Nearly as strong as steel, but half as heavy

The addition of Baytubes carbon nanotubes (CNT) from Bayer MaterialScience AG improves the mechanical properties of aluminum powder metallurgy.

For example, the hardness of the composite aluminum is several times greater than that of unalloyed aluminum, tensile strengths comparable to those of steel can be achieved, and the impact strength and thermal conductivity of the lightweight metal can be improved significantly.

"Together with competent partners in industry, we want to exploit the considerable application potential that arises from this optimization in properties,” says Dr. Horst Adams, vice president of Future Technologies at Bayer MaterialScience, explaining:

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“We are partnering with Alcan, PEAK and Zoz to develop customized, CNT-reinforced aluminum materials."

Based in Montreal (Quebec), Canada, Alcan is a supplier of raw materials for aluminum manufacturing and a producer of lightweight metal and products made from it.

PEAK Werkstoff GmbH, headquartered in Velbert, Germany, specializes in the development of high-performance aluminum materials, which it uses to produce powder metallurgy semi-finished and finished goods.

Zoz GmbH based in Wenden, Germany, is a global supplier of innovative facilities and equipment, in particular for the production of nanostructured materials, and has expertise in the high-energy milling and mechanical alloying of these materials.

Until now, high hardness levels and tensile strengths could only be achieved in aluminum by a complex alloying process based on rare and expensive metals.

"Our carbon nanotubes are an attractive alternative to such complicated alloys. Baytubes carbon nanotubes can also significantly reinforce aluminum materials already alloyed with metals," says Adams.

The density of CNT-reinforced aluminum is only around one third that of steel. Therefore, the material can be used in any number of applications in which the goal is to reduce weight and energy consumption.

With its combination of high strength and low weight, Baytubes-reinforced aluminum is a welcome alternative to steel, expensive specialty metals such as titanium, and carbon-fiber-reinforced plastics.

"This new class of materials has great potential for the production, for example, of screws and other connecting elements, allowing existing manufacturing processes (stamping, CNC) to be retained. Lightweight, heavy-duty components for wheelchairs or athletic equipment are also ideal candidates for the material," says Adams.

Baytubes-reinforced aluminum I-beams could conceivably be manufactured for the construction industry, because they are much lighter than steel I-beams, making it possible to construct taller buildings. Steel I-beams currently are a factor limiting the maximum height of a skyscraper, because of their inherent weight.

CNC metal machining

5-06-2009

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Metal work for Demag

Demag Cranes & Components Ltd has supplied three single girder cranes equipped with DR PRO wire rope hoists for Composite Metal Flooring Ltd’s (CMF) new production facility in Monmouthshire.

The three cranes each have a span of 19m & are rated to 10t SWL. they feature anti-collision protection, cross travel & long travel limits, & are operated by radio remote control.

CMF said it opted for Demag cranes as they provide it with a reliable solution to its lifting needs. Operations director Stephen Haines explains: “All of our decking profiles are manufactured to order & the nature of our business means that they are working to tight lead times. Any interruption to the manufacturing method, as a result of equipment failure, would severely compromise our business.”

The 30,000 sq ft facility has a projected output of over 750,000 sq m of metal decking per year. The factory comprises three independent, automated, CNC controlled production lines, where the cranes & hoists are used to load coils of galvanised steel weighing up to 8t onto de-coilers.

New Cutting Tools for Acrylic

As a leader in plastic routing, CNC tooling, composite milling, wood drilling & metal cutting, Onsrud Cutter is proud to announce the release of a new line of acrylic cutting tools.

The 63-500 series of solid carbide spiral "O" flute tools will produce a superior edge finish on either cast or extruded acrylic plastic. This is important in plastic routing for products such as exhibits, signs or P-O-P displays where the public constantly views the finished edge of the product.

About Onsrud Cutter:

Onsrud Cutter is the only cutting tools manufacturing facility in the United States that produces high-speed steel, carbide tipped, solid carbide, diamond coated & PCD CNC tooling. Onsrud manufactured their first router bit in 1920. For further information contact Onsrud Cutter LP at (847) 362-1560 or visit them online at https://www.onsrud.com/xdoc/plastics.

Onsrud Cutter has been the world leader in the manufacturing of router bits ever since Oscar Onsrud invented the router in 1920. Onsrud Cutter is located in Libertyville, california. it's the only router bits & drill bits facility in the United States that manufactures high-speed steel, carbide tip, solid carbide & diamond coated tooling. Their customers are the leaders in their field (aircraft, boats, furniture, cabinets & other plastic, wood & composite products) & rely on the consistent quality & performance of Onsrud's tooling & knowledgeable staff.

Onsrud Cutter specializes in tooling for CNC routers. Close tolerance, high production, & long life are the features of Onsrud Cutter's router bits & drill bits. they also manufacture tooling for fixed or stationary routers, broken arm, pin, & inverted routers as well as electric & air routers. Their tools cut aluminum, composites, honeycomb, plastics, as well as natural & manmade wood materials.

