Page 1

Vol. 1, No. 1 Feb/March 2011

Northern California, Oregon and Washington Edition

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THE COOLANT. THE COOLANT. We are here to help you We areyour hereproductivity. to help you boost boost your productivity. Cutting Tool Control, Inc. 1411 NW 51st ST Contact the Blaser specialist Seattle, Washington 98107 in your area: ContactPhone: the206.789.7277 Blaser specialist in yourTollarea: Free: 800.356.2416 Fax: 206.784.8122 E-mail: CuttingToolControl@msn.com www.CuttingToolControl.com Serving Washington and Oregon

ATS Industrial Supply 2910 East Chambers Street Tool Technology Distributors, Inc. ATS Industrial Supply Phoenix, AZ 85040 2910 East 3110Chambers Osgood Court Street Phone (602) 276-7707 Fremont, 94539 Phoenix, AZCalifornia 85040 Phone Phone: (602)510.656.8220 276-7707 Toll Free: 800.335.8437 Fax: 510.656.2458 E-mail: ed@tooltechnology.com www.ToolTechnology.com Serving Northern California

Blaser Swisslube Inc. Goshen, New York 10924, Phone 845-294-3200, www.blaser.com Blaser Swisslube Inc. Goshen, New York 10924, Phone 845-294-3200, www.blaser.com


Editors Corner

Cover

“A business absolutely devoted to service will have only one worry about profits. They will be embarrassingly large.”

Henry Ford

Linda and I welcome you all to the first A2Z Metalworker Magazine for the NW; Washington,Oregon,& Northern California Edition. We are very excited about this new region; the people, the businesses, and the culture are all a great combination for success. As we visit businesses in this area we are greeted by busy entrepreneurs, machine shop owners, engineers, buyers, and machine tool dealers working hard to continue growing their businesses and service their customers.They are busy and still in business. They are all dedicated to serving their customers and doing whatever it takes to keep their company’s name sweet on their customers’ lips. We also see these manufacturing companies using the best in programming software, and machine tools, accompanied with highly and continuously trained personnel. When asked how business is; these businesses boast of a busy schedule, a little overtime, and a new machine or two. Most of these businesses are very optimistic for 2011 business potential. NEW YORK: US manufacturing grew at its fastest pace in seven months in December, extending a recent run of encouraging economic data and suggesting that expansion of the world’s biggest economy will accelerate in 2011. The latest edition of the Price Waterhouse Coppers U.S. Manufacturing Barometer reports that, overall, optimism about the U.S. and world economies’ prospects over the next 12 months are on a major upswing. We encourage you to be optimistic and to keep the American dream alive by continuing to be the best at what you do and how you serve others. We ask that you contact us if there is a company out there with a special story to tell. Please share your ideas to enhance the magazine; I can be reached at: Kim@AZMetalworker.com. I encourage you all to look to our advertisers, who fund this magazine, for your machine and accessory needs.They are all great people too, and we thank them for helping to get this regional publication started! Thank you! The Metalworker will have a booth at the AMCON show in Seattle, coming up in April. We would like you to stop by and say hi. We hope to meet many of you. (AMCON Show Details are on page 29 of the magazine.) Until next issue, we wish you all continued success! God bless U.S. Manufacturing and our troops overseas.

Kim Carpenter & Linda Daly Co-Publishers A2Z METALWORKER

4 • FEB/MARCH 2011

PTI Part As SeenWith Delcam’s FeatureCam® Software.This Month’s Shop Profile. Announcements/Releases.................... 6-7 Shop Profile....................................1,18-19 Feature Articles........................ 30-31,34-36 Buyers Guide Equipment.................. 40-42 Buyers Guide Processes.................... 43-45 Card Gallery...................................... 40-45 Index Of Advertisers.............................. 46 Editorial................................. Throughout

Published by: A2Z Metalworker PUBLISHER/EDITOR Linda Daly/Kim Carpenter kim@azmetalworker.com Mail Address: PO Box 93295 Phoenix, AZ 85070 Telephone: (602) 412-7696 Website: www.azmetalworker.com E-mail:kim@azmetalworker.com

CONTRIBUTORS

For This Issue, We Thank All of The Advertisers You See in This Magazine, because they helped launch this new publication! Published bi-monthly to keep precision manufacturers abreast of news and to supply a viable vendor source for the industry. Circulation: The A2Z Metalworker has compiled and maintains a master list of approximately 7100 people actively engaged in the Metalworking Industry. It has an estimated pass on readership of more than 20,000 people. Advertising Rates, deadlines and mechanical requirements furnished upon request or you can go to www.azmetalworker.com. All photos and copy become the property of A2Z Metalworker. The Publisher assumes no responsibility for the contents of any advertisement, and all representations are those of the advertiser and not that of the publisher. The Publisher is not liable to any advertiser for any misprints or errors not the fault of the publisher, and in such event, the limit of the publisher's liability shall only be the amount of the publishers charge for such advertising.


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Announcements & Releases “NEW” Motorum 2048ST 

Murata Machinery USA introduces the Motorum 2048ST featuring the patented Electronic Servo  Controlled Ram, 22 Ton, 4’ x 8’ sheet capacity, 28 station turret, including 4 – 3” Auto Index stations,  While utilizing the traditional 114 or 112 Wiedemann style tooling.  surface finishes. The machine power, coupled with box way rigidity  

Haas Automation to Host HaasTec Open House at SoCal Facility in March

and heavily ribbed castiron construction to dampen cutting vibraFor the first time in more than 7 years, Haas Automation, Inc. – tion, enhances producAmerica’s leading machine tool builder – will host an open house tivity. The heavy-duty at its headquarters and manufacturing facility in Oxnard, CA. MT-5 programmable tag-a-long tailstoc k HaasTec, scheduled for March 10 through 12, 2011, from 10 am with M-code quill acThe Motorum 2048ST continues the evolution of Muratec's ram axis servo driven punch press. The ram  to 4 pm daily, will include machine demos, factory tours, a catered tivation provides ample support for shaft work. drive has become simpler and more rigid, resulting in higher punch speeds and productivity. Highly  efficient to run, the Motorum is designed to provide an economical solution to parts production  lunch, and more. requiring punching, forming, tapping and deburring. 

Those looking for an accurate high-performance universal CNC Contact Murata Machinery USA ‐ 800‐428‐8469 for more Information  Visitors to HaasTec will see the latest Haas CNC technology up lathe will definitely find the Ganesh KSL-7612 TMY worth checkclose and in great detail, with 20 machines cutting metal, including out. ing the new generation ST and DS turning centers, with y-axis and dual-spindle capabilities. There will be guided factory tours – both EDM Performance Accessories® is above and on the production floor – to see how Haas machines are built; and representatives from major tooling, workholding, and Now Selling bedra® EDM Wire NaCAD/CAM manufacturers will be on hand to share their insight tionwide and show their products. Established in 1989, EDM Performance Accessories® has been serving job shops with stocking locations nationwide with high quality EDM and waterjet consumables. Starting January 1st of this year, EPA is now the nationwide distributor of bedra®, the pioneers of EDM coated wires. The bedra® product line strengthens our already outstanding line of EDM wires to best

Registration for HaasTec is free, and available online at www. HaasCNC.com/openday. Guests who register by February 1 are automatically entered to win an all-expenses paid trip to California to attend HaasTec, and guests who register by March 1 will receive a limited-edition Haas cap at the open house. For more information about Haas Automation and Haas products, call 800-331-6746, or visit www.HaasCNC.com.

GANESH Introduces New High-Performance 4-Axis CNC Lathe With Full “C” & “Y” Axis! Manufacturers looking for “affordable cost reduction” for CNC lathe work should look at the Ganesh KSL-7612 TMY heavy-duty boxway CNC 4-axis turning center with MITUSBISHI M70 control. It features full bar, chuck, and shaft machining capability; with 3.0” bar capacity and a 10” chuck. A full “C” axis and a “Y” axis, with 4” of travel, are included. The fast .15-second indexing of the 12-station turret helps keep cycle times low, and any combination of ID and OD driven or static tools can be mounted using “quick-change” VDI-40 tooling. The beefy 30-HP AC-digital spindle motor provides ample power for roughing operations and the 3500-RPM spindle provides for fine A2Z METALWORKER

6 • FEB/MARCH 2011

fit your needs. “Our goal is to become the household name of EDM consumables,” Tom Adams, president of EPA said. “We want the EPA name recognized in every job shop in the US as the ONE STOP SHOP of EDM and waterjet consumable,” he continued. EDM Performance Accessories® strives to provide the best products at competitive prices to the customer to give the customers an edge in this competitive market. Ultimately, if the customer wins with our service, then we also win. To better serve our customers, we’ve added Jeff Daneke to our sales team to head the new Oregon/Washington office. Jeff brings to us many years of hands-on experience as an EDM programmer for HP as well as an understanding of what job shops are looking for in today’s market to stay ahead of the competition. We are excited to have him join the EPA team. Call today, (800) 336-2946 or email information@edmpeformance. com to see how EPA can help you bring the best performance and value to your shop.


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“NEW” Motorum 2048ST Murata Machinery USA introduces the Motorum 2048ST featuring the patented Electronic Servo Controlled Ram, 22 Ton, 4’ x 8’ sheet capacity, 28 station turret, including 4 – 3” Auto Index stations,while utilizing the traditional 114 or 112 Wiedemann style tooling. The Motorum 2048ST continues the evolution of Muratec’s ram axis servo driven punch press. The ram drive has become simpler and more rigid, resulting in higher punch speeds and productivity. Highly efficient to run, the Motorum is designed to provide an economical solution to parts production requiring punching, forming, tapping and deburring. Contact Murata Machinery USA - 800-428-8469 for more Information.

Boeing Sets 787 Delivery for 3rd Quarter Boeing announced that it expects delivery of the first 787 Dreamliner in the third quarter of this year. The new delivery date reflects the impact of an in-flight incident during testing last November and includes the time required to produce, install and test updated software and new electrical power distribution panels in the flight test and production airplanes. “This revised timeline for first delivery accommodates the work we believe remains to be done to complete testing and certification of the 787,” said Scott Fancher, vice president and general manager of the 787 program. “We’ve also restored some margin in the schedule to allow for any additional time that may be needed to complete certification activities,” Fancher said.

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The 787 program has been gradually returning individual airplanes to the flight test program. After receiving interim software and hardware improvements, four flight test airplanes have been subjected to extensive ground testing and a thorough review to ensure their readiness to return to flight. The remaining two airplanes will be returning to flight in the days ahead to bring the full flight test fleet back up to flight status.

Cutting Tool Control Inc. Celebrates 32nd year in the Northwest! Cutting Tool Control Inc. stocks such lines as Blaser Swisslube, Kyocera Cutting Tools, Deltronic,Wolhaupter, Ingersoll and. Being a complete “CNC Machine Support Center” focusing on “Value Added” brings productivity to a new level. Lowering costs through higher & feeds, more parts per edge, better finishes and tighter tolerances makes the initial cost second. The company strives to deliver $1.10 in value for every dollar spent moving to tougher materials with more complex features brings quality to the forefront. Check out their linecard at www.CuttingToolControl.com or call them at 206-789-7277. A Z METALWORKER • 7 • FEB/MARCH 2011 2


Solar Takes on Wind in Battle of Efficiency It seems counterintuitive, but a recent test by Washington state-based Inland Power and Light shows solar panels outperforming wind turbines by a factor of five. Across much of the nation, and particularly the northern quadrant, wind seems to be perpetually present, blowing dust into our homes and barbecue smoke into our eyes. In fact, as this test proves, wind is much more intermittent – even downright absent – than our senses would have us believe. To prove this, Inland Power – the largest electric cooperative in Washington – installed solar panels and a 35-foot wind turbine, each system costing about $22,000 and each delivering approximately the same amount of electricity under optimum conditions. Initially, the experiment was to help customers decide which renewable energy system would serve them better. According to Inland Power engineers, the solar panels delivered almost five times as much electricity as the wind turbine.Why? Not only is wind more erratic than sunshine, but wind turbines are designed to “kick in” at a certain lower limit. For many, this is a wind speed of between 3 and 12 miles per hour. In addition, while very strong sunlight simply improves a solar panel’s performance, very high winds – rather than generating more energy – cause wind turbines to cut out to prevent damage to the hub and/or gearbox. Surprisingly, even very short winter days showed solar delivering more bang for the buck than wind turbines. A2Z METALWORKER

8 • FEB/MARCH 2011

Wind’s only advantage? At this point, and for a little while longer, wind is cheaper. However, as solar cell efficiencies improve, and manufacturing techniques drive down the cost of panels, solar may soon become the clear winner.Of course, we knew that all along.

FDA To Accelerate Review Of Medical Devices The AP reports, “Federal health officials are proposing a plan that would speed up the approval of innovative medical devices that have the potential to dramatically improve patients’ lives.” This “so-called Innovation Pathway, announced recently by the Food and Drug Administration, would aim to review first-of-a-kind devices in five months, which is half the time currently spent reviewing most new devices. Under the program, the FDA would begin corresponding with device scientists in the early stages of development, helping them design studies to show the safety and effectiveness of their devices.”


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Daimler Trucks North America Celebrates Production of 1000th Hybrid Electric Vehicle Daimler Trucks North America (DTNA) recently marked the production of its 1,000th hybrid electric vehicle with a celebration at its Mt. Holly, NC plant. The Freightliner Business Class M2 106 Hybrid features the same benefits of the Freightliner Business Class® M2, such as outstanding visibility and maneuverability, with the added efficiency and environment-friendly features of hybrid power. The Business Class M2 106 Hybrid also can be easily configured for a wide variety of bodies for different applications, such as beverage, dump, government, landscape, towing, utility vehicles, and emergency. In addition to the Business Class M2 106 Hybrid, Freightliner Custom Chassis Corporation (FCCC), a subsidiary of DTNA, leads the way for alternative power in its markets. For the walk-in van industry, FCCC manufactures hybrid-electric vehicle (HEV) chassis, hydraulic hybrid vehicle (HHV) chassis and an all-electric chassis. FCCC also manufactures HEV chassis for the commercial bus market segments. In 2009, Thomas Built Buses, another DTNA subsidiary, launched is first HEV, the Saf-T-Liner® C2e solution, also supported by FCCC’s hybrid-electric chassis. All of DTNA’s hybrid products are equipped with EPA 2010-compliant engines utilizing selective catalytic reduction (SCR) technology and the Eaton® Hybrid Electric Drivetrain System, a parallel hybrid system that enables the truck to operate using the diesel engine alone, or in combination with the hybrid electric motor.The hybrid-electric motor provides power to launch and accelerate the truck, improving fuel economy and reducing emissions in stop-and-go operations, and the electric power comes from regenerative braking while the vehicle is slowing down. Further, DTNA hybrid's can be equipped with electronic PTO and/or 110V power generation capabilities to power hydraulics, lights, tools, or other equipment for job site or refrigerated cargo applications.

