt membranegrade may be about 10 cents/pound higherthan diaphragm grade caustic but shouldhave chloride levels that are ~175 timeslower (i.e. 60 ppm vs.10,500 ppm typicalchloride levels).
2) Maintain low chloride and fluoridelevels in the sulfuric acid pickling bath:Because sulfuric acid recovery systemsallow for re-use of sulfuric acid, chloridesand fluorides have been found toaccumulate in the pickling solution.Chlorides and fluorides are known tocorrode zirconium and most other metals.Elevated chlorides can cause a localizedpitting and elevated fluorides can result
FIGURE 5. Effect of Chloride Level on Zr 702 in Sulfuric Acid.
0 5 10 15 20 25 30 35 40
10000
1000
100
Wt% Sulfuric Acid
Am
ou
nt
of
Ch
lori
de
Io
n,
pp
m
Pitting Possible
Pitting Likely
No Corrosion Expected
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OUTLOOK6 SECOND QUARTER 2004
Tips for Success: Zirconium Heat Exchangersin Sulfuric Acid Pickling Processes[ continued from page 5 ]
in general surface corrosion. Refer toFigure 5 for maximum recommendedchloride levels for sulfuric acid picklingsolutions. Fluoride concentration shouldbe maintained below 10 ppm with levelsbelow 5 ppm being preferred (see Figure6). This data is based on laboratory analysisusing reagent grade chemicals. NOTE: Zirconium heat exchangers inpickling solutions with elevated chloridelevels do not always exhibit pitting corrosion.Some organics and other contaminants thatbuild up in pickling solutions over time mayhave an inhibiting effect on corrosion andreduce the corrosion rate or reduce the
potential for the onset of localized pittingcorrosion. The limits in Figure 5, however,are considered to be a conservativeapproach. For existing zirconium heatexchanger installations where chloride levelsare high and no corrosion is evident,chloride levels should at least be stabilized.Preferably, they should be reduced to levelsbelow the limits in Figure 5. If chloridelevels are allowed to rise, localized pittingcorrosion may eventually occur.
3) Check chloride and fluoride levels inthe acid tanks, rinse tanks, and caustictank on a routine basis: Representativeacid samples may be properly packaged
and sent to a laboratory for analysis. TheATI Wah Chang Analytical Laboratoryprovides chloride, fluoride, and otherinorganic chemical analysis services (seeAnalytical Lab article on page 3). If thechloride and fluoride levels are known,corrective measures can be instituted beforecorrosion problems occur.
4) Understand chloride and fluoride levelsof all additives prior to use in picklingbaths: This includes sulfuric acid, inhibitors,accelerators, fume control agents, caustic,and even water. Softened water can havehigh levels of chlorides. Municipal watermay have chlorides and/or fluorides. If anyadditives are found to have high chlorideor fluoride, reasonable alternatives shouldbe considered. Again, ATI Wah ChangAnalytical Laboratory provides chloride,fluoride, and other inorganic chemicalanalysis services as well as water analysis.
5) Consider chemical cleaning ofzirconium heat exchangers: As aprecaution, consider chemical cleaning ofnewly fabricated zirconium heat exchangersin a mixture of nitric acid-hydrofluoric acid.Chemical cleaning will remove embeddedparticles or surface contaminants renderingthe zirconium more resistant to corrosion.Chemical cleaning also improves the surfacefinish, which may reduce the crystallizationof ferrous sulfate monohydrate salts (seeTip #9). Chemical cleaning of zirconiumshould be performed in at least a 10:1 ratioof nitric acid to hydrofluoric acid tominimize the potential for hydrogenabsorption. Because of the hazardousnature of hydrofluoric acid, a properlyequipped facility should be used to performthe chemical cleaning. For questions relatedto nitric acid-hydrofluoric acid cleaning,please contact ATI Wah Chang CustomerService at [email protected] or bycalling 1-541-967-6977.
