METALS POLYMERS CERAMICS - ASM International

METALSPOLYMERSCERAMICS

Mars lander to explore the history of water in the arcticScheduled for launch in August 2007, the

Phoenix Mars Mission is the first in NASA’sScout Program, designed to be highly inno-vative and relatively low-cost complementsto major missions being planned as part ofNASA’s Mars exploration effort. The goal ofPhoenix is to study the history of water andhabitability potential in the Martian arctic’sice-rich soil. If Phoenix looks familiar, itshould: It is a modified and enhanced ver-sion of the Mars Surveyor lander from 2001.The Lockheed Martin engineering team isrestoring and enhancing the 2001 lander to a flight-ready Phoenix spacecraft. Throughout allphases of the mission, the Lockheed Martin team will closely monitor Phoenix’s health by linkingtheir spacecraft operations centers with those at the Jet Propulsion laboratory and the Univer-sity of Arizona. For more information, visit http://phoenix.lpl.arizona.edu. Lots more informa-tion and images are available at www.lockheedmartin.com. (Type “phoenix” in the search box.).Watch an animation of the landing and deployment of the Phoenix on Mars athttp://phoenix.lpl.arizona.edu/video/phoenix_landing_low.mov

Nanodispersions of NbC strengthen austenitic steelAfamily of inexpensive, Al2O3-forming, high creep-strengthaustenitic stainless steels has report-

edly been developed by researchers at the Materials Science and Technology Division of OakRidge National Laboratory, Oak Ridge, Tenn. The alloys arebased on Fe-20Ni-14Cr-2.5Al, withstrengtheningachieved through nanodispersions of niobium carbides. These alloys offer the po-tential to substantially increase the operating temperatures of structural components, and canfunction under the aggressiveoxidizing conditions encountered in energy-conversion systems.Protective Al2O3 scale formation was achieved with smaller amountsof aluminum in austenitic al-loys than other alloys, because titanium and vanadium alloying additions were eliminated. Thesmaller amountsof aluminum permitted stabilization of the austenitic matrixstructure and enabled

excellent creep resistance. Creep-rupturelifetime exceeds 2000 hours at 750°C and100 MPa (1380°F and 14.5 ksi) in air, andoxidation resistance has been demon-strated in air with10% water vapor at 650and 800°C (1200 and 1470°F).

For more information: Michael P. Brady,Materials Science and Technology Divi-sion, Oak Ridge National Laboratory OakRidge, TN 37831–6115; tel: 865/574-5153;[email protected]; www.ornl.gov.

Flexible metallic micro-ringsengineered into smart fabric

A fabric that consists of a network ofmetallic rings about 500 microns in diam-eter and even smaller links about 400 mi-crons long has reportedly been made byscientists at the University of Illinois, Ur-

INNOVATIONS IN MATERIALS TECHNOLOGY

BRIEFSAlcoa announces a newname for its investment castand forged products business unit: AlcoaPower and Propulsion.Additionally, the two divisions that make up this business unit were renamed. Howmet Castings is now AlcoaHowmet. HowmetAerospace & IndustrialProducts division is nowAlcoa Forged and CastProducts.www.alcoa.com

The American Iron andSteel Institute has madeavailable online the PowerPoint presentations from the 2007 Great Designs in Steel seminar. These include 38 highly informative and technicalpresentation. www.autosteel.org

Argonne National Laboratory researchershave developed manganese-basednanocrystalline compositesfor the positive electrode ofrechargeable lithium-ionbatteries. The materialshave charge-storage capacity more than twicethat of conventionalrechargeable lithium batteries, and cost muchless than cobalt-nickel versions. www.anl.gov

Ceres Inc. and Rohmand Haas Co. announcea research collaborationthat will determine if energycrops planted for cellulosicethanol could simultaneously producemethacrylate monomers, a key raw material in manyproducts. www.rohmhaas.com; www.ceres.net

ADVANCED MATERIALS & PROCESSES/JULY 2007 7

Cast aluminum alloy has highductility and strength for autos

A high ductility cast aluminum alloy that also provides highstrength has reportedly been developed by Thresher

Industries, Armona, Calif. The company casts parts by its proprietary Direct Metal Induction Cast Process.

Thresher Industries Foundry Group has been working withTalon Composites on the development of the alloy, and has

just completed testing. When the alloy is cast with Thresher’s Nautilus Core technology, it will allow engineers

greater design freedom.Nautilus Core Technology is a biodegradable recyclable

process that enables internal shapes and passages in castingswithout the sand or binders normally needed.

For more information: Roger Rowell, Thresher IndustriesInc., 13400 Hanford-Armona Road, Armona, CA 93230; tel:

559/585-3400; www.thresherindustries.com.

bana-Champaign. The rings and linksare built upon a planar substrate andthen released to create a flexible sheetthat can bend along two axes anddrape over curved surfaces. Com-bined with existing processing tech-niques, the flexible metallic fabricholds promise for fully engineeredsmart textiles.

Because the rings and links can slideand rotate against each other, the fabric possesses unique mechanicaland electrical properties. For example, the electrical resistance changeswhen the fabric is stretched. These properties could prove useful for thedevelopment of smart fabric and wearable electronic devices.

“The first layer of fabric could consist of silicon islands with em-bedded circuits or sensors,” says Prof. Chang Liu. “The resulting fabriccould generate electricity, detect movement or damage, or serve someother active role.”

For more information: Prof. Chang Liu, University of Illinois, Cham-paign, IL 61820; tel: 217/333-4051; [email protected]; www.uiuc.edu.

High-temperature polymersresist friction and wear

High-temperature, wear-resistant plastics designed for friction andwear applications in both dry and lubricated environments have re-portedly been developed by Solvay Advanced Polymers, Alpharetta,Ga. The new formulations are specifically designed for wear-resistantapplications requiring long-term service at temperatures between 120and 265°C (250 and 500°F), with short-term excursions to 280°C (535°F).

Enhancing current wear-resistant offerings in Amodel polyphthal-amide (PPA) and Torlon polyamide-imide (PAI), Solvay has also an-nounced wear-resistant formulations in its KetaSpire PEEK, AvaSpiremodified PEEK, and Ixef polyarylamide plastics. These plastics exhibitexceptional attributes in a range of performance areas, including re-sistance to heat and chemicals. Modified and reinforced with fibers andother additives, the wear-resistant grades give design engineers excep-tional mechanical performance for an array of demanding applications.

For more information: Mark Wheeler, Solvay Advanced PolymersLLC, 4500 McGinnis Ferry Road, Alpharetta, GA 30005-3914; tel: 770/772-8849; [email protected]; www.solvayadvancedpolymers-us.com.

Stronger aluminum alloyenables lighter, stronger pistons

The high-strength and durable LiteKS aluminum piston already invarious turbocharged, gasoline direct injected, and other gasoline en-gines has been further improved to meet the requirements for betterfuel economy, reduced emissions and NVH, and better performance,says Kolbenschmidt Pierburg, Southfield, Mich.

Improvements are largely due to an innovative aluminum pistonalloy called V4. This alloy is stronger than previous alloys and requiresless metal for pistons, resulting in a lighter design. Because of its greaterstrength, V4 also provides better resistance to high temperatures tomeet increased performance and emission reduction requirements, es-pecially for higher power-density engines.