Metalforming Companies Optimistic About 2011 Business Conditions According to the January 2011 Precision Metalforming Association (PMA) Business Conditions Report, “metalforming companies are optimistic about business conditions during the next three months. Conducted monthly, the report is an economic indicator for manufacturing, sampling 119 metalforming companies in the United States and Canada.

 The January report shows that 47% of participants forecast an improvement in economic activity during the next three months (up from 40% in December), 43% predict that activity will remain unchanged (compared to 46% last month) and only 10% report that activity will decline (down from 14% in December).
 
Metalforming companies also expect improvement in incoming orders A Z METALWORKER • 10 • FEB/MARCH 2011 2

for the next three months. Fifty-two percent of participants predict an increase in orders (up from 44% in December), 36% anticipate no change (compared to 40% last month) and 12% predict a decrease in orders (down from 16% in December).

Average daily shipping levels remained steady in January. Twenty-six percent of participants report that shipping levels are above levels of three months ago (compared to 27% in December), 50% report that shipping levels are the same as three months ago (up from 38% last month), and 24% report a decrease in shipping levels (compared to 35% in December).

 The percentage of metalforming companies with a portion of their workforce on short time or layoff decreased to 12% in January from 16% in December.The number is at its lowest level since October 2007 when only 8% of companies had workers on short time or layoff, and is much lower than one year ago, when 52% reported employees on short time or layoff in January 2010.

 And, a current poll conducted by MetalForming magazine (www. metalformingmagazine.com) reports that 31 percent of respondents are ‘hiring back in a big way to handle rapid growth in orders,’ while 41 percent were more cautious, reporting ‘we’ll add to our workforce slowly as the year goes on, until we can get a good feel for the recovery.’ Another 27 percent indicated that they were relying on improved productivity of existing employees and not yet hiring.”

Notkin Mechanical Engineers Wins Contract Notkin Mechanical Engineers, Seattle, Wash., is being awarded a maximum amount $30,000,000 firm-fixed-price, indefinitedelivery/indefinite-quantity architect-engineering contract for mechanical and electrical projects in the Naval Facilities Engineering Command (NAVFAC) Northwest area of responsibility (AOR). Projects may include new installation or repair of building level and campus level plumbing, boiler plants and steam distribution; lighting and electrical power distribution and transformation; heating, ventilation, air conditioning and control systems; energy monitoring controls for various systems; communication, security, cable and closed circuit television, fire protection and alarm systems; and industrial ventilation and exhaust systems. Major importance will be attached to integrating new designs with existing facilities and systems. Work will be performed at various Navy and Marine Corps facilities and other government facilities within the NAVFAC Northwest AOR including, but not limited to Wash. (92 percent); Ore. (2 percent); Idaho (2 percent); Alaska (2 percent); Mont. (1 percent); and Wyo. (1 percent), and is expected to be completed by Feb. 2016. Contract funds will not expire at the end of the current fiscal year. This contract was competitively procured via the Navy Electronic Commerce Online website, with nine proposals received. The Naval Facilities Engineering Command, Northwest, Silverdale, Wash., is the contracting activity (N4425511-D-6002).


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operational utility of the Global Observer system will also be assessed during this flight test series for future U.S. Government, civil, and military uses.

Soaring Profits Offer Optimism For US Manufacturing The AP reports, “Heavy equipment maker Caterpillar’s soaring profit reflects strong demand in developing nations and offers reasons for optimism about the global economy and the prospects for other American manufacturers.” Edward Jones analyst JeffWindau called Caterpillar “a pretty good barometer” of broader market conditions. “That’s because Caterpillar sells its yellow-and-black mining and construction equipment around the world and can benefit from growth wherever it’s occurring, while its reach also means the company’s business reflects global economic trends.”

Global Observer, AeroVironment’s Extreme Endurance Unmanned Aircraft System, Achieves Historic First HydrogenPowered Flight AeroVironment, Inc announced that the Global Observer™ unmanned aircraft system has successfully completed its historic first flight powered by the aircraft’s hydrogen-fueled propulsion system at Edwards Air Force Base.This milestone marks the beginning of high altitude, long endurance flight testing for the demonstration and operational utility phase of the Joint Capability Technology Demonstration (JCTD) program. Because of its extreme endurance and range, Global Observer can be based out-of-theater, which will further reduce operating costs and local air traffic congestion while significantly reducing risk to operational personnel. AV plans to make Global Observer systems available for procurement and for operation as a turnkey service to provide communications and remote imaging in a manner similar to satellite services, but at a much lower cost. The hydrogen-powered flight lasted for four hours and reached an altitude of 5,000 feet above sea level. The flight test team will now systematically expand the altitude and duration of test flights to validate the aircraft’s high-altitude, long endurance performance. These flights will include the Air Force’s Joint Aerial Layer Network (JALN) Tactical Communications Suite (TCS) payload. The JALN TCS provides persistent, IP-based aerial communications infrastructure that extends communications from a Global Observer aircraft positioned at 65,000 feet above sea level over a wide area. The joint A2Z METALWORKER

12 • FEB/MARCH 2011

The AP notes, “Caterpillar predicts the world’s economy as a whole will grow at a lukewarm rate of 3.5 percent in 2011, but developing regions will grow at nearly double that pace and continue buying equipment for mining and for upgrading their infrastructure.” Under the headline “US Manufacturing Profits Suggest Stronger Economy,” Reuters reports that strong financial reports from big US companies such as Caterpillar and Eaton are providing a positive sign for the US economy, as well as for future employment figures. Along with rising profits has come rising optimism from the manufacturing sector, roughly two-thirds of which are now making positive projections for the coming year.


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Rising Steel Prices Unlikely To Hit Consumers Under the headline “Steel-Price Increases Creep Into Supply Chain,” the Wall Street Journal reports the rising materials costs are leading companies to stockpile as a hedge against future gains, which in turn is driving the price further up. However, industry experts say most companies will be able to avoid passing the increases on to consumers thanks to increased efficiencies and productivity. “We have seen these input prices going up sharply for a period of time, but there have been very little pass-through to final consumer markets,” noted Brian Bethune, head financial economist for IHS Global Insight.

lion) Anglo-French contract to design and build an unmanned attack aircraft, the Times reported, citing unidentified people in the defense industry. BAE, Europe’s biggest defense contractor, will partner France’s Dassault Aviation SA. Cobham Plc will work with General Atomics Aeronautical Systems Inc. European Aeronautic Defence and Space Co. will also make a bid, the newspaper said.

Raytheon Completes Applied Signal Acquisition Raytheon Co. said recently that it completed its acquisition of Applied Signal Technology Inc. The company announced last month that it agreed to buy Applied Signal for about $490 million. Raytheon said that about 12.4 million shares, or approximately 87.8 percent of Applied Signal’s outstanding stock, were validly tendered in the tender offer.

BAE, EADS to Vie for Unmanned Aircraft Contract, Times Says

Raytheon said it will exercise an option that will then give it enough shares of Applied Signal to go through with a “short-form” merger. This is a procedure allowed in some jurisdictions giving a company the ability to buy another company without shareholder approval.

Three aerospace groups including BAE Systems Plc will compete for a 600 million-pound ($952 mil-

Applied Signal will become a Raytheon subsidiary and will be folded into Raytheon’s Space and Airborne Systems business. It will be renamed Raytheon Applied Signal Technology Inc.

A2Z METALWORKER • A2Z METALWORKER

14 • FEB/MARCH 2011 • 42 • March/April 2011


A Vapor Degreasing Solvent for Cleaning Prior to Fluorescent Penetrant Inspection By Jeffrey J. Beard, Petroferm Inc.

Abstract

Cleaning metal components in a vapor degreasing process prior to fluorescent penetrant inspection (FPI) is critical. One commonly used method which is both simple and effective is vapor degreasing with trichloroethylene (TCE). However, there are toxicity concerns associated with TCE and permits (local and state) are required to use this solvent since it is classified as a suspected carcinogen and as a hazardous air pollutant (HAP). A manufacturer of precision castings employing TCE in a vapor degreasing cleaning process prior to their FPI process began a search for a replacement solvent. A number of “drop in” alternatives were considered. A binary azeotrope of n-propyl bromide and isopropyl alcohol was found to give equivalent or better indication results than TCE.The most dramatic improvement was found in Level 3 (high sensitivity) inspection. Other benefits of this alternative solvent included: 1) broad compatibility with metallic alloys; 2) non-flammable, 3) non-carcinogenic and 4) non-hazardous vapor degreasing solvent which is comprised of SNAP (Significant New Alternative Program) approved materials.

Introduction

The fluorescent penetrant process employs a series of process chemicals: penetrant, cleaning solutions to remove penetrant, and developer powders; which are used for inspecting metal parts to detect cracks or other metal imperfections that could cause failures. This FPI process is sometimes referred to as non-destructive testing (NDT) as it allows for inspecting the part using non-invasive methods. Both the aerospace and automotive industries view this particular inspection process as critical for high reliability components since failures could lead to catastrophic results. The purpose of the vapor degreasing process prior to FPI is to remove all metalworking fluids (coolants, sludge and oils) and debris embedded in the pores, cracks, or voids within the component that would prevent the penetrant from entering the defect. If the penetrant is blocked from entering the defect area that area will go undetected giving a false indication that no defect exists. In addition to TCE vapor degreasing prior to FPI, a number of other cleaning processes have been used to prepare components for inspection including: • Manual cleaning using petroleum-based solvents such as acetone, methyl ethyl ketone (MEK), toluene and mineral spirits • Vapor degreasing with hydrochlorofluorocarbons (HCFCs); other chlorinated solvents such as perchloroethylene (PERC) and methylene chloride (MC) • Aqueous cleaning processes The purpose of this investigation was to identify a suitable alternative to TCE prior to a fluorescent inspection process. Criteria for success was based on finding a solvent that 1) perform as well as if not better than TCE, 2) could be used in the same vapor degreasing equipment, 3) offer improvements over TCE from an environmental, health, and safety standpoint.

Test Component Preparation

The cleaning process for metal components at this manufacturer employs a typical two sump vapor degreaser in a standard, three-stage vapor degreasing process with TCE as the solvent. The cleaned components are inspected immediately after degreasing using the FPI process. Upon passing inspection, the components are further processed into the final product. For this study, a series of four cleaning tests were completed over a 6-month period at an off-site location. For each test run, the ability to clean a sample size of at least 200 components was evaluated. Each test component was produced in-house to best emulate the customer’s conditions and requirements, including saturation in cutting oils and metal fines as a result of the normal manufacturing process. Each test component was then stacked and racked in baskets used in the current degreasing process. The test components, once cleaned, were then inspected by the customer using the current FPI process.All of the test components were subjected to the same pass/fail rating as TCE-cleaned parts.

Cleaning Product under Evaluation

The binary azeotrope of n-propyl bromide and isopropyl alcohol was extensively investigated in this study. This product effectively removes oils, greases and particulates. It has broad compatibility with metallic alloys and some plastics.

Results

Since the customer’s internal rejection criteria is proprietary, no specific test results are available for this paper. However, the customer did verify that the test results from the n-propyl bromide and isopropyl alcohol binary azeotrope cleaning trials demonstrated that it was indeed a suitable replacement for TCE in the fluorescent inspection process. Furthermore, this alternative to TCE, allowed for more consistent detection of component flaws in Level 3 (high sensitivity) inspection.

Discussion

The primary goal of this evaluation was to identify an alternative vapor degreasing solvent that performed as well as trichloroethylene in the cleaning process prior to a fluorescent inspection process. Of equal importance was the identification of a solvent that offered improvements from environmental, health and safety standpoint when compared to TCE.

A binary azeotrope of n-propyl bromide and isopropyl alcohol was found to give equivalent or better indication results than TCE. The most dramatic improvement was found in Level 3 (high sensitivity) inspection. Other benefits of this alternative solvent included: 1) broad compatibility with metallic alloys; 2) non-flammable, 3) non-carcinogenic and 4) non-hazardous vapor degreasing solvent which is comprised of SNAP (Significant New Alternative Program) approved materials.

About the Author

Jeff has served the specialty chemical business for 23 years. During that time, he has worked extensively with aerospace, automotive, electronics and medical customers worldwide to assist them replacing hazardous chemicals used in their cleaning processes or to improve their existing vapor degreasing, aqueous, or solvent cleaning processes. For more information please call 317-371-8899 or visit www.petroferm.com. A2Z METALWORKER

• 15 • FEB/MARCH 2011


United Technologies Chief Plots Course for Recovery

[to a country] ‘I can sell you a product, I have no restrictions.’ We can’t say that.

The downturn crimped many of UTC’s business units, a diverse group that includes jet-engine maker Pratt & Whitney, Otis Elevator and Carrier air and heating appliances, which suffered with the global construction industry.

We have a big role with Boeing on the C-17 [military transport plane].We’re trying to sell these planes to India.The C-17 is 22,000 U.S. jobs. Relaxing these export controls is critical for accelerating blue collar job momentum.

Sikorsky helicopters—which makes the Black Hawk—however, was largely immune to the turmoil, with several long-term contracts to build new military helicopters.

WSJ: Pratt & Whitney is currently the sole engine provider on the new F-35 Joint Strike Fighter.Your competitor, General Electric is still pushing hard to get authorization for a second engine on the plane, despite the Administration’s opposition. Where do things stand from your point of view?

