Oremet-Wah Chang Showcases Hew
International Hearth Melting Facility
IHM uses the latest in metal processing
and electron beam technology to produce melted slabs and ingots' of pure and
alloyed titanium and zirconium. Shown above: The melting-casting facility -
capable of producing multiple near-net shape heats.
On Thursday, October 22, 1998,
Oremet-Wah Chang officially opened its International Hearth Melting (IHM)
facility and, with the new titanium/zirconium reprocessing center, the
possibility of new opportunities for its customers. Richland, Washington-based
IHM is now home to one of the world's largest electron beam cold hearth
refining furnaces, a giant melting and casting facility capable of producing 22
million pounds of high performance metals per year.
IHM is already off to a good start,
according to Mr. Ingo Grosse, the facility's General Manager. In a speech
before a Grand Opening crowd of approximately 200, Grosse praised his start-up
team for its progress. "The first melt was performed on July 17, 1998.
We have since produced both 30-inch
round ingots and 26-inch x 54-inch slabs," he said. "We are moving
quickly through the start-up phase and plan to be in full production in the 1st
Quarter of 1999. We are very proud of our team -they have come a long way in a
short time."
In his speech, Mr. Ralph Nauman,
President of Oremet-Wah Chang, said he sees IHM benefiting the company's
customers immediately. "With the advent of this new hearth furnace,
Oremet-Wah Chang will be able to compete with the world's best to supply our
customers with low cost, high quality ingot, plate, and sheet," Mr. Nauman
said. "We will be able to reduce the cost of our traditional ingot
product, and we hope to support our colleagues around the world with our new
materials, so that we can participate in foreign markets that we are not in
today."
According to Mr. Nauman, customers
outside the aerospace industry will also benefit from IHM: "For example,
we plan to process zirconium slabs in this furnace for corrosion applications
in the Chemical Process Industries, and as we provide more cost-effective
zirconium
products to existing customers and
lower our costs, we think we can grow the use of zirconium products to new
customers in new applications," he said.
Dr. Carlos Aguirre who, as President of
OREMET, first envisioned International Hearth Melting, spoke about what the
addition of the facility to Allegheny Teledyne's High Performance Metals Group
means to customers. "By combining the resources of IHM with those of the
other metals companies of Allegheny Teledyne, Oremet-Wah Chang, Allvac,
Allegheny Ludlum, Rome Metals, Rodney Metals, and Titanium Industries, we
expect to become the lowest cost producer of high quality titanium and
zirconium products for the aerospace, industrial, military, and consumer markets,"
he said.
Dr. Aguirre also took the opportunity
to press for new aerospace industry specifications. "The High Performance
Metals Group and IHM will work hard to achieve universal qualifications for all
hearth melted products and will, in addition, cooperate with the industry to
permit the hearth melt to be the last melt for alloyed plate, alloyed sheet,
bar, billet, and wire, or, in other words, for all non-rotating titanium parts
in aerospace applications." He continued, "This is not going to be
easy. It will really take the cooperation and the teamwork of all of the hearth
melters to achieve this goal; but we do need to change the specifications, so
that we can advance the technology further."
Over 200 people attended IHM's Grand
Opening, which included tours of the metals processing and melting facilities.
IHM's EBCHR furnace melts up to 8,000
pounds of sponge and recycled titanium or zirconium per hour.
The Grand Opening wrapped up with
afternoon recreation and tours hosted by TRIDEC, the business development
agency for Washington's Tri Cities area, and an evening reception. Customers
who weren't able to attend the event and would like more information on or a
tour of the International Hearth Melting facility should phone Oremet-Wah Chang
at 541-812-7081 or fax requests to 541-812-7447.
AIIvac's John V. Andrews Named
President of High Performance Metals Group
Allegheny Teledyne Incorporated recently announced that Mr. John V. Andrews,
President of the company's
Allvac operations, has been named President of the company's High Performance
Metals Group. Mr. Andrews succeeds Mr. Carlos E. Aguirre, who announced his
intention to leave the company at the end of 1998.