The LiteKS piston also features a unique, nano-reinforced, low-fric-tion skirt coating called NanofriKS that significantly reduces wear and

8 ADVANCED MATERIALS & PROCESSES/JULY 2007

B R I E F SCPS Technologies Corp. offers AlSiC metal matrix com-posite lids for Systems in Packaging (SiP) IC approaches.The SiP technology combines multiple dies with multiplefunctionalities into a single package, including componentsusually found on motherboards. www.alsic.com

Goodfellow announces the availability of metal, carbon,and ceramic reticulated foams. These low-density, perme-able structures of cells and continuous ligaments are avail-able in aluminum, stainless steel, nickel, vitreous carbon,alumina, and silicon carbide. www.goodfellow.com

Indium Corp. announces that it has won the InnovationAward at Nepcon China in Shanghai for its Indium 5.1ATlead-free solder paste, and its air-reflow, no-clean solderpaste that provides increased reliability over conventionalsolder pastes. www.indium.com

IPSCO Inc. and SSAB Sevnskt Stal AB announcethat they have entered into an agreement providing forIPSCO to be acquired by SSAB for $160 per share.IPSCO produces energy tubulars and steel plate in NorthAmerica. www.ipsco.com

Morgan Technical Ceramics (MTC), comprisingMorgan Advanced Ceramics and Morgan ElectroCeramics, has released a CD-ROM that features descrip-tions of the range of materials from which MTC manufac-tures its products, including advanced ceramics, electroceramics, braze alloys, MIM, coatings, and glass.www.morganadvancedceramics.com

Pacific Cast Technologies Inc., a wholly owned sub-sidiary of Ladish Co. Inc., plans to build a new state-of-the-art VAR casting furnace at its plant in Albany,Oregon. The furnace will provide additional melting ca-pacity for 2009 and beyond. www.paccast.com; www.ladishco.com

Raytheon Co. has been awarded a two-year, $7.5 mil-lion contract by the Defense Advanced ResearchProjects Agency, to develop an improved compositematerial for infrared windows and missile domes.www.raytheon.com

Rennworx Ltd. Inc., is now the first and exclusive U.S.distributor for the world’s lightest street/race carbonfiber/magnesium wheels. Each Dymag wheel is madeup of a carbon fiber barrel and forged magnesium centerdisk. Center disk and barrel are attached by speciallycoated titanium hardware. www.rennworx.com

Republic Engineered Products Inc. has entered intoan agreement with Kobe Technologies, which will pro-vide technical assistance in the form of experienced engineers to Republic’s plants in Ohio and New York to focus on maintaining and improving quality. www.kobelco.co.jp

Solutia’s Saflex unit has collaborated with glass man-ufacturer PPG to develop Enhanced Technology Glassor ETG. It is a laminate consisting of two layers of glasswith an interlayer of Saflex K, a tough and resilient com-posite polyvinyl butyrate structure. www.ppg.com

ThyssenKrupp Electrical Steel GmbH has increasedits annual production capacity for grain-oriented electricalsteel to 260,000 metric tons. www.thyssenkrupp.com

friction, and is suitable for all passenger car engine liner technologies, including cast iron andaluminum.

For more information: Kolbenschmidt Pierburg, 26261 Evergreen Road, Southfield, MI 48076-4447; tel: 248/327-9020; www.usa.kolbenschmidt-pierburg.com.

Boron steel reduces mass and improves fatigue resistanceAstudy that explored the opportunity to reduce the mass and improve the fatigue resistance of

the cross members of a truck frame by replacing the conventional steel parts with hot-stampedboron steel has been reported by S. Laxman and R. Mohan Iyengar of Severstal NA Inc.; and N.Brownbill, K. Knop, and M Amaya of Daimler-Chrysler Corp. The study was reported at the2007 SAE World Congress in a papertitled “Boron Steels for Superior Dura-bility in Automotive Structures.” (SAEpaper 2007-01-0796)

The frame study showed that theparts made of boron steel exhibit farsuperior durability than the baselinemodel, even with downgaging. Atotalweight savings of 20% was achievedby replacing the medium grade steelwith boron steel.

For more information: SAE Interna-tional, 400 Commonwealth Drive, War-rendale, PA 15096-0001; tel: 724/776-4841; www.sae.org.

Magnesium matrix composites fabricated via squeeze casting

Aviable technique for making mag-nesium matrix composites by asqueeze casting technology was re-ported in a paper presented at the 2007SAE World Congress. “MagnesiumMatrix Composites for Elevated Tem-perature Applications” (SAE paper2007-01-1028) was presented by JasonLo and Raul Santos, Natural ResourcesCanada.

Squeeze casting combines gravitydie casting with closed die forging ina single operation, resulting in com-posite products with properties su-perior to those produced by stircasting, pressureless infiltration, invest-ment casting, or gravity casting. In fact,it was found that pore-free casting arepossible under an applied pressure of100 MPa (14.5 ksi) for magnesium alloy

AZ 91 SiC/AZ91 Property as cast as cast

Density, g/cm3 1.8 2.4

Young’s modulus, GPa 45 120

Shear modulus, GPa 17 48

Tensile strength, MPa 196 326

CTE, ppm 27.3 13.8

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AM50. Furthermore, transmission electron microscopy shows that the reinforcement particlesare well bonded to both the reaction layer and the matrix.

For more information: SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001; tel: 724/776-4841; www.sae.org.

Composite wings and fuselage for Dreamliner are deliveredThree large composite fuselage sections for the Boeing 787 Dreamliner have been delivered

to the Boeing Company in Everett, Wash. The all-composite forward section is manufacturedby Spirit AeroSystems at its facility in Wichita, Kan. The complex structure is 21 feet in diameterand 42 feet long. Its landing gear is installed.

Sections 47 and 48 are the two aft composite sections of fuselage for the Dreamliner. Theywere manufactured and joined by Vought Aircraft Industriesat its facility in Charleston, S.C. Section 47 is 23 feet long and19 feet in diameter while section 48 measures 15 feet long and 14feet in diameter.

Composite wings have been delivered by Mitsubishi HeavyIndustries. Each wing is 98 feet long, a size that has never beenbuilt before. Since the 787 is assembled from these large assem-blies rather than many smaller pieces, traditional monumentassembly tools are not necessary. Portable tools, designed withergonomics in mind, move the assemblies into place. No over-head cranes are needed to move the airplane structure. Al-though the first airplane will take about seven weeks to as-semble, the 787 team looks to continuously improve flow timeas production ramps up. Ultimately, a 787 will roll out of thefactory every three days. The first 787 will roll out of the fac-tory on July 8, 2007. www.boeing.com

Keeping pace with material testing demands means adapting readily to evolving standards and requirements. TestWorks® software from MTS is a critical tool for thriving in such an environment. When combined with MTS Insight™ or ReNew™ EM frame technology, easy-to-use TestWorks delivers all the functionality and flexibility you’ll need to perform a full spectrum of static testing – now and well into the future.

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TESTINGCHARACTERIZATION

BRIEFSAgilent Technologies

Inc., announced that itwill focus on developing a

microscopy optical spectroscopy business

that can be leveraged intothe electronics, materialstesting, life sciences, and

chemical analysis markets.

www.agilent.com

Asylum Research, a premier manufacturer of

atomic force microscopes,announced that it has purchased a majority

interest of Atomic ForceF&E GmbH. Atomic

Force has been AsylumResearch Research’s European distributor

since 1999. www.asylumresearch.com

ASTM Internationalhas developed the G189-

07 Standard Guide forLaboratory Simulation of

Corrosion Under Insulation. This guide

covers the simulation ofcorrosion under isolation

(CUI), including both general and localized

attack, on insulated specimens cut from pipe

sections exposed to a corrosive environment

usually at elevated temperature.

www.astm.org

System rates nonmetallic inclusions in steel alloysA system for detecting nonmetallic inclusions in modern steel alloys has been introduced

by Leica Microsystems, Germany. The Leica Steel Expert system consists of high-end software,the automated inverted industrial microscope Leica DMI5000 M, and a highly sensitive dig-ital color camera. Inclusions are classified and assessed fully automatically on the basis of theircolor, brightness, shape, and arrangement. The measurement data of one or more samples of anysize are available to the user as raw data and asresults complying with international standards.Leica Steel Expert supports all common interna-tional steel inclusion rating standards: ASTM 45 A,D and E, ISO 4967 A and B, DIN 50602 K and M,JK and JIS 0555. In addition, the software is pre-pared for the latest steel inclusion rating standardDIN EN 10247, which is exactly defined mathe-matically and expected to be released in 2007. Allassessments are carried out during a single meas-urement and are simultaneously available forcomparison purposes.

