SAF 3007 is the latest addition to the growing duplex family of Alleima, a super-duplex stainless steel grade developed for subsea umbilicals.

The new tube offers a safe, lighter, stronger and more efficient alternative to SAF 2507, the current standard. With superior strength, fatigue properties and excellent corrosion resistance, SAF 3007 delivers superior performance in harsh deepwater environments.

Alleima is a global manufacturer of high value-added products in advanced stainless steels and special alloys. Since the 1960s, the company has been at the forefront of developing modern duplex grades and now offers a broad portfolio.

The new tube product represents the next generation of super-duplex seamless tubing developed specifically for the offshore oil and gas industry. It builds on the success of market-leading SAF 2507 (UNS S32750), which has become the industry standard, and further advances the duplex revolution that Alleima pioneered decades ago.

Strong Energy Demand

“Across the globe, the demand for energy is growing strong. We see a rising tide of activity in the oilfields off the coast of Brazil, in the Gulf of Mexico, North Sea and Southeast Asia. Following a dip during Covid, this new surge comes, underscoring the need for reliable, cost-efficient energy production,” says John Tokaruk, Global Product Manager for umbilical tubing at Alleima.

“As the market leader in umbilical steel tubing, we often get requests for a material matching SAF 2507 in reliability, but with reduced costs, improved fatigue life and enhanced pressure handling. SAF 3007 (UNS S83072) accomplishes all this with a ‘less is more’ approach. Thinner tube walls, thanks to its superior strength and fatigue properties, results in lower cost per meter. It offers the excellent corrosion resistance of SAF 2507, and a similar microstructure, as well as simplified welding due to thinner walls,” explains John Tokaruk.

Pioneers Of Super Duplex

For more than 40 years, Alleima has been at the forefront of developing modern duplex grades, which are typically more than twice as strong as standard stainless steel, with superior corrosion resistance. Within the oil and gas sector, the company has been active for more than 60 years, supporting most major oil and gas companies, fabricators and service companies.

For example, one Alleima customer in the Gulf of Mexico relies on umbilicals connected to the world’s deepest spar, moored in waters with depths of 2,450 metres (8,000 feet). Under such extreme conditions, system pressures may run up to 20,000 psi or more.

These “dynamic” umbilicals are floating and twisting beneath the sea surface with high stress in chloride-rich environments – precisely the kind of harsh environments where Alleima specializes.

In the mid-1990s, Alleima pioneered the utilisation of high alloy SAF 2507 as a groundbreaking alternative to thermoplastic subsea umbilical tubing. In essence, umbilicals serve as a “lifeline” connecting surface installations with subsea critical infrastructure such as wellheads. They include hydraulic lines, chemical injection fluids and electrical cables for controlling and monitoring infrastructure.

160 Million Meters Sold

The optimisation of SAF 2507 for subsea umbilicals, coupled with the dedicated Alleima mill in Chomutov, Czech Republic, ensuring fully integrated production from a single melt of 80 % recycled steel in Sandviken, Sweden, guarantees high quality. The large reels, with long lengths of orbitally welded coils, soon set the industry standard. Over the past 30 years, Alleima has supplied more than 160 million metres (525 million feet) to all major fabricators and applications, equal to circling the world three times.

More Tungsten And Chrome

“To enhance the performance of SAF 2507, we fine-tuned the chemical composition. As a result, SAF 3007 features additional chromium at 30%, reduced molybdenum at 1% and, for the first time, Alleima introduces tungsten at 3.4% to the duplex family of tube alloys. The inclusion of tungsten in preference to molybdenum maintains the corrosion resistance after welding, which is crucial for the umbilical application. Taken together, these properties are ideal for ‘dynamic umbilicals’ that are floating and twisting below the ocean surface with high stress in chloride-rich environments,” says Charlotte Ulfvin, Senior R&D Researcher at Alleima.

SAF 3007 Chemical Composition (nominal), %

C	Si	Mn	P	S	Cr	Ni	Mo	W	N
≤0.030	0.2	1.0	≤0.030	≤0.030	30	7	1.0	3.4	0.40

“The launch of SAF 3007 marks the next step in our duplex evolution, fulfilling customer demands for a next generation umbilical tube with less material and thinner walls. Thanks to the refined chemical composition we provide a lighter tube that streamlines the entire manufacturing process. It will be made available in a broad size range by the end of 2024,” concludes Tom Eriksson, Executive Vice President and Head of R&D at Alleima.