Mr. John V. Andrews
Allegheny Teledyne's High Performance
Metals Group consists of Oremet-Wah Chang, Allvac, and Allvac-SMP. The group
produces a variety of specialty metals, including titanium and titanium alloys,
nickel-based alloys and super-alloys, specialty steel alloys, zirconium and
zirconium alloys, hafnium, niobium, and tantalum. HPMG's products serve diverse
global
markets, including commercial and
military aerospace, chemical processing, consumer products, oil and gas, power
generation, biomedical, and transportation.
"John has nearly 40 years'
experience in high performance metals and has been Allvac's President since
1971," said Mr. Arthur H. Aronson, Executive Vice President of Allegheny
Teledyne Incorporated and head of the company's Specialty Metals Segment. His
leadership, market knowledge and management skills have been key to Allvac's
profitable growth and to the development of its reputation as a high quality
producer of nickel-based alloys and superalloys and titanium alloys for global
markets. "John is uniquely qualified to help us fully realize the
synergies and growth opportunities available as we work to create a seamless
High Performance Metals Group," Mr. Aronson noted.
"Carlos has played a key role in
integrating OREMET with Wah Chang and our other specialty metals operations,
and managing the development of the new electron beam furnace. Oremet-Wah
Chang's new melt facility is unique and contains one of the largest and most
advanced electron beam furnaces of its type. The facility has recently begun
commercial production of titanium ingots and slabs and is expected to enhance
Allegheny Teledyne's cost position in the production of high quality titanium
ingots and slabs," Mr. Aronson added.
In addition to his new role, Mr.
Andrews will also continue as President of Allvac. For more information on
Allegheny Teledyne and its High Performance Metals Group companies, visit the
corporate web site at www.alleghenyteledyne.com.
IHM Fast Facts
Did you know…
• IHM is
the home of the world's largest electron beam cold hearth refining (EBCHR)
furnace in the world, with an annual capacity of 22 million pounds?
The EBCHR furnace is equipped with
eight EB guns, which provide 5.4 megawatts of power, and is capable of casting
up to 8000 pounds per hour of revert titanium. Current slab sizes include
26-in. x 54-in., producing a 43,000-pound slab, and 14-in. x 52-in., producing
a 23,000-pound slab, as well as a 30-in. diameter ingots. IHM provides
conversion services, machining and rolling the "as-cast" MEGA slab
into intermediate slab for customer's further processing.
• IHM melts CP titanium, titanium
alloys, zirconium, and zirconium alloys?
IHM will melt to standard chemistries
or work with customers to provide slab, ingot, or plate with custom chemistries
in a wide range of CP titanium, titanium alloys, zirconium, and zirconium
alloys to meet specific customer needs.
•The cold hearth
process is able to eliminate both high-density and low-density inclusions?
IHM just successfully completed
qualification for a program requiring demonstration of the removal of
high-density defects.
•IHM processes
recycle titanium ranging in size from turnings to bar and heavy plate for use
as feedstock for the furnace?
The furnace has both bar and loose feed
capabilities. The material processing department has batch and continuous shot
blasters to clean the material, metal cutting capabilities, and two compacting
presses capable of supplying 500 tons of force to compact turnings, sponge, and
master alloy.
•IHM is currently
taking orders for material and tool conversion operations and expects to be at
full production capacity by the 1st quarter of 1999? IHM currently is very competitive with
regard to price and is striving to become the low cost producer.
•IHM is a toll
converter?
IHM will process and convert customer's
recycle material to produce slab, ingot, or intermediate plate in CP titanium,
titanium, zirconium, and zirconium alloys.
If you have questions about IHM,
contact Sales at (541) 812-7026.1
Customers in search of more information
on International Hearth Melting can contact Oremet-Wah Chang at 541-812-7026
and request the latest IHM Facility Overview. This data sheet includes details
on the facility's capabilities, such as current mold sizes and available
conversion services
ANPSG Recap
Oremet-Wah Chang would like to thank
Coastal Chem, Inc. for all of its hard work in hosting the recent 1998 Ammonium
Nitrate Producers Study Group in Jackson, Wyoming. The meeting, which featured
exhibitors and vendors from around the world, was a big success, thanks in part
to the efforts of Phil Morrow and Trish Becklinger of Coastal Chem., Inc.