For more information: Dr. Kirsten Henze, LeicaMicrosystems GmbH, Germany; 49 6441/29-2550;[email protected]; www.leica-microsystems.com.

Sensor system helps to detectfatigue cracks in aircraft

Asensor system that allows engineers to contin-uously monitor the condition of aircraft and detectany damage at an early stage is under develop-ment at the Fraunhofer Institute for StructuralDurability and System Reliability LBF in Germany.

The system is based on piezoceramic sensorsthat are attached to the aircraft body in a network pattern. The sensors start to oscillate when avoltage is applied to them, and when they are subjected to pressure, they generate voltage. The sci-entists make use of both effects: While the piezo foils cause part of the hull to oscillate, the othersmeasure the component’s response to this stimulation.

If a component is defective, it oscillates at a different frequency from one that is intact whenstimulated by the piezoceramics. In this way, the researchers can accurately track down faultsand monitor their development, whether fatigue cracks in the hull and wings, or rivets andother joining parts coming loose. This form of observation is also referred to as “structuralhealth monitoring” (SHM). The researchers have already performed tests on a hull componentin the laboratory, and are now implementing the new technology with standardized piezo andelectronic components. The system will then also be suitable for vehicle manufacture or engine and plant construction.

For more information: Fraunhofer Institute, Darmstadt, Germany; www.fraunhofer.de.

Mini-spectrometer enables accurate laser calibrationAtiny device for calibrating or stabilizing precision lasers has been designed and demonstrated

at the National Institute of Standards and Technology (NIST). The spectrometer is about the sizeof a green pea and consists of miniature optics, a microfabricated container for atoms in a gas,heaters and a photodetector, all within a cube about 10 millimeters on a side. The package could

Materials and Corrosion Research Center to develop new technologiesA Materials and Corrosion Research Center is beinglaunched by Det Norsk Veritas in Columbus, Ohio, in close cooperation with Ohio State University and CC Technologies. The center will develop new technologyand methodologies related to the challenges the U.S.economy is facing due to material corrosion.The center has appointed as manager Narasi Sridhar, a recognized expert in the corrosion research and development community in North America. He comes from a position as program director of the mechanical and materials engineering division of the Southwest Research Institute in San Antonio, Texas.The total annual economic impact of corrosion on the U.S. economy is estimated to be $276 billion in direct costs. Indirect costs, including social costs, could easilydouble this amount.For more information: Neil Thompson, CC Technologies,Dublin, OH 43017 ; tel: 614/761-1214; [email protected]; www.dnv.com; www.cctechnologies.com. CC

be used to calibrate laser instruments, or, if a miniature laserwere included in the device, could serve as a wavelengthor frequency reference. The key to the device is a tiny glass-and-silicon container that holds a small sample of atoms.The instrument works by measuring the intensity of a laserbeam after it interacts with the atoms. The amount of lightabsorbed at a particular wavelength produces a characteristicsignature.

NIST has demonstrated the spectrometer with rubidiumand cesium atoms, which absorb light at infrared, near-visible wavelengths, commonly used in atomic physics research. The mini-spectrometer would offer greater preci-sion than the physical references now used to separate fiber-optic channels, with the advantage that more channels mightbe packed into the same spectrum.

For more information: Svenja Knappe, National Institutesof Standards and Technology, 325 Broadway, Boulder, CO80305-3328 ; tel: 303/497-3334; [email protected]; www.nist.gov.

Integrated instrument characterizes SMA wires

An instrument designed to characterize the properties ofshape-memory alloy (SMA) wires has been developed bySAES Getters, Colorado Springs, Colo. Designated SMAq,the instrument can carry out thermo-mechanical loadingsin many different conditions with maximum flexibility. Itcan simultaneously measure quantities such as wire defor-mation, temperature, diameter, and electrical resistivity.Thermal and mechanical loadings can be applied graduallyto observe the material characteristics in quasi-static condi-tions, or as pulses to observe dynamic phenomena.

SMAq is a highly automated system that requires an op-erator only for mounting the wire and setting the softwarerequirements. The flexibility and simultaneous monitoringof different physical quantities can provide a comprehen-sive picture of the transformation phenomena. A largeamount of information can be retrieved and used to finelytune process parameters and to rapidly develop wire prod-ucts, thus shortening time to market.

For more information: SAES Getters USA Inc., 1122 EastCheyenne Mountain Blvd., Colorado Springs, CO 80906; tel:719/576-3200; www.saesgetters.com.

Bending fatigue performance evaluated for 8620 sheet steel

The results of a study of the bending fatigue performanceof high-temperature vacuum carburized niobium-modified8620 steel were reported in a paper presented at the 2007SAE International World Congress. The paper was titled“The Fatigue Performance of High-Temperature VacuumCarburized Nb-Modified 8620 Steel,” (SAE paper 2007-01-1007) by Richard E. Thompson, David K. Matlock, and JohnG. Speer, Colorado School of Mines, Golden.

The fatigue results from this research follow the generaltrend of decreasing endurance limit with increasing grainsize, irrespective of grain size distribution. Intergranular fa-


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Carestream Health Inc. announces that EastmanKodak Company’s former nondestructive testing (NDT)group is officially operating as part of CarestreamHealth. Last January, Onex Corp. announced its intentionsto acquire Kodak’s Health Group, which included theNon-Destructive Testing business. Now that the purchase iscomplete, the health group is doing business as Care-stream Health. www.carestreamhealth.com

Evans Analytical Group LLC has acquired the oper-ations and assets of Accurel Systems InternationalCorp. from Implant Sciences Corp., a leadingprovider of advanced failure analysis, microscopy, andfocused ion beam technology. www.eaglabs.com

GE Inspection Technologies introduces a new ultra-sonic, phased array transducer, featuring “hard water”acoustic material. The Phasor XS ultrasonic flaw detectorcan now provide even more effective scanning of compositecomponents and structures. www.geinspectiontechnologies.com

Hytec Inc., Los Alamos, N.M., a maker of dental specialtyproducts, announces its merger with Imtec Corp., Ard-more, Okla., a maker of dental implants, PTFE membranes,and resorbable membranes. www.hytecinc.com

Instron announces the release of Bluehill Lite, a new gen-eral purpose software package that provides a wide rangeof tailored application solutions. It is ideal for fundamentalapplications and standardized tensile, compression, flexure,peel, tear, friction, and simple cyclic test requirements.www.instron.com

JETCAM International, leaders in CAD/CAM andnesting for the sheet metal and composites industries, andVISTAGY Inc. a leading global provider of specialized en-gineering software, have created a seamless exchange of3D product data between VISTAGY’s FiberSIM compositesdesign software and JETCAM’s Expert CAM and nestingsoftware. www.jetcam.com; www.vistagy.com

The Metal Powder Industries Federation has pub-lished the 2007 Edition of Standard Test Methods for MetalPowders and Powder Metallurgy Products. www.mpif.org

Thermo Fisher Scientific Inc., has available a new tech-nical poster to highlight the unique plate handling capabil-ities of Thermo Scientific Nautilus LIMS for high throughputapplications. www.thermo.com/informatics

tigue fracture in duplex microstructures initiates at those grainsresulting from abnormal grain growth. The abnormally growngrains also contribute to an overall increase in transgranular fracture.