6) The heat exchangers must include asecond concentric zirconium tube oflarger diameter at the acid/air interfaceof the riser pipes: This outer tube section
FIGURE 6. Effect of Fluoride Level on Zr 702 in Sulfuric Acid.
is known as a solution level protector, aircover, or air baffle as shown on the inlet andoutlet pipes of Figure 3C. Solution levelprotectors are especially important whenhigh pressure steam (e.g. 100 psi) is used asthe heating medium. Acid residues on thepipe just above the solution level willconcentrate to very corrosive levels due toevaporation of water. Solution level protectorsprovide an extra layer of protection to thisvulnerable area of the heat exchanger aswell as give a visual indication of corrosionas shown in Figure 7. Solution level protectorsshould be as long as possible, perhaps 8-12inches or more, to account for the evaporativecycle of the tank. Solution level protectorsshould be inspected periodically to preventheat exchanger leakage.
7) Mount heat exchangers so that thecoils are always immersed: Evaporationof the pickling solution during off-shift and
other down-times may cause the solutionto drop to a level that exposes the heatingcoils to air. Acid residues on the exposedcoils will then concentrate to very corrosivelevels as they dry, similar to thephenomenon described in Tip #6.
8) Insulate heat exchangers from straycurrents: Stray electrical currents canreach a heat exchanger via piping, tankswalls, hangers, or other metal objects.Because corrosion is an electrochemicalprocess, metallic heat exchangers need tobe electrically isolated from contact withother metals. To eliminate the potentialof stray currents, a piece of pressure hoseor a dielectric union should be placedbetween the heat exchanger fittings andthe water/steam line. Consider using aPTFE insulator as shown in Figure 8. Also,insulate metal hangers that support theheat exchanger from contact with othermetal objects.
9) Avoid gray colored “monohydrate”crystal build-up on the coils: Build-upof ferrous sulfate monohydrate crystals isusually lower when using hot waterheating versus high pressure steamheating. Techniques that have been usedto minimize crystal build-up on the heatexchanger include:a) Maintaining a smooth surface on the
heat exchanger,b) Bubbling or sparging of air beneath the
heat exchangerc) Keeping the bath at a temperature
where ferrous sulfate monohydrate ismost soluble (i.e. 140-150˚F)
Wah Chang combines over 50 years’ experience in a variety of industries with a widearray of laboratory and test equipment to provide a broad range of testing solutions.Whether you are considering outsourcing your testing requirements on a more permanentbasis, looking for specific capabilities, or simply needing support when work load exceedscapacity, Wah Chang Laboratory and Testing Services can help.
You can also reach us at [email protected], by dialing, 541.967.6913,or visit our website: www.corrosionsolutions.com.
Providing a Wide Range of Testing Solutions
“Put us to the Test”“Put us to the Test”
w w w . c o r r o s i o n s o l u t i o n s . c o m
Commit Your Testing Needs to Our Care.
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Tips for Success: Zirconium HeaTips for Success: Zirconium Heat Exchangersin Sulfuric Acid Pickling Processes[ continued from page 7 ]
P E O P L E
Stan Kirsch recentlyaccepted an offer to join WahChang’s Technical MarketingGroup as a Senior Engineer- Technical Marketing.
Mr. Kirsch brings 17years of experience in thechemical and petrochemical
manufacturing industry. In his last position, hewas the Operations and Maintenance Managerfor Singapore Syngas Private Limited. Mr. Kirschhas also worked for Praxair Industrial Gases, SaudiPetrochemical Company, Mobil ChemicalCompany, and Dow Chemical Company.
According to Rick Sutherlin, Manager of theTechnical Services Group, “Stan has extensiveexperience in day-to-day operations involved inengineering and maintenance of chemical process
equipment. This wide range of experience willbroaden Wah Chang’s Technical Marketing group’scapabilities, enabling us to better support thechemical process industry.”
