Electro Magnetic Impact Treatment
Outline Goals and vision Nomasico’s main activity is the introduction and management of novel industrial services and products, with the prospect of introducing significant changes in manufacture via the introduction and establishment its innovative techniques. Nomasico Strategic goals Development, management and realization of novel production methods and services. Clientele selection in accordance to preset selection criteria. Focus on the client and configuration of novel solutions with regard to the specific needs. Constant quality improvement of processes, services and methods. Continuous development on novel technologies and investigation of existing novel processes to broader fields of application.
Industrial applications Naval Automotive Gas & oil Crankshaft Gearshift fork Rollers Piston Crown Door locks Loaders Exhaust Valve Spindle & Seat Body parts Stabilizers Exhaust Valve Housing Brakes Drill collars Cylinder Cover Cylinder liners / sleeves Valve components Heat Exchanger Construction Energy production Grader blades Aerospace Bulldozer components Turbine blade sand diaphragms Landing gear Trenchers Steam bypass top valves Gas turbine engines Drilling Pump shafts Propeller hubs Asphalt and concrete pavers Water wall panels Hydraulics Defense & homeland security Transport Agriculture Blisks Ballast sprocket Chisel ploughs MEMS Skirt plate Plough shoes Tracked vehicles Retarder yoke Cultivator disk Track pins Axle box Crushers Hard Chrome replacement Blades
Work Hardening Work hardening, also known as strain hardening or cold working, is the strengthening of a metal by plastic deformation occurring due to dislocation movements within the crystal structure of the material. Many non-brittle metals with a reasonably high melting point as well as several polymers can be strengthened in this fashion. Alloys not amenable to heat treatment, including low-carbon steel, are often work- hardened. Some materials cannot be work-hardened at low temperatures, such as indium, however others can only be strengthened via work hardening, such as pure copper and aluminum
Work Hardening Advantages & Disadvantages Advantages Disadvantages No heating required Greater forces are required Better surface finish Heavier and more powerful equipment and tooling Superior dimensional control required Better reproducibility and interchangeability Metal is less ductile Directional properties can be imparted into Metal surfaces must be clean and scale-free the metal Intermediate annealing may be required to compensate Contamination problems are minimized for loss of ductility that accompanies strain hardening The imparted directional properties may be detrimental Undesirable residual stress may be produced The technological evolution and the modern composite and complex structures, combined with the shrinkage of natural resources, demands the strengthening and metal fatigue life extension of components.
Applications Aeronautics Airframe, wing skins and undercarriage protection from fatigue and stress corrosion cracking. Aero-engine or turbine protection by adding beneficial compressive stresses. Maximize the fatigue-life of components which have complex geometries such as fans, rotors, hub-propeller connector, impellers, ball bearings. Fatigue-life maximization of cockpit and cabin frames, metallic frames and fastening systems, wheels and brakes, internal or external metal sheets.
Applications Automotive Improving life and performance for suspension, gears and transmission including crankshafts, connecting rods, Valves, pistons, cam shafts, cylinder heads and blocks. Enhancing fatigue loading of metal components such as aluminum breaks, brake drums, injectors. Improvements in surface stress and finish in competitive automotive (i.e. F1) that increases the endurance limit of 20-30% with life extension up to 30 times
Applications Defense Maintenance support and quality enhancement in materials such as Ceramic, Steel, Stainless Steel and Tungsten Carbide, materials used in military applications Expanding the applications of Aeronautics specifically to Defense Aeronautics
Applications Energy Protection for energy turbine components against erosion, fretting, fretting fatigue, fatigue and stress corrosion cracking (SCC). Reproducibility, high uniformity, surface quality for treating high value parts such as low and high pressure blades, disks and bilsks, fans, rotors and stators, gears and gearboxes
Applications Medical Protection from corrosive and high load conditions – Surgical Instruments Improved tissue adhesion - Orthopedic prosthesis and implants
Applications Nuclear Material integrity against Thermal Fatigue Cracking and Stress Corrosion Cracking. Fatigue-life improvement of Primary Pump Shaft, Pipes for reactor cooling, Partition plates, J-weld
Applications Oil & Gas Enhancing the fatigue life performance of metal critical components used in Oil & Gas Implementations
Applications Ship Const. & Repair Typical applications of shipping construction and repair Diesel Engine Fatigue sensitive parts Cam shafts Crank shafts and counterweights Connecting rods Propulsion Turbine Fatigue sensitive parts Shafts Gears Propeller
Applications Transportation Typical applications of Transportation Frogs Switch blades Welded railways structures Boggies Chassis parts
Market Analysis The market of Work Hardening seems to be a niche market. All the competitive companies rely on their know-how and patented methods to attract specific costumers. The cost of services per application is very expensive due to the expensive equipment and utilities. Industry innovation will lead to application expansion. Competitors Pfeifer: High Frequency Impact Treatment Curtiss-Wright Surface Technologies: Shot Peening, Laser Peening, Coating Surfaces Empowering Technologies: Ultrasonic Shot Peening, Ultrasonic Impact Treatment Lambda Technologies Group: Low Plasticity Burnishing, Controlled Impact Burnishing Applied Ultrasonics: Ultrasonic Impact Treatment
Competitors The currently most popular available treatments include: • Laser peening • Ultrasonic Impact Treatment • Low plasticity burnishing By introducing a certain amount of plastic deformation these techniques produce a level of residual stress so as to improve damage tolerance and fatigue or stress corrosion performance. Laser peening is a mechanical surface enhancement process. Using a high energy pulsed Laser peening laser beam, shock waves which are generated and propagate through the material are responsible for inducing cold work into the microstructure and contributing to the increased performance of the material. The laser peening process requires a laser beam a target confining media. The application of the overlays is crucial to the performance of the process and thus requires time and extreme attention from certified technicians. Furthermore as any laser related process, it is expensive.
Competitive technologies Ultrasonic Impact Treatment In Ultrasonic Impact Treatment, ultrasonic waves are produced by an electro- mechanical ultrasonic transducer, and applied to a workpiece. An acoustically tuned resonator bar is caused to vibrate by energizing it with an ultrasonic transducer. The energy generated from these high frequency impulses is imparted to the treated surface through mandatory contact of specially designed tools for impact treatment with freely movable strikers that are mounted in a holder. Low Plasticity Burnishing Low plasticity burnishing is a method that provides surface compressive residual stresses. The basic tool is a ball that is supported in a spherical hydrostatic bearing. The tool is usually held in a CNC. The machine tool coolant is used to pressurize the bearing with a continuous flow of fluid to support the ball. The ball rolls across the surface of a component in a pattern. The tool path and normal pressure applied are designed to create a distribution of compressive residual stress.
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