The higher niobium alloys were processed to produce fine, uni-form prior austenite grain structures. These alloys exhibited thebest fatigue performance, as shown by their higher endurance limitsand higher low-cycle-fatigue life.

For more information: David K. Matlock, Colorado School ofMines, Golden, CO 80401; tel: 303/273-3775; [email protected];www.mines.edu.

Database mining technologyenables ten times faster searches

Adatabase mining technology designed to enable users to gather,process, and distill massive amounts of information up to ten timesfaster and more thoroughly than possible unassisted has been de-veloped by VuBotics Inc. and Oak Ridge National Laboratory.Called the Virtual Information Process Agent for Research (VIPAR),it utilizes hundreds of individually deployed intelligent softwareagents to autonomously gather and organize massive amounts of in-formation. It then distills the information into relevant clusters foranalysis.

Disparate databases connected with the Internet throughout theworld can be searched to locate target information without the needfor any complex integration systems. Combined with VuIT Mine,users can direct research remotely or directly through an XML inter-face. The software integrates itself directly into the native applicationprograms through its dock, and presents information through aproprietary graphical user interface designed specifically for theuser's industry, role and responsibility.

For more information: David Rollo, VuBotics Inc., 235 PeachtreeSt, Atlanta, GA 30340; tel: 404/474-2576; www.vubotics.com.

Confocal, AFM microscopesare combined in one platform

Confocal and atomic force microscopes have reportedly been com-bined on one platform by Hyphenated Systems, Burlingame, Calif.,and Karma Technology Inc., Agoura Hills, Calif. It will be geared forthree-dimensional metrology applications in semiconductor manu-facturing and laboratory environments.

Hyphenated’s advanced confocal microscope technology is saidto provide extremely fast, accurate, structural characterization ofmaterials, including steep slopes, rough surfaces, and subsurfacefeatures in transparent media, many of which are difficult or im-possible to measure with alternative techniques. The combinedACM/AFM tool will provide the speed and 3D imaging advan-tages of ACM, combined with atomic-level resolution measure-ment capabilities of an AFM, eliminating the need to move thesample.

Geared for the semiconductor industry, the system will be builtto accommodate wafers up to twelve inches in diameter. It will alsofeature a patented probe module that is easily replaceable, elimi-nating the need for time-intensive probe tip changes of the AFM.

For more information: Hyphenated Systems, 1826 Rollins Road,Burlingame, CA 94010; tel: 650/651-3000; www.hyphenated-systems.com.


B R I E F S

PROCESSTECHNOLOGY

Molten aluminum plus water generates hydrogen for enginesAtechnology in which aluminum dissolved in molten gallium is combined with water to generate

hydrogen has been demonstrated at Purdue University, West Lafayette, Ind. The method makes itunnecessary to store or transport hydrogen, two major challenges in creating a hydrogen economy,says Prof. Jerry Woodall.

When water is added, the aluminum reacts because it has a strong attraction to the oxygen inthe water. This reaction splits the oxygen and hydrogen contained in water, releasing hydrogen inthe process. Gallium is critical because it melts at a low temperature and readily dissolves alu-minum. The gallium does not react, so it is not used up and can be recycled over and over again.An Indiana startup company, AlGalCo LLC., has received a license for the exclusive right to com-mercialize the process.

For more information: Jerry M. Woodall, Purdue University, West Lafayette, IN 47907; tel:765/494-3479; [email protected]; www.purdue.com. Avideo describing how the

hydrogen-producing technology works isavailable online at http://hydrogen.ecn.purdue.edu.

Ceramic composite bore coating protects against sliding wear

A low-cost durable ceramic compositefor diesel engines that protects againstsliding wear while operating under severeconditions was reported in a paper at theSAE 2007 World Congress by LloydKamo, Philipe Saad, and Dorsaf Saad ofAdiabatics Inc.; and Walter Bryzik andMilad H. Mekari of the U.S. Army TardecR&D Center.

“Diesel Engine Cylinder Bore Coatingfor Extreme Operating Conditions” (SAEpaper 2007-01-1439) describes a coatingconsisting primarily of iron oxide, iron ti-tanate, and partially stabilized zirconia.Called low-temperature iron titanate, thecoating has been tested against a widerange of cylinder bore treatments, in-cluding hard chrome plate and nickel sil-icon carbide, and has been found to pro-vide a superior sliding wear surface.

Apatented low-temperature thermal-chemical binding system is produced by blending the twopowder compositions together. Because both powders are based on iron, they work well together.Compared with other liner treatments, it provides superior running-in and break-in performance ofthe ring against the cylinder liner, and yields better wear rates under extreme loading conditions.

For more information: Lloyd Kamo, Adiabatics Inc., 3385 Commerce Drive, Columbus, IN47201-2201; tel: 812/372-5052; [email protected]; www.adiabatics.com.

Aluminum precision die casting prevents porosityDeveloped for the Air Force tactical aircraft equipped with ejection seats, such as the F-4 Phantom

and the F-15 Eagle, the CRU-60/P is a two-piece connector made by Alloy Die Casting, Buena


BRIEFSThe American Galvanizers Association announcesa new course on the inspection of hot-dip galvanized steel. It is intended to train inspectors on the propertechniques and requirements for hot-dipgalvanized steel productsper ASTM standards.www.galvanizeit.org

BASF Coatings isforming a global partnership to provide refinish coatings productsas well as training services and support forHyundai Motor Company’s aftermarketnetwork. www.basf.coatings.com

Dymax Corp. has developed MD 209-CTHlight-curing adhesives thatare solvent free and cureupon exposure to UVand/or visible light. Theydeliver optimum speedand performance for medical device assemblywhile enhancing workersafety.www.dymax.com.cn

EOS, the manufacturer of laser-sintering systems,announces that Paramount DDS haspurchased an EOSINT P700 to address demandsfor large, laser-sinteredparts and e-manufacturingproducts. www.eos.info


Coated steel spot-welded to6000 aluminum sheet for autos

A study that investigated the interface structure in spot friction welding of aluminum to coated steel was reported in

“Spot Friction Welding of Aluminum to Steel” (SAE paper 2007-02-1703), a paper presented at the 2007 SAE World

Congress. Authored by T. Gendo, K. Nishiguchi, M. Asakawa,and S. Tanioka, Mazda Motor Corp., Japan, the paper shows

that zinc from the coatings was incorporated into the stirnuggets, and that intermetallic phases may have formed, butnot in continuous layers. Some Al-Zn oxides that appeared to

be amorphous were also found in the joint interfaces.In spot friction welding, the rotating tool is positioned on

the aluminum side, and steel is on the anvil side. The tool is rotated into the aluminum to a depth that does not contact the

steel, to induce plastic deformation only in the aluminum layer. The aluminum and the coating are softened by friction heatfrom the rotating tool. Then, the interfacial oxide films are

destroyed by the plastic flow of aluminum. The coating of thesteel layer is removed at the same time. As a result, the fresh

surfaces of aluminum and steel come in direct contact, enablinga metallurgical joining of aluminum with steel.

For more information: SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001;

tel: 724/776-4841; www.sae.org.

Park, Calif. The connector joins the air-craft’s oxygen supply to the pilot’soxygen mask, delivers positive locking,and prevents flailing during an ejection.

The connector is cast from A380 alu-minum on a 250- ton Toshiba press,which features automated ladling and extraction, as well asair jets to cool the parts as the conveyor takes them to thetrim press. Ingots of raw material are melted in a gas fur-nace at approximately 650°C (1200°F), and a measuredshot is injected at about 8000 pounds per square inch, pro-ducing a gate velocity around 1200 inches per second.

For more information: Courtney Hall, Alloy DieCasting, 6550 Caballero Blvd., Buena Park, CA90620; tel:714/521-9800; [email protected]; www.alloydie.com.