Michael Colombo joinedWah Chang’s CommercialNuclear Sales team inMarch 2004. Mr. Colombo,Sales Manager - Nuclear,has been assigned to majorcustomers and will work todevelop growth
opportunities in nuclear markets.According to Michael Moyer, Manager,
Nuclear and Zirconium Products Sales, “Mike
Colombo brings metals industry experience toWah Chang. This will allow him to engagecustomers sooner than normal. He alreadypossesses a firm commercial background that isvaluable to his position.”
Mr. Colombo worked in sales and marketingmanagement for Oregon Steel Mills, a diversifiedsteel company based in Portland, Oregon. Inprevious positions, he has managed large diameterpipeline projects as well as rod and wire products,rail products, bar, and seamless pipe.
“After leaving Oregon Steel Mills, I researchedinnovative companies that were positioned tosuccessfully compete in a global economy,” hesays. “Wah Chang is one of the fewmanufacturers in Oregon that have invested thecapital, developed the technology and assembleda team of people that can compete in Europe,Asia and other countries and win.”
OUTLOOK8 SECOND QUARTER 2004
Stan Kirsch
Michael Colombo
These ten tips will greatly increase thelikelihood of success in using zirconium heatexchangers, especially when using an AcidRecovery System (ARS).
For more than 30 years, zirconium has beensuccessfully used in hot sulfuric acid tanks forpickling steel. Zirconium is uniquely suited forconstructing the heating coils for maintainingthe optimum operating temperature of thesulfuric acid pickling solution. The uniquephysical properties and superior corrosionresistance of zirconium in these sulfuric acidconditions give it a tremendous advantageover other metals and non-metallic materialslike graphite and thermoplastics. Zirconiumcan be a superior material for equipment usedin sulfuric acid steel pickling as long as theseten tips are followed.
in a wide variety of sulfuric acid steel picklingconditions, the best way to determine amaterial’s suitability for a particularenvironment is to perform a corrosion test.Zirconium corrosion coupons are availablefrom ATI Wah Chang for field testing. Thesetests can be an indicator of how zirconiummight hold up under actual process conditions.ATI Wah Chang also has a fully capablecorrosion laboratory for testing and detailedanalysis of specific sulfuric acid compositionsand other corrosive environments. For furtherinformation or any questions regarding theuse of zirconium in sulfuric acid steel picklingapplications, please contact ATI Wah ChangCustomer Service at [email protected] by calling 541-967-6977.
About the AuthorSteve Sparkowich (pictured on cover) managesATI Wah Chang’s Corrosion Laboratory. Mr.Sparkowich is a Metallurgical Engineer, with15 years’ experience in reactive metals and
If crystal build-up occurs, do not damagethe surface of the zirconium by scraping,scratching, or marring when trying toremove the salts. These actions may embediron particles or other contaminants thatreduce the corrosion resistance ofzirconium. Non-contact techniques suchas soaking in hot water, pressure washing,or steam cleaning may be employed. Donot sandblast zirconium heat exchangersto remove crystal build-up or for any otherreason. Sandblasting media may embedforeign particles in the surface that increasethe potential for corrosion.
10) Protect the heat exchanger fromdamage using a barrier or shield: Theheat exchanger should be protected toprevent it from being damaged. Considerhaving zirconium angle welded to the sideof the unit as a shield. Other possibleshielding materials include plastisol-coatedsteel, some grades of fiberglass, thermally-stable plastics, or even hardwood.
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Customers can reach Mr. Colombo at 541-812-7024 or by e-mail at [email protected].
Beth Gillette recentlyjoined Wah Chang as aMarketing Specialist. In thisrole, Ms. Gillette will providemarketing communicationsand trade show support inaddition to working ongovernment bid
development and other special projects.“Beth’s experience as a trade publication editor
is definitely a value add for Wah Chang,” accordingto Kirk Richardson, Manager of MarketingCommunications. “She will be central to updatingthe company’s data sheets and web site and willbe involved in special projects, such as development
accounts. “Wah Chang is working hard to providemore value to its customers, working as adistributor for the wide range of products utilizedin the nuclear industry,” according to CarrieJackson, Government Contracts Manager. “Scottwill play an integral part in this new business.”