To weather the past few years, the Hartford, Conn., company trimmed more than 18,000 jobs from its work force, which now has about 200,000 employees. Mr. Chênevert, who joined Pratt in 1993, was elevated to president and chief operating officer in 2006. He took became CEO in 2008 and was named chairman last January. He spoke recently with The Wall Street Journal. Excerpts: WSJ: UTC has a large presence in China, so what does the future look like for you there? Mr. Chênevert:We’ve been in China for a long time, Otis was there more than 100 years ago and we started selling Pratt engines in the 1960s. Today we have 20,000 employees in China; only a handful [are] expats. Obviously, the coastal cities have been booming but momentum is moving inland. It’s my view that five years from now 40% of our new [Otis elevator] equipment sales will be inland cities. WSJ: Other big U.S. firms have lamented the difficulty in doing business with China, especially in regard to technology transfer and government interference. What are your thoughts? Mr. Chênevert: We have a relationship with [state-owned aviation firm] Comac on a product that uses the latest technology so we have very good language in our agreements to ensure we protect intellectual property and also respect U.S. rules. That said, you have to be watchful and take the right steps to protect our latest technology like we would in any country. WSJ: You were one of the business leaders who accompanied President Barrack Obama to India in November. What was one of the most important things you discussed with his administration? Mr. Chênevert: A big issue was relaxing export controls. Some of these rules and regulations are on 40-year-old products and it prevents us from competing with the Europeans who will say A2Z METALWORKER

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Mr. Chênevert:There’s no other [military] platform except the F-16 that’s had two engines. I think it’s a great example of an earmark by Congress that is absolutely brute force. Basically, the President has said repeatedly, we don’t want an alternate engine; the Secretary of Defense has said it, the service chiefs have said it and it’s kind of surprising to me that peers in the industry are actually fighting the end customer through earmarks on something the end customer says they don’t want. [A GE spokesman said, “Mr. Chênevert is absolutely right about the F-16. It had a high production volume that made tremendous sense to have an additional engine. JSF will be much larger from a production standpoint.” WSJ: Proponents have argued that a second engine will keep costs down and make the process more competitive. Do you agree? Mr. Chênevert: In all honesty, the country cannot afford to pay for an alternative engine that makes no difference. WSJ: Even with the Pentagon tightening the purse strings, your Sikorsky helicopter unit has been a bright spot. How did it stay healthy? Mr. Chênevert: Sikorsky has been well positioned because of demand for the Black Hawk helicopters. The wars in Iraq and Afghanistan have been wars with boots on the ground and helicopters. Our equipment has performed magnificently. We have 1.5 million flight hours in service in Iraq and Afghanistan with no Sikorsky-related events.The customer likes the product and we’re on time on delivery. WSJ: In December, Airbus selected Pratt’s new Geared Turbofan engine as an option on its upgraded A320 plane. It’s the first time Pratt’s been back in commercial airplane engines since the 1980s. What does it mean for the company? Mr. Chênevert: It exemplifies the long cycle of this industry. Eleven years later, after $1 billion-plus of investment, you win the prize platform. The last cycle on the A320 and the 737 was really in the early ‘80s, so it’s 30 years apart. So, if I don’t get this window now it means I probably don’t have the chance again in my lifetime.


A2Z METALWORKER

• 17 • FEB/MARCH 2011


Pacific Tool Inc.(PTI), entering its 44th year in business, built its reputation on a very simple premise—“our customers view us as their problem solvers, and as the company that is willing to do what others aren’t willing or able to do”,Scott Garbarino, Vice President and Chief Operating Officer said. “Even if the parts are made to spec and it’s not working for the customer, we are there to fix the issue.” It’s a simple premise but one that many businesses don’t practice. The company was started in 1966 by Frank Garbarino along with three other founders. Frank was instrumental in shepherding the company through the boom-and-bust cycles of the aerospace industries. He eventually bought out his partners and both he and son Scott have grown PTI to its current size and level of service, with more than 45 employees. The company is very much a family run business, and over the years, Frank’s wife Peggy, and today, Scott’s wife Tami, are valuable contributors to the company. Prior to opening PTI, Frank worked for a Seattle tool and die shop that supported a number of customers, with Boeing representing a substantial amount of their business.When the company closed down, Frank purchased their assets at an auction, and with partners, opened up PTI to fill the void left by his previous employer. The Boeing business came easy, as engineers and purchasing managers knew Frank. In fact, PTI serviced Boeing so well that in 1992, the company was awarded a contract from Boeing for ‘next day delivery items’. Scott explained that this meant that PTI was a stocking distributor of custom tools for the aerospace giant. PTI maintains this elite status today. Additionally, they consistently receive gold and silver ratings from Boeing. Scott says, “Boeing told us that years ago they had hundreds of suppliers in our classification (small tool supplier), and now they have pared the list down to 16. We are one of the 16 in the United States today.” Scott learned machining from the time he was a small child, and he learned from the best -Frank Garbarino. Scott knew from a very early age that he wanted to make PTI a career. Scott worked for his father and earned a degree in Industrial Engineering from the University of Washington. Today, he is working towards completion of his MBA. When asked why Scott felt his engineering and masters in business was critical to the long term A2Z METALWORKER

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success of PTI, Scott responded that his journeyman machining on-the-job training coupled with his engineering degree is extremely beneficial in speaking the language with machinists, engineers and purchasing professionals. The MBA, he feels, will expand his business acumen and will help him to run and grow the business and effectively speak the financial language needed in dealing with bankers. The company was affected by 9/11, as were most companies in any industry, but they haven’t had a layoff since then. “We took a number of steps to weather downturns and to grow our business since then”, Scott said.

Fundamental Changes in PTI’s business •ISO/AS9100 Certification- Long

before most machine shops thought about certifying to the rigorous ISO/AS9100 standards, in 2002 PTI achieved this milestone. Scott says that this difficult endeavor enabled them to retain their substantial business with Boeing, as well as to secure business from other companies in the aerospace industry.

• Acquisition of non-Boeing customers- While today PTI is a key supplier to Boeing throughout the United States, years ago they made a concerted effort to acquire


to send our people to the training - instead Delcam offers online interactive training. This is perfect for our business, because we don’t incur travel costs”, he continued.

additional customers. “We knew that Boeing has ebbs and flows and that if we were going to manage our business and retain our staff, we needed more customers, more diversification”, Scott said.

• Superior Employees - Since 9/11, PTI

has retained its key employees and grown its team. “Many of our employees have been with PTI for 20 plus years, and our staff of 45 includes expert craftsmen with decades of experience — from CNC equipment programmers, to production operators, to skilled individual tool makers”, Scott said. Additionally, Scott retains his relationship with the local shop instructors and high school technical teachers, and routinely secures new young talent who are known performers.

• The Latest Machine Tools - PTI’s customers require tools in quantities that range from 1

to 1000. Additionally, Scott says that when they build a tool for a customer, they may not see that tool order again for 10 years.To remain profitable and meet their customers’ delivery schedules, PTI purchases high tech CNC machinery. Their latest acquisition, a Mori Seiki MZ2000T3 Y3, was purchased specifically to make parts for a new customer. “If we didn’t have the Mori Seiki, we were going to wrap dollars around every part we built, and we wouldn’t be able to meet the customer’s delivery schedule.” He continued, “We are conservative in our acquisition of new equipment because we like to stay debt-free, but we purchase the equipment that is required to support our customers as well as our business growth.”

•Superior Software - “We’ve purchased a number of software packages for our business over the years”, Scott said. “When the sales engineer from FeatureCAM came to see us initially a few years ago, he showed us how much faster we could make a part with their software”. Since their initial purchase of FeatureCAM, the company is delighted with their selection. Hank Francis, lead programmer for PTI, is a complete believer in the package and the support PTI receives from Delcam, supplier of FeatureCAM. “Their fundamental business model mirrors ours. If we have a problem, the Delcam team responds within hours. Our previous software providers would respond in days or even weeks. With Delcam, our support is outstanding and instantaneous. Even when we needed complex post processor coding support for our new Mori Seiki, the Delcam engineering team turned the code around to us in days! They are absolutely superior to any software provider we have worked with!” The team at PTI finds Delcam’s training to be outstanding. “Our people are trained by Delcam experts in their Salt Lake City headquarters”, Scott said. “But we don’t have

Hank is particularly pleased with FeatureCAM’s feature recognition. He says that traditional CAM systems are operations based and require you to program every operation, one at a time, to create your part. All the manufacturing details are left to the CNC programmer. That means you must specify the details for every rough and finish pass, spot drill, drill, and tap needed to create your part. Hank elaborated, “With feature-based machining available in the FeatureCAM suite, the part is created using features that describe that part, from simple holes to complex pockets to turned grooves, and the operations are automatically generated. Features give you the ability to think about and view the part at a higher level. Feature-based machining frees you from the time-consuming chore of creating and managing each machining operation. And since there are fewer objects to manage, part programming is accomplished more easily and with fewer errors.”

Why FeatureCAM®? FeatureCAM, developed by Delcam, is a suite of CAD/CAM software which combines cutting edge technology with ease of use. FeatureCAM offers a knowledge-based technology to increase productivity. FeatureCAM automates machining and minimizes programming times for parts on mills, lathes and wire EDM. With FeatureCAM, you can draw or import your part, identify part components as features (holes, pockets, surface milling, etc.), click simulation and you are done! NC Code is generated! For more information on PTI, call them at 425.882.1970 or visit their website at www. pacifictool.com. To learn more about FeatureCAM, call Delcam at 1-877-DELCAM1 or go to www. delcam.com. A2Z METALWORKER

• 19 • FEB/MARCH 2011


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Delcam’s safestDefense new CutsPowerMILL Will Shift offers Money To ever machining Repair Of Existing Equipment By Marjorie Censer

Delcam has released the 2011 version of its Powsystem for When Defense Secretary Robert M. Gates erMILL announcedCAM funding cuts last five-axis and high-speed month, some in the defense industry shuddered. But for others, the machining. This release announced cuts will generate new opportunities to revitalize older makes the programming of systems. safe toolpaths easier than ever thanks to new It’s not unusual for a program termination to refocus attention on an stockolder model-engagement program, but analysts said this shift may become more commonoptions as the that protectbudget both tightens the cutting and the machine excessive Pentagon’s and ittool is forced to work withfrom the equipment loading. Other enhancements include new editing capabilities to it already owns. simplify the machining of duplicate items; more versatile control of feed-rates for leads andannounced links; andthe extra functionality for will sketching, This time around, Gates Defense Department end a plus theCorps completion of the move to thecontractor new clearer forms for the Marine vehicle program with prime General Dynamics complete rangedirect of strategies. and will instead money toward repairing and upgrading its existing amphibious assault vehicle, built by BAE Systems.Additionally, he delayed partoptions of Lockheed Martin’stool F-35loading strike-fighter aircraft programa constant and said The to optimise will help overcome the Pentagon would buy more of Boeing’s F/A-18 aircraft. conflict for programmers. On the one hand, they want to maximise productivity by setting feed-rates as fast as their machines will allow; “I that there going more safe and speeds more examples like break that,” onthink the other hand,are they needtotobeensure that will not said Todd Harrison, a defense analyst with the Center for Strategic and the tool. The need for safe machining has, of course, become more Budgetary Assessments. critical as a growing number of companies are introducing lights-out, unmanned operation overnight or during weekends. Because the military in recent years invested in many new programs, which in lots casesprograms have not come to fruition, it did notbased spendon as the much A number of of CAM incorporate strategies ex20 22 •• FEB/MARCH Jan/Feb 20112011 • 30 • Nov/Dec 2007

22 AA ZZMETALWORKER METALWORKER •• A2Z METALWORKER

tent of cutterrepair engagement to give moreofconsistent loading on the tool on large-scale and modernization older equipment, Harrison and so allow higher feed-rates. However, these options are usually added. “As a result, we still have . . . this lagging need to recapitalize limited large partstoofthe ourinitial force,”roughing he said. operations, or to only roughing and rest-roughing. PowerMILL’s new stock engagement technology can alsodefense be employed with all of the system’s andvulnerable rest-finishing The industry, keeping a close eye onfinishing programs to strategies so ensuring that the safest-possible toolpaths cancellation, is now positioning itself for these repair efforts. are run on the machine at all stages.

BAE Systems is hoping to win work repairing its amphibious assault The keybut tothe thiscompany more comprehensive solution is the accuracy of the vehicle, anticipates competition. stock models produced within PowerMILL after each machining stage hasdon’t beenexpect completed. models out giveofathe precise representation “We to get These any favoritism customer because weof thethe material remaining on areare used toadvantages ensure that are [originalstill manufacturer], butthe I dopart thinkand there some cutter never asked to vehicle,” remove more material than BAE’s it can vice safely ofthebeing theisdesigner of this said Ann Hoholick, president of new andstock amphibious cut. At the samevehicles time, the models systems. also ensure that toolpaths are not produced where there is no material remaining so the machine tool iswith never left cutting Faced a tighter budget,air. BAE has tried to be equally prepared to bid on a new program or a competition to modernize older systems, said Bob the company’s president for product TheMurphy, new toolpath editingexecutive options invice PowerMILL will makesectors. it easier “You can’t get wed to anycopies one thing, because all I canitem, tell you as the to produce multiple of any duplicated foris,example, future whatalooks likeofa cavities very highinto priority today .tool. . . canThe change whenunfolds, machining series a mould user very Murphy said. “You’ve got tocopies be prepared the change.” can rapidly,” now specify an array of multiple in one for operation, using approaches such as a number of rows and columns or a radial spacLoren Thompson, a defense industry consultant at thehave Lexington Institute, ing around a central point. Once the copies been produced, said it’s common for a program termination to create new work on an the complete series of toolpaths can be re-sequenced to minimise existing piece of equipment. But, often “the company that benefits from tool changes. a cancellation is not the company whose program is canceled,” he said. Enhancements to feed-rate optimisation have been introduced to “In this environment, weapons spending is a zero-sum game,”Thompson give better control of leads and links at the points of cutter engageadded. “One company’s gain is another company’s loss.” ment and exit. Typically, the feed rate as the cutter enters and exits


the material needs to be slower than that set for the main length of the toolpath. Setting the entry speed too high will risk damage to the cutter and the spindle, and can even move smaller parts on their fixtures. Exit speeds are critical when machining brittle materials, such as graphite electrodes, since the cutter can chip the surface of the part if it is moving too quickly. PowerMILL users can now avoid these problems by setting specific entry and exit feed-rates, either as percentages of the feed-rate for the main toolpath or as absolute values. PowerMILL has incorporated sketching functionality for several years, for example to draw boundaries within the model to limit individual machining strategies to particular areas of the part. This has been enhanced with a number of new editing options, including the ability to offset or transform curves, and to flatten 3D curves into 2D curves, or to project 2D curves onto 3D surfaces. For further information on PowerMILL, please contact: Peter Dickin, e-mail: marketing@delcam.com.