We also thank our 40
co-exhibitors/co-hosts: AKZO Nobel, Alloy Engineering, Betz Dearborn, BSL
Industries, C&I Engineering, CECO Group, Chemineer, Cominco Engineering Services,
CRI Catalyst, Degussa, Detection Limit Inc., Dollinger, Doyle & Roth
Manufacturing, Dynamic, Ellett Industries, Engelhard, ENPRO Rotating, Monsanto
Enviro-Chem, FBM Hudson Italiana,
H. A. Simons Ltd., H. C. Starck,
Industrial Alloy Fabricators, Johnson Matthey, Joseph Oat, KTI Fish, Lobeco,
Mid-America Industrial Liners, Nalco/Exxon, Nooter, PGP Industries, Phoenix,
Revak, Sabin Metal, SPF America, Stockhausen, Surface Chemists of Florida,
Titanium Fabrication, Tricor, Weatherly, and Yuba Heat Transfer. Special thanks
to golf scramble organizers Peter Howard and Bob Gill of Ellett Industries for
a job well done.
For specific information covered at the
show, look in two excellent industry publications, Finds and Nitrogen
magazines. Contact Finds' at 203-454-0704 (or www.finds.net) and Nitrogen
at 44-171-837-5600 (or www.cru-int.com).
We look forward to seeing you all at
next year's show. Look for an announcement in the upcoming 1st Quarter '99
issue of Outlook.
"Lucky" Bill Stamp of IMC
Agribusiness won the grand prize (a cowboy hat filled with goodies and a travel
voucher) at the '98 ANPSG Meeting. From left to right, "Cowboy' David
Gilbert, BSL; Todd Allen, BSL; and Kirk Richardson, Oremet-Wah Chang enjoy the
reception and "Lucky's" victory speech.
Corrosion/NACExpo '99
Corrosion/NACExpo '99 will take place
at the Henry B. Gonzalez Convention Center in San Antonio, Texas, April 25-30,
1999. NACE is planning 35 symposia, featuring 500 paper presentations and
expects more than 325 exhibiting companies.
Among the sea of exhibitors, will be a
total corrosion solutions team of Allegheny Ludlum, Allvac, and Oremet-Wah
Chang at Booth 355. The three companies, part of Allegheny Teledyne
Incorporated's High Performance Metals Group, offer everything from stainless
steels to nickel alloys to titanium, niobium, and zirconium, metals solutions
for a variety of corrosive environments. The group will have metal samples,
videos, and literature on hand as well as a few surprises.
Exhibit hours at NACExpo are: Monday,
April 26 - 5:30 to 8 p.m.; Tuesday and Wednesday, April 27 and 28 - 10 a.m. to
5 p.m.; and Thursday, April 29 - 10 a.m. to 2 p.m. Remember to stop by and see
us at Booth 355 in San Antonio!
Note: For conference registration
information, contact NACE at 281-228-6223.
GCAP Meeting '99
The Gulf Coast Ammonia Producers (GCAP)
Association is hosting its 20th Annual Meeting at the Radisson Hotel in Baton
Rouge, Louisiana, April 19-21, 1999. GCAP is an organization of ammonia
producing companies formed to meet at an annual meeting and share information
on the technical, environmental, safety, maintenance, and overall operational
elements of ammonia manufacturing. For information on attending or exhibiting
at the meeting, contact Betty Helm at 225-922-4351.
Stop by Oremet-Wah Chang's booth
(location TBD) for information about the company's corrosion resistant metals.
For a pre-show peek at our products, check us out at corrosionresistant.com.
Reactive Metals in Corrosive Applications Conference
Call
for Exhibitors
Oremet-Wah Chang's 1999 Reactive Metals
in Corrosive Applications Conference is now reserving space for exhibitors.
This first-of-a-kind conference, which will feature presentations from leading
chemical companies, fabricators, and consultants from around the world, will
take place at Sunriver, Oregon, September 12-16, 1999.
The Reactive Metals in Corrosive
Applications Conference will feature case histories and studies on the use of
zirconium, titanium, tantalum, and niobium as well as stainless steels in a
variety of applications where corrosion is a constant challenge, including
mineral and chemical processing, pulp and paper production, and more.
