Corrosion- A Problem

Today, with the economy being what it is and few dollars being spent on research, one wonders where growth is occurring. Everything seems to be at a standstill waiting for Washington to do something. It used to be that Defense drove the country and the research dollars spun off for the benefit of all. Today, cyber technology and robotics seem to be where the action is. The big action in materials research remains as advanced manufacturing.
However, there are still mundane things to consider. One area still costing the world billions of dollars in losses is corrosion. This covers a wide area. One need only look at autos after a good snowy winter, when tons of salt have been put on roads. If you live in areas such as Buffalo, New York, you can expect to see large areas where the salt has corroded the fenders and the body of automobiles.
If you live at the shore, not only are autos the problem, but also aluminum window frames succumb to what is known as pitting corrosion.
I could continue, but I would like to center in on high temperature corrosion. In this case we have equipment that we would like to run at higher and higher temperatures in corrosive atmospheres. Currently nickel base superalloys are the workhorse materials for these applications, such as jet engines. We have just explored Mars and experienced a fly-by of Pluto. There is less and less space on earth, and earth is becoming a more dangerous place to live. Perhaps we are ready to establish a new frontier, such as the moon for starters. To do that we need alloys thaat surpass the performance of superalloys. What alloys will be developed?
What I am saying is that there is a vast area that is important to our every day living and to our future that is currently being ignored, or so it seems. Recently we have an opportunity to use our technology to resolve one of these problems. Originally the technology was developed to provide wear resistance to components subjected to movement and shock. We are now discovering that the technology just might solve some corrosion problems as well. MagnaTech hopes to enjoy the opportunity to resolve one of these problems. Perhaps you too may have a similar type problem. MagnaTech would be delighted to assist you in the resolution of this problem.

Memorial Day

It is hard to believe that MagnaTech P/M Labs has been in business for 30 years. MagnaTech started as a partnership with a company known as Windfall Products, located in St. Marys, Pennsylvania. This relationship lasted for five years, at which point Windfall was requested by General Motors to install their own laboratory and in-house metallurgist. Since then, MagnaTech has been owned and operated by Ken Moyer. During this time MagnaTech has cooperated with a large number of commercial customers to upgrade and to introduce new products. MagnaTech's most recent accomplishment was completion of a Phase II SBIR contract with the Navy to provide improved wear, corrosion, impact and fatigue resistance for hook points.
Current interests of MagnaTech include advanced manufacturing and efforts to bring new products to market that will eliminate the expensive material waste and  labor to reduce a solid billet to a part of a specified geometry. Often as little as 15 % of the material may remain after the billet has been reduced to final desired geometry. In addition,  labor cost to accomplish this reduction to size may be extremely expensive. Often processing of the material can contribute to both damage to the environment and also to the welfare and health of the workers  necessary to produce the final part. Advanced manufacturing offers the promise of reducing if not eliminating these troublesome problems . Advanced manufacturing, using either a laser or an electron beam for energy, with the assistance of a three dimensional computer design, can construct a part to size with little waste of material and reduced human labor, in a safe non-hazardous environment. The catch is that the initial cost of equipment is of the order of a million dollars. With time and demand this initial cost should be reduced to a more reasonable price range.
One area of interest that could be satisfied using this new technology is aircraft. Currently, progress is limited by the capability of present day superalloys. These alloys are expensive, and they are at their limit of capability. There are always solutions however, most at cost for material for advantage provided. Most obvious solutions require heavy, expensive, scarce refractory metals. These are unacceptable at a time where we are looking more and more for dollar value and increased return on investment. MagnaTech believes that we have solutions that will inexpensively produce improved superalloys  to deliver increased payloads faster in advanced aircraft design.
MagnaTech is a veteran owned company, totally devoted to research and consulting with our own arrangement of supporting laboratories. Should you be interested in this kind of research, MagnaTech would be delighted to work with you to resolve your problems.