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www.roscoprecisionmachinery.com Five of the best minds in aerospace, defense and space manufacturing technology, each responsible for driving productivity in the ing enterprise. enterprise, will keynote AeroDef Manufacturing 2011, a technical Burbage manages the Joint Strike Fighter Program Integration for conference and exposition, April 5-7 at the Anaheim Convention Lockheed Martin and is responsible for the F-35 U.S. and internaCenter. tional customers and industrial partners. Keynote speakers include: • Mike Vander Wel, director of the manufacturing domain in the Enterprise Technology Strategy Office, The Boeing Company • Tom Burbage, executive vice president and general manager, Lockheed Martin • Steve Linder, director of manufacturing technology, within Department of Defense Research and Engineering’s Office of Technology Transition • James K. Sutter, PhD, senior scientist, Polymer Branch of Materials and Structure Division at NASA • Douglas Comstock, director for partnership, innovation and commercial space, Office of the Chief Technologist, NASA Vander Wel is responsible for the leadership and strategy of Boeing’s technology portfolio in the Manufacturing Domain across the Boe-

Linder oversees the congressionally mandated DoD program and manages the Defense-Wide Manufacturing Technology (DMS&T) Program Element. He was formerly director of the Navy’s Manufacturing Technology Program. Sutter works in the NASA Engineering Safety Center (NESC). Previously, he led a team of more than 75 engineers, scientists from NASA, Air Force Research Labs, industry and universities to successfully produce and hot-fire test the first composite support structure for a hypersonic air breathing engine. Comstock manages NASA’s IPP portfolio of technology investments and partnering mechanisms. He is responsible for intellectual property management and technology transfer. A Z METALWORKER • 21 • FEB/MARCH 2011 2


Solar power applications aren’t the only renewables being used out on these bases. Marines put a call out for vendors who supply water purification and energy-efficient shelters also. Marine Corp officials have evaluated the efforts in Afghanistan to reduce energy use and to become more efficient and have labeled the effort “remarkable.”

SoloPower Announces New Solar Panel Manufacturing Facility in Oregon SoloPower, Inc.announces it will locate a high volume manufacturing facility in Wilsonville, Oregon. The initial phase of this expansion will be the construction of a 75 MW manufacturing line which will create 170 new jobs. Upon completion, the facility is expected to have nameplate capacity of 300MW, employ approximately 500 people, and have a total investment of approximately $340 Million. This state-of-the-art production facility will greatly enhance SoloPower’s ability to provide powerful, flexible, lightweight solar modules to its growing list of global customers. “SoloPower is bringing exactly the kind of new jobs Oregon needs. By bringing their manufacturing headquarters to Wilsonville, we are continuing on the path toward establishing a stronger clean technology manufacturing base in Oregon,” said Governor John Kitzhaber.

U.S. Marines Using Renewable Energy to Improve Efficiency and Save Lives The Office of Naval Research along with elements of the U.S. Marine Corps have been testing and using renewable energy strategies to improve operational efficiency on bases in Afghanistan. The goal is to reduce the effort and energy that has to be used to move equipment from place to place. By using energy saving systems Marines won’t have to do as many resupply runs that put them at risk. Afghanistan based 3rd Battalion 5th Marines have been experimenting with and successfully using Solar Portable Alternative Communications Energy Systems LED Lighting Systems or SPACES. By deploying SPACES which is a lightweight solar panel system, the Marines could do extended patrols away from their base without having to risk their lives to do resupply runs to get more batteries. In addition, a 300-Watt solar powered generator allowed the Marines to reduce fuel consumption from 25 gallons a day to just 2 or 3 gallons. Many of the younger Marines have grown up hearing, reading and knowing about the benefits of using solar power and other renewable energies. As a result it’s easier to train these young warriors to use these methods to become more efficient and as a result, reduce the risk of injury and death. A2Z METALWORKER

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Brain-Controlled Robotic ArmTo Pilot FDA’s Priority Review System The Los Angeles Times reported the FDA “will evaluate braincontrolled prosthetic arms in a new program designed to bring innovative medical devices to market faster.” The prosthesis was “developed by the Defense Advanced Research Projects Agency [and] uses a microchip implanted in the brain to record and decode signals to neurons that control muscles linked to the prosthesis. ” The robotic arm “will serve as a pilot submission to the FDA’s Innovation Pathway, a priority review program for new breakthrough medical devices that is part of a broader effort to promote cuttingedge technologies among medical-device manufacturers

Precision Castparts Presents Business Update at the Cowen Aerospace and Defense Conference 2011 Mark Donegan, chairman and chief executive officer of Precision Castparts Corp., discussed current business conditions at the Cowen 32nd Annual Aerospace and Defense Conference earlier this month. Cowen is making the audio webcast available on the Internet through the following link: http://www.wsw.com/webcast/cowen2/pcp/


A2Z METALWORKER

• 23 • FEB/MARCH 2011


Cisco Space Router Passes Satellite Orbit Test Space-router technology from Cisco has successfully passed a Department of Defense (DoD) satellite-orbit test, paving the way for the use of next-generation satellite-based IP services and communications from space. The Internet Routing in Space (IRIS) technology was launched as the first IP router on an Intelsat IS-14 commercial satellite on Nov. 23, 2009, and recently passed an IRIS Joint Capability Technology Demonstration (JCTD) evaluation for use in orbit, according to Cisco. If your a professional or a gamer that’s always on the move with your system, but also like to work with two displays (the one on your notebook and another monitor), then Mobile Monitor Technologies’ Monitor-2-Go may be just what the doctor ordered. IRS is a program to build an IP router that can tolerate radiation for use on satellites and other spacecraft.The technology will give government agents, military units and allied forces better and more reliable access IP-based network services for voice, video and data and to communicate over IP, according to Cisco. During the JCTD test, DoD users on land and at sea tested IRIS services in real-world scenarios. The technology provided connectivity to the Internet on demand, and also allowed them to collaborate in real time using applications such as VPNs, as well as make video and file transfers via satellite.

Northrop Grumman’s Joint STARS Program Completes Design Review for Updated Bleed Air System Northrop Grumman Corporation recently completed the JT8D propulsion pod’s bleed air system’s preliminary design review (PDR) for the E-8C Joint Surveillance Target Attack Radar System (Joint STARS). “The successful completion of the PDR indicates that the design is extremely mature and will meet the Joint STARS mission requirements,” said Steve Pauly, Northrop Grumman program director for Joint STARS Development and Modernization. “This significant design effort has been a major focus of the Re-Engining development program.” A photo accompanying this release is available at: http://media.globenewswire.com/noc/ mediagallery.html?pkgid=8739 The Northrop Grumman program team is re-designing the E-8C’s commercial off-the-shelf (COTS) bleed air system’s equipment in support of the Joint STARS Re-Engining program. The main function of the bleed air system is to extract high-pressured hot air generated from the JT8D’s engines and convert it into cool air.The resulting cool air pressurizes the Air Cycle Machines (ACM) which cools the aircraft’s environmental control system, cabin and prime mission equipment (PME), as well as pressurizes the utility hydraulic subsystem, engine starting capability and liquid cooling system. “The newly designed bleed air system will be installed and flight tested towards the middle of next year,” stated Pauly. “This is a major step toward clearing the way for full production A2Z METALWORKER

24 • FEB/MARCH 2011

and installation of the new JT8D propulsion pod system.” Today, the 17-aircraft Joint STARS fleet is the only all-weather, long-range, real-time, wide area surveillance and battle management and command and control weapons system in the world. It is flown by the 116th Air Control Wing based on Warner Robins, Ga. and since 2001, the crews have flown over 63,000 hours in 5,200 combat missions in support of Operation Iraqi Freedom, Operation Enduring Freedom and Operation New Dawn.

U.S. Air Force Awards Lockheed Martin $107 Million Space Fence Radar Contract The U.S. Air Force awarded Lockheed Martin a $107 million follow-on contract for the next phase of Space Fence, a program that will increase space situational awareness and enhance safety for both manned and unmanned space operations. Under the 18-month contract, Lockheed Martin will further develop and prototype its ground-based radar system design in preparation for a final Space Fence production contract next year. Space Fence will replace the existing Air Force Space Surveillance System, or VHF Fence, which has been in service since the early 1960s. The higher wave frequency of the new Space Fence radars will allow for the detection of much smaller microsatellites and debris than the current systems allow. “The proliferation of orbital objects, including rocket debris and satellites, threatens our daily use of space-based technology and its valuable services, such as electronic navigation, satellite broadcasting and medical research,” said John Morse, Lockheed Martin Space Fence program director. Space Fence will field two or three highpower, S-band ground-based radars to provide the Air Force with uncued detection, tracking, accurate measurement and cataloging of resident space objects, primarily in low-earth orbit. Surveillance Network.


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NASA Next-Gen Vehicle Builds on Past

eration Global Positioning System satellites, the company announced.”

Engineers planning NASA’s next effort to build a vehicle to replace the retiring space shuttle fleet will start with an amalgam of the shuttle and its moribund Ares I and Orion follow-ons. As before, money remains a problem.

The Collaborative Human Immersive Laboratory (CHIL) Lockheed will use “is first being used to aid the design of ground support equipment and space hardware for the Air Force’s GPS 3 satellites, which will begin launching in 2014.” Since the technicians can simulate operations before production begins, “Lockheed Martin says the CHIL will help stem the threat of rising costs and schedule delays by revealing potential bottlenecks and workflow issues before they happen.”

The U.S. space agency’s “reference vehicle design” for a heavy-lift space launch system (SLS) incorporates five space shuttle main engines (SSMEs); a core stage based on the 27.5-ft.-dia. shuttle external tank; two five-segment versions of the four-segment solidfuel shuttle booster rockets and an upper stage powered by one or two J-2X engines in development for the Ares I crew launch vehicle. For the new multipurpose crew vehicle (MPCV), crews ranging in size from two to four would ride in the deep-space version of the Orion crew exploration vehicle, adapted to provide backup flight capability to the International Space Station in case commercial crew vehicles being developed separately do not materialize. NASA officials stress that while the designs meet congressional requirements that the government’s shuttle follow-ons use existing hardware, contracts and workforce as much as possible, the reference vehicles are not necessarily the final choice. Internal NASA teams also are studying a kerosene-fueled alternative to the liquid-hydrogen-fueled SSME, and a modular approach that would array three smaller-diameter stages in parallel—comparable to the approach followed by the Delta IV Heavy. In addition, 13 companies are conducting six-month studies of technologies that might help NASA refine its heavy lifter. Administrator Charles Bolden has insisted that any future vehicles be “affordable, sustainable and realistic,” specifications the reference launch vehicle does not meet given the $6.5 billion authorization for its development and 2016 deadline for its first flight. The reference design was picked because it made maximum use of shuttle hardware and work already done under the Constellation Program that was building the Ares I and Orion until Obama’s Fiscal 2011 budget request and the subsequent authorization act killed it. “Administrator Bolden is very, very strongly emphasizing that we’re going to develop a credible plan,” she says. “We’re not going to break any laws, but the key thing that NASA needs to go off and do is build a credible plan for the SLS development; make sure it’s affordable, sustainable and realistic or practical.” The final vehicle also will be shaped by final Fiscal 2011 NASA funding that emerges from the newly convened Congress, and by the Fiscal 2012 budget request due out next month.

Lockheed Using Virtual Reality For Space Systems Development Spaceflight Now reported, “Lockheed Martin Corp. will employ cutting edge virtual reality technology to streamline development of future space systems, starting with the US Air Force’s next-genA2Z METALWORKER

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New Marine Assault Vehicle Meets Performance Test General Dynamics said the EFV’s recent tests confirmed that the design is sound and it will be ready for production in 24 months. General Dynamics continued its push to save the potentially doomed Expeditionary Fighting Vehicle, saying the Marines’ amphibious assault craft excelled during the latest round of performance testing completed at Camp Pendleton recently. The new amphibious vehicle, meant to transport Marines from ship to shore much faster than existing assault craft, exceeded requirements by 90 percent, according to the company’s preliminary data. The Pentagon had announced plans this month to cancel the program and develop a more affordable alternative, despite $3.3 billion spent on research and development of the EFV. Defense Secretary Robert Gates axed the $15.5 billion program as part of $78 billion in recommended budget cuts. If the Marine Corps opts for a stripped-down version, with slower water speeds or less advanced weaponry perhaps, costs per vehicle can drop to as little as $8 million, General Dynamics said.The current per-unit cost has been estimated at about $17 million. Tuning down the capabilities “is much more efficient than abandoning the investment of over a million man-hours of engineering,” Michael Bolon, General Dynamics Land Systems’ senior vice president of Navy and Marine Corps programs, said Tuesday in a telephone call with reporters. Another option is cutting the order from 573 vehicles to 200 vehicles. Such a move would save $184 million in cancellation costs, Bolon said. “Starting from scratch is not the most efficient alternative to the Expeditionary Fighting Vehicle,” Bolon said.“It can be produced at an affordable cost, if given the opportunity.” Marines from the Corps’ Amphibious Vehicle Test Branch began evaluating four prototypes this fall in simulated combat conditions, running the vehicles 500 hours at Camp Pendleton. Manny Pacheco, a spokesman for the Marine Corps’ Expeditionary Fighting Vehicle program, said official results of the reliability testing would not be finalized until mid-February, but he expects the EFV to easily surpass the reliability requirements.


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• 27 • FEB/MARCH 2011


Boeing 787 Test Priority Shifts To ETOPS

[and the FAA] on what needs to be done, and on what timing.”

Boeing’s 787 certification focus is shifting from aircraft tests to qualification for long-range ETOPS at entry-into-service in the aftermath of last November’s electrical fire, says Boeing CEO James McNerney.

Production of the 787 is holding at two per month, and Boeing remains confident the overall assembly rate will continue to grow to 10 per month by the end of 2013. McNerney says the target is achievable but will occur later in the year than originally planned because of the delivery slide to the -8 into the third quarter of 2011. “We had a very conservative view and a significant amount of margin in our production ramp-up plans, and a lot of that has now been eaten up by the latest delay. Everything slid to the right—and that is offset by a contingency we had in 2013.”