Long carbon nanotubes areformed into fibers and yarns

Long, pure, continuous carbon nanotubes have report-edly been produced at high growth rates by NanocompTechnologies Inc., Pembroke, N.H. Longer nanotubesmean greater strength, higher conductivity, easier han-dling, and greater product safety. These pure materialsrequire no post-growth purification, and high outputrates hold the promise of achieving excellent process eco-nomics and product affordability.

Applications of carbon nanotubes have been limitedup to now because no commercial methods are availablefor volume production methods of long-nanotube fibersor mats. However, these novel methods will enable fab-rication of long nanotubes into structurally strong andelectro-thermally conductive fibers, yarns, and felts thatcan be easily incorporated into final products.

For more information: Nanocomp Technologies Inc.,162 Pembroke Road, Concord, NH 03301; tel: 603/442-8992; www.nanocomptech.com.

Fiber laser system is capableof hardening, cutting, welding

A fiber laser system that is capable of hardening, cut-ting, and even welding if required has reportedly beendeveloped by the Fraunhofer Institute, Germany. In thelast few years, fiber lasers have been developed that cangenerate light with an output of several kilowatts in fiberswith a thickness of only 50 microns. The fibers are as flex-ible as a cable, allowing them to get close to componentswith a complex geometry.

Additionally, fiber lasers generate light with a wave-length of around one micron, a good wavelength for ab-sorption by metals such as steel and aluminum. The fibersgenerate very uniform light and a very small focal spot,operating more rapidly and with greater precision. More-over, the fiber laser has an energy conversion efficiencyof 20%, compared to the 6 to 10% achieved by CO2 lasers.

For more information: Thomas Himmer, FraunhoferInstitute, Dresden, Germany; tel: 49 351-2583-238; www.fraunhofer.de.

B R I E F S


ESAB Welding & Cutting Products has signed an agreementwith the Robotics Division of ABB Inc. to jointly develop andmarket robotic welding packages and systems. www.esabna.com

Fuchs Lubricants Co. was awarded the Precision MetalformingAssociation’s Next Gen Innovation Award for the “Best New Mate-rials” at the 2007 Metalform trade show in Chicago. Fuchs was rec-ognized for the development of Renoform Syn 7940. www.fuchs.com

Gales Industries Inc. of Colombia will acquire all of the outstandingshares of Welding Metallurgy Inc., a metallurgical engineeringand welding services provider and manufacturer based in WestBabylon, Long Island, N.Y. www.industriasgales.com

Cincinnati Inc. has opened a powder metallurgy compacting pressreconditioning facility near its main plant and headquarters in Cincin-nati, Ohio. The new 38,000 sq. ft. plant has deep pits and 50-toncranes to handle large machines. www.e-ci.com

GE Plastics has installed a high-temperature melt spinning fiber linefrom Hills Inc., at its Polymer Processing Development Center. Thenew equipment will evaluate materials and optimize process condi-tions for making low-denier fibers with GE’s high performance, flame-retardant Ultem polyetherimide resin and other high-temperature resins.www.geplastics.com

Ipsen International and VFS have combined forces into a newentity called Ipsen Inc. Together, they will offer their furnace cus-tomers better technical expertise, a broader product base, and themost extensive customer service network in North America. www.vfscorp.com

The Marathon Automotive Group has completed its acquisi-tion of Contech from SPX Corp., a leading light metals die castingand machining company. www.marathonfund.com

The Navy Metalworking Center, Concurrent TechnologiesCorp., has begun a 24-month project for the Office of Naval Re-search that mechanizes the process of weld grinding removal onhull and deck panels for DDG 1000 Class ships to substantially increase productivity and reduce costs. www.nmc.ctc.com/index.cfm?fuseaction=nstory&id=70

The Navy Metalworking Center has also published a “FrictionStir Welding for Ship Construction” Tech Bulletin. The unique propertiesof friction stir welds make possible some completely new structural de-signs with significant impact to ship design and construction.www.nmc.ctc.com/Library/publications/FSW%20Ship%20Construction.pdf

Stratasys introduces the FDM 200mc, a rapid prototyping andmanufacturing system that pairs a new material, ABSplus, with high-endInsight software. It produces parts up to 67% stronger than standardABS, with improved feature detail. www.Stratasys.com

The U.S. Council for Automotive Research’s Vehicle RecyclingPartnership (VRP) is evaluating a process that could potentially divert250,000 tons of post-consumer shredder residue foams from landfillsannually. The process, developed by Troy Polymers Inc., is based on gly-colysis that converts post-consumer shredder residue foam into usablepolyurethane foam. www.uscar.com

The North American Die Casting Association (NADCA) nowprovides access to Design for Die Casting information on its web site.The online version includes information on alloy composition and prop-erties, casting tolerances, die design, and die processing information.www.diecasting.org/oem/designcd


High-quality titanium powder will make cheap complex parts

A process in which high-quality titanium powders are produced at a fraction of the cost of tra-ditional methods has been developed by International Titanium Powder, Lockport, Ill. We have re-ported this before, but now LMC of DeKalb, Ill., has designed and built a machine capable of econom-ically forming the powder into high-quality, complex parts that require little additional machining.

In addition, Materials Modification Inc. (MMI), based in Vir-ginia, has developed a process that can further consolidate thematerial to near 100% density, healing minute flaws in the finalpart. Still another company, Super Materials Inc., Rockford,Ill., will take the lead in commercializing the MMI process.

Companies such as Ingenium, Hamilton-Sundstrand,Woodward Governor, and Ingersoll Machine Tools are ex-pected to provide demonstration parts and designs duringthe research and development phase.

All of these commercial enterprises are being brought to-gether by Northern Illinois University of Rockford, in aproject called Rapid Optimization of Commercial Knowl-edge. The goal is to lower the price of titanium to about $2a pound by simplifying the processing for making titaniumpowder and then compacting it into shapes suitable for finalmachining.

For more information: Richard N. Johnson, Northern Illinois University, DeKalb, IL 60115; tel: 815/753-8938; [email protected]; http://www.niu.edu/northerntoday/2006/nov13/rock.shtml

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Hearing aid made by rapid manufacturing A compact, fast, low-cost hearing aid manufacturingsystem has been introduced by 3D Systems Corp.,Rock Hill, S.C., in partnership with Dreve Otoplastik,Germany. The system is based on its new film transfer imaging(FTI) technology, the V-Flash HA 230 ManufacturingSystem.The HA 230 Desktop Manufacturing System can build high-quality, three-dimensionalhearing aid shells within hours. It will enable hearingaid manufacturers to extend and expand the production of precise hearing aid components in adistributed model to their satellite operations and developing marketplaces. For more information: 3D Systems Corp., 333 Three DSystems Circle, Rock Hill, SC 29730; tel: 803/326-4080; www.3dsystems.com; www.dreve.com.

EMERGINGTECHNOLOGY


Conductive carbon coatings enhance electrode materials Carbon coatings that enhance electrochemical performance of LiFePO4 lithium ion battery

electrodes without sacrificing the energy density of the battery have reportedly been developedat Berkeley Lab, Calif. Very thin carbon coatings (<10 nm) on nonconductive LiFePO4 particlesare said to increase the electronic conductivity of the composite by as much as six orders of mag-nitude compared to the native material. The low carbon content (<2 wt. %) allows high poweroperation without compromising energy density. The coatings are extremely durable; no evi-dence of degradation was found after more than 100 full charge/discharge cycles.

Key to the invention was the discovery that highly graphitic conductive carbon coatings onLiFePO4 improve material utilization and power performance at a given discharge rate com-pared to those coated with more disordered or amorphous carbon. Catalytic graphitization pre-cipitated out graphitic carbon at the low temperatures that are typical for producing phase-pureLiFePO4.

