Fernando M. Diez

Mushy Zone No this is not what happens if your cereal sits around too long. For #MetallurgyMonday let’s talk about a term that seems like it can’t actually be the scientific term, but is. Mushy zone refers to when a metal is partially melted and partially solid. On a phase diagram with two elements, it’s the region highlighted in yellow. For pure metals there is one melting point at a given pressure. But most metals are actually alloys and these tend to have a range of melting points. On a phase diagram the lower line that separates the completely solid region from where it starts melting is called the solidus line. The upper line that separates the completely liquid region from the partially solid and liquid region is called the liquidus line. In between you have the mushy zone. What actually happens is that the metals are compositionally different even if just slightly. If you are coming down from above the liquidus at a given composition, you will hit the liquidus line. The horizontal line connecting the two is called a tie line. I’m not going to type out the algebra, but you can calculate what is the amount and the composition of the solid and the liquid at any given temperature at equilibrium if you want using something called the Lever Rule.   The mushy zone influences how microstructure forms during solidification, resulting microporosity, and segregation. Then all of these things impact the resulting properties of the as cast structure. Then the starting point as cast structure will influence any microstructure and properties of subsequent heat treat and/or wrought processes.   

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🔬 Advanced Microstructural Analysis of Alloy G4879-micro in Reformer Tubes Exposed to Critical Over-Temperature Conditions As a specialist actively involved in direct reduction processes, my ongoing project work with G4879-micro alloy in reformer tubes has revealed critical insights into the effects of elevated temperatures exceeding the material's critical threshold. This alloy, widely used in high-temperature applications, exhibits significant microstructural changes when subjected to improper operational conditions, as observed in this SEM image. The resulting phase formations have critical implications for the alloy's mechanical properties and thermal stability, aligning with standards such as ASTM E407 for microstructure preparation and ASTM A335 on high-temperature alloy integrity. Detailed Interpretation of the Microstructure Bright White Phase The bright white regions in the microstructure are indicative of chromium- and niobium-rich carbide precipitates. These carbides migrate toward grain boundaries under high-temperature stress, leading to localized embrittlement and reducing the alloy's toughness. Such carbide segregation at grain boundaries is a documented risk factor in high-temperature alloys, as defined by ASTM E112 standards on grain size and boundary influence on mechanical properties. Intragranular Black Phase The intragranular black phases within the grains are oxide precipitates primarily containing chromium and iron, formed due to extreme thermal exposure. These oxide formations degrade the ductility and creep resistance of the alloy, contributing to structural instability under prolonged high-temperature service conditions. This aligns with findings under ASTM G28 guidelines on intergranular corrosion testing, which highlight similar phase impacts on material properties. Grain Boundary Gray White Phase The gray-white phases along the grain boundaries are M23C6-type chromium carbides, a known contributor to grain boundary embrittlement. Under the elevated temperatures encountered, these carbides migrate to the grain boundaries, increasing susceptibility to intergranular fracture, a phenomenon well-described in the ASTM E1245 standards on inclusion assessment and microstructural evaluation for high-temperature materials. Intragranular Gray White Phase Intragranular gray-white phases indicate M7C3 carbides, which form within the grains due to prolonged exposure to elevated temperatures. These carbides compromise the alloy's ductility and enhance brittleness within the grains, reducing its high-temperature deformation resistance. Such carbide formation patterns are critical under ASTM A297 standards on high-temperature alloys, specifying microstructural stability requirements for alloys in extreme conditions. #damage #rupture #creep #overheat #hopspot #DRI #reformertube #mateenpasha

