newtek nº 104 | An industrial meeting point

INTERVIEW “Increasingly more sophisticated Industrial lubricants”

PROJECT Additive manufacturing for very large and complex parts

SCIENCE, TECHNOLOGY AND KNOWLEDGE

PROJECT Laser technology replaces standard physical reference patterns

JULY 2016 | No. 104 ENGLISH EDITION

An industrial meeting point

INTRODUCTION

IK4-TEKNIKER’S proximity to o the the market market as as a key key element for technology transfers to the industrial fabric was clearly visible at the successful events organised during BIEMH 2016 and at LUBMAT 2016, the international conference on industrial lubrication, maintenance and tribology that took place in May and June.

We invite you to take a tour of both events!

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INDEX

THE EXPERT’S VIEW

C04 The expert’s view:

by Luis Uriarte, IK4-TEKNIKER Market Manager

INTERVIEW

C06 Dr. Luis Fernández Ruiz-Morón. Project Manager at the Repsol R&D Centre

NEWS

C08 A positive assessment of BIEMH 2016 by IK4-TEKNIKER C10 LUBMAT 2016 brought together 260 professionals from five continents

PROJECTS

C12 Additive manufacturing for very large and complex parts

C14 Laser technology replaces standard physical reference patterns

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THE EXPERT’S VIEW

LUIS URIARTE

On the right path…

THE EXPERT’S VIEW:

by Luis Uriarte, IK4-TEKNIKER Market Manager

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A blend of ideas, creativity and knowledge connected to different technologies. These are the ingredients that IK4-TEKNIKER needed to produce significant changes in the way companies design and manufacture their products. This requires a high degree of specialisation in our technologies, an understanding of market needs as well as a close cooperation with our customers because they are the specialists in their own fields.

I would like to underscore a few of their most relevant watershed landmarks.

For instance, I remember the time when the fi rst-ever high-speed linear drive motors were made in our country. They were named BIZKOR and won the 1998 national design award.

During the design and construction stage we travelled to Germany on several occasions to visit reference centres such as ZTF in Stuttgart to learn more about linear motors recently launched in the market. That was a turning point, not so much because of the award itself, but rather because we managed to dispel any reluctance present in the machine tool sector with regard to using linear motors as a suitable constructive solution for highly dynamic machines.

Focusing now on the smallest scale of manufacturing, i.e., the micro and nanoscale, it can also be stated that our fi rst major industrial project related to applying micromanufacturing capabilities was another outstanding landmark.

In 1997, IK4-TEKNIKER implemented a Specialisation Plan that included setting-up an R&D unit for ultraprecision technologies. In 2001, the plan gave rise to a new micro-manufacturing laboratory called “Tekniker Micro Machining” (TMM).

By the year 2005 we were already producing the first range of dental brackets using microinjected high performance materials. To achieve this goal, a process had to be implemented that consisted in resizing polymer brackets and manufacturing single units directly by micro-milling in order to pass functional tests and obtain health accreditations to eventually manufacture micro moulds to be used at a later stage. This was done in close cooperation with EuroOrtodoncia under patent PCT/ES2005000346.

Since then, our micro-manufacturing laboratory has developed several ranges of increasingly complex brackets.

Our specialisation in the design and construction of unique, ultra- high precision equipment has allowed us to work with reference centres such as the Spanish Metrology Centre, Spain’s primary laboratory.

I also remember, thinking now about other pieces of complex equipment, the construction and implementation of the current national pressure standard reference pattern. Although it was introduced in 2009 it can still be rated as the world’s most accurate barometer capable of discerning atmospheric pressure differences between the upper and lower segment of the palm of a hand.

These and other landmarks have allowed us to provide the industry with the know-how generated by our research activities at different points in time.

It is frequently difficult to put your stakes on one technology or another because the market does still not exist. As a technology centre, we must anticipate the future needs of our industry and its firms. Whenever we address many of the projects mentioned here, not only are we aware of the path we’re following but also know their significance as landmarks when we imagine what our lives would be like without them.