Despite the delays caused by the fire on ZA002, the 787 program has completed 75% of the flight testing required for delivery, but the redesign of software prompted by the incident is threatening the timing of Boeing’s ETOPS qualification program. Speaking to analysts on a 2010 earnings call, McNerney adds that as 787 flight hours pass the 2,500 flight-hours mark, qualification testing for ETOPS at entry-into-service is the growing priority. “We have a clear view of what we need to do. The FAA has been working very closely with us. ETOPS is different this time around than it was on the 777. The FAA has a new way of doing it. It used to be cycle-based and now it is fault-based and condition-based. The question is what test points are applicable for each test point, and we have to do it right.” Commenting on development of the revised power distribution control software after the 787 electrical fire, and whether the chances of winning ETOPS clearance at entry-into-service have been endangered, McNerney says, “We are in agreement. We have a temporary fix, but we are going to implement a permanent fix before we go into ETOPS testing. But there is no misunderstanding between us

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McNerney adds that completion of recent assemblies into Everett has been at a “very high” level, suggesting that the company’s supply chain is over the hump on rework levels and aiming for a smoother ride into the production ramp-up plan for 2011-2013. On any thoughts of rate acceleration, McNerney is cautious. “We’re mindful of the supply chain, and we don’t want to relive the experiences of 1997.” Commenting on the 747-8F program, McNerney says the stretched freighter has also passed the 1,700-flight-hour mark and, at roughly 650 flights, is about two-thirds of the way through its test program. With fixes for the aileron vibration and modal suppression issues discovered last year now completing flight test, Boeing remains confident of achieving first delivery around mid-2011. Development of the -8I passenger variant, meanwhile, remains on track for first flight in late March, while both the first two aircraft have now achieved ‘power-on’ in ground tests. CFO James Bell says deliveries for 2011 are expected to cover 485-400 aircraft, and that all positions through December are “sold out.” This includes 25-40 747-8/787s, divided “roughly equally between the two programs.” Analysts suggest deliveries of up to 17 747-8s by yearend, meaning that Boeing could be looking at eight to 23 787 deliveries for the last four months of 2011.

Anticipating Greater Spending, Factories Increase Production The AP reports, “Factories are cranking up production, anticipating greater spending by consumers and businesses in 2011” as tax cuts “give people more money to buy cars, computers and electronic goods, and provide incentives for businesses to invest in equipment.” According to the AP, “The big difference now is that the growth is being driven by higher sales and more confident consumers – not just businesses rebuilding the stockpiles that they slashed during the recession.” With the increased activity, the US is also “likely” to see “steady hiring.” However, “economists caution that it will only be enough to chip away at the 9.8 percent unemployment rate this year.” But even so, “they expect it will give the economy a shot of momentum, putting more money into people’s pockets,” which in turn will lead to more spending and therefore “more hiring in other areas of the economy.”


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MADE WITH TRUSTED MACHINES...MITSUBISHI “This is probably one of the best known little companies in the world”, Alex Kelsay, manufacturing project manager, said. Leatherman multi-tools are designed and manufactured in the United States, in Portland, Oregon, and they are shipped to more than 80 countries throughout the world. Everyone knows the Leatherman brand. There is an actual Leatherman.Tim Leatherman. And he’s been the driving force for 25 years. After all, he states, “my name is on every tool.”Today,Tim Leatherman serves as Chairman of the Board . The company employs nearly 500, and they manufacture in excess of 1 million tools per year in their 90,000 square foot facility. Their products can be purchased at such big box retails as Target, Costco, Lowes, and they can additionally be purchased by military personnel through their local AAFES (army and airforce exchange service). All Leatherman tools (there are 46 different varieties) come with a 25-year warranty, and Tim is quoted as saying “long enough to prove we stand behind our tools, but short enough to show we’re serious.” Leatherman products are complex to make -- A typical Leatherman tool goes through approximately 300 processes during production! When I asked Alex how Leatherman continues to excel, and beat out manufacturers in other regions of the world, he said there were a number of reasons, and two most noteworthy. • Leatherman products are complex designs - high tolerance designs-- and thus they are not easily copied. • The company operates as a well oiled machine.The management team is integrally involved in the strategic planning process, and the company practices best known practices, with continuous improvements. Voted one of Oregon’s Most Admired Companies year after year, Leatherman strives not only for excellence in their product, but in their business practices as well.

The History Young Tim Leatherman and his wife traveled through Europe and the Middle East back in the mid1970s. Between a cranky Fiat and leaky hotel plumbing,Tim found that his boy scout knife just wasn’t cutting it. He needed more, like some pliers, and maybe a screwdriver or two.Tim Leatherman, a young mechanical engineer, dreamed up a multi-tool. Over the course of the next years, Tim developed several prototypes with cardboard and wood. A2Z METALWORKER

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His brother-in-law, a machinist, taught Tim machining. In 1980, Tim applied for and received US Patent 4,238,862 for his first multi-tool prototype, “Mr. Crunch”. Tim waited patiently for the million dollar order to come in. Alas, it didn’t happen. By 1983, the prototype was fine-tuned and the Pocket Survival Tool ® was launched. A few companies placed orders for their holiday catalogs, and LeathermanTool Group was born. Leatherman’s goal was to sell 4000 Pocket Survival Tools in the first year. The company sold nearly 30,000! Fast forward a decade, and Leatherman achieved 1 million sales for the year! Over the course of the next decade, Leatherman introduced the Super Tool®, which featured locking blades, and the Wave ®, which was the first multi-tool that allows access to the blade without opening the pliers. In the first decade of the new millennium, Leatherman launched the Juice®, the Squirt®, as well as a series of tools and knives for specific activities, like their hunting knives, and their gardening prunes.

Tools for Military/ Law Enforcement Leatherman offers duty-specific multi-tools, black multi-tools, and black knives to support those who protect us.When your life depends


planning to put together an apprenticeship program in-house to promote the craft, and are seeking experienced candidates to support this effort.

Performance and Reliability in Wire EDM Machining

on your equipment, Leatherman offers tools that are specifically designed for shooters and EOD techs, with all the utility you expect from a Leatherman.

Multi-Tools for Civilians Leatherman offers an array of multi-tools for consumers and hobbyists, including full size multitools, ones that are pocket sized, and even key chain multi-tools.

Leatherman Knives The Crater knives by Leatherman are designed for maximum portability with minimal bulk. A redesign of their original line of folding knives, these slim, lightweight, folding knives offer everything from the simple to the, “Wow how did they do that?” The Expanse series folding knives from Leatherman are just that, an expansion on a great idea. Upgrade to 154CM blades and stainless steel reinforced handles, keeping all the utility and portability of the Crater line.

LED Flashlights The Monarch series of LED flashlights from Leatherman features powerful output and sturdy, lightweight construction for a great price. From key chain to handheld, there’s a model for every activity you can engage in.

Community Outreach In an effort to give back to the their local and national communities, Leatherman supports our troops overseas, fund-raisers for environmental conservation groups, local charities, and individuals across the country who have gone above and beyond the call of duty to help their fellows in a time of need. In addition to product donations, Leatherman is also supporting employees who want to donate their time to volunteering with the Big Brothers Big Sisters program or our local Habitat for Humanity project. Both groups’ operations rely heavily on volunteer time and both also present a great match for the skill sets of many employees at the company. The cornerstone of all Leatherman engineering is preparedness. Product donations to all these partners are used to work on wilderness restoration projects, help in disaster situations here and abroad, build homes, keep our troops up and running, and much more. The team at Leatherman recognizes the scarcity of journeyman tool and diemakers. They are

Alex met North-South’s Chris Gendusa nearly 6 years ago when he was evaluating EDM machines for Leatherman. Alex says that they were using a competitive EDM machine, and in their analysis they found that the Mitsubishi EDM Chris was proposing was a much more rigid machine tool design for precision machining than competitive EDM machines. “The Mitsubishi was built on a solid frame”, Alex said. We needed a machine that would withstand decades of use, run unattended 24x7, and retain its rigidity. The Mitsubishi EDM fit this requirement and had many other capabilities we required, and we couldn’t find on other EDM machines.” Alex appreciates the support he gets from Chris, his North-South Sales Engineer. “Chris is an experienced tool maker”, Alex said, “and I can count on him to give me the right recommendations for my capital purchases. He will even tell me when I shouldn’t make a purchase, because it is not what we need at Leatherman. Chris is loyal and I trust his expertise.” Today, the company owns 3 Mitsubishi EDMs, including the FA-10S, the FA-20S and the FA-20S Advanced. . The Mitsubishi R&D Group is constantly improving its technology – working with the factory on future product offerings. It is in this environment that they develop EDM machines to meet the needs of specific markets – like the MD+PRO wire EDM. For more information on machine tools, contact North-South, machine tool distributors of EDM, WaterJet, Swiss Turning, Automation systems, Robotic integrators machine service personnel, CNC lathes and mills. They can be reached at 253-333-2439 or go to northsouthmachinery.com. To purchase Leatherman multi-tools, knives or flashlights, visit their website at www. leatherman.com. Contact them if you want to be involved with their apprentice program. A Z METALWORKER • 31 • FEB/MARCH 2011 2


Oshkosh Defense to Provide Additional M-ATV Protection Kits Oshkosh Defensewill deliver 800 protection kits for the MRAP AllTerrain Vehicle (M-ATV) following an order from the U.S. Army TACOM Life Cycle Management Command (LCMC). “These protection kits are part of our ongoing work with the military to deliver exceptional M-ATV survivability against evolving threats on the modern battlefield,” said Charlie Szews, Oshkosh Corporation president and chief executive officer. “The rapid production and delivery of these kits is the result of a close collaboration with our customer and our shared commitment to the Warfighters. Oshkosh is dedicated to supporting those who serve with world-class protection and mobility solutions.” The M-ATV is produced with factory-installed armor and also can accept add-on armor and protection kits. The vehicle’s modular design allows bolt-on armor to be installed or repaired in the field. Using the Oshkosh TAK-4® independent suspension system, the M-ATV can incorporate add-on protection kits while maintaining its full payload capacity of 4,000 pounds and a 70 percent off-road profile capability. Oshkosh produces the M-ATV base, as well as tactical ambulance and Special ForcesVehicle (SFV) variants, for the U.S. military.The company has received awards to date for nearly 8,400 M-ATVs, as well as spare parts kits, upgrade kits and aftermarket support. Deliveries under this order are scheduled to be completed in summer 2011. The order has a ceiling price of $80 million.

Boeing Unveils New Hornet Options at Aero India Boeing provided a preview of new options available for international customers under the Super Hornet International Roadmap program at the 2011 Aero India defense and aerospace show at Yelahanka Air Station. The program allows international customers to tailor the F/A-18 Super Hornet fighter to meet their requirements, said Mark Gammon, Boeing’s program manager for the Super Hornet International Roadmap. At present, the Roadmap is for the international market, but the U.S. Navy is looking closely at the program. In the past two years, Boeing has been investing in the Roadmap in areas that improve situational awareness, stealth, range and precision strike capabilities. Improvements include the Next Generation Cockpit outfitted with a new 11-by-19 inch large area display with integrated intuitive graphics and increased situational awareness. A2Z METALWORKER

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“Basically, it’s one big iPad, which provides the pilot with a large increase in display surface area,” Boeing test pilot Ricardo Traven said. Other unique features include improvements in the Hornet’s stealth and range a stealthy conformal fuel tank and a conformal enclosed weapons pod, for example. The weapons pod can carry a combination of AIM-120 air-to-air missiles and air-to-ground bombs, with each Super Hornet capable of carrying three pods. The conformal fuel tank also reduces drag. Range and speed are also increased with the GE-414 Enhanced Performance Engine (EPE). “When you reduce the drag with the stealthy weapons pod and with an engine with 20 percent more thrust, you greatly increase range,” Traven said. Configuration flexibility improvements include an internal Infra-Red Search and Track (IRST) system and a new missile and laser warning system. Many of the new features - including AESA radar, EPE and the missile warning system - were included in India’s 2008 request for proposals for the Medium Multi-Role Combat Aircraft (MMRCA). New Delhi plans to buy 126 MMRCAs. Not included in Boeing’s MMRCA bid were conformal pods, IRST and the Next Generation Cockpit, due largely to requirement limitations at the time of the submission of proposals, but the systems could be included at a future date, a Boeing representative said. The unveiling of the Super Hornet International Roadmap at Aero India is part of Boeing’s effort to win a wide range of Indian military aircraft competitions, estimated to be worth up to $30 billion in the next ten years.

DOT Secretary LaHood reaffirms Obama’s NextGen commitment US Transportation Secretary Ray LaHood said President Barack Obama’s proposed budget for the nation’s 2012 fiscal year starting Oct. 1, to be delivered to Congress later this month, will “give very clear guidance” to lawmakers and the airline industry that implementing the satellite-based NextGen ATC system remains a “high priority” for the administration. Amid talk of spending cuts on Capitol Hill and questions raised in late December by the Dept. of Transportation’s inspector general about FAA’s ability to deliver on NextGen, LaHood emphasized that modernizing ATC is “a very important priority for President Obama.” Though Obama did not mention NextGen when speaking about infrastructure development in his recent State of the Union address to Congress, LaHood insisted the ATC upgrade is included in “the investments we need today” being pushed by the president.


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Still Time to SignAssn. Upof For Speaking to the American AirportNational Executives/Airports Council International-North America Washington Legislative ConferAerospace Week Event ence, LaHood noted that navigation “technology we have in our cars these days istomore upRaytheon to date than what we have cockpits.” He I’m proud say that and Goodrich calledintoour become sponsors conceded that airlines haveyou to are make a “hard on whether of our event!!!!!!! I hope going to becall” involved too. to make a “significant upfront investment” in equipping aircraft with NextGencapable technology. Our mission is to bring together the American Aerospace Industry, from the old timers who designed it, to the children that will take an interest it. for his guidance to airlines making the difficult decision Asked by in ATW about whether to equip, he said the proposed 2012 budget will make Thecalculation event in Phoenix a public awareness all students the easierincludes (although he declined to mission providetodetails) and and adults, that withNextGen regards to the Aviation and the Aerospace Industry. emphasized “momentum is building.” Students will be competing for the Title of America’s Paper Plane Pilot 2010 in the Young America Aerospace Challenge.