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Over 118,000 square metres of the Düsseldorf Fairgrounds are occupied. Trade visitors from all over the world are expected. With around two thirds of the exhibitors, wire and Tube are among the trade fairs with the highest internationality in Messe Düsseldorf’s portfolio. They come mainly from the strong European production countries, from the USA, Central and South America, Asia and the African continent.

Daniel Ryfisch, Director wire/Tube & Flow Technologies at Messe Düsseldorf

“The Düsseldorf trade fair venue is the absolute front-place for the wire and Tube sectors when it comes to presenting innovations from the relevant industries to a broad, international audience,” says a delighted Daniel Ryfisch, Director wire/Tube & Flow Technologies at Messe Düsseldorf.

In addition to the classic themes such as machinery and equipment for wire, cable and tube production, processing and end products, wire and Tube place a strong focus on topics such as stainless steel, hydrogen, plastic tubes, cutting and slitting technologies and e-mobility. In addition, the topics of fastening and joining technologies, spring manufacturing technology and glass fibre technologies continue to move to the fore.

The main industries here are the chemical, oil and gas sectors, the automotive industry, the construction sector and the entire telecommunications sector.

wire 2024 occupies exhibition halls 9 to 17: wire, cable, wire products and technologies are scheduled in halls 9 to 12 and hall 15. Meet China`s Expertise can be found in Hall 14.

Hall 16 will become a special hall for fastening and fixing technologies and for spring making technology, including their end products such as screws, grooves, eyelets and technical springs. This creates an exclusive, separate technology area here. The large area for heavy, space-consuming mesh welding machines will be located in the central Hall 17.

Tube 2024 occupies exhibition halls 1 to 7a: tube accessories, tube manufacturing and the tube trade are located in halls 1, 3, 4, 5, 6 and 7a. A new feature is the special area for plastic tubes and pipes in Hall 1, which provides the space for plastic tubes that they currently occupy with increasing tendency in the manufacturing and processing industries.

Forming and bending technology is to be found in Halls 4, 5 and 6, and pipe processing technology in Halls 6 and 7a. Machinery and equipment will follow in Hall 7a. Hall 7 is once again reserved for Chinese pipe producers and pipe processors with Meet China’s expertise.

Numerous specialist forums, congresses and tours such as the international meeting of experts from the sectors, a hydrogen and e-mobility congress, the ecoMetal-trails and the daily after-business-chill enrich the range of events in the exhibition halls and on the open-air site.

Even more information about exhibitors, products, industry news and trends can be found on the internet portals at www.wire.de and www.Tube.de and on linkedIn: https://www.linkedin.com/showcase/wire-and-tube-leading-international-trade-fairs/

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Metal matrix composites (MMCs) comprise metallic matrix with ceramic or metallic reinforcement. Exhibiting high strength, modulus, hardness, and improved tribological properties, MMCs replaced monolithic alloys in aerospace and transportation.

A variety was developed with different matrices like aluminium (Al), copper (Cu), and stainless steel. Aluminium matrix composites (AMCs) reinforced with various particulates including Al₂O₃, SiC, TiC, and B₄C were studied.

Studies on AMCs’ electrochemical properties reinforced with various ceramic reinforcements, including Al₂O₃/SiC, B₄C, SiC, and AlN, indicated composites exhibit decreased corrosion resistance compared to monolithic alloy. This is from continuous passive film on matrix–reinforcement interface’s breakdown, formation of galvanic couples between Al and reinforcement, voids at matrix–reinforcements interfaces, interfacial layers around the reinforcement promote galvanic effect, and up the dislocation density around particles clusters.

Al-based composites’ decreased corrosion resistance compared to monolithic alloys is from  pitting corrosion at interfaces between reinforcing particulates, secondary precipitates, and reduced oxygen on cathodic particles and precipitates. Introducing reinforcement in the Al matrix leads to improved corrosion performance.