Is Aluminum In Our Future

MagnaTech is currently working to develop a system of aluminum alloys for one of its customers. Aluminum powders have been available for some time now, but  the application for their use has not progressed. Both ASTM and MPIF have specifications that define mechanical properties of both 2014 and 6061 alloy sintered parts. However the difficulty in reducing the stable oxide and the limited possibilities for alloying to improve strength and retain ductility are limited. Other possibilities for consolidation to improve sintered density are cost prohibitive.
However, improvements in alloy technology have increased interest, particularily in the automotive industry where weight reduction to improve fuel economy and emissions control are driving factors.Current usage includes marine transport, hand tools and office machinery.
In the automotive industry, the major application is the cam shaft bearing cap.Additional potential applications include connecting rods and oil pump gerotors for automatic transmissions.
MagnaTech is proud to share a small part in this research that may have impact on future materials. MagnaTech has  experience in alloy development, especially developing powders for emerging applications. Therefore MagnaTech has interest in the development of advanced materials for turbine applications as well and has proposed work for development in that area as well..

Welcome 2015

 Well, 2014 is just about finished. It was a transition year for MagnaTech P/M Labs. In January we successfully completed our Phase II SBIR contract to develop a process to modify the surfaces of low alloy, ferritic and martensitic stainless steels to improve wear, corrosion, fatigue and toughness. Unfortunately we were not favored with a Phase 2.5 contract to go to the next step to qualify the technology. However, the Navy wishes that the technology be commercialized. One of the steps to achieve this goal is application and award of patents. We now have received five patents protecting the technology that was developed. In addition, MagnaTech has five years of SBIR rights protection after the contract is completed.
As an additional step to assist in commercialization, the Navy provided the services of Dawnbreaker to prepare MagnaTech for a Navy sponsored two-and-a-half-day exhibition showing the technology to top Navy personnel and Prime Contractors for the Navy. In addition, we were alloted a twenty minute slot to present the technology to a select audience. From these activities MagnaTech made two contacts that are starting to appear as strong potential for additional development for the Navy next year. Not only will our patented technology be required for this work, but also new laser melting technology will be necessary. Therefore, MagnaTech expects to be busy pursuing this opportunity in early 2015.
In addition, MagnaTech has also been active in attempting to establish licensing or a partnership to commercialize the patented technology. MagnaTech has made presentations to several companies that could benefit from the technology. MagnaTech continues to work with SCORE to develop additional strength in developing this kind of relationship. MagnaTech realizes that our strength resides in research and development, and that is where we wish to use our time. However, we are looking for opportunities for furnace manufacturers, heat treaters or powder metal fabricators either to license or co-operate to form a company that will introduce the technology to the market place for financial gain to the partner or licensee as well as MagnaTech.
With this, MagnaTech wishes all of our customers, friends and supporters a very prosperous New Year.

Fall Beginnings

Well, here it is Labor Day and the beginning of Fall. Vacations are mostly gone and it is time to review how best to close this year and start freshly with a new year. Don't get me wrong because there are still four productive months this year. The question is, for many of us, where are we going? MagnaTech has been in business for 29 years. It has been an exciting time with plenty of research that was needed to make life better for all. Now we are into the age of miniaturization, robots, drones, electronic devices, and we appear to be running faster and faster with no direction in mind. MagnaTech has specialized in materials development and processing. When we started up, there was a need for better ferritic stainless steels. MagnaTech led the way in development of these alloys from powder metallurgy processing to produce injectors and sensors for the automotive industry. MagnaTech continued with assisting other powder producers to develop processes to make ferrophosphorus powders for developing magnetic applications. MagnaTech then saw a need for improved properties of soft magnetic alloys. We developed high temperature atmosphere sintering to improve structure sensitive magnetic properties through larger grained higher purity parts. This activity led us to assisting others to develop processes to improve corrosion and wear resistance of surfaces of parts. This occurred from development of technology of partial pressure vacuum processing. Through this technology we then improved on the processing by developing carburizing and nitriding processes that provided improved wear, impact and corrosion resistance of surfaces of ferrous materials. These developments resulted from NAVAIR contracts that were awarded for improvement of these properties for advanced hook points for aircraft landings. MagnaTech has been awarded five patents as a result of these efforts. So what does the future hold? MagnaTech specializes in research and development. The government would like to commercialize what has been developed on taxpayers' money. We are in the process of exploring ways of doing this. MagnaTech does not wish to enter into manufacturing, but we are exploring ways in which we could develop a relationship with other companies that will permit them to use the technology developed, while permitting MagnaTech to continue exploration of ideas to continue the development of the technology, while capitalizing on what is ready for production. MagnaTech expects that much of our activity during the last quarter of this year will be expended in attempting to establish relationships in this area.