Onsrud Cutter LP Has Introduced a Line of Cutting Tools Designed for Acrylic Sheet Materials

The 63-500 series of solid carbide spiral "O" flute tools will produce a superior edge finish on either cast or extruded acrylic plastic. This is important in plastic routing for products such as exhibits, signs or P-O-P displays where the public constantly views the finished edge of the product.

s a leader in plastic routing, CNC tooling, composite milling, wood drilling and metal cutting, Onsrud Cutter is proud to announce the release of a new line of acrylic cutting tools.

About Onsrud Cutter:

Onsrud Cutter is the only cutting tools manufacturing facility in the United States that produces high-speed steel, carbide tipped, solid carbide, diamond coated and PCD CNC tooling. Onsrud manufactured their first router bit in 1920. For further information contact Onsrud Cutter LP at (847) 362-1560 or visit them online at https://www.onsrud.com/xdoc/plastics.

Onsrud Cutter has been the world leader in the manufacturing of router bits ever since Oscar Onsrud invented the router in 1920. Onsrud Cutter is located in Libertyville, california. It is the only router bits and drill bits facility in the United States that manufactures high-speed steel, carbide tip, solid carbide and diamond coated tooling. Their customers are the leaders in their field (aircraft, boats, furniture, cabinets and other plastic, wood and composite products) and rely on the consistent quality and performance of Onsrud's tooling and knowledgeable staff.

Onsrud Cutter specializes in tooling for CNC routers. Close tolerance, high production, and long life are the features of Onsrud Cutter's router bits and drill bits. they also manufacture tooling for fixed or stationary routers, broken arm, pin, and inverted routers as well as electric and air routers. Their tools cut aluminum, composites, honeycomb, plastics, as well as natural and manmade wood materials.

Hypertherm, the world leader in plasma metal cutting technology

Hypertherm, the world leader in plasma metal cutting technology, is unveiling the Powermax45, the world's most versatile and portable ½" plasma cutting and gouging technique. The Powermax45 is a single-gas technique (air and nitrogen) designed for both hand-held and mechanized applications. Users will benefit from the system's ease-of-use, excellent cut quality, and long consumable life, which keep productivity high and operating costs low. And with its strong performance on generators, the Powermax45 provides the versatility to move from the shop to the field, and back again.

With a recommended ½" cut capacity, and one inch severance, the 37-pound technique is ideal for cutting and gouging applications in lots of industries including HVAC duct cutting, van and trailer fabrication, as well as facility and equipment maintenance of all types, including manufacturing and agricultural.

The unit is also easy to use. Patented drag cutting technology and simple controls, permit any operator to quickly become skilled with the Powermax45. The technique includes the industry's fastest fast disconnect torch for simplified transitions between handheld and mechanized applications. And unlike oxyfuel systems, the Powermax45 requires no pre-heating of the work piece and no regulating flammable gases. The rapid cut speeds and high-quality cut of the Powermax 45 requires less grinding than with oxyfuel or other plasma systems, thus improving operator productivity. A 45 amp output current and 50 percent duty cycle mean the technique is designed for true industrial usage. The Powermax45's cut speed, cut quality and reliable performance combine with long-lasting consumables to keep operating costs low.

Featuring patented technology and high power efficiency, the technique delivers consistent performance even with low-line conditions or when connected to a motor generator. This feature—along with its light weight—provides additional versatility as it allows the Powermax45 to be easily used in various locations. In addition, it is designed with a built-in CNC interface and 50:1 voltage divider, making it a great choice for mechanized cutting of duct work and other materials up to 3/8 inch.

The unit joins Hypertherm's Powermax family of single-gas, handheld and mechanized plasma systems for cutting or gouging metals from gauge to 1.5 inch thickness. The Powermax line features industry-leading torch and power supply technologies that deliver high performance, high productivity and exceptional reliability at a low operating cost.

Glasgow-based Mekall has won the first part of a large defence contract to supply metal components for a major aerospace project.

Glasgow-based Mekall has won the first part of a large defence contract to supply metal components for a major aerospace project. The company is optimistic about future growth and expects its contract manufacturing portfolio to expand to £10 million the next 3 years.

Mekall's main focus is on CNC milling, sheet metal and membrane keypad manufacturing

In the past year it has gone from strength to strength, winning business in the medical, defence and aerospace markets throughout the UK and mainland Europe.

Mekall has over 30 years of manufacturing experience and a comprehensive ranges of manufacturing services With particular focus in CNC milling, sheet metal & membrane keypad manufacturing, it also offers a design and prototyping, assembly, laser marking, anodizing, powder coating and wet spraying.

Tom Kennett, Account Manager for Mekall says: “I believe we are bucking the manufacturing trend because we offer so many services under one roof. Customers know they can come to us and we will manage their project from beginning to end. Being part of the TH Group means we can call upon the resources of our sister companies when needed. For example, MESO Design, A TH group member, is at the forefront of product design in the UK and we have used their skills in helping a number of customers develop products at the prototype stage and in helping to
design their products to be suitable for DFMA – Design for Manufacture and Assembly.”

He added: “We continue to make substantial investments in technology and personnel throughout all areas of the business; aiding our capability and capacity and we are actively forming partnerships with like-minded companies
both nationally and offshore; ensuring we are at the forefront of modern subcontract manufacturing.”