Exhibit space is limited and will be
sold on a first come, first served basis (Note: OWC's 1997 show sold out well
in advance.) Chemical Engineering magazine already has its spot
reserved! The $1,250 exhibitor fee includes a table, two conference
registrations (valued at $495 each), and admission to all breakfast, lunch and
dinner conference functions (excluding golf and other recreational activities).
For more information on exhibiting, contact Ms. Molly Burger, Exhibition
Manager, at 541-926-4211 Ext: 6530 or e-mail questions to mollytwca@proaxis.com.
Payment information
Domestic exhibitors make checks payable
to: Oremet-Wah Chang and mail them to: Oremet-Wah Chang RO. Box 460 Albany,
Oregon 97321 Att: Sheryl Renzoni,
RMCA Conference Secretary. International exhibitors contact Ms. Renzoni for
payment instructions. She can be reached by fax at 541-924-6892 or by e-mail at
srenzoni@twca.com.
We at Oremet-Wah Chang look forward to
your participation in this unique event. For more information on the
conference, check out our web site at corrosionresistant.com.
Featured Abstract
In coming issues, Outlook will feature
selected abstracts from the upcoming Reactive Metals in Corrosive Applications
Conference (September 12-16 at Sunriver, Oregon). This issue's abstract was
submitted by Etienne Soutif of BSL Industries, France with Pr Surendar Marya
and Nicolas Perry of Ecole Centrale de Nantes, France. Following is the
abstract for their paper, titled "New Perspectives of Flux Assisted GTA
Welding in Titanium Structures:
Welded titanium structures are exposed
to severe conditions in corrosive environments. Titanium grades and its alloys
are sensitive to grain growth and atmospheric contamination during welding.
Whereas, atmospheric pollution can be prevented by using properly designed
inert gas trailing shields, the grain growth reduction requires low heat
inputs. However, in case of thick components where multipass GTA welding with
chamfered bevels is a prerequisite, the epitaxial grain growth then becomes a
serious handicap.
This paper describes new developments
that involve flux application before welding in order to assemble thicknesses
up to 8-10 mm in one single layer, without any specific joint preparation.
The weld pool formation is governed
mainly by convection flow induced by two body forces, i.e., electromagnetic and
two surface shear forces, which are surface and aerodynamic drag. It is
believed that, at nominal currents, surface tension forces are the most
important factor. Based on these considerations, a systematic study on the effect
of different inorganic fluxes on weld penetrations in GTAW and convection LASER
welding has been carried out on two Titanium Grades, namely T-40 and TA6V. The
arc characteristics generated by flux application during GTAW are analyzed by
video monitoring. The results on GTAW relate arc modification and weld
morphology.
Some of the most efficient fluxes are
found to drastically reduce surface tension leading to weld depressions and
increased weld penetrations. The LASER welds in non Key-Hole mode indicate the
effect of temperature gradients of surface tension on weld penetrations.
Comparison of flux behavior in GTA and LASER welding in non Key-Hole mode
allows differentiation of arc modification and surface tension effects.
This paper will present a summary of
results and discuss a theoretical model of enhanced penetrations. The new
perspectives offered by this technique will also be detailed through different
examples of weld configurations and potential industrial application cases.
Look for more Reactive Metals in
Corrosive Applications Conference abstracts in upcoming Outlooks. For more
information on the show, contact Conference Secretary, Sheryl Renzoni, at
541-926-4211 ext: 6280.m
ZR-702 impact Strength
By Jack Tosdale and Derrill Holmes
Toughness or impact strength of a
material is a measure of its ability to resist fracture. Toughness is usually
measured in a notch type-impact test, with the Charpy V-notch test being most
common. In this test, a notched
specimen is placed in a vise so that both ends are supported. A swinging
pendulum of a known weight strikes the specimen on the opposite side from the
notch, fracturing the specimen at the notch. The energy absorbed to fracture
the specimen is measured from the swing of the pendulum. This result is usually
expressed in foot pounds (ft-lbs) or joules and is a relative indicator of the
material's toughness.
The tendency of most metals to fail in
a brittle manner is affected by several factors, including the presence of
stress concentrators (notches, scratches, etc.), rate of stress application
(impact), and temperature. The metal characteristics, such as grain size and
presence of non-metallic or intermetallic particles, generally affect the
concentration of stresses.