“Scott started his career at Wah Chang in theQuality Organization. Coupled with his backgroundin engineering, he has a great understanding ofthe requirements of this position. We look forwardto using his experience to assist us in puttingtogether complex quotation packages that covera broad scope of product lines.”
Prior to joining Wah Chang in 1985, Mr.Anthony spent more than two years at BattellePacific Northwest Laboratories (Richland, WA),working as a Quality Engineer on many projectsin the nuclear waste repository programs.
Mr. Anthony can be reached at 541-812-7119. A
OUTLOOK 9SECOND QUARTER 2004
Wah Chang LaunchWah Chang Launches OnlineQuoting and Inventory Portal
Wah Chang’s new Online Quotingand Inventory Portal allowscustomers to submit requests forquotes and check inventory ofselected finished goods 24-7. Italso ensures requests are routed tothe correct sales representative,generates an email confirming itsreceipt and routes the quoteelectronically.
Why is this so exciting?“It is the first step in and the front end ofan overhaul project that will enablecustomers to view requests for quotationand actual order information at any pointin the production process,” explains ParryWalborn, Vice President, Wah Chang. “Weare investing in a large expansion projectthat will restructure the back-end computersystems of our company. Upon completionof the project, our shop floor, inventoryand engineering systems will be integrated
so that web-based portals can be used toprovide vital order information directly tothe customer,” Walborn describes.
The new Online Quoting system allowsa customer to view their past three quotes.Eventually customers will be able to trackcurrent and past quotations. And this isonly the front end — on the back end,customers will be able to track where theirproducts are in the production process.With the addition of a shipping link to thewebsite, customers will be able to track
[ continued on page 12 ]
N E W S
Beth Gillette
of a new CRM system. You’ll also see her bylinein Outlook, starting with this issue.”
Ms. Gillette’s background includes a stint asAssistant Editor with Cygnus Business Media, whereshe edited and wrote articles for ConstructionDistribution magazine. She was also a freelancecopywriter for Madison Newspapers, Inc.
To contact Ms. Gillette, phone 541-812-7017or e-mail her at [email protected].
Wah Chang’s GovernmentContracts Group is pleasedto announce the addition ofScott Anthony, ContractAdministrator. Mr. Anthonyis currently managingnuclear- industry-relatedgovernment contractScott Anthony
metals finishing technologies. He can bereached at 541-926-4211 x6078 or by e-mailat [email protected]. A
References1) OUTLOOK, VOL. 1, NO. 4, Fall 1980,
Zirconium Heat Transfer Coils Fight Corrosionin Sulfuric Acid System, by Te-Lin Yau
2) OUTLOOK, VOL. 9, NO. 1, Winter 1988,In Sulfuric Acid Pickling, ZirconiumContinues to Provide Excellent CorrosionResistance, by Te-Lin Yau
3) OUTLOOK, VOL. 25, NO. 1, First Quarter2004, How Does Surface Condition Affectthe Corrosion of Zirconium in AcidicChloride Solutions?, by Steve Sparkowich& Te-Lin Yau
4) Paper # 319, Zirconium in a Sulfuric AcidPickling Application, by Te-Lin Yau,presented at Corrosion ’88, March 21-25,1988 in St. Louis, Missouri.
5) Corrosion Engineering Handbook, editedby Philip Schweitzer, Chapter 10, 1996.
