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What Are The Super Duplex Steel Flanges?

At room temperature, Duplex is a Fe-Ni-Cr alloy with a two-phase ferritic-austenitic stainless-steel microstructure. Combining austenitic and ferritic grades has its benefits. It signifies that the finished metal has a better metallurgical structure. It is made up of two phases that benefit from both microstructures' features. Duplex steel is also widely used in heavy sectors such as chemical processing, gas, nuclear power, and oilfield service because of these qualities.

Super Duplex Steel Flanges are Available

Molybdenum (up to 5%), high chromium (19-28%), and reduced nickel content distinguish Duplex steels from austenitic stainless steels. 2205 (5 percent nickel, 22 percent chromium) and 2507 are the most often used duplex stainless steels (7 percent Nickel, 25 percent Chromium). Because of its superior corrosion resistance, 2507 is sometimes CNMG Insert called a "super duplex."

Duplex steels date back to the 1920s, with the first cast being created in Sweden in 1930. However, as steelmaking technology evolved, the popularity of employing solely duplexes began to increase roughly 30 years ago. Ferritic and austenitic metallic structures are the two forms of metallic structures utilized to create a duplex. They are suitable for a wide range of circumstances, however, they both have a flaw that prevents them from being used in 100% of cases.

Combining ferritic and austenitic steels can be made easier by creating a chemical composition. As a result, the metal has better stress corrosion cracking resistance, toughness, weldability, and strength. Because of the high strength of Super Duplex Steel UNS S32950 Flanges, the 0.2 percent PS range for Carbide Drilling Inserts contemporary duplex grades is 400-500 MPa. It may result in a reduction in section thickness and flange weight. This is especially advantageous for structural applications like bridges, storage tanks, and pressure vessels.

Advantages of Super Duplex Steel Flanges

Corrosion Resistance

Corrosion resistance is determined by the composition of the stainless steel, with nitrogen, molybdenum, and chromium being critical. Duplex stainless steel is corrosion-resistant, and it can withstand sulfide and chloride conditions. It also has a high resistance to stress corrosion cracking (SCC). It's a sort of corrosion that can happen when certain conditions are met, such as a corrosive atmosphere, tensile tension, and a high enough temperature.

Strength

Duplex stainless steels are about twice as strong as normal ferritic and austenitic stainless steels.

Ductility and Toughness

Duplex stainless steel can outperform ferritic grades in terms of ductility and hardness, albeit it is not as soft as austenitic grades.

Weldability

The weldability of duplex stainless steel variations is generally good. Even though they are more difficult to weld than austenitic grades, you may utilize typical welding procedures.

Heat Resistance

In comparison to austenitic steel, duplex stainless steel has a lower thermal expansion and a higher heat conductivity. Duplex grades can withstand temperatures of at least -50°C with ease. They are more ductile than ferritic steel grades at low temperatures.

Cost

The molybdenum and nickel content of duplex stainless steel is lower than that of austenitic stainless steel. This stainless steel can be less expensive due to its reduced alloying concentration. You may also be able to reduce the thickness of the material since duplex stainless steel has a higher yield strength. Thinner items have the potential to save you a lot of weight.

Ductility and Toughness

Duplex stainless steel outperforms ferritic grades in terms of ductility and toughness, while it is not as tough as austenitic grades.

Benefits of Super Duplex Steel Flanges

In comparison to austenitic and ferritic grades, stainless steel super duplex Flanges are less expensive. The material's yield and tensile strength are outstanding. For businesses, the two material properties provide the greatest option. Super Duplex Flanges have a thin wall thickness, which prevents performance and quality from becoming commoditized.

Super duplex is a word that was used in 1980 to describe a material's high alloying ability and performance. These Flanges have a high chromium content. It makes the Flanges resistant to caustic solutions comprising chlorine and acid and allows them to be used in them. In the petrochemical and chemical industries, these circumstances exist. When possible, super duplex stainless steel is used as a substitute for regular mild steel.

Features of Super Duplex Steel Flanges

Super duplex stainless steel Flanges are corrosion-resistant and have high strength. They are extremely beneficial in the chemical and maritime sectors. These Flanges are ideal for use in wire lines and architecture. Pulley equipment for lifting can also benefit from these Flanges. When compared to conventional duplex steel, super duplex stainless steel Flanges have better corrosion resistance. The ability of stainless-steel super duplex Flanges to resist stress corrosion and cracking corrosion makes them beneficial in a wide range of industrial applications.