In steels, an increased carbon level (a
non-metallic) decreases the impact strength, especially when the carbon is
present as acicular shapes rather than spheroidal precipitates. When the carbon
precipitates are more acicular, they act as stress concentrators at their
points or tips. This same mechanism will act in zirconium (Zr) with carbides,
nitrides, hydrides, phosphides, and sulfides if they are sharp enough to act as
stress risers.
Fine grains will increase the toughness
by acting as barriers to the propagation of a crack, either from the notch or
within the metal• Each grain, being mono-crystalline, is much more resistant to
crack initiation at its surface.
Once a crack is initiated in a grain,
its continued propagation under stress requires much less energy than the
initiation of the crack. This means that each time a fracture front moves
through a grain into its boundary, it must reinitiate the fracture into the
next grain•
Under some conditions, especially in Zr
weld material, intermetallics can precipitate into large particles, more notably
in the grain boundaries. This condition requires a higher temperature heat
treatment to diffuse these intermetallics into the grains• This heat treatment
produces a material with better corrosion resistance and impact strength.
In 1991 and 1992, Wah Chang tested many
lots of Zr-702 plate for impact strength, using the Charpy V-notch test.
Derrill Holmes, a corrosion specialist in our Corrosion Lab has compiled and
reviewed that impact data to see what correlations and conclusions could be
drawn from it. Variables studied included the non-metallics, C, O, N, and H,
and metallics Fe and Cr on the impact values of Zr-702 plate from 1/8 in. to
just over 1 in. thick.
The impact values for those elements
having a significant effect are shown in the table below. This table shows
first, that impact values are much higher in the transverse direction to
rolling than in the longitudinal direction (sample length in the rolling
direction). Also, thicker plates were lower in impact strength than thinner
ones. Neither carbon nor nitrogen showed a significant effect on the impact
values in either direction. This may be the result of the low concentrations of
these two elements. However, oxygen, hydrogen, iron plus chromium, and
thickness all showed significant effects on impact strength.
Higher hydrogen levels appeared to
improve the toughness in the longitudinal samples• This may be from a cooling
rate effect, where thicker pieces cool slower so more hydrides may form as
discrete precipitates. These hydrides then act as stress concentrators
promoting fracturing. In faster cooled thinner plates, the hydride will be more
apt to remain in solution and help the toughness. The opposite effect in the
transverse direction is probably due to the resultant hydride orientation.
The Fe and Cr levels appear to have a
minor effect; however, more study will need to be done to confirm the noted
effects.
Oxygen helps to improve the impact
strength in both directions by increasing overall material strength without
forming precipitates of a size to act as stress risers.
The results posted here show there is
considerable variability in impact values. Some of this variability is inherent
in the testing method and some is attributable to the chemical makeup of the
Zr-702. We intend to test further to better understand cause and effect
relations for material chemistry, metallurgy, and fabrication variable,
especially heat treatments.
For more information on impact and
corrosion testing services, contact Mr. Jack Tosdale at 541-917-6777.
An inside Scoop on ASTM
Mr. Jack Tosdale, who heads Oremet-Wah
Chang’s Corrosion Laboratory effort, submitted this month’s Q&A. Since Mr.
Tosdale is involved in several ASTM committees (including Chairman of the Zr/Hf
subcommittee), he is often asked about the standards development organization.
He answers a few of these questions in this issue of Outlook. Incidentally,
ASTM, which stands for The American Society for Testing and Materials, is
celebrating its 100th birthday this year (1998)!
Question: What is ASTM?
Answer: The
American Society for Testing Materials is one of the largest standards
development systems in the world, consisting of 32,000 volunteers from all over
the world and a staff of approximately 200 to support the publication of over
10,000 standards each year. This development effort is distributed among 132
writing committees. Standards under the ASTM jurisdiction include test methods,
material specifications, practices, guides, classifications, and terminology.
They encompass metals, paints, plastics, textiles, petroleum, construction,
energy, the environment, consumer products, medical services and devices,
computerized systems and databases, electronics, sporting apparel and
equipment, exercise equipment, fire protection devices, and many others. As you
can see, ASTM's work covers many items you come in contact with every day.
Question. How are standards
established?