For more information: Marca Doeff, Lawrence Berkeley National Laboratory, Berkeley, CA94720; tel: 510/486-5821; [email protected]; www.lbl.gov.

System precisely positions nanowires on semiconductorsA system for manipulating and precisely positioning individual nanowires on semiconductor

wafers has been devised at the National Institute of Standards and Technology, Gaithersburg,Md. The technique allows fabrication of sophisticated test structures to explore the properties ofnanowires with optical microscopy and conventional photolithographic processing, rather thanadvanced (and expensive) tools such as focused ion or electron beams.

To achieve better control, the NIST engineers modified a standard probe station that tests indi-vidual components in microelectronic circuits. The station includes a high-resolution optical mi-

croscope and a system for precisely posi-tioning work surfaces under a pair ofcustomized titanium probes with tips lessthan 100 nanometers in diameter. In a two-step process, silicon nanowires suspendedin a drop of water are deposited on a specialstaging wafer patterned with a grid of tinyposts. Resting on the tops of the posts, se-lected nanowires can be picked up by thetwo probe tips by static electricity. The teststructure wafer is positioned under theprobes, and the nanowire is oriented bymoving either the probe tips or the wafer,and then placed on the wafer in the pre-ferred position.

For more information: Curt Richter, Na-tional Institute of Standards and Technology,100 Bureau Drive, Gaithersburg, MD 20899-8120; tel: 301/975-2082; [email protected];www.nist.gov.

Silver-coated solar cellsboost energy efficiency

A16-fold enhancement in light absorptionin 1.25-micron silicon thin-film solar cells forlight with a wavelength of 1050 nm has been

BRIEFSAscent SolarTechnologies Inc. hasbeen selected by the U.S.Air Force to develop anew transparent conductive oxide material to serve as thetop electrical contact forflexible integrated thin-film copper-gallium-selenium solar cells.www.ascentsolar.com

The Automotive Research Alliance hasbeen launched by sevensoutheastern universities,along with the NationalTransportation Research Center,Oak Ridge NationalLaboratory, and theTennessee Valley Authority. It will provide a broad rangeof research resources to automotive manufacturers and suppliers. www.autoresearchalliance.com

A team from the University of Pennsylvania andRice University havefurther developed a technology known as interfacial polymerizationto evenly disperse carbonnanotubes throughoutnylon. They have addedalkyl segments as“carbon spacers” that actas linking segments, covalently bonding thenanotubes with the nylon chains.www.upenn.edu


Platinum nanocrystals boost catalysts for new fuel cells

A new form of platinum 24-facet nanocrystals whose catalytic activity per unit area can be as much as four times

higher than existing commercial platinum catalysts has beendeveloped by a research team at the Georgia Institute of

Technology, Atlanta. The new platinum nanocrystals, whose tetrahexahedral structure had not previously been

reported, could improve the efficiency of chemical processessuch as those that catalyze fuel oxidation and produce

hydrogen for fuel cells. The nanocrystals, produced electrochemically from platinum nanospheres on a carbon

substrate, remain stable at high temperatures. Their size can be controlled by varying the number of cycles of “square

wave” electrical potential applied to them.The nanocrystals have high energy surfaces that include

numerous “dangling bonds” and “atomic steps” that facilitatechemical reactions. These structures remain stable at high

temperatures, up to 800°C (1470°F) in testing done so far.That stability will allow them to be recycled and re-used in

catalytic reactions..For more information: Zhong Lin Wang, Georgia Institute of

Technology, Atlanta, GA 30308; tel: 404/894-8008;[email protected]; www.gatech.edu.


B R I E F Sreported by researchers at the University of New South Wales, Australia. They have also re-ported a seven-fold enhancement in light absorption in light wavelengths of 1200 nm.

The UNSW researchers have devised a way to deposit a thin film of silver (about 10 nmthick) onto a solar cell surface and then heat it to 200°C (390°F). This breaks the film into 100-nanometer “islands” of silver that boost the cell’s light trapping ability, thereby boosting itsefficiency. “Most thin-film solar cells are between eight and 10% efficient,” says Dr. KylieCatchpole. “But the new technique could increase efficiency to between 13 and 15%.”

For more information: Prof. Kylie Catchpole, University of New South Wales, City ofSydney, Australia; tel: 612 9385-5155; fax: 6129385-5412; [email protected]; www.unsw.edu.au.

Catalyst helps eliminate NOx from diesel exhaust

A catalyst that could help diesel truckmanufacturers eliminate harmful nitrogen-oxide emissions from diesel exhausts hasbeen developed by researchers at ArgonneNational Laboratory, Argonne, Ill. Cu-ZSM-5 is a zeolite with copper ions attachedwithin its micropore structure. Zeolites arecommon catalysts, but do not work well atremoving NOx from diesel exhaust. Theyrequire temperatures higher than normaldiesel exhaust temperatures and don’t workwell in the presence of water vapor, whichis almost always found in engine exhausts.

According to Christopher Marshall, “Ournew cerium-oxide additive is the break-through that makes it work. When it’s com-bined with Cu-ZSM-5, the resulting catalystworks at normal exhaust temperatures andis actually more effective with water vaporthan without it. With a lean fuel-air mixture,it removes as much as 95 to 100% of NOxemissions.”

For more information: Christopher Marshall, Argonne National Laboratory, Argonne, IL60439; tel: 630/252-4310; [email protected]; www.anl.gov.

NIST nanotech user facilitynow accepting proposals

The National Institute of Standards and Technology (NIST) has announced that its newCenter for Nanoscale Science and Technology (CNST) is now accepting proposals for workin its user facility for nanotechnology research. The CNST offers researchers access to state-of-the-art and beyond-state-of-the-art facilities to study a wide range of nanotechnologytopics.

The center focuses on overcoming major technical obstacles to cost-effective manufac-turing of products made with components the size of atoms and molecules by developingmeasurement methods, standards, and technology that help emerging nanotechnologiesmove from the laboratory to production.

The national user facility includes a 1486 square-meter (16,000 square-foot) nanofabricationfacility, about half of which is devoted to class 100 cleanroom space. The nanofabrication fa-cility includes more than 30 state-of-the-art tools such as photolithography, ion beam, andetching equipment capable of creating, measuring, and inspecting nanoscale devices withdimensions as small as 10 nm.

Detailed information about the proposal process, available facilities, current CNST re-search programs and contact information for fee schedules is available at http://cnst.nist.gov.

Johnson Matthey has re-leased the Platinum 2007 re-view, which reports thatglobal demand for platinumrose by 2.4 metric tons to21.7 metric tons in 2006. Theautocatalyst market grew byover 10%, mainly due to emis-sion controls for light andheavy-duty vehicles. www.matthey.com

Superconductive Compo-nents Inc., a manufacturerof high-quality sputtering targets for the physical deposition industry, has or-dered $300,000 of newequipment to scale its produc-tion of sputtering targets forthin film batteries. www.sciengineeredmaterials.com

The U.S. Department ofEnergy has selected the firstrecipient of a Methane Hy-drate Research Fellowship.Ms. Monica Heintz, a doc-toral student at the Universityof California at Santa Bar-bara, will receive the inau-gural award, which is part ofa new program that providessupport for graduate and post-graduate scientists in fields re-lated to the study of methanehydrates. Ms. Heintz receivedher undergraduate degree ingeological engineering fromthe Colorado School ofMines.