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Can Aluminum Milling Inserts Enhance the Precision of Machined Components

Aluminum milling inserts are a great way to enhance the precision of machined components. They are specially designed to work with aluminum, and they offer high-quality results. Aluminum milling inserts provide a smooth and accurate finish to machined components, making them suitable for high-end applications. With the use of these inserts, one can achieve high-precision machining and achieve better results.

Aluminum milling inserts are made from a variety of materials such as carbide, ceramic, and diamond. Each material has its own advantages and disadvantages in terms of performance. Carbide inserts are the most commonly used because they are resistant to wear and provide a smooth finish. They are also cost-effective and can provide a good finish for a wide range of materials. Ceramic inserts are suitable for machining aluminum with higher cutting speeds and provide a better surface finish. Diamond inserts are the most expensive option but they are the most durable and can provide excellent results.

These inserts are designed to reduce friction between the insert and the machined component. This reduces the heat generated during the process and helps to prevent the insert from being deformed due to the heat. The inserts also provide a precise cutting edge which helps to eliminate chatter marks and burrs. This helps to improve the accuracy and quality of the machined components.

Aluminum milling inserts can be used in a variety of applications such as CNC machining, milling, drilling, and even grinding operations. They are available in standard sizes and can be customized according to specific requirements. These inserts can provide a high level of accuracy and precision, making them a great choice for high-end machining operations.

In conclusion, aluminum milling inserts can be a great way to enhance the precision of machined components. They provide a smoother and accurate finish, while reducing friction and heat generation. They can also be customized to fit specific requirements and are available in standard sizes. With the use of these inserts, one can achieve a high level of accuracy and precision in machining operations.

Aluminum milling inserts are a great way to enhance the precision of machined components. They are specially designed to work with aluminum, and they offer high-quality results. Aluminum milling inserts provide a smooth and accurate finish to machined components, making them suitable for high-end applications. With the use of these inserts, one can achieve high-precision machining and achieve better results.

Aluminum milling inserts are made from a variety TCMT Inserts of materials such as carbide, ceramic, and diamond. Each material has its own advantages and disadvantages in terms of performance. Carbide inserts are the most commonly used because they are resistant to wear and provide a smooth finish. They are also cost-effective and can provide a good finish for a wide range of materials. Ceramic inserts are suitable for machining aluminum with higher cutting speeds and provide a better surface finish. Diamond inserts are the most expensive option but they are the most durable and can provide excellent results.

These inserts are designed to reduce friction between the insert and the machined component. This reduces the heat generated during the process and helps to prevent the insert from being deformed due to the heat. The inserts also provide a precise cutting edge which helps to eliminate chatter marks and burrs. This helps to improve the accuracy and quality of the machined components.

Aluminum milling inserts can be used in a variety of applications such as CNC machining, milling, drilling, and even grinding cemented carbide inserts operations. They are available in standard sizes and can be customized according to specific requirements. These inserts can provide a high level of accuracy and precision, making them a great choice for high-end machining operations.

In conclusion, aluminum milling inserts can be a great way to enhance the precision of machined components. They provide a smoother and accurate finish, while reducing friction and heat generation. They can also be customized to fit specific requirements and are available in standard sizes. With the use of these inserts, one can achieve a high level of accuracy and precision in machining operations.


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Enhancing Precision and Tool Life with Carbide Rods Featuring Coolant Holes


Tungsten carbide rods with coolant holes are cylindrical bars made of tungsten carbide material that have holes drilled into them to allow coolant to flow through. These rods are often used in metalworking, specifically in high-speed cutting applications where heat buildup can be a problem.

The addition of coolant holes helps to reduce the temperature of the cutting tool, which can prolong its life and improve the quality of the machined part. The coolant also helps to flush away chips and debris from the TCMT Insert cutting area, further improving the performance of the tool.

Tungsten carbide is a very hard and durable material, making it an excellent choice for cutting tools. It is made by combining tungsten and carbon at high temperatures, which creates a material that is extremely resistant to wear and abrasion.

Overall, tungsten carbide rods with coolant holes are a great choice for applications where high-speed cutting is required, and where the temperature of the cutting tool needs to be carefully controlled.

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ESOP Solidifies Culture of Continuous Improvement

What kind of machine makes a licorice stick? The level of specialization required for this machine means it could never be produced in high enough quantities to warrant a spot in a regular catalog, or as part of an OEM’s traditional offerings. Instead, customers must reach out to custom machine builders, such as Astro Machine Works.

Astro Machine Works was founded in 1984 by four friends who wanted to build custom machines. Over the course of almost four decades, the Ephrata, Pennsylvania-based company has expanded its range of markets based on capabilities it developed as a result of its initial focus on custom machines — an expansion that has also greatly benefited from passing the shop into its employees’ hands.