Answer: ASTM standards are credible and
official because they are established by consensus, involving the combined
efforts of producers and users. This ensures a product standard that is
acceptable to all parties. Consensus standards are developed through the
cooperation of all parties who have an interest in participating in their
development and use. A consensus standard must be accepted by all interested
parties; if however, there is a negative vote on a controversial item, the
standards committee has the authority to overrule that vote.
Question. How is Oremet-Wah Chang
involved with ASTM?
Answer: OWC is very involved with the B10
Committee on reactive and refractory materials. Four subcommittees of B10
exist, covering titanium (B10.01), zirconium and hafnium (B10.02), niobium and
tantalum (B10.03), and tungsten and molybdenum (B10.04). The standards covered
by each of the four B10 material subcommittees are shown in the table below.
Question: How can I participate?
Answer: To further promote standards development,
ASTM sponsors symposia and technical training sessions. The B10 Committee has
sponsored symposia on Zr in the nuclear industry (the 13th is now being planned
for 2001) and Zr and Ti in industrial applications. In addition, ASTM provides
continuing education and training on the use and application of ASTM standards.
For more information about serving on a committee or attending symposia and
other events, contact ASTM at 610-832-9500 or visit its web site at
www.astm.org.
OWC Offers Corrosion Laboratory Services
Wah Chang began performing corrosion
testing on zirconium and hafnium alloys in high temperature/ pressure water or
steam for the nuclear industry in the 1950s. In the 1970s, the Chemical
Processing Industry (CPI) increasingly demanded high performance materials for
severe services. The company addressed the need for corrosion data on
zirconium, hafnium, tantalum, niobium, titanium, and other materials,
establishing and staffing a Corrosion Lab.
Over two decades later, Oremet-Wah
Chang, still places a high priority on corrosion testing and analysis. OWC
employs a full-time staff devoted to materials development and testing.
Facilities include autoclaves and furnaces, a corrosion test loop and various
test vessels, a metallography laboratory, mechanical and electrochemical
testing equipment, and much more.
OWC's Corrosion Laboratory offers a
variety of services, including corrosion fatigue analysis (shown in foreground)
and slow strained rate
testing (shown in background).
The Corrosion Group offers the
following consulting services:
1. Materials
selection and evaluation of customers' test results and specimen.
2. Corrosion testing according to the methods established by ASTM, NACE, EPA,
as well as other groups and agencies.
3. Corrosion testing according to the methods established by Oremet-Wah Chang
customers.
4. Material failure analysis.
For more information on these services
or to discuss research services not covered in this article, contact Mr. Jack
Tosdale at 541-917-6777 or reach him by fax at 541-967-6987.
OWC Sales and
Marketing News
Oremet-Wah Chang is pleased to announce
that Mr. Parry Walborn was named Director of Marketing and Mr. Gary Kneisel,
Director of Sales, effective January 1, 1999. Both Mr. Walborn and Mr. Kneisel
report directly to Mr. Ralph Nauman, President of Oremet-Wah Chang. Mr.
Walborn, has worked in Accounting, Production, and most recently, Sales and
Marketing in his 17 years with the company.
Parry Walborn
Gary Kneisel
Mr. Kneisel started with the company as
a titanium salesman in 1985 and, most recently, was Business Development
Manager for OWC's niobium and titanium product lines. These gentlemen fill the
void left by the retirements of Mr. David Floyd, Vice President of Commercial,
and Mr. Tom Cordier, General Manager, Sales.
In addition to these changes, Ms.
Carolyn Gardener was named Manager of House Accounts. Ms. Gardener joined
Oremet as Sales Service Coordinator in 1981 and, most recently, was Manager of
Inside Sales. In her new position, Ms. Gardener is responsible for all of OWC's
titanium re-roll customers and all of International Hearth Melting's products
and services. She also handles all titanium sponge customers and is responsible
for all titanium byproduct sales. Ms. Gardener reports to Mr. Kneisel.
Caroline Gardener
Ms. Robin Lettman was recently promoted
to Manager of Inside Sales and Government Contracts. Ms. Lettman, who has been
with the company since 1990, was most recently Manager of Government Contracts.
Robin Lettman
She now reports to Mr. Kneisel. To
contact Sales, call 541-967-6977. Contact Marketing at 541-926-4211 ext: 6280.