Formation of reaction products acting as barriers, interrupting matrix channel continuity, and decoupling matrix/reinforcement improve corrosion performance. Other researches revealed AMCs exhibited comparable corrosion resistance with monolithic alloy.

The reinforcement effect on AMCs’ corrosion performance vary from environment and processing route. Other factors modifying corrosion behaviour include primary interfacial reaction products between matrix/reinforcement, secondary precipitates as cast and heat-treated states, aging kinetics, and electrolyte type.

Read more here 

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The post Microstructure And Corrosion Performance Of Aluminium Matrix Composites Reinforced With Refractory High-Entropy Alloy Particulates appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

Electro-chemical Machining (ECM) is for tricky materials such as alloy steel, Ti alloys, super alloys including stainless steel. Studies were conducted to evaluate the effect of ECM process parameters such as electrolyte concentration, current and voltage, surface finish, material removal rate (MRR), tool and workpiece gap current and voltage for its optimisation with different materials.

ECM is non-contact and gives exact replica of the tool, a cavity in the job material. A high current is passed through the anode and the cathode through an electrolyte and a cavity (as the shape of the tool) is obtained in the workpiece. EDM is better for smaller batch sizes whereas ECM is suitable for large scale production.

Researchers Neto J., et. al.’s found feed rate affects the material removal rate. In ECM, NaNO₃ showed good results on surface roughness (Ra) and overcut. Material removal rate increased with heightened tool feed rate due to decrease in machining time. Sodium chloride (NaCl) had better machining results on MRR than Sodium Nitrate as NaCl solution is a non-passivated electrolyte and has constant current efficiency.

Milan Kumar Dasa, et.al.’s ANOVA results revealed the electrolyte concentration has maximum influence on metal removal rate and Ra characteristics. P. Rodriguez et. al. current intensity increase affects the material removal rate and as it increases, surface finish decreases in the ECM process.

There should be a balance in between material removal rate and the surface finish. Kai Egashira et.al. suggested a semi-cylindrical tool electrode, long pulse width, high pulse frequency, high low-level voltage, and high electrolyte concentration were preferable for high-speed drilling without widening the lateral gap between tool electrode and hole.

Ming-Chang Jeng et al. found material removal rate and current efficiency increases with carbon content. Moreover, quenched microstructure and tempered microstructure have a greater removal rate and current efficiency than those of annealed microstructures, work-piece machined at a pressure of 3-4 kg/cm² has highest removal rate and current efficiency. Roughness of machined surface of the annealed microstructure is greater than quenched and tempered steels.

Read more here  https://rb.gy/gj45jl

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The post Effect on Material Removal Rate and Surface Finish In ECM Process When Machining Stainless Steel-316 with Cu Electrode appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

This marks another major achievement by Professor Huang’s team in its ‘Super Steel’ Project, following the development of the anti-COVID-19 stainless steel in 2021, and ultra-strong and ultra-tough Super Steel in 2017 and 2020 respectively. The new steel developed by the team exhibits high corrosion resistance, enabling its potential application for green hydrogen production from seawater, where a novel sustainable solution is still in the pipeline.

The performance of the new steel in salt water electrolyser is comparable to the current industrial practice using Titanium as structural parts to produce hydrogen from desalted seawater or acid, while the cost of the new steel is much cheaper. The discovery has been published in Materials Today in the paper titled “A sequential dual-passivation strategy for designing stainless steel used above water oxidation.” The research achievements are currently applying for patents in multiple countries, and two of them has already been granted authorisation.

Since its discovery a century ago, stainless steel has always been an important material widely used in corrosive environments. Chromium is an essential element in establishing the corrosion resistance of stainless steel.

Passive film is generated through the oxidation of chromium (Cr) and protects stainless steel in natural environments. Unfortunately, this conventional single-passivation mechanism based on Cr has halted further advancement of stainless steel.

Owing to the further oxidation of stable Cr₂O₃ into soluble Cr(VI) species, tranpassive corrosion inevitably occurs in conventional stainless steel at ~1000 mV (saturated calomel electrode, SCE), which is below the potential required for water oxidation at ~1600 mV. 254SMO super stainless steel, for instance, is a benchmark among Cr-based anti-corrosion alloys and has superior pitting resistance in seawater; however, transpassive corrosion limits its application at higher potentials.