On a typical dark winter evening lastFebruary, Doug Brenizer, Sales Manager forWah Chang’s Zirconium 702 product line,decided to brighten the garage in his Salem,Oregon home with a little decorating. “Ihad recently received a banner with theMercedes Benz logo on it and was eager tohang it on the wall for all to see and enjoy,”says the affable Brenizer. “Since I only neededto go a few feet up to place the banner, Igrabbed the extension portion of my extensionladder (the base, with feet on it, remainedstored for larger projects) and leaned it upagainst the wall.”
“As I began to climb the ladder, a smallvoice in my head began reminding me of themessages from my ladder safety trainingsessions (at Wah Chang). I thought, ‘this isnot the right way to do this,’ but continuedon up the ladder. I was able to get the bannerpositioned and climb down the ladder withoutincident. ‘That was lucky’ I thought once backon the ground.”
But as Brenizer looked up to survey hiswork, he found that the banner was slightlylower on one end than the other. Emboldenedby and unscathed from his first trip, herepositioned the ladder and climbed to thetop again. “So there I was, 5 feet off theground,” Brenizer continues, “on a ladderwithout feet, sitting on a slick garage floor,leaning over to my left to reach the bannerwhen, without warning, the ladder slipscompletely away from the wall, and we’re onour way to the ground.
“As the ladder and I are falling, I’m justsort of riding on top of it for the short trip tothe concrete floor. What I wasn’t aware of wasthat my left foot had slipped off the rung ofthe ladder that it was resting on and was nowbetween the rung and the floor.” The would-be “decorator’s” left foot hit the floor justbefore the rung (with his “full weight on topof it,” he notes), breaking his left heel in threeplaces and severely spraining his ankle - nolaughing matter.
Not surprisingly, Brenizer spent the rest ofthe evening in an emergency room.
Industries’ thoughtfulness and creativity.”Gill implies that worry inspired Ellett’s
innovative efforts. “After I heard of Doug’saccident, I was concerned for him,” he says.“Handicapped for so long, we knew Doug hadlost all his strength, so I thought we shouldtry and help him with something he couldhandle age-wise, strength-wise, weight-wise.”Gill, from arid Vancouver B.C., also joked that“Oregon weather is noted for its continualrain,” and that “this cane would stand up tothe demands of the inclement weather it wouldbe exposed to.”
“Tongue and cheek” comments aside,Brenizer puts a positive spin on his laddermishap. “Two good things have come fromthe accident,” he says. “I have a very coolcane and I was able to quit smoking.” He’salso learned a concrete-hard but valuable
lesson in ladder safety. “Alwaystake the time to do it right... noshortcuts,” he advises. A
After a few subsequent trips to theOrthopedic Surgeon, it was determined that“I had gotten lucky and my injury would notrequire surgery,” he says, but adds, “Therecovery, I'm finding out, is a very slow andlimiting process.”
In April, Brenizer was finally able toabandon his crutches and begin walking withthe assistance of a cane. “This is a majorliberating event,” he says. “I was sharing thestory of my liberation with Bob Gill, VicePresident of Sales for Ellett Industries, Inc. inCanada.” Typically, Ellett fabricates equipmentfor the chemical processing industries usingtitanium, zirconium, and other AlleghenyTechnologies’ metals. “Bob listened patientlyand told me that he was glad to hear that Iwas progressing according to schedule andwished me the best during my recovery.”
“The following afternoon, I receiveda package from Bob, opened it, andfound a beautiful Titanium Cane, whichwas immediately dubbed ‘Ti-Canium’(by Barry Valder, Manager of WahChang’s Niobium Sales Group).
“I was caught completely off-guard,” says Brenizer. “Bob Gillhad mentioned that heshould make a titaniumcane for me, but I didn'tknow that he wasserious.” The “Ti-Canium is a thing ofrare beauty,” helaughs. “It’sconstructed from 1-inch diameter weldedTitanium Grade 2tubing and is light andstrong. Everywhere Ihave gone with it, peoplehave commented on it’sappearance and admiredit. I’m not sure how longthe ‘cane period’ of myrecovery is supposed to last,but I’m definitely enjoying itthanks to Bob’s and Ellett
S A F E T Y F I R S T
N
Doug Brenzier and his“Ti-Canium” cane,
compliments ofEllett Industries.