Veeco Instruments Inc.announces the sale and ship-ment of its new Dektak 150Surface Profiler to PrimeStarSolar, a manufacturer of cad-mium telluride photovoltaicmodules for the solar energymarket. It delivers increasedresolution for measuring thinfilms to 10 nm and less. www.veeco.com

Carbon nanolayers designed to absorb carbon dioxideA nanotechnology called electrostatic layer-by-layerself-assembly is under development by scientists from the Dept. of Energy’s National Energy Technology Laboratory, the West Virginia University School of Medicine, and the University of Pittsburgh’s Chemical Engineering Department.Originally developed for medical applications, the technology shows promise in the development of sorbent technology for the capture of carbondioxide. The LBL process involves repeatedly dipping a substrate into an amine solution, each dip creating a layer of approximately one to two nanometers. The process has the potential to produce highly efficient, highly uniform solid sorbents containing perhaps 100 times more of the amines than are deposited by the sorbent-preparation technologies common today.For more information: McMahan Gray, National Energy Technology Laboratory, Pittsburgh, PA 15236-0940; tel: 412/386-6000;www.netl.doe.gov.

BRIEFSBAE Systems plcannounces that its whollyowned U.S. subsidiaryBAE Systems Inc. hasentered into a definitivemerger agreement to acquire Armor Holdings Inc., a majormanufacturer of tacticalwheeled vehicles and aleading provider of vehicle and individualarmor systems and survivability technologies.www.baesysstems.com

General Electric andHitachi Ltd. are tocreate a global alliance oftheir nuclear businesses.They will form cross-share-holding companies in theUnited States, Canada,and Japan. They will combine their expertise inmodularization and standardization capabilities, together withthe latest nuclear powergeneration reactors.www.ge.com

GE Plastics announcesthat it has expanded itsproduction of LNP Faradex compounds tothe Pacific region. Thesecompounds provide inherent electromagneticinterference shielding,and are being manufactured at GE Plastics’ Moka facility inJapan.www.geplastics.com


GLOBALECONOMY

India’s Bharat Forge to set up non-automotive components unit Bharat Forge, the world’s second largest forgings maker, says it will set up an $85 million green-

field non-automotive parts manufacturing unit in India as an entry into the $20 billion globalhigh technology components market. Thecompany plans to manufacture critical com-ponents for aircraft and helicopters, railwayand locomotive sector, construction ma-chinery, and large diesel power generatingplants at the proposed unit in Pune district.The facility will have a capacity of 30,000metric tons and will manufacture 100,000crankshafts in the first phase. It will go onstream by May 2008. www.bharatforge.com

Alcan to build mine-to-metalaluminum plant in Saudi Arabia

Alcan announces that it has signed a Headsof Agreement with Saudi Arabian mining

company Ma’aden to develop a proposed $7-billion integrated aluminum “mine-to-metal” projectincluding bauxite mining, alumina refining, power generation, and aluminum smelting. Alcanwould hold a 49% stake in the project and would provide technology and operating manage-ment support, with Ma’aden holding the balance of 51% ownership.

As one of the world’s largest vertically integrated projects of its kind, the initial operations fea-ture a power plant delivering 1400 megawatts; a 90-million metric ton bauxite reserve repre-senting a potential 30 years of mining; an alumina refinery with a capacity of 1600 thousandmetric tons per year; and an aluminum smelter with a capacity of 720 thousand metric tons peryear. The alumina plant, aluminum smelter, and power generation facilities would be located inthe new Minerals Industrial City at Ras Az Zawr, on the east coast of Saudi Arabia. First metalwould be expected during the first quarter of 2011, and first alumina a year later. www.alcan.com.

Alcoa announces expansions of manufacturing facilitiesAlcoa has announced the completion of multiple global manufacturing expansions. Aluminum

manufacturing capacity has been expanded at Alcoa mills in four countries, reinforcing the com-pany’s leading position in aerospace structural metallics and solutions. New capabilities in thecompany’s heat-treated sheet and plate capacity were announced in Davenport, Iowa, USA; KittsGreen, UK; Fusina, Italy; and Belaya Kalitva, Russia. These additions represent a 50% expansionin these critical aerospace product forms. Expansion of Alcoa’s Power and Propulsion Systemsglobal manufacturing capabilities included a new airfoil post-cast operation in Szekesfehervar,Hungary; an expansion of airfoil post-cast operations in Acuna, Mexico; expansion of turbineairfoil casting capacity in Whitehall, Mich.; and additional turbine airfoil core capacity in Mor-ristown, Tenn. The company also plans to bring on line five additional single-crystal casting fur-naces in the next two quarters. www.alcoa.com

ThyssenKrupp to build steel mill in AlabamaThe Supervisory Board of ThyssenKrupp AG has approved the $3.1 billion investment in a

steel mill to be operated jointly by the Steel and Stainless segments in Mount Vernon, Alabama. Theplant is scheduled to start operation in 2010. The joint plant will employ 2700 people and gen-erate at least 38,000 indirect jobs in the region over the next 20 years. The company offers tech-nological advantages for demanding customers, coupled with a favorable cost structure. ThyssenK-rupp Steel will leverage these advantages in North America. The region is currently the world’s


Lexus announces luxury hybrid MSRP, hybrid sales increase

Toyota Motor Corp. has announced the manufacturer’ssuggested retail price (MSRP) for its 2008 Lexus LS 600h Lluxury hybrid sedan: $104,000. The LS Hybrid is equippedwith a 5.0-liter V8 gas engine with a high-output electronic

motor and is expected to receive a Super Ultra-Low Emission Vehicle Rating and produce 70% less emissions

than its cleanest competitors. In addition, the vehiclefeatures a full-time all-wheel drive system and a

dual-stage electronically controlled continuously variabletransmission. The combination results in power and performance similar to that of 12-cylinder engines.

www.lexus.com

biggest importer of flat steel and will continue to relyheavily on imports in the future.

Through direct entry to the USA, the Stainless groupaims to sustainably expand its business in NorthAmerica. Significant growth is forecast for the USA,Canada, and Mexico. Experts predict average growthrates of over 3% per year in the NAFTA region up to2012. ThyssenKrupp Stainless intends to participate inthis growth of the North American market. www.thyssenkrupp.com

Goodrich ships first thrust reversers for Boeing 787 Dreamliner

Goodrich Corp. has delivered its first set of Boeing787 Dreamliner thrust reversers to be installed on Rolls-Royce Trent 1000 engines for the 787 flight test programscheduled to begin later this year. Goodrich shipped thethrust reversers from its site in Chula Vista, Calif. whichalso performed final assembly, to a Rolls-Royce enginefacility in Derby, U.K. Goodrich’s team in Chula Vistais building the thrust reversers and nacelle systems forboth engine options offered on the 787, the Rolls-RoyceTrent 1000, and the General Electric GEnx. Goodrich willmanufacture nacelles and thrust reversers for six flighttest airplanes — three for each engine type — as well asa spare set for each engine variant. www.goodrich.com

Swedish metal powder technology group Hoganas AB says that itssubsidiary Hoganas Brazil Ltd. has decided to invest approximately$7 million to build a new manufacturing plant in Mogi das Cruzes,Sao Paulo. The new 3000 m2 plant will be built within its existing man-ufacturing complex in Mogi das Cruzes, and will double its manufac-turing capacity for iron powder in Brazil. www.hoganas.com

Hyundai Motor Co. broke ground for the construction of its $1.5billion manufacturing plant in Nosovice, Czech Republic. It will havethe capacity to build 200,000 vehicles annually beginning in 2009.