By using a “sequential dual-passivation” strategy, Professor Huang’s research team developed the novel SS-H₂ with superior corrosion resistance. In addition to the single Cr₂O₃-based passive layer, a secondary Mn-based layer forms on the preceding Cr-based layer at ~720 mV. The sequential dual-passivation mechanism prevents the SS-H₂ from corrosion in chloride media to an ultra-high potential of 1700 mV. The SS-H₂ demonstrates a fundamental breakthrough over conventional stainless steel.

“Initially, we did not believe it because the prevailing view is that Mn impairs the corrosion resistance of stainless steel. Mn-based passivation is a counter-intuitive discovery, which cannot be explained by current knowledge in corrosion science. However, when numerous atomic-level results were presented, we were convinced. Beyond being surprised, we cannot wait to exploit the mechanism,” said Dr Kaiping Yu, the first author of the article, whose PhD is supervised by Professor Huang.

From the initial discovery of the innovative stainless steel to achieving a breakthrough in scientific understanding, and ultimately preparing for the official publication and hopefully its industrial application, the team devoted nearly six years to the work.

“Different from the current corrosion community, which mainly focuses on the resistance at natural potentials, we specialises in developing high-potential-resistant alloys. Our strategy overcame the fundamental limitation of conventional stainless steel and established a paradigm for alloy development applicable at high potentials. This breakthrough is exciting and brings new applications.” Professor Huang said.

At present, for water electrolyser in desalted seawater or acid solutions, expensive Au- or Pt-coated Ti are required for structural components. For instance, the total cost of a 10-megawatt PEM electrolysis tank system in its current stage is approximately HK$17.8 million, with the structural components contributing up to 53% of the overall expense.

The breakthrough made by Professor Huang’s team makes it possible to replace these expensive structural components with more economically steel. As estimated, the employment of SS-H₂ is expected to cut the cost of structural material by about 40 times, demonstrating a great foreground of industrial applications.

“From experimental materials to real products, such as meshes and foams, for water electrolysers, there are still challenging tasks at hand. Currently, we have made a big step toward industrialisation. Tons of SS-H2-based wire has been produced in collaboration with a factory from the Mainland. We are moving forward in applying the more economical SS-H₂ in hydrogen production from renewable sources,” added Professor Huang.

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The post HKU Engineering ‘Super Steel’ Team Develops New Ultra Stainless Steel For Hydrogen Production appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

Electro-chemical Machining (ECM) is for tricky materials such as alloy steel, Ti alloys, super alloys including stainless steel. Studies were conducted to evaluate the effect of ECM process parameters such as electrolyte concentration, current and voltage, surface finish, material removal rate (MRR), tool and workpiece gap current and voltage for its optimisation with different materials.

ECM is non-contact and gives exact replica of the tool, a cavity in the job material. A high current is passed through the anode and the cathode through an electrolyte and a cavity (as the shape of the tool) is obtained in the workpiece. EDM is better for smaller batch sizes whereas ECM is suitable for large scale production.

Researchers Neto J., et. al.’s found feed rate affects the material removal rate. In ECM, NaNO₃ showed good results on surface roughness (Ra) and overcut. Material removal rate increased with heightened tool feed rate due to decrease in machining time. Sodium chloride (NaCl) had better machining results on MRR than Sodium Nitrate as NaCl solution is a non-passivated electrolyte and has constant current efficiency.

Milan Kumar Dasa, et.al.’s ANOVA results revealed the electrolyte concentration has maximum influence on metal removal rate and Ra characteristics. P. Rodriguez et. al. current intensity increase affects the material removal rate and as it increases, surface finish decreases in the ECM process.

There should be a balance in between material removal rate and the surface finish. Kai Egashira et.al. suggested a semi-cylindrical tool electrode, long pulse width, high pulse frequency, high low-level voltage, and high electrolyte concentration were preferable for high-speed drilling without widening the lateral gap between tool electrode and hole.

Ming-Chang Jeng et al. found material removal rate and current efficiency increases with carbon content. Moreover, quenched microstructure and tempered microstructure have a greater removal rate and current efficiency than those of annealed microstructures, work-piece machined at a pressure of 3-4 kg/cm² has highest removal rate and current efficiency. Roughness of machined surface of the annealed microstructure is greater than quenched and tempered steels.