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INTERVIEW

DR. LUIS FERNÁNDEZ RUIZ-MORÓN

Increasingly more sophisticated Industrial

lubricants Dr. Luis Fernández Ruiz-Morón Project Manager at the Repsol R&D Centre

Dr. Luis Fernández Ruiz-Morón is a project manager at Repsol’s R&D Centre and is also responsible for the tribology section. He recently attended the LUBMAT 2016 conference as a keyspeaker. During this interview, Fernández Ruiz-Morón explains how important it is to manage lubrication properly.

REPSOL’S R&D CENTRE

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Environmental regulations are being tightened up, more advanced formulations are being developed and the industrial sector is exploring new pathways to become more efficient and competitive. These are some of the reasons that are transforming the lubricant market. What is this revolution actually all about?

Generally speaking, lubricants and the oil & gas sector are undergoing significant changes because due to the above mentioned factors. As the environment in which we operate is technically complex, it is becoming increasingly necessary to network via consortiums and multi-disciplinary teams. End users are demanding better performance: more protection for their machines and less oil changes. Environmental restrictions, on the other hand, are increasing and this limits the number of substances used in the formulation of lubricants. It means that equipment manufacturers are forced to make changes in their designs to reduce emissions carrying CO2, particles and other contaminants: new materials, processes, after-treatments, etc., that influence lubricant composition. Lastly, more and more people are asking for a simplification of specifications issued by manufacturers and international bodies such as ACEA or API.

Tribology is playing a key role in the development of increasingly advanced lubricants, but how exactly?

Every tenth of a second matters in the struggle to reduce CO2 emissions. Advances made in lubrication systems are proving to be the most cost-effective way of doing things. But not only that: Machines and motors that are more efficient, ecological and advanced require more complex lubricants: they must be compatible with biofuels and their negative effects in terms of friction control, and must adapt to downsizing and increases in thermal stresses. They must feature friction modifier systems for protection against wear in the so-called ultra-light grades and must be capable of dealing with systems such as start-stop that multiply events beyond the range of hydrodynamic lubrication, just to mention a few examples. Mention must also be made of the progress made in terms of surface coatings and which has made it necessary to readdress lubricant formulations.

How would a company benefit nowadays from decidedly putting its stakes on incorporating lubrication management to its value chain?

For many years, users have rated lubricants as a “process constant” with which you had to coexist and adapt to. Nowadays, we have over 1,000 lubricant references adapted to different applications. Many of these lubricants have been exclusively developed for specific customers who have managed to increase production, improve efficiency or reduce maintenance costs by incorporating

lubricants with suitable bases and additives via an in-service oil monitoring system.

Some of the most outstanding European experts attended the LUBMAT conference held in Bilbao on June 7. What would you underscore about this edition of the conference?

As this is my hometown, I feel extremely proud to say that this international conference hosted by UCLA and IK4-TEKNIKER has not only become an outstanding event over the years but also a must for professionals working in the field of lubrication and maintenance, equipment manufacturers, scientists, tribologists, chemical engineers, physicists... Not only because of the quality and novelty of the presentations, but also because of the opportunity offered in terms of networking in a privileged setting like Bilbao (in this edition).

You were one of the keynote speakers. Could you briefly summarise some of the issues you discussed in your presentation?

As I’ve already spoken about the environment and the situation we are currently dealing with, I would now like to say something about how these environmental, economic, political and technical changes have affected lubricant formulations. In particular, we have reviewed the use of synthetic bases, new friction modifiers and activation systems. We have also addressed the complexity of the current specifications (the new ACEA 2016), the phenomenon of LSPI (Low Speed Pre-Ignition), fuel economy property testing and performance durability.

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BEC | BARAKALDO | BIZKAIA MAY 30 > JUNE 4 | 2016

A positive assessment of BIEMH 2016 by IK4-TEKNIKER The technology centre can only draw very positive conclusions with regard to the event. It must also be underscored that, compared to previous editions, visitorship has increased.

IK4-TEKNIKER has reviewed BIEMH 2016 and can only draw some very positive conclusions such as a larger number of visitors compared to previous editions, new spaces dealing with issues speciďŹ cally related to the sector itself and many interesting enquiries received.

That is how IK4-TEKNIKER participated in BIEMH 2016.