24168-Outlook V25N2_X 6/17/04 8:28 AM Page 12
Composite
C M Y CM MY CY CMY K
Wah Chang’s Alabama OperatiSince 1984, Alabama Operations has beenproducing niobium-titanium and other rodand wire products from its five-building,90,000 square-foot facility. In only the pastdecade, NiTiNOL wire has emerged as a metalproduct that has shaped the medical, commercialand industrial markets, among others. Inparticular, the innovative NiTiNOL stent, a smallexpandable wire mesh tube that is inserted inpatients’ arteries to hold them open, has madea particular impact on the medical community.
The life-saving stent is manufactured bydrilling a hole into rod, inserting a mandrel intothe newly formed tube, and co-reducing the tubeand mandrel to the final stent size. Wah Chang’sHuntsville, Alabama location provides thematerials for the rod and mandrel required toproduce this unique product.
There are two broad classifications for thewire products manufactured at the Huntsvillelocation: shape memory and superelastic. Andwhile the stent is a more well-known product,there are many other NiTiNOL products that comein the form of wire. Typically, shape memory wireis used in actuator applications, such as inshowerheads, but has now become a key partof stent production as the core mandrel for tubereduction. Superelastic wire is used for manyapplications where flexibility is an importantcharacteristic, including cellular antenna wire,
Wah Chang’s Alabama Operation ManufacturesWire Products that Connect with CustomersBY: BETH GILLETTE — Wah Chang
Wah Chang is pleased to announce thethird niobium commemorative in its Firstsin Flight series. The coin commemorates Fritzvon Opel’s first successful rocket-poweredengine flight. On September 30, 1929 inFrankfurt-am-Main, von Opel flew the RAK.1,powered by 16 rockets (each with 50 poundsof thrust), roughly two miles in 75 seconds...and lived to tell about it.
Nicknamed “Rocket Fritz”, von Opelbecame interested using rockets for publicitystunts in the 1920s. In addition to successfullypiloting the first rocket-engine-powered plane,he tested a rocket-powered car in 1928, alsonamed the RAK.1 and reached a top speed of
75 km/h. A few months later, von Opelsped along at 230 km/h, propelled by24 solid rockets in his RAK.2 car. RocketFritz even applied his favorite method ofpropulsion to a railway car, using 30 solidrockets to achieve a speed of 254 km/h.
The latest Firsts in Flight coin is available atHotMetalShop.com or by calling 541-926-4211x6280. The von Opel commemorative is availablefor $29.95 while supplies last. For thoseinterested in purchasing all three niobium coins,including the Lindbergh and Wright Brotherscommemoratives, visit HotMetalShop.com fora special price of $99.95. The individualLindbergh coin is currently available for $39.95
and theWright Brothersedition for $34.95 while supplies last. For moreinformation or to order by phone, contact SherylRenzoni at 541-926-4211 x6280.
Be sure to visit hotmetalshop.comfrequently for the latest niobium, titanium,and zirconium gifts. A
Huntsville’s unique processing techniquesproduce a wide range of sizes and forms. Thecurrent rod and wire sizes available at theHuntsville plant are 2.0 to 0.016 inches indiameter, but recent capital investments willexpand Huntsville’s capabilities to as small as0.004 inches by late 2004. Although the typicalwire form is round, hexagonal shapes have beenproduced (although not regularly), and Huntsvillealso has the capability to form square andrectangular shapes.
There are many final surface conditionsavailable such as black, blasted, and pickled, andfinal material conditions, such as annealed orstraightened, are driven by customer’s aestheticdemands. A selected amount of cold work is alsodone and plays an important role in the finalproperties of wire for specific applications.