Read more here  https://shorturl.at/mpL03

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The post Effect on Material Removal Rate and Surface Finish In ECM Process When Machining Stainless Steel-316 with Cu Electrode appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

Combined Design And Welding Competence

Founded by Hannes Holl in 2009, FERRUM.AT is not only known for its immense flexibility in high-quality contract manufacturing work, but also supports the development of new products and prototypes that are ready for series production. Aluminum, steel, stainless steel, brass, and copper are welded in different sheet thicknesses.

Dedicated professionals, SolidWorks 3D software, and high-quality machinery including laser, rolling, and bending systems, as well as digital high-tech welding systems are all available for this purpose. Many of the often challenging tasks begin with extensive feasibility checks, during which the experienced experts evaluate the component weld ability in terms of design, material, dimension, suitability of welding processes, or the effect of welding sequences on component distortion. Even complex clamping devices are designed.

The cross-industry service and product portfolio is extremely broad and ranges from outdoor facilities to roof components, facade and steel construction elements, pressure vessels, machine and wagon components, and designs for bridge construction. The company welds for customers from Germany to Greece.

MIG/MAG & TIG—Two Welding Systems Were One Too Many

Often, component accessibility, material, and design require individual components be welded using both the MIG/MAG and TIG processes at FERRUM.AT. Before the multifunctional welding systems from Fronius, two different device types were required: one MIG/MAG and one TIG.

The space needed was enormous, and the constant switching between two welding systems was inefficient. Therefore, they were looking for efficient and reliable multifunctional welding systems. These systems should provide significant time savings, without compromising on welding quality and causing downtimes.

Read more here !

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In this study, the data used in GRA were normalised. Due to the desired smaller roughness and kerf width, Equation (2) was used for normalisation. In this equation, minx_i⁰(k) represents the minimum value of x_i⁰(k), maxx_i⁰(k) represents maximum x_i⁰(k), and yi^(k) represents the normalized value. x⁰ also represents the best optimized value.

After normalisation, the grey relational coefficient (GRC) is defined with Equations (3) and (4) to discover the relation between the real and ideal sequences. The weight factor determinations for each response are crucial in the GRA method. However, the effect of surface roughness and kerf width on the quality of the cutting surface is greater than other quality characteristics. Therefore, the weights of the responses should not be chosen without a reasonable quantitative basis to increase or decrease its importance.

In most of the studies, the weights of the responses are generally determined to be equal. ξ represents the coefficient of identification as 0 . . . 1, and is usually accepted as 0.5. Δmax represents the maximum and Dmin represents the Δminimum value of  Δ0i. y_i0^(k) represents the comparable sequence and yi(k) represents the reference sequence. Δ0i also states the difference between y₀^(k) and y_i^(k).

In the last step, the grey relational grade (GRG) is obtained with the help of a normalized weight factor. The grey relational grade represents the correlation level between the comparable sequences and reference sequences. The best optimum level of cutting process parameters is defined by the highest grey relational grade.

Read more here —> https://shorturl.at/abgru

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The post Multi-Objective Optimisation Of Fiber Laser Cutting Of Stainless Steel Plates Using Taguchi-Based Grey Relational Analysis (Part 2) appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

1. Introduction

Developments in laser technology have been evolving in the recent years. Laser cutting stands out due to machining quality and cost saving, among other conventional material cutting processes for both metal and non-metallic substrates.

The advantages of laser cutting are precision, automation, high speed, reproducibility, quality, cost effectiveness, and non-contact cutting possibility. A laser beam is focused on the cutting area of the metal surface.

With heat generated by the beam, evaporation occurs in the material, resulting in a hole. Afterwards, metal is melted by moving the laser beam, and melted material is removed from the part with auxiliary gas. Another key advantage is creating a narrow heat affected zone with the beam, which can be focused on a very small area — minimising material loss.

Nd:YAG, carbon dioxide (CO2), and fiber lasers are commonly used for the laser cutting process. Before fiber lasers became widespread, CO2 lasers were more advantageous for cutting thick materials, while Nd:YAG lasers were for thin materials requiring precise cutting.