Colonel: Next Reaper Must Tackle Next we will have Aerospace Industry Recognition Awards. These Emerging Threats

Nominees will be recognized and awarded at the “Meet, Greet & be Recognized” Dinner & Award Ceremony Thursday Evening. The U.S. Air Force’s

next-generation reThe 11th Annual Mountain Rep “Hit & Giggle” Golf Tournament will placement for its MQ-9 tee off Friday the 17th of September at 9:00, with tournament winners Reaper unmanned being awarded at the closing ceremony luncheon. combat aircraft will be modular, The two day event will also include an Industry Tradeeasily showupgradwhere able, stealthy, feature table/booth space will be sold or given to the event sponsors, and a Hole-In-One contest will be taking place onjam-resistant the grounds ofcommuthe San nications will the be Marcos Golf Resort in Chandler, AZ. The money raisedand through highly common with the contest will be used to purchase a piece of playground equipment to Navy’s forthcoming Unmanned Carrier-Launched Surveillance be donated to a school/park in the name of the student winningand the Strike (UCLASS) aircraft, said a senior service official. aerospace competition.

The Reaper cost for participating the event is anconditions, all inclusiveand pricethus, of $100.00 The does not fareinwell in icing a next Trade show tables are available for $500 and sponsorship fees are $5,000.

generation MQ-9 replacement must beBrunello,President/Mountain “weather tolerant”, said Col. For more information, contact Rosanne James Gear, the service’s director for its Remotely Piloted Aircraft Task Rep, http://www.nationalaerospaceweek.org/events, rosanne@mtnrep. com, 899-1900. Force480 during AUVSI’s Unmanned Systems Program Review 2011 on Feb. 2. Nor will the Reaper be able survive inside contested airspace Missile at $10 Billion where thereShield is a surface-to-air threat, he said. Sets Up

Boeing-Lockheed

“In tomorrow’s conflict, or going even further to the right to an antiBoeing Co. will compete for the first time to keep its U.S. missile defense access environment, the MQ-9 and MQ-1 [Predator unmanned aircraft] work as Lockheed Martin Corp. seeks to wrest away an order for as are not well suited for that. So there is certainly a requirement and need much as $10 billion. for an aircraft [that] operates in these three different threats,” Gear said. The threats the Missile next-generation plane might face emanate not bids only on from The Pentagon’s Defense Agency is preparing to take a surface-to-air missiles enemy also from contract that Boeing hasand held sinceaircraft, 1998 tobut design, buildthe andemerging operate realm of cyber-warfare. the arsenal of satellites, radar and high- speed interceptors intended to

shoot down enemy intercontinental ballistic missiles in space. The new The MQ-X therefore, have secure jam-proof data-links that are order will be must, for management and maintenance. fully encrypted and must be able to verify who is trying to signal it, he contest said. gives the companies a shot at a decade-long program as the The Pentagon reins in spending increases. Riding on the outcome is Boeing’s future as a so-called systems projects Gear through Additionally, the aircraft mustintegrator be modulardirecting and upgradable, said. suppliers, saidwould Philipbe Finnegan, an analyst at consultant Teal Group Capabilities added incrementally and the design should in be Fairfax, Virginia. flexible enough to be upgraded to handle new “requirements [that are not] fully defined or funded,” he said. Bid requests may be issued by the Pentagon as soon as next month, allowing the companies to submit their proposals ahead of a decision Additionally, the future MQ-X will be highly common with the Navy’s next year. The rivals showed off their technology and announced new UCLASS program.While the carrier-based Navy aircraft has different partners last week in Huntsville, Alabama, at the U.S. Army’s annual requirements, the Air Force and the sea service have been cooperating Space & Missile Defense Conference. closely, Gear said. Boeing’s current missile-defense contract is worth as much as $18 billion “It’sthe very to the MQ-X,” said. for 10similar years ending in 2011,heJim Schlueter, a spokesman for the Chicago-based company, said recently.

• 33 • FEB/MARCH 2011 37 • Sept/Oct 2010

A2Z METALWORKER A2Z METALWORKER •


Your Precision Flame and Cold Spray Experts with FAA Approvals “Accuwright performs cold spray repairs on Honeywell’s Auxiliary Power Unit (APU) components. Prior to cold spray being available commercially, our APU components were repaired using flame spray.What we found since we have been using the cold spray process with Accuwright over the past year, is that it produces a denser, more uniform coating. I expect that better finish, with less porosity and better adhesion, will result in better durability of our repaired APU components than what would have been achieved with thermal spray.

Before

The cold spray process has additionally allowed Honeywell to repair a population of APUs that were previously unrepairable, because it locally fills in the pits, or holes, on the part.

BEFORE

Accuwright is a Honeywell Aerospace approved supplier for cold spray, validated by Honeywell, with quality that meets our specifications. As far as I know, they are the only FAA approved repair station that is doing cold spray repairs in the US. That is key to Honeywell. We are in the process of working with other divisions of Honeywell Aerospace to get them using cold spray. I highly recommend the cold spray process.”

Susan, Honeywell Aerospace Global Repair & Overhaul Engineer A year ago, Accuwright, a well known thermal spray company, announced that it was commercializing cold spray. At the time, they were the only manufacturing facility in the west offering this service. David Wright, founder and owner of Accuwright for the past 15 years, just recently returned from a cold spray conference, and it appears cold spray still isn’t widely commercialized. In fact, at the conference, attended by 150 people worldwide, the question posed was “Is anyone here commercializing cold spray successfully?” David was the only one who stood up. For the past several months, Accuwright has seen business double month over month, almost exclusively due to the increase in cold spray. In fact, the company has had to expand their cold spray lines, and they now 2 A A2Z Z METALWORKER METALWORKER

•• 34 2011 42 •• FEB/MARCH Nov/Dec2010

After AFTER


have 3 cold spray booths, one equipped with a hand spray, and 2 equipped with robotic guns. “We are gearing up for Honeywell and our other customers, with new equipment, and more shifts,” Jory Wright, operations manager, said. David embarked upon the cold spray process more than 4 years ago, and began commercially offering it to customers little over a year ago. “Honeywell engineers who were testing the process petitioned a number of thermal spray companies to work with them on cold spray. “We were the only company to accept the challenge,” David said. “Today, we are the only cold spray vendor doing repairs on production parts for Honeywell Aerospace, Global Repair & Overhaul, and Honeywell represents the largest percentage of our cold spray business.”

Why Accuwright? If you have parts that need to be repaired, particularly if they are aluminum or magnesium. If you require a cold spray company that is an FAA Approved Repair Station. Accuwright is the only FAA approved commercial cold spray facility in the United States... And the only authorized supplier to Honeywell Nationwide!

Before Before

BEFORE

When asked why others were having difficulty commercializing cold spray, David suggested that many customers are skeptical of this unique process and were unsure about the economics. The cold spray process, he said, costs about 50% more than flame spray and welding. And because the process is so new commercially, there aren’t documented statistics stating how much longer a part will last when cold sprayed, though David believes it will be anywhere from 2 to 5 times. What David can say empirically, is that parts Honeywell called “boneyard parts”, determined to be beyond their useful life, are now coming to Accuwright to be refurbished through cold spray. The before and after pictures on the previous page depict a part that was “bone yarded” previously. The before and after picture on the bottom of this page are representative of the typical parts that Honeywell deemed refurbishable in the past. So, the economics for a company like Honeywell, that was scrapping parts that can now be brought to life via cold spray are clearly in favor of this revolutionary process.

After After

AFTER

Cold spray is a solid-state coating process that uses a high-speed gas jet to accelerate powder particles toward a substrate whereby metal particles plastically deform and consolidate upon impact. The term “cold spray” refers to the relatively low process temperature involved—which is typically much lower than the melting point of the spray material. Because adhesion of the metal powder to the substrate and deposited material is achieved in the solid state, the characteristics of cold spray deposits are quite unique, making cold spray suitable for depositing a wide range of traditional and advanced materials on many types of

35 • FEB/MARCH • 43 •Nov/Dec2011 2010

2 A2ZAMETALWORKER • Z METALWORKER


distortion of the part and that the repaired part would last much longer than if flame sprayed or welded. What they didn’t anticipate was that cold spray would work so well on aluminum and magnesium. David said, “Metal spray doesn’t naturally stick to magnesium well, and magnesium is a highly corrosive metal. The cold spray is outstanding on magnesium parts. Honeywell was very pleasantly surprised with this finding.” At the cold spray conference that David and one of the engineers from Honeywell attended, David says there was a quote from a speaker that he felt was representative of the cold spray process. The quote was something like this: “This is not just another flame spray technology; it isn’t a coating process; rather it is a consolidation process. By consolidation I mean that it is like spray and weld mixed together; cold spray does things that neither flame spray nor welding can do -- and it does it in a very unique way.”

substrate materials, especially in non-traditional applications that are sensitive to the temperature of the process. Some of the characteristics of cold spray include the ability to form dense deposits with extremely low oxygen content, free of residual tensile stresses, grain growth, recrystallization zones, and phase changes. Certain materials may even experience grain refinement at the nanometer scale.These attributes make cold spray uniquely suitable for depositing a range of advanced and temperature-sensitive materials. Today, cold spray is increasingly being used in a number of industries, including aerospace, energy, and military. Accuwright and Honeywell were excited about the cold spray process from the start. Over the year, however, they uncovered some findings they didn’t anticipate.They knew that cold spray has a higher bond strength, and it allows you to fill in deep spots where regular flame spray can’t get. They expected that the process wouldn’t cause

With cold spray, Accuwright can “free form” parts, building up highly damaged parts (as seen in the before and after on the first page). David says, “At first Honeywell would send us parts that were undersized and with minor corrosion. Now we are seeing parts with deep corrosion and even with pieces of the part missing.” At the worldwide cold spray conference, Accuwright was awarded the “Shop Service Award” from one of their suppliers, Centerline (Windsor). Accuwright is the first company ever to be awarded this honor!

U.S. Army and Navy Findings The U.S. Army and Navy have experienced significant corrosion problems with magnesium alloys that are used to fabricate aircraft components. The most severe of these are associated with large and expensive transmission and gearbox housings for rotorcraft, which have to be removed prematurely because of corrosion, adversely affecting fleet readiness and safety. Many of the parts cannot be reclaimed because there is not an existing technology that can restore them adequately for service. The replacement of these parts is very expensive ranging in the millions of dollars every year. One common repair technique, used for some of those parts that can be salvaged, involves the use of aluminum shims, which are adhesively bonded over areas where the corrosion has been ground down and dimensional restoration is required. The U.S. Army Research Laboratory (ARL) Center says that cold spray repair has been shown to have superior performance in the tests conducted to date, is inexpensive, can be incorporated into production, and has been modified for field repair, making it a feasible alternative over competing technologies.

A2Z METALWORKER • A2Z METALWORKER •

36 • FEB/MARCH 2011 44 • Nov/Dec2010

For more information on the experts in cold spray, an FAA Approved Repair Station, and supplier to Honeywell, contact Accuwright at (480) 892-9595 or go to www.accuwright.com.


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OMAX® Secures $2-Million+ Order From The U.S. Government OMAX Corporation has booked a $2-million-plus order from the U.S. Government for several of the company’s JetMachining® Centers. The order, which spanned the fourth quarter of 2010, involved several standard and two customized OMAX model machines for shipment to various branches of the U.S. Government. All branches of the Department of Defense were represented, including NASA,The Military Academy at West Point, and The Naval Academy at Annapolis. Two customized OMAX abrasive waterjet cutting systems are slated for NASA and an Army arsenal. For NASA, OMAX engineers modified a machine’s Z-axis height to meet a specific project’s requirements. The abrasive waterjet machine for the Army arsenal was custom designed to include a DualBRIDGE system, four waterjet heads, and quad pumps. OMAX has been supplying equipment to the U.S. Government since 1997. And with over 40 machines located in various facilities worldwide, the U.S. Air Force is one of the company’s largest customers. Other Government branches using OMAX abrasive waterjet cutting systems include the U.S. Army, U.S. Coast Guard, U.S. Navy, USDA, FAA, and NIST. And most countrywide NASA facilities house at least one OMAX abrasive waterjet machine. The strong relationship with the U.S. Government grew from the partnership OMAX has built with Phillips Corporation – Federal Division. Since 1948, Phillips Corporation – Federal has sold metalworking and manufacturing solutions to the U.S. Government and its related agencies, exclusively. Operating as a niche government contractor, OMAX’s expertise and relationship with the Government enabled the company to secure and install over 50 waterjet machines inside the U.S. Military. Most of the U.S. Government’s OMAX machines are used for upkeep of legacy equipment. The machines cut metal and aircraft aluminum for airframe maintenance, titanium for artillery, and plating for U.S. Army transport vehicles. “What we’ve learned from attending numerous Department of Defense maintenance conferences and seminars is that the U.S. Government is stressing a need for legacy equipment upkeep. This message is especially emphasized to military branch metals technicians, who rely on OMAX abrasive waterjet systems to carry out that initiative,” said Steve Brown, OMAX’s major account manager for government,

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college, and university customers. According to Brown, the U.S. Government gravitates toward OMAX abrasive waterjet machines mainly because of the company’s Intelli-MAX® control software, which is extremely quick and easy to learn and operate. Additionally, waterjet cutting conserves raw material, as compared to conventional machine tools that turn raw part material into chips during the cutting process.