August Issue

Well my dog is shedding like crazy and so get ready for a scorching August. For MagnaTech it is always a hot and an opportune time. It is tough to contact people and to get things done, yet life moves right along at its own pace.MagnaTech has five patents and one pending, mostly aimed at improving surfaces of steels for improved wear and corrosion resistance. In June MagnaTech participated at a Navy forum. This forum generated many leads from Navy branches regarding this technology. Among these were leads for restoration of worn parts. MagnaTech is offering proposals to use our technology coupled with advanced manufacturing to restore these surfaces for renewed use of expensive parts. MagnaTech has also been talking with various sources to partner the technology to the next level or production. In addition, although it has been stated that there is water, water, everywhere, this is not really the truth. Many regions are arid; some do not have the facilities, and yet others may be in trouble from overpopulation.I guess the first thought is of how do you gain water where there is none, and that began with our manned space flights. It was then that novel ideas were studied to maintain the self preservation and comfort of the astronauts. Since then, many communities have encountered threat to our groundwater supply. This, in many locations, result from hot weather when we fertilize our lawns with phosphates, and in the winter, when salt is used to permit safe driving conditions. Other areas where fresh water supply is endangered include waste water from the reclamation of oil from oil sands. Still others include arid regions that are adjacent to seawater. New techniques are needed to recover both energy and waste product from these sources. MagnaTech has ideas on how to resolve some of these problems, and intends to participate in some of the required research to resolve these pressing problems. Last there is the excitement of advanced technology processes that are just beginning to be explored. MagnaTech will be a participant in this area as well. MagnaTech therefore is actively seeking companies that are forward thinking to co-operate with to participate in these new avenues of interest, where solutions of current problems are mandatory. Please contact us if you believe that we have something to contribute to your program.

Recent Activity at MagnaTech

For a year now MagnaTech has been working with Dawnbreaker to present our developed surface modification technology to Navy communities and to their prime contractors to advance the technology to the commercial level. In June the Navy Opportunity Forum was held and MagnaTech maintained a booth, spoke with key personnel in the Navy and prime contractors, and presented a paper describing the developed technology. The two and a half day conference was well attended, with key Naval personnel as well as representatives of prime contractors working on Navy projects.
As a result of these activities, MagnaTech has opportunities for several potential contracts for current needs that the Navy has identified. In addition, MagnaTech has emerged with contacts for support of research activities with several prime contractors as well.
In addition to the above, MagnaTech continues activities to identify a company that has strong commercial production potential to partner with to advance the current developed technology to satisfy the needs of current markets. Several companies are interested and MagnaTech is currently discussing possibilities with several of these companies.
Life also goes on, and the new buzz word common to the industry is Advanced Manufacturing. This technology is being sponsored by the government and has the direct endorsement of the President. It is currently being touted in several Universities. The technology was initially developed by NASA for space applications back in the 1990s. Recently German, Swedish and English companies have developed machines and powders using Three D computer programing to construct a part using either laser melting or electron beam melting, among other concepts, to produce solid geometric shapes of interest. One of the initial efforts was to replace expensive prototype shapes to construct forging dies and casting molds. Current efforts are to expand this concept into production of short run parts that are expensive to manufacture because the material costs are high and the parts are labor intensive to machine. MagnaTech is exploring how some of our concepts can be used in this new developing technology.
As you can see, MagnaTech currently has their plate full of new activities and opportunities. If your company has a materials or process development process problem, however, MagnaTech is always ready to assist you in resolving this problem. We are especially adept at surface modification to provide improved wear, corrosion and fatigue life while maintaining desired core properties for proper functioning of the part. We also participate in the magnetics field, where our expertise in powder metallurgy and magnetic theory and testing is of importance. Should you have current problems in these areas, MagnaTech would welcome the opportunity to discuss our concepts with you and offer timely service to assist you in resolving these costly problems.