With its high power, high beam quality and efficiency, operating at wavelengths of 1060–1080 μm, fiber lasers are employed in the industry more than other types. Fiber lasers allow a deeper effect to be created, long-focus lenses to be used with less damage to optical lenses, and long-distance applications achieved.

Since the produced laser beam is transmitted with a flexible fiber optic cable without any need for a mirror in the cutting head, there is
neither power loss nor a need for an additional cooling system.

Read more here —> https://shorturl.at/bOT36

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The world-renowned cutting tools players unveiled its latest at the show, maintaining its commitment to quality and standards in one of the world’s leading metalworking shows.

New High-Performance Grade For Thread Whirling

SG3P is the name of the newly developed Horn high-performance grade offering the user new possibilities in terms of performance and tool life when whirling medical screws. The new carbide grade also enables shorter cycle times for thread production thanks to higher cutting values, including when processing materials that are difficult to machine.

In addition, the combination of an ultra-fine grain carbide powder and the high temperature resistant coating results in high process reliability and better component quality. The carbide grade is available for all standard Horn thread whirling systems. Furthermore, in-house coating enables fast delivery times.

The production of bone screws must necessarily be carried out using a metalcutting process, as the material for this type of screw must not be compressed, as is the case with thread rolling, for example. Titanium in particular, which is mainly used in the human body because of its good biocompatibility, tends to burn if the material is compressed too much.

As a machining process, thread whirling has been established for many years. Conventional thread whirling is a process that is mainly used on Swiss-type lathes to manufacture bone screws, but also on a larger scale for the production of threaded spindles.

In the process, the rapidly-rotating whirling head is positioned eccentrically to the workpiece axis in front of the guide bush of the sliding-headstock lathe and the slowly rotating workpiece is guided into the whirling head with an axial feed movement.

High Performance In Stainless Steels

Horn has developed a new, solid carbide milling cutter range especially for machining stainless steels. The tools are for milling stainless materials in the food, chemical and pharmaceutical industries as well as the precision engineering and watchmaking industries.

Due to their geometry and good chip breaking, the milling tools are suitable for machining numerous other materials. With the precise combination of the substrate, the macro and micro geometry as well as the IG3 coating, the milling system exhibits high performance and long tool life. The coating in particular offers high temperature resistance for machining steels alloyed with chromium, nickel and molybdenum.

Horn offers the solid carbide milling tools from stock in two types. The DSHPR variant is suitable as both a finishing and a roughing tool. The geometry is also adapted for trochoidal machining and plunging. The DSR type, with its very sharp cutting edge geometry and short design, is suitable for very small parts and unstable clamping conditions, such as in the medical and watchmaking industries. In the DSHPR line, all tools are available with four teeth and in diameters from 2 mm (0.079″) to 20 mm (0.787″). Horn offers the DSR variant with three teeth in diameters from 1 mm (0.039″) to 10 mm (0.394″).

Superfinishing Of Bores

Horn presented an innovative extension for the Supermini system in the field of ultra-fine machining. The precision tool manufacturer added a variant with a precision-ground rake face to the Supermini system especially for ultra-fine machining of bores.

Due to precision grinding of the cutting edge, it is free from notches when magnified approximately 200 times. The tool system can be used from an inside diameter of 0.3 mm (0.012″).

The sharp insert geometry enables process reliability even with very small infeed and cutting feed rates. The specially developed coating is suitable for stainless steels, non-ferrous metals and other metallic materials.

The insert of the Supermini Type 105 system requires only one tool holder for well over 1,000 insert variants. This applies equally to left-hand and right-hand versions. The carbide inserts are available in coated and uncoated versions in different grades for every application including hard machining up to 66 HRC. The patented droplet shape of the cross-section has a vibration-damping effect and delivers excellent repeatability when changing the insert.

Internal coolant supply to the insert increases tool life, enhances cutting performance and improves chip removal. Horn offers the tools with elements for face clamping. This allows, for example, the insert to be changed easily without having to remove the holder from the machine.

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Letter to the Editor
Do you have an opinion about this story? Do you have some thoughts you’d like to share with our readers? APMEN News would love to hear from you!

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The post P Horn Pushes Boundaries At EMO Hannover 2023 appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.