Astro’s 10-foot by 20-foot by 5-foot APEC G3060 gantry mill not only produces the long frames some of the company’s custom machines require, the mill can also machine multiple sides of five-axis parts. This versatility has led Astro’s customers to book jobs requiring the gantry mill half a year in advance. Photos courtesy of Astro Machine Works.

Building a Custom Machine Company

Building a custom machine from scratch requires a wide array of capabilities: milling and turning, certainly, but also welding, assembly, painting, electrical, hydraulic, quality, and more. Organizing these operations requires dedicated back-of-house departments and benefits from in-house HR and IT teams. Leaders from each team report to an overall operations manager, whose work is slightly eased by assigning sales and project managers to either commercial work or government work. The company tries to balance its work between these two markets 50/50.

This comprehensive range of capabilities requires Astro’s employees to undergo equally comprehensive training. This emphasis on training manifests both in robust internship and apprenticeship programs as well as a culture of continuous improvement. The internship program draws students from local high schools and technical schools, simultaneously bolstering their skill sets and furthering their education, while its state-certified apprenticeship program is a fully on-the-job, in-house training program. Apprenticeships exist for both the machining and tool-and-die departments — apprentices train on machines across their departments while also receiving instruction through ToolingU, a learning management platform developed by the Society of Manufacturing Engineers. Although many apprentices have already attended technical schools, Astro president Eric Blow says this hybrid approach is especially useful for teaching those students with no previous formal machining education, but who are good culture fits and show interest and aptitude in manufacturing.

Both inside the apprenticeship program and out, shop floor employees at Astro train on progressively more difficult machines — first on manual Bridgeport-style machines, then on three-axis machines, then on four-axis machines and those with rotary chucks, progressing to five-axis machines, and finally learning to use the shop’s multitasking Mazak Integrexes. Ideally, the company’s machinists should be able to machine anything from small parts to those requiring Astro’s five-axis gantry mill with a 10-foot by 20-foot machining area. Outside of the apprenticeship program — and outside of initial training sessions when new equipment hits the shop floor — there is no formal process for this training, with Blow describing it as simply “a matter of stepping up to a more complex unit and just putting in the time to master that new piece of equipment.”

As for how to motivate employees to push themselves, learn Cermet Inserts these new skills and act as mentors for interns and apprentices, Blow says it hasn’t been a challenge. The cooperative culture at Astro makes continuous education a regular part of the workday for most employees — and the company’s open-book management and ESOP have been heavy lifters, besides.

Management Is an Open Book

Astro has long given its employees as full a picture as possible: In late 2007, it moved to what Blow calls “open book management.” Anyone in the company could see its finances, from lines of credit to more production-focused metrics such as quoting targets and backlogs. In addition to the morale benefits of trusting employees with financial data, Astro also began a twice-yearly bonus program based on free cash flow after expenses. Employees can see how their work affects the APMT Insert accumulating bonus pool from month to month, encouraging them to be knowledgeable about the company and giving them more of a stake in day-to-day operations. Blow credits this shift in management style for growing the company through the 2008 recession into the early 2010s.

An additional shot in the arm came in the form of an employee stock ownership program (ESOP). Three of Astro’s founders have already retired, with only Blow remaining. While an initial deal with a local, hands-off private equity firm in 2006 during the first founder’s exit went very well for Astro, by 2016, the ownership of that firm was also looking to retire. While Blow and the owners of the private equity firm initially searched for another buyer, they ultimately determined that rolling the dice with another private equity firm would put Astro’s successful culture and operation at risk.

Employees know that expanding their own knowledge of machining techniques and teaching their coworkers will increase productivity — and, therefore, the value of everyone’s shares in the ESOP.

An ESOP “gave us the most potential to maintain our employee base, our culture, our identity,” Blow says, and in 2018, Astro began its ESOP program. While Blow is still the CEO pending his eventual retirement, the company has also created a five-person senior leadership team that works alongside him. The idea is that this team will be able to consult with and advise a future CEO, ensuring that Astro’s successful strategies continue long into the future. Astro has also safeguarded its future by developing a board of directors, which Blow is slated to join after his retirement.

What does this leadership restructuring mean for the people on the shop floor? Not too much of a change (just as planned), but the ESOP acts as a secondary retirement fund for all employees, one that grows in value when the shop performs well. As a leveraged ESOP program, share values started at $1.12, but have risen over the course of four years to a value of $114.50 per share. This rapid increase in value has made an impression on employees, who know that expanding their own knowledge of machining techniques and teaching their coworkers will increase productivity and, therefore, the value of everyone’s shares.