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Energy Alloys Global Solutions and Steel Alloys & Services Announce Merger Agreement Merged Entity to Become a Leading Global Supplier of Corrosion-Resistant Alloy Products Strategic Merger Unites Two High-Caliber Management Teams to Maximize Synergies and Enhance Global Reach HOUSTON, TX, September 29, 2024 – Energy Alloys Global Solutions (“EAGS”), a subsidiary of BioUrja Group (“BioUrja”), and Steel Alloys & Services (“SAS”) have come to terms on an agreement to merge their operations. This merger will create a leading global manufacturer and supplier of corrosion-resistant alloy products, enhancing service capabilities and geographic reach across critical markets. The integrated business will deliver advanced manufacturing and supply chain solutions to customers in oilfield services across the United States, Canada, Mexico, the United Kingdom, Norway, Dubai, and Singapore. The companies also plan to rebrand their collective metal alloy operations under a new name following the close of the merger expected by December 31, 2024. Upon closing, the merged entity will rank among the largest global suppliers of corrosion-resistant alloys, reinforcing its strong position in the oilfield services sector. Amit Bhandari, Chairman and CEO of BioUrja and current CEO of EAGS, will assume the role of Chairman of the newly formed company, while Daniel Benditz, Chairman and CEO of SAS, will lead as CEO. The full executive leadership team will be determined by the close of the transaction. Amit Bhandari expressed enthusiasm for the merger, stating, “Uniting these two businesses marks an exciting new chapter for BioUrja. Both companies fit like hand and glove with complementary strengths and capabilities. By merging our expertise and resources, we’re poised to enhance and extend high-quality solutions to our customers on a global basis.” Daniel Benditz echoed this sentiment, adding, “We are excited to join forces with EAGS and view this as a transformative opportunity for both companies. This merger significantly enhances our global footprint and processing capabilities, particularly outside of the U.S. We’ll be able to capitalize on EAGS’s value-added operations in the U.K., Dubai, and Singapore, offering broader and more sophisticated solutions to our oilfield services customers worldwide.”

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There are five key metallurgy concepts that engineers must understand to be able to apply metallurgy to make design and manufacturing decisions involving metals and solve problems related to stock metal and metal components. This includes: -Producing stock metals such as rod, bar, and sheet -Designing and fabricating low-cost, reliable metal components -Figuring out the root cause of component failures and production quality problems. This 30-minute video recording discusses the five concepts that apply to all metals. https://lnkd.in/gc-NWsMF #metallurgy #metallurgicalengineering #metals #engineering #industrialmetallurgists

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CNC parts reshoring is taking many stateside suppliers by surprise. While this article highlights many tools to assist companies with automation, labor shortages, etc., it doesn't discuss one of the most critical aspects of successful on-time delivery, which is the SIOP process. Having spent the last decade in and around machine shops, here are some critical elements of the SIOP process that are often overlooked and cause chaos both internally and externally. Sales Planning: It's essential to know what business fits your capabilities. Not all business is good business, and it can be hard to turn away RFQs in times of high demand. Inventory Planning: As demand continues to increase, it can be difficult for smaller CNC shops to compete against the primes as their demand will also likely be increasing. Understanding the entire value stream is critical in times of ramp up. Production Planning: I have found that this area is often the most mismanaged due to many small CNC shops not fully understanding their true capacity and bottlenecks. This also counts non-machine centers. Financial Planning: Growth requires cash, and many small CNC shops don't have the reserves to float increases in demand. Having a solid cash flow plan and forecast will be critical to long-term sustainability and success. Cross-Functional Collaboration: Ramp-ups can create intense friction within an organization, and proper upfront planning and over-communication will be critical in these times. KPI: Establishing a few key metrics to identify the impact of increased business flowing through the facility is critical. If you struggle in any of these areas, please don't hesitate to reach out. Bracket Management specializes in smoothing out the bumpy operational road so all parties can achieve great success and exponential results. If you are a machine shop with less than $30M in revenue, we would love to help you get to $50M in a controlled, methodical manner. #CNC #manufacturing #SIOP #supplychain #operations