Leica Microsystems has established a new Sales Subsidiary officein Belgium, to directly handle sales and after-sales support of its com-plete product range. The news sales subsidiary is Leica Microsys-tems Belgium BVBA, located near Brussels. www.leica-microsystems.com

Rolls-Royce Fuel Cell Systems (US) Inc., has acquired the assetsof Ohio-based SOFCo-EFS Holding, LLC from McDermott Inter-national Inc. www.rolls-royce.com

SeverCorr announces plans to accelerate expansion of its plant inMississippi. Plans include the installation of a second production linethat will more than double the mill’s capacity, increasing its annual pro-duction to 3.4 million tons of high-quality steels. www.severcorr.com

Tata Steel has completed its $12 billion acquisition of Corus Groupplc. The enlarged company will have a crude steel production of 27 mil-lion metric tons in 2007 and will be the world’s fifth largest steel pro-ducer with 84,000 employees across four continents. www.tatasteel.com

B R I E F S


BUSINESSTRENDS

U.S. R&D increased by 6% in 2006Current-dollar R&D conducted in the United States increased 6.0%, or $19.3 billion, in 2006

to a level of $342.9 billion, according to projections released by the National Science Foundation.In 2005, current-dollar R&D had increased by 7.8%, or $23.5 billion, to $323.5 billion. Estimates

for 2005 and 2006 are based on projections andsurvey data that are incomplete or subject to fur-ther revision.

Real domestic research and development, de-fined as expenditures on R&D adjusted to ac-count for inflation, increased by 3.5% in 2006. In2005, real R&D had increased by 5.0%. The in-crease in real R&D in 2006 primarily reflectedgrowth in R&D by for-profit companies oper-ating in the United States. R&D by federal agen-cies and in federally funded research and devel-opment centers declined in 2006. R&D byuniversities and colleges and by nonprofit insti-tutions both increased. For more informationand detailed tables, visit http://www.nsf.gov/statistics/infbrief/nsf07317/#fn2#fn2.

Auto industry plans to boostproduction of flex-fuel cars

General Motors Corp., Ford Motor Co., andthe Chrysler Group have vowed to ramp up pro-duction of vehicles that can run on either gaso-line or ethanol blends at a time when energy se-curity and global warming concerns are topissues for policy makers, says the NationalEthanol Vehicle Coalition. However, the auto in-dustry’s ability to successfully bring the so-called“flex-fuel” vehicles to market faces a number of

obstacles, including a limited distribution system, a small number of gas stations, and low con-sumer awareness.

Leaders of GM, Ford and DaimlerChrysler AG’s Chrysler Group met with President Bush re-cently to discuss ways of getting more motorists to buy vehicles powered by E85, which is 85%ethanol and 15% gasoline. The Detroit automakers, which have produced about six million flex-fuel vehicles (FFVs) since the mid-1990s, reissued a pledge to double production to about 2 mil-lion a year by 2010, amounting to 20% of their expected production. www.e85fuel.com

Bombardier forecasts 9950 corporate aircraft deliveries Aircraft maker Bombardier Inc. says it expects demand will remain strong for the planes it

makes for the next ten years. The Montreal-based company’s air division, Bombardier Aerospace,says that the corporate aircraft market is expected to see 9950 deliveries, excluding very light jets,between 2007 and 2016, for market-wide revenues of $227 billion. In its 20-year commercial aircraftmarket forecast, Bombardier says demand for 20-to 149-seat commercial aircraft will reach about11,200 new planes with a total value of $393 billion. www.bombardier.com

Steel gains market share with aggressive partnership tacticsThe North American steel industry and its strategic partners are advancing steel’s competi-

BRIEFSAcciona, the world’slargest wind power developer, announces thatit will develop its first windturbine production plant in the United States, in the state of Iowa. www.acciona-energy.com

Alcoa announces that thefirst quarter 2007 incomefrom continuing cash fromoperations in the firstquarter rose to a record$527 million, an improvement of more than$700 million from the firstquarter of 2006.www.alcoa.com

Continental Alloys &Services (formerly Continental CasingLtd.) announces the acquisition of the businessof Alloy & Oilfield Pte.Ltd. (formerly Alloy &Oilfield MachiningServices Pte.Ltd.) andOilfield MachiningServices Pte. Ltd. Singapore. www.contalloy.com

Diaphorm Technologies LLC, aleading fabricator of continuous fiber reinforced composite partsfor sports, automotive aftermarket, and ballisticarmor applications, hasacquired Pro Police Products, a top U.S. distributor of helmets and accessories for police,paramilitary, and correctional forces.www.diaphorm.com

U.S. factory orders jump by largest amount in a year

Orders to U.S. factories surged in March by thelargest amount in a year, an encouraging sign that the

recent slowdown in manufacturing may be ending, saysthe U.S. Commerce Department. Total factory orders

rose by 3.1% in March, pushed higher by a big jump indemand for commercial aircraft and the biggest rise in

the category that tracks business investment in newequipment in 2.5 years.

The increase was far better than the 2% figure thatanalysts had been expecting and offered hope that manufacturers were beginning to experience rising demand after a recent weak period brought on by

troubles in housing and auto sales. The good news onfactory orders followed a report from the Institute forSupply Management that its closely watched gauge ofmanufacturing activity rose to 54.7 in April, the best

showing in 11 months. The index had dipped below 50in November and January, indicating the manufacturing

sector was contracting, as companies trimmed inventories to cope with the serious slump in housing

and an overhang of unsold autos. Orders for nondurablegoods, such as petroleum and chemicals, rose by 2.3%,

the biggest gain since January 2006.www.commerce.gov


B R I E F S

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tive edge in today’s marketplace with their commitment to investment in advanced tech-nologies and the development of advanced design solutions, says the American Iron andSteel Institute. Through a collective annual investment of nearly $25 million, steel is redefiningcompetitive materials decisions in the automotive, construction, and container markets. Re-sults include a 44.6% increase in advanced high-strength steels for automotive design, anda 47% increase in cold-formed steel framing for commercial construction.

Steel’s impact on the marketplace is documented in the AISI Market Development Progress Re-port 2006-2007, released at the American Iron and Steel Institute’s General Meeting held May6-8, 2007, in Henderson, Nevada. With the theme “Advancing Steel’s Competitive Edge,”the report shows how the industry’s investment in strengthening traditional markets anddeveloping new-growth markets is providing customers with steel-intensive, cost-effectivesolutions. www.steel.org

NASA awards heat shield contracts for Orion spacecraftNASA has selected the Boeing Company, Huntington Beach, Calif., and Textron Systems,

Wilmington, Mass., to develop alternate heat shield materials for the Orion crew explorationspacecraft. The two contracts for Alternate Block 2 Thermal Protection System(TPS) Ma-terials and Heat Shield Systems Advanced Development will support development andtesting of three alternative heat shield materials, designs, and manufacturing processes. InSeptember 2006, Boeing was awarded a contract to develop the primary heat shield ma-terial, Phenolic Impregnated Carbon Ablator (PICA), manufactured by its subcontractor,Fiber Materials Inc., Biddeford, Maine. The Alternate Block 2 contract awarded to Boeingcalls for Boeing to investigate a proprietary material, the Boeing Phenolic Ablator (BPA).

The contract awarded to Textron calls for Textron Systems to investigate two proprietarymaterial options, Avcoat (used on Apollo) and Dual Layer.

For more information: John Bluck, NASAAmes Research Center, Moffett Field, CA 94035; tel: 650/604-5026; [email protected]; www.arc.nasa.gov.


Ducommun Inc. an-nounces that its Ducom-mun AeroStructures Inc.(DAS) subsidiary has beenawarded a follow-on contractfor the fabrication and de-livery of additional advancedcomposite main rotor bladesfor the S-61 helicopter.ww.ducommun.com

Edgen Murray Corp. hassigned an Asset PurchaseAgreement to acquire sub-stantially all of the assets andcertain liabilities of Petro-Steel, a U.S. based distrib-utor of specialty offshoregrade steel plates and pro-files. www.edgenmurray.com

Intermet Corp., a manu-facturer of cast metal automo-tive components, has sold itsEuropean operations toSakthi Auto Compo-nents Ltd. www.intermet.com

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