With large parts comes the need to provide quality assurance over a large area. Astro’s FaroArm portable CMM can “leapfrog” from section to section of a large part by using data points as references, according to Eric Blow.

Large Parts Are a Big Deal

This determination to expand on skills grows more important by the day as Astro invests in more complicated machines. In addition to the Mazak Integrexes, Astro uses seven five-axis machines for part production — one of which is a gantry mill designed to machine large parts.

The APEC G3060 from the Asia Pacific Elite Corporation has been producing parts 10 feet by 20 feet by 5 feet since 2016. Originally, the machine was meant to produce the 15- or 20-foot frames some custom machines required, a task Astro farmed out to other partners for many years. While the APEC gantry mill still sees much use for finish machining of large machine frames and bases, it has also proved useful for machining multiple sides of large five-axis parts, a capability that Astro’s clients quickly noticed. Orders suited to the machine arrived in such high quantities that the machine can be fully booked six to eight months in advance.

This overbooking has led Astro to order an additional gantry mill, this one a Parpas machine with a 10-foot by 10-foot workspace. This not only saves floor space (even with a grand total of 72,000 square feet of floor space, there are limits), but Blow says 80% of jobs for the APEC mill could fit onto a machine of this size. Thus, the new machine will double up on capacity for most jobs and enable the APEC machine to better focus on jobs that make use of its full range.

Multipurpose Value-Adds

This strategy of acquiring capabilities to bring more aspects of custom machine manufacturing in-house, then expanding on these capabilities as they bring in additional business, expands beyond large-part machining.

Astro purchased a fabrication shop in March 2021 — not because it lacked fabrication capabilities, but because the acquired shop had long-established relationships with the energy distribution market, which Astro hoped to enter. It also filled a fabrication niche Astro’s existing department was too busy to handle. The nine full-time welders already with Astro focused on complicated, highly technical work, leaving them with little time to complete more traditional tasks like framework for machine bases or conveyors. While the acquired fabrication shop has largely continued to focus on its existing customer base, expansion plans for the shop involve both increasing business with current customers and looping in the shop to assist with Astro’s fabrication backlog.

This expansion of capabilities also applies to the company’s certifications. While the company is already ISO 9001- and AS9100-certified, management decided to go a step further and seek NQA-1 qualification for further work in the nuclear industry. This is not a formal accreditation, but a standard companies will insist upon before scheduling work. Astro rewrote its quality management manual to fit these standards (encompassing ISO and AS quality standards), and its quality manager’s role expanded to become what Brian Hess, commercial sales manager at Astro Machine Works, describes as a “safety-related auditor.” Once a nuclear customer audits Astro, a successful result will mean Astro enters a database of shops qualified for nuclear work. While qualifying for this database will not make much of a difference for most of the shop’s clients, it adds enough to deepen their relationship with a key handful of customers.

What comes next? Astro already maintains three production buildings, but plans are in motion to construct another building with a ceiling 40-50 feet high for even larger custom machines — and whatever new capabilities Astro adds next.

Landscape Photo Credit: Astro Machine Works
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Understanding the Different Choices in Metal and Fluid Recycling

 

Why would a company choose a chip wringer system for metal recycling over a briquetter system that compresses the chips into compact pucks? Is one of the two a more cost-effective choice?

Not necessarily, says Mike Hook, national sales manager for Prab. One consideration is the local scrap dealer, and what premium this firm is willing to pay for pucks over chips. Another consideration is transportation distance and cost, since the pucks are easier to ship.

This question was one of the points addressed in the recent webinar presentation Mr. Hook gave on managing waste streams in the machine shop—both metal waste Milling inserts and fluid waste. Investing to manage either of these streams more effectively can save cost in various ways, including via reuse, control of disposal and even the conversion of some of the waste into a revenue stream.

The value in the webinar (an archived version is available here) is that it touches quickly on various options for chip and coolant handling. Equipment discussed includes shredders, chip wringers, briquetters, tramp oil separators, magnetic and filter-media separators, centrifuges and coolant recycling systems—all arguably underappreciated equipment with the potential for significant impact on the economics of the shop.

In the area of chip handling, Mr. Hook discussed the familiar option of a conveyor system under the floor. He also showed the application of a cleaner alternative: a shop that had implemented a system that shreds chips at the machine tools so they can be sent through an above-ground pneumatic system to a cyclone for drying and a silo Carbide Turning Inserts to await pickup. For this shop (which has high cleanliness requirements), the result is an environmentally friendly system realizing hands-off chip management from generation to pickup.


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