The Alabama facility’s protective surfaces onall its machinery and handling equipment enableit to maintain high yields and unparalleledmetallurgical and surface qualities.
Alabama Operations also manufactures avariety of other products, including rivet-gradeniobium-titanium and various diameters ofzirconium and its alloys, and hafnium rod andwire. The facility performs conversion processingof copper clad superconductor rod and wire for
outside customers, processes nickel-based alloysand draws various grades of titanium for otheroperations within the company.
NiTiNOL wire continues to play an importantrole in several markets as many new and excitingapplications are being innovated with its uniqueproperties, and Wah Chang’s Alabama Operationsis always ready for the challenge to meetcustomers’ size, form, and performanceproperties. For more information, visitwww.wahchang.com or call 541-967-6977. A
Wah Chang is taking registrations for its 2004Reactive Metals Welding Seminar. The seminar,now in its 22nd year, will be held July 13-15,2004 in Albany, Oregon. A second seminarmay be held August 3-5, 2004.
According to Rick Sutherlin, Manager ofWah Chang’s Technical Marketing group, thecourse will consist of classroom lectures aswell as hands-on welding. The hands-onportion includes real-world experience of typicalzirconium, titanium, and titanium-niobiumweldments. Space is limited, and available ona first-come, first-served basis. Prerequisitesfor the course include some experience inwelding as well as knowledge of gas tungstenarc welding of stainless steel or aluminum.
The fee for the seminar is $299. Luncheswill be provided, and a list of localaccommodations is available upon request.For more information or to register, contactSheryl Renzoni at 541-926-4211 x6280.Register soon, while space lasts!
Farnborough International 2004
Allegheny Technologies Incorporated (ATI) ispleased to announce that it will be participatingin Farnborough International 2004, July 19-25. Farnborough International is an aerospaceconference and exhibition organized by theSociety of British Aerospace Companies, thetrade association for the UK aerospace industry.ATI will be exhibiting its high strength,
lightweight metal products and associatedservices at Aerospace USA, Hall 4, space B07.
“Farnborough International is the world’spremier aerospace business event,” accordingto show organizers. This exhibition is heldevery two years at the Farnborough Aerodromein Hampshire and is the largest temporaryexhibition in the UK.
In 2002, attendance reached 290,000 visitorsover the five trade and two public days. “Thevalue of orders announced reached $9 billion,”according to farnborough.com.
The 2004 show will offer a few new features.Acknowledging the growing importance of spaceprograms and systems to civil, commercial andmilitary capabilities in the air, on land and at sea,Farnborough International 2004 will launch itsfirst International Space Pavilion. In addition, theshow will feature an Unmanned Aerial Vehicle(UAV) Forum on Friday 23 July 2004, which willbe held in the main conference room at theMedia Centre, incorporating a mix of civil,commercial and military issues.
For more information, visit the show website at www.farnborough.com. A
ATI AllvacPO Box 5030Monroe, North Carolina 28111-5030T 704.289.4511www.allvac.com
ATI Allegheny Ludlum1000 Six PPG PlacePittsburgh, Pennsylvania 15222T 800.258.3586www.alleghenyludlum.com
OUTLOOK12 SECOND QUARTER 2004
their products from production all the way totheir receiving dock, according to Walborn.
The Online Quoting and Inventory Portalsystem is the first step in this process andstreamlines Wah Chang’s work load to getinformation to customers more quickly.
Initially launched in September 2003, theOnline Quoting and Inventory Portal system isnow available to accept information directly
through an Excel document. As Wah Changand many of its customers use Excelspreadsheets, this format saves time for allinvolved. The new system also features onlineinteractive help screens to guide customersthrough the Online Quoting process.
For more information about the OnlineQuoting and Inventory Portal, please visitwww.wahchang.com or call 541-967-6977. A
Wah Chang LaunchesWah Chang Launches OnlineQuoting and Inventory Portal[ continued from page 9 ]