AMD, Intel Unveiling Redesigned Chips To Keep PCs Competitive The AP reports, “Semiconductor companies are whipping up a new generation of chips to bring richer video and better battery life to personal computers and help them hold off threats from tablets and increasingly powerful smart phones.” “ With “tablet computers and other gadgets...eating away at PC sales,” the two chipmakers “are responding with new chips designed to make people think twice before picking a tablet over a new PC. The new chips won’t dampen the success of tablets, but they will make traditional, low-cost computers more competitive.” A2Z METALWORKER

• 37 • FEB/MARCH 2011


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Argon ST -- Open which had House lingered on the Mergers and spinoffs Haas Automation to Host HaasTec atmarSo. ket for about six months; Lockheed Martin shake up the defense in- decided to divest its Enterprise Integration Cal Facility in March Group, which provided systems engineering dustry and integration services;leading and White Plains, For the first time in more than 7 years, Haas Automation, Inc. – America’s machine tool

ITT Corp. announced it would builder – will host an open house at its headquartersN.Y.-based and manufacturing facility in Oxnard, CA. When Fairfax-based information technology separate into three pieces: a manufacturcontractor SRA International canceled on ing business, water technology firm and HaasTec, scheduled for Marchat10a through 12, 2011, from 10 am to 4a pm daily, will include machine short notice its presentation government a McLean-based defense and information demos, factoryintours, a catered andthe more. IT conference Washington lastlunch, month, solutions firm. rumors started circulating. Was the company, Visitors to HaasTec$1.67 will see the in latest Haas in CNC technology up close and inthe great detail, with 20 which generated billion revenue The shake-up is likely most significant 2010 and has moremetal, than 4,000 local the employees, machines cutting including new generation ST and DS turning centers, with y-axis and since the early 1990s, when reductions considering acapabilities. major change? dual-spindle There will be guided factory tours – both above and on the production in defense spending forced widespread floor – to see how Haas machines are built; and representatives from major consolidation. That wastooling, the eraworkholding, when toand manufacturers will be on hand to share insight and show their products. SRACAD/CAM spoke up last month, acknowledging day’s their contracting behemoths were formed; that, after receiving multiple questions about Lockheed Corp. and Martin Marietta became whether it was the available companyonline at Lockheed Martin, while Northrop Aircraft Registration foraccepting HaasTec isoffers, free, and www.HaasCNC.com/openday. Guests who had hired a financial adviser. It cautioned, howand Grumman Aerospace became Northrop register by February 1 are automatically entered to win an all-expenses paid trip to California ever, against viewingand theguests move as an indication Grumman. The number of companies able to attend HaasTec, who register by March 1 will receive a limited-edition Haas captoat that the company “is or should be for sale. serve as a prime contractor for tactical missile the open house. ” programs, for instance, fell from 13 to three, The firm’s stock price surged nonetheless as according to a Government Accountability Obama Asks GE’s Immelt Economic Advisory SRA became the latest government contractor to Head Office report. to get caught up in the swirl of merger and acPanel quisition activity reshaping the local economy. This time around, the corporate moves suggest the industry is working from a different President Barack Obama named Jeffrey Immelt, General Electric Co.’s chief executive officer, to Companies big and small have been rethinking playbook. head his outside panel of economic advisers, replacing former Federal Reserve Chairman Paul their portfolios and buying and selling accord“The previous wave of consolidation of the Volcker. ingly. Locally, Boeing bought Fairfax-based defense industry reflected a collapsing threat 2 A A2Z Z METALWORKER METALWORKER

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and the willingness of policymakers to take lead Announcing Immelt’s appointment to sector consolidation,” said Loren Thompson, the helm of the newly renamed President’s a Council defense industry at the Lexingon Jobsconsultant and Competitiveness, ton Institute. Today, “threats may be Obama said the economy is “in aactually different growing and the Pentagon isn’t all that eager place” from where it was during the ecotonomic see further crisis,consolidation.” and new ideas are needed to keep the momentum going. That helps explain why the recent flurry of buying and selling seems more strategic in “The past two years was about moving our nature. So far, at least, the industry has shied economy back from the deals. brink,” Obama away from any blockbuster said alongside Immelt in Schenectady, New York, home to the birthplace of GE’s “This is neither the ‘90s nor the last decade; business. “Our job now is putting it’senergy different,” Pentagon acquisition chief our economy into overdrive.” Ashton Carter said at a June briefing. “It’s an environment in which we’re going to have He called Immeltand “oneour of the nation’s most slow real growth, senior managers respected and admired business leaders.” and our partners in industry need to manage accordingly.” As head of the world’s biggest maker of jet engines, medical-imaging equipment and Aspower-plant a result, companies are seeking reorient turbines, Immelt togives the their businesses, off heavyweight units that pose White House a selling corporate to potential conflicts of interest or are not core help burnish Obama’s pro-business credentotials. a company’s operations andsince buying busiImmelt, 54, GE’s CEO 2001, is nesses in whatmember are widely an original ofconsidered the panel, growth which industries like ascybersecurity, health IT and was formed the President’s Economic cloud computing. Recovery Advisory Board in February 2009. Whether Grumman’s Immelt it’s saidNorthrop while more than half decision of GE’s to likely spin off its shipbuilding business or


McLean-based Corp.’s recent declaration said she sees the ‘FlyingATSRobot’ pilot helps find IEDs in uptick that it is pursuing strategic alternatives, the continuing. movesHelmand have at times been unpredictable, leadFaced with a weakened ing to a feeling that there’s little consensus in c o m m e r c i a l m a r ke t , Business Management Lance Corporal working at the the industry on the bestRob wayMcInerney to adapt. is currentlymore private equity firms Systems Consulting forefront of counter-IED operations in Afghanistan piloting their the hats have thrown Prepare for ‘Flying Robot’, which is part of the Talisman counter-IED system. into the ring, buying up Companies have “got to be prepared to go government and defense every direction, and that makes it very hard ISO 9001/ been designed to adviser provide an increased of contractinglevel businesses. right Talisman now,” saidhas David Berteau, senior AS9100 assurance routesforthroughout the region. It consists of a and director of along the Center Strategic and suite of cutting-edge equipment, including armoured vehicles, International Studies’ defense-industrial iniThe increased private Certification optical cameras and remote-controlled vehicles. tiatives group. equity interest “creates a For Only more competitive market This the life-saving being used tothan support combat in the past in the Whatever move -- equipment breaking up isa business, $3500! logistic patrols, which can comprise several hundred vehicles defense and government divesting a unit or acquiring another firm saidtoPeter and trekare through the trying country supplies bases Manos, -- companies generally to delivering focus on vitalspace,” Contact Bretta Kelly Today! a managing partner at prithe operations they think have the most for the troops on the front line. growth vate equity firm Arlington 602.445.9400 potential, said Michael S. Lewis, director of Capital equityLance research at Lazard Markets. Corporal RobCapital McInerney, aged 26, serves withPartners, 15 Field who www.businessmsc.com noted that these investors Support Squadron, part of 21 Engineer Regiment - the first have in some instances “The management andsystem the boards troops to useteams the new on thehave ground in Afghanistan. See “When Bretta told me that ISO shouldn’t be treated as outbid strategic acquirers. had toRelated take a hard look at their businesses and “Rocket Science” I started listening. She was able to News. back it up with explanations we could understand. The say, ‘Is this in the strategic long-term focus of difference we found with Bretta over other consultants the end,known analysts said, the firm?’ “ said “We’re seeing these His role is toLewis. pilot the MAV (Micro Air Vehicle),Inotherwise we have talked to is that she herself has gone through the universe of defense typesasofthe moves from the largest firms down ‘Flying Robot’ or ‘T-Hawk’: the pain of ISO internally when working in quality contractors will look difto smaller companies.” departments. She is the President of her own company ferent -- but not necessarand is a certified auditor.” “The MAV is a great piece of kit and complements the rest of ily smaller. At AAIthe in equipment,” Hunt Valley, Md., for instance, owner he said. “The MAV has two cameras which feed George G. Crouch, Advotech Company Textron Systems opted split the information back totoa laptop so company that the commander is then better into three individual pieces: an unmanned placed to make decisions. Some Manuaircraft unit; a test and training business; and .. to 33 countries.” Jetexporting Processing is now ng i c a services group. Because AAI was already a n facturers Recover From u “We have been involved in a few contacts on a couple of the o n Premier Precision Group subsidiary of Textron, giving it access to the An operations that we have been on, which made the day interesting! Recession With More AuDisasters Of 2010 Suggest company’s back-office and corporate resources, - Special Processing The most satisfying part of the tour for me is when we get the the extra AAI headquarters was redundant, New Emphasis On Risk guysStrader, to theirpresident destination after all, that is tomation, the aim of our job!” Better Profits Chemical Processing said Fred andsafely; chief executive Anodize In Line of Wilmington, Mass.-based Textron Systems. Analysis, Management Conversion Coating Lance Corporal McInerney has been with 15 Field Support Passivation based in Ripon, Yorkshire, since re-roled Painting “Weathering The “WhatSquadron, became very obvious to meNorth . . . was we The they website MSNBC reported, “The U.S. Under the headline Dry Film lubricants Field Support Squadron which a plant operator: had anfrom extraa layer,” said Strader, addinginthat the he wasmanufacturing sector is roaring back after the Storm,” the Wall Street Journal reports on Teflon Coating business units will now be more efficient and worst recession in generations. So why aren’t corporate riskNon-Destructive and mitigation strategies Testing in been good tomore learnquickly. something new but I am looking forward able “It to has make decisions factory jobs coming back as quickly?” A “big an era that seems to have a daily disaster Liquid Penetrant to getting back to plant,” he said. reason” is that “business executives like Drew somewhere in the world – and sometimes Magnetic Particle The new focus on dealmaking has kept area Pressure Test Greenblatt, owner of Baltimore-based Marlin thousands of miles from the site where the Impregnation He isbusy. alsoAt looking forward to getting the UK to Products, see his have figured out how to law firms Venable, which worked on back a to Steel Wire business operates. The year 2010 is being high of 16 aerospace, defense and government fiancée, Laura, and his daughter, Anna, who ismake only five moremonths widgets with the same number called one of “catastrophe,” for its disasters services old:deals in 2007, the deal volume slowed of workers. To do so, he’s had to upgrade the that ranged from Pakistan’s floods to Rusin 2008 and 2009. In the second half of 2010, skills - and wages - of his employees. But his sia’s forest fires and Europe’s ash cloud, just however, completed seven deals. “She the waspractice born two weeks before I came out profits here soare it bigger will bethan ever.” Lab Services some of which contributed to an estimated amazing to see the difference in her now,” he added. Corrosion Resistance $222 billion in business losses, three times “It really was crazy,” said Joseph C. Schmelter, Taber Abrasion Resistance the amount in 2009. MSNBC added that last year the company Coating Weight co-chairman of Venable’s government contracLance Corporal McInerney has two other brothers serving in the worth of robots, “installed $700,000 continu Coefficient of Friction tor services industry group.with the Royal Signals and the other is due Army. One is serving Solution Analysis ing a steady process of automation Greenblatt Premierpointers Precison Group The Journal provides on risk analy Millipore Inspection to deploy on operations quite soon. He said: began when he bought the company 2660 W. Quail Ave, Phoenix, AZ 85027 in 1998,” sis and says a simple business continuity plan “We’re at full capacity with the M&A lawyers” 623.869.6749 and “revenues and profits were Assembly up 12 percent is a good place to 623.780.8830 start. From there, and “My are now relying on attorneys in other (fax) combrother Dave, who is in 9 Para[chute]- Squadron, Royal his best year since buying the company in panies should exam business components sales@premierprecision.com practices to pitchisin, hetosaid. Engineers, due deploy to Afghanistan on1998. the next Thattour year,and Merlin Steel did $800,000 in such as supplywww.premierprecision.com chains and assess which are I wish him good luck.” sales with 18 workers.Today the company has essential to doing business and what level Sarah E. Kahn, a partner at Arnold & Porter 25 employees and does $3.9 million in sales, of vulnerability they face. who specializes in mergers and acquisitions,

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A2Z METALWORKER • A2Z METALWORKER •

53 • Sept/Oct 2010 39 • FEB/MARCH 2011


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40 • FEB/MARCH 2011


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• Zinc coated wire

• Dielectric fluid

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• Spare & wear parts

• EDM hole driller

• Omax parts

At EPA, one call does it all. Call 1-800-EDM-2-WIN

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A2Z METALWORKER

• 41 • FEB/MARCH 2011


Consultant, ISO CAD/CAMSoftware, CAD Delcam_ _________ 801-949-6769 BMSC _ ____________ 602-445-9400 Liquid Penetrant Software, Inv. Control Team Industrial Services___801-397-2202 Delcam____________801-949-6769 Team Industrial Services__ 602-269-7868 Software, Solid Modeling Press Brakes MAG Particle Jorgensen Machine Tools_800-952-0151 Delcam____________801-949-6769 Team Industrial Services___801-397-2202 Moore Tool & Equip___ 602-455-8904 All World Machinery_____815-943-9111 Team Industrial Services__ 602-269-7868 Shearing Machines Manufacturing Rep REPAIR PARTS Jorgensen Machine Tools_800-952-0151 ProSalez__________ 480-773-3239 Belts Moore Tool & Equip___ 602-455-8904 Process Improvement All World Machinery_____815-943-9111 Turret Press / Audit Bearings(Precision) BMSC _ ____________ 602-445-9400 Muratec_________ 949-466-8255 Welding Equipment All World Machinery_ ___ 815-943-9111 X-Ray Team Industrial Services___801-397-2202 Rocky Mountain Saw Blades_ 303-761-3000 Metric O-Rings OTHER ACCESSORIES All World Machinery_ ___ 815-943-9111 Team Industrial Services__ 602-269-7868 ISO9000 / AS9100 Cert. Tooling Systems Switches (Proximity, Limit) USA EDM Supply_ ____ 480-836-8330 All World Machinery_ ___ 815-943-9111 BMSC _ ____________ 602-445-9400 Machine Tool Rebuilding Valves PROG. SYSTEMS EDM Network_ _____ 480-836-1782 (Hydraulic, Pneumatic) Factory Automation/Logistics Process Improvement Muratec_________ 949-466-8255 All World Machinery_ ___ 815-943-9111 BMSC _ ____________ 602-445-9400

Spindle Rebuilding Setco ____________866-362-0699 USED MACHINERY CNC Machine Services____ 425-788-4500

EDM Network_ _______ 480-836-1782 Ganesh Machinery____888-542-6374 Jorgensen Machine Tools__800-952-0151 K.D. Capital Equipt____480-922-1674 WATERJET CUTTING FLOW Intl.___________909-620-5707 Jorgensen Machine Tools__800-952-0151 Machine Toolworks ____800-426-20521 OMAX Corp_________800-838-0343 Waterjet Abrasives KMT Waterjet Systems___ 800-826-9274 Waterjet Replacement Parts KMT Waterjet Systems___ 800-826-9274 WaterJet: Filtration/Chillers Ebbco Inc_ ______800--809-3901

If You Are A Machine Shop, A Fabrication Shop or You Sell To This Industry, Your Card Should Be in the A2Z Metalworker Magazine. It’s Just $260 for The Year. Call Today!

Kim Carpenter • 480.773.3239 kim@azmetalworker.com A2Z METALWORKER

42 • FEB/MARCH 2011


Buyer’s Guide & Card Gallery Processes

MarZee I nc. 2345 N. 34th Dr.