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Are you the owner or senior leader of a manufacturing business and concerned about: - Growing customer complaints? - Poor on-time deliveries? - Low profit margins? Watch this video from a recent presentation we gave at a North Texas Chapter of the National Tooling & Machining Association (North Texas Chapter NTMA) meeting, where we explained the case with one of our clients. We also explain how we can reduce lead times, reduce defects, and help manufacturers increase their profit margins by 25% and often more. We can help you achieve similar results. To get started, CLICK THE LINK to schedule a complimentary introductory call. We'll help uncover your frustration-free roadmap to better execution and satisfied customers. CLICK HERE: https://lnkd.in/gjdiUyu9 Don’t let your bottom line suffer because of poor execution. Start improving your business with our support, and let us help you eliminate these challenges. #lean #leadership #manufacturing  #operations #leanmanufacturing 

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Have you read about the new class of refractory high or medium entropy alloys (RHEAs/RMEAs) metals, composed of niobium, tantalum, titanium, and hafnium? Key Takeaways -Unlike most materials, the new alloy keeps its shape and resists cracking at both high and low temperature extremes, making it potentially suitable for demanding applications like high-efficiency aerospace engines. -This alloy is one of the toughest materials on record, with a resistance to cracking on-par with cryogenic steels. -Microscopy reveals that a type of defect in the material’s structure historically thought to promote fracture in reality does the opposite and is responsible for its high toughness.

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Investigating the Impact of Process Parameters on Thinning and Formability in Aluminum Alloy AA 1050 Incremental Sheet Metal Forming https://lnkd.in/dGwpWBgk Abstract ISMF is a potential manufacturing technology that uses progressive deformation to create complicated shapes. ISMF produces sheet metal consecutively using targeted tool movement. This innovative method increases component precision, material waste reduction, and design flexibility. A tool is moved along a set path over a flat metal sheet while twisting forces are applied to get the needed shape. SPIF could be used in the medical equipment, aerospace, automotive, and building industries, but it is only profitable in certain situations because it is slower than other sheet-forming methods. SPIF-based die-less making makes it easier to shape. To make cone-shaped structures with SPIF, the spindle speed (1000, 1500, and 2000 RPM), feed rate (200, 400, and 600 mm/min), tool width (8, 10, and 12 mm), and step-down (0.2, 0.4, and 0.6 mm) at the specimen interface were all changed. For aluminum alloy AA 5010, the maximum thinning (mm) and formability (%) were the important mechanical qualities. The L9 orthogonal array was used for a complete look at these qualities. Making high-quality cones using a computer numerically controlled machine was the aim of this research. (CNC) machine. The important factors affecting engineering and forming quality were studied using the Taguchi and analysis of variance methods. The most influential factor on maximum thinning was the rotational speed followed by the feeding, which is inversely proportional to it. In contrast, the most effective factor on the formability is the feeding followed by the rotational speed, which is directly proportional to it. It was discovered that a spindle speed of 1500 revolutions per minute (RPM), a feed rate of 200 millimeters per minute (mm/min), a tool diameter of 10 millimeters (mm), and a step down of 0.4 millimeters provide the least amount of maximum thinning (mm) and formability (percent). Highlights: - Nine specimens were fabricated with different processing parameters using a CNC machine - Investigating the influence of Spindle speed, Feed, tool diameter, and step down on the maximum thinning and formability - The dominant factor affecting Maximum thinning is the spindle speed large effect Keywords: - Incremental Sheet Metal - Taguchi Method - Analysis of Variance - Maximum Thinning - Formability Journal: https://lnkd.in/dgnvtdte Issue: https://lnkd.in/dpm9x4PB Article: https://lnkd.in/dwGdq2xD ETJ LinkedIn: https://lnkd.in/d_8SPqAt #Engineering_and_Technology_Journal #UOT #engineering #technology #etj

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In today's powder metallurgy, sintering is unlocking doors to high-strength parts for a wide range of markets. Learn how the process impacts performance & price: https://hubs.li/Q02SbXnb0

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It's been called the bubble chart and the banana diagram, but we call it the global formability diagram. It compares strength and elongation of current and emerging steel grades. Get the details: https://ow.ly/7E3O50Rv0gr #Metallurgy #Automotive #Engineering

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