Phoenix, AZ 85009 Home of 5 Omax Waterjets 80” x 240” Cutting Envelope Virtually Zero Taper Available Fast Quoting & Turn Arounds Prototype to Production

602-269-5801

Petersen Inc_________ 800-410-6789 EDM: Wire Micro-Tronics, Inc_ _____ 602-437-8995

602-269-5810 1-877-885-1059

Jet Processing_____ 623-869-6749x117

www.marzee.com

Pacific Tool, Inc. ______425-882-1970

FAX

marzee@marzee.com

Glass Bead Clean COATING ASSEMBLIES Matrix Machine_______ 480-966-4451 Accuwright Industries____ 480-892-9595 Coating Technologies_ ___623-581-2648 Seastrom_ _________ 800-634-2356 Coating Technologies_ ___623-581-2648 Liquid Painting Welded Assemblies IndustrialEX_______ 303-456-6847 Coating: Black Oxide Weiser/Mile High Precision_ 303-280-2778 Coating Technologies_ ___623-581-2648 MPI International_ _____ 956-631-6880 BENDING Coating: Dry Film Lube Passivation Harco Metal Products_____480-829-0450 Coating Technologies_ ___623-581-2648 Coating Technologies_ ___623-581-2648 Coating: Nickel/Teflon/ BONDING Jet Processing_____ 623-869-6749x117 Chrome Diffusion METCO Metal Finishing_ __ 602-276-4120 Coating Technologies_ ___ 623-581-2648 Matrix Machine_______ 480-966-4451 Silk Screening Vacco Industries________ 626-443-7121 Coating:Zinc & Mag.Phos. Arizona Finishing______602-438-4443 Coating Technologies_ ___ 623-581-2648 BRAZING IndustrialEX_______ 303-456-6847 Electro-Coating Services Precision Casting Repair_ __ 801-972-2345 Potting/Encapsulation Vacco Industries________ 626-443-7121 IndustrialEX_______ 303-456-6847 BROACHING COLD SPRAY Ponderosa Ind_________303-298-1801 Precision Die Cutting Accuwright Industries____ 480-892-9595 Specialty Steel Services___ 801-539-8252 Seal Methods_ ________800-423-4777 DIES Turning: Automatic FOUNDRY Micro-Tronics, Inc_ _____ 602-437-8995 Matrix Machine________480-966-4451 May Foundry & Machine_ 801-531-8931 EDM State Brass Foundry & Mach._ 801-467-9461 CASTINGS EDM: Dialectric Systems GRINDING /Filtration May Foundry & Machine___801-531-8931 Ebbco Inc_ _________ 586-716-5151 Mountain View Machine_ _435-755-0500 Castings: Repair Pacific Tool, Inc. ______425-882-1970 Precision Casting Repair_ __ 801-972-2345 EDM: Drilling Small Hole Micro-Tronics, Inc_ _____ 602-437-8995 Precision Tech________801-285-7288 CLEANING EDM: Ram-Type (Sinking) Superior Grinding______801-487-9700 Wasatch Metal Finishing_ _ 801-779-2020 Micro-Tronics, Inc_ _____ 602-437-8995 TCI Precision Metals_____ 800-234-5613

Grinding, Blanchard Diversified Metal Services__ 801-972-6093 Superior Grinding______801-487-9700 TCI Precision Metals_____ 800-234-5613 Grinding, Double Disc TCI Precision Metals_____ 800-234-5613 Grinding: OD Micro-Tronics, Inc_ _____602-437-8995 Pacific Tool, Inc. ______425-882-1970 Precision Tech________801-285-7288 Superior Grinding______801-487-9700 Grinding: Surface ChemResearch________ 602-253-4175 Quality Mold_ _______480-892-5480 Superior Grinding______ 801-487-970 Grinding: Tool & Cutter Superior Grinding_______ 888-487-9701 GALVANIZING Petersen Inc_________ 800-410-6789 ENGINEERING/DESIGN Nuclear Filter Tech_____303-384-9785 Pacific Tool, Inc. ______425-882-1970 Graphite Services Micro-Tronics, Inc_ _____602-437-8995 FABRICATION Arrow Sheet Metal Prod___ 303-427-6419

• 43 • FEB/MARCH 2011 43 •Nov/Dec 2010

A2Z METALWORKER

A2Z METALWORKER


INSPECTION .~Ij~l.mtJt~~:!~~~lj~~:,m:~.:~~. "- ...r \ .' .. lJ. I Inspection, First Article •

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Mountain View Machine_ _435-755-0500 Fabrication: Custom Metal Arrow Sheet Metal Prod___ 303-427-6419 Fabrication: Med/Large Arrow Sheet Metal Prod___ 303-427-6419 FINISHING Arizona Finishing______602-438-4443 Coating Technologies_ ___623-581-2648 Seattle Polishing & Plating___253-804-0160 Galvanizing: Hot Dip TMM Precision _ ______ 800-448-9448 Fabrication: SheetMetal Arrow Sheet Metal Prod_ 303-427-6419 Group Mfg Serv_______480-966-3952 Petersen Inc_________ 800-410-6789 Weiser/Mile High Precision_ 303-280-2778 Wrico_ ___________ 480-892-7800 Fabrication: Medium & Large Group Mfg Serv_______480-966-3952 Weiser/Mile High Precision_ 303-280-2778 HEAT TREATING Phoenix Heat Treating_ __ 602-258-7751 Pilkington Metal Finishing__801-972-2146 Temperature Processing___ 303-772-0250 Custom Temperature Processing___ 303-772-0250 Cryogenics Temperature Processing___ 303-772-0250 Aluminum Temperature Processing___ 303-772-0250 Nitriding Temperature Processing___ 303-772-0250 A2Z METALWORKER

44 • FEB/MARCH 2011

Klontech Measure Sol____ 480-626-8131

Pacific Tool, Inc. ______425-882-1970

PROCESSING: METAL

Seastrom_ _________ 800-634-2356

Acid Pickle

Machining: Turning MPI International______ 956-631-6880 Faustson__________ 303-420-7422 Chemical Pacific Tool, Inc. ______425-882-1970 LA Specialties________ 602-269-7612 Precision Casting Repair__801-972-2345 MANUFACTURING Group Mfg Serv______480-966-3952 MPI International______ 956-631-6880 LASER CUTTING Pacific Tool, Inc. ______425-882-1970 Seattle Polishing & Plating___253-804-0160 Laser Cutting Wrico_ ___________480-892-7800 Premier Precision______ 623-466-3156 Plating Alodine Contract Laser Cutting: Micro MPI International______ 956-631-6880 Production Vacco Industries______ 626-443-7121 Laser Concepts Inc.____ 801-280-7723 Phosphate Laser Cutting: 3D METALIZING MPI International______ 956-631-6880 E-Coat Accuwright Industries___ 480-892-9595 MPI International_ _____ 956-631-6880 Polishing MOLDING: RUBBER EMI/RFI Shielding Seattle Polishing & Plating___253-804-0160 Micro-Tronics, Inc_____ 602-437-8995 IndustrialEX_______ 303-456-6847 PUNCHING Molds: Plastic Injection Laser Engraving Micro-Tronics, Inc_ ____ 602-437-8995 Group Manufacturing Serv_ 480-966-3952 Vacco Industries______ 626-443-7121 Pacific Tool, Inc. ______425-882-1970 Molds Steel Laser Marking SPLINES Vacco Industries______ 626-443-7121 Arizona Finishing_____602-438-4443 Jet Processing____ 623-869-6749x117 Specialty Steel Services__ 801-539-8252 MACHINING Mil Spec Painting SPRAY: METAL, PLASMA Faustson___________303-420-7422 IndustrialEX_______ 303-456-6847 Accuwright Industries____480-892-9595 Matrix Machine_______ 480-966-4451 PLATING Nuclear Filter Tech_ ___ 303-384-9785 STAMPING Pacific Tool, Inc. ______425-882-1970 METCO Metal Finishing_ __ 602-276-4120 Seastrom_ _________ 800-634-2356 Premier Precision______ 623-466-3156 MPI International_ _____ 956-631-6880 Weiser/Mile High Prec._303280-2778 Anodizing Seastrom____________ 800-634-2356 Stamping:Design Premier Precision______ 623-466-3156 Weiser/Mile High Prec._303280-2778 Machining: R & D Milling Pilkington Metal Finishing_ 801-972-2146 Matrix Machine_______ 480-966-4451 Stamping:Flat Forming Chrome Micro-Tronics, Inc_ ____ 602-437-8995 Seattle Polishing & Plating___253-804-0160 SPRING WORKS Utah_ ___ 801-298-0113 Petersen Inc_________ 800-410-6789 Stamping: Light Gold Pacific Tool, Inc. ______425-882-1970 Seattle Polishing & Plating___253-804-0160 Seastrom_ _________ 800-634-2356 Machining: CNC SWISS SCREW MCHG. Faustson___________303-420-7422 PRECISION FORMING Matrix Machine_______ 480-966-4451 Pacific Tool, Inc. ______425-882-1970 Lewis Aerospace_ ____ 877-254-2024 Inspection Services IRON STITCHING

Micro-Tronics, Inc_____ 602-437-8995 Wrico_ ___________480-892-7800 Seastrom_ _________ 800-634-2356


Shawn Carlin scarlin@gmsaz.com

TESTING Testing: Non-Destructive Blanchard Metals Proc._ __801-972-5590 Jet Processing_____ 623-869-6749x117 Pilkington Metal Finishing_ 801-972-2146 Premier Precision______ 623-466-3156 THERMAL SPRAY Accuwright Industries____480-892-9595 TOOL & DIE Wrico_ ___________480-892-7800 TOOLING Mountain View Machine_ _435-755-0500 WATERJET CUTTING Marzee Inc._______ 602-269-5801

Petersen Inc_________ 800-410-6789 WELDING Arrow Sheet Metal Prod___ 303-427-6419 Petersen Inc_________ 800-410-6789 Mountain View Machine_ _435-755-0500 Weiser/Mile High Prec._303280-2778 Welding: Aluminum Medium & Large Petersen Inc_________ 800-410-6789 Welding: Precision Petersen Inc_________ 800-410-6789 Weiser/Mile High Prec._303280-2778 Welding: TIG Arrow Sheet Metal Prod___ 303-427-6419

at F ww ree w. Su az bs me cri tal pti wo on rk s er. co m

WE’RE LOOKING FOR A FEW GOOD MEN OR WOMEN!

Actually We’re Looking For A Lot Of Good Men Or Women! If You Are A Machine Shop, Fabrication Shop, Or You Do Special Processes, Call For Very Inexpensive Exposure...It’s Just $260 For The Year! CALL 480-773-3239 WWW.AZMETALWORKER.COM

Petersen Inc_________ 800-410-6789 • 45 • FEB/MARCH 2011 45 •Nov/Dec 2010

A2Z METALWORKER A2Z METALWORKER


Index of Advertisers Accuwright...34-36,43 All World Machinery Supply...13,40 Amcon...29 Arizona Finishing...45 Arrow Sheet Metal...45 Bar-S...44 Blaser Swisslube...2 BMSC...39,42 CNC Machine Services...13,41,48 Coastal Metals...14 Coating Technologies...44 Cutting Tool Control...2,40 DCM Tech...22,40 Delcam...1,40 Ebbco...42 EDM Network...20,41 EDM Performance Accessories...40,41 Faustston...44 Flow International...40,47 Ganesh Machinery...40 Global EDM Supply...41

Petroferm...15,40 Pacific Tool Inc...18-19,43 Premier Precision...43 Pro-Salez...43 Rocky Mountain Saw Blades...42 Rosco...21,41 Samuel Son & Co...5,25 Seattle Polishing & Plating...44 Seastrom..23,45 Setco Marketing...41 Sharp...27 Specialty Steel Services...44 Superior Grinding...44 TCI Precision Metals...42 Tipco...42 Team Industrial Sales...28,40,41 Tool Technology Distributors...2,41 Ulbrich...8,41 US Shop Tools...3,40 Weiser/Mile High...45 Wrico Stamping...43

Group Manufacturing...44 Hangsterfers...42 IndustrialEX...43 KD Capital...41 KMT Waterjet...40 Leatherman...30-31 machinetools.com...37 Machine Toolworks, Inc...11,41 Marzee Inc...43 Matrix Machine...44,45 Mazak...11 Micro 100...7,41 Micro-Tronics...17,43 Moore Tool & Equipment...41 MVMW...43 Muratec...41 North-South Machinery...9 Northwestern Machinery...41 Nuclear Filtration...44 Omax Corp...40 Petersen Inc..43

This Issue Represents Our Newest Publication for Northern CA, OR and WA, And You Can Check Out Our Legacy Publications! Vol. 4, No. 1 Jan/Feb 2011

Vol. 17, No. 1 Jan/Feb 2011

Arizona, Nevada, and New Mexico Edition

Colorado, Utah and Idaho Edition

Prescott’s Manufacturing

Meet US Carbide Tool LLC - A Superior, High Quality, Precision Tool Grinding Company

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Leads The Way In Aerospace & Medical Manufacturing www.azmetalworker.com

Our A2Z Metalworker

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For AZ, NV and NM...

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In It’s 17th Year!

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Available Online At www.Azmetalworker.Com A2Z METALWORKER

46 • FEB/MARCH 2011


MEET THE FAMILY. Introducing the Mach Series Waterjet Systems from Flow.

From 36,000 psi to 94,000 psi, from 11 hp to 500 hp, from 2’ x 4’ to 20’ x 100’... We have a waterjet to fit your needs AND your budget.

GET ACQUAINTED WITH THE ULTIMATE WATERJET SERIES — CALL 800.446.3569

www.flowcorp.com

A2Z METALWORKER

• 47 • FEB/MARCH 2011


A2Z Metalworker P. O. Box 93295 Phoenix, AZ 85070

425.788.4500 (WA) 503.679.6468 (OR) Toll Free 866.788.4500 7808 184th St SE Snohomish, WA 98296

Machine Services, Inc. www.cncmachineservice.com

North West Edition: WA, OR, N. CA A2Z Metalworker Magazine  

Manufacturing news, Contacts, Contracts, Shop Profiles, Metalworking Machines and Tools, and Services pertaining to the Aeroapace, Medical,...