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NEWS

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NEWS

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LUBMAT 2016 brought together 260 professionals ffrom five continents The conference about lubrication, maintenance and tribology The ďŹ fth edition of the LUBMAT 2016 conference, organised by IK4-TEKNIKER and the Jost Institute for Tribotechnology, brought together 260 professionals from ďŹ ve continents in Bilbao, featuring 100 international speakers and discussing issues related to lubrication management, among others. Participants included experts in the sector of industrial lubrication in plenary sessions, and an international committee made up of a team of professionals in the world of lubrication evaluated the abstracts presented during the event.

The assessment and closure of the conference was a success.

Congratulations!

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PROJECTS

Additive manufacturing for very large and complex parts LASER METAL DEPOSITION TECHNOLOGIES TO MANUFACTURE AND REPAIR COMPONENTS

Additive manufacturing is an advanced manufacturing technique that allows structures and parts to be made by successively depositing layers of material.

One of the most widespread additive technologies of recent years is called Laser Metal Deposition (LMD) in which a laser melts a metal powder that is injected on to the surface of a substrate to generate 3D structures and coatings. j This technique has numerous applications to address surface wear and corrosion resistance or perform repairs on components used in the automotive business, moulds, aeronautics or railways. It has also been used lately to manufacture 3D structures and parts.

The Basque Technology Centre, IK4-TEKNIKER, has applied LMD to the reinforcement of components and repairs involving tools, moulds and dies that have previously failed in machining operations or have undergone design modiďŹ cations and develop defects during their operating life. Researchers have also addressed the production of metal parts and components used in complex structures, prototypes and on elements of a more functional character.

IK4-TEKNIKER has also made high quality stainless steel alloy structures with deposition rates close to 2 Kg/h.

It is within this ďŹ eld of specialisation that experts at the technology centre have also used other kinds of materials such as tool steel grades for cold and

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The Basque technology centre, IK4-TEKNIKER specialises in material addition techniques that use laser to manufacture components. Additive manufacturing is applicable to sectors such as the automotive business, moulds, aeronautics or railways.

hot operations, nickel, titanium and cobalt-based alloys or tungsten carbide composites embedded in cobalt matrices on a number of metal bases.

the materials used on it can be barely be machined or are hard or abrasive. These are features commonly found in sectors related to energy, aeronautics and prototypes.

Profitability in large sizes

In addition to a short ‘lead time’, LMD responds quicker compared to sectors involving castings or injected parts. The absence of moulds also reduces lead time by more than 50% whenever single parts are involved.

The LMD process is specifically geared towards the production of medium and large metal parts that in the past were produced by using conventional processes such as subtractive or forming techniques.

This new technology allows raw material consumption to be drastically reduced as the ratio between the amount of starting material required and what is actually deposited is close to 1:1.

Both the savings obtained and shorter process times have made it possible to significantly cut back the fi nal cost of manufacturing processes.

The LMD process is profitable in those sectors in which more than 80% of the workpiece is machined and when

The end results of the research work carried out by IK4TEKNIKER in the field of additive manufacturing were presented at the last edition of the Spanish Machine Tool Biennial (BIEMH) that was held from May 30 to June 4 at the Bilbao Exhibition Centre.

Additive manufactu-ring techniques will play a very active role in the field of industry 4.0 as they will allow for the customisation of products and processes.

Industry 4.0, or the so-called fourth industrial revolution, is a new manufacturing paradigm based on integrating electronic, information and communication technologies within the scope of productive technologies.

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PROJECTS

Laser technology replaces standard physical reference patterns IK4-TEKNIKER IS UNDERGOING AN ENAC CERTIFICATION PROCESS TO CALIBRATE HEAVY-DUTY COORDINATE MEASURING MACHINES.

The revision carried out in 2010 by ISO (the International Organization for Standardization) of the ISO 10360 technical standard introduced the possibility of using laser interferometry as a valid standard reference pattern for the calibration of coordinate measuring machines (CMM) used to measure linear dimensions.

It is within this context that IK4-TEKNIKER is currently involved in a process aimed at obtaining a certificate awarded by the National Accreditation Body (ENAC) for the calibration of medium-large CMMs (with axial lengths ranging between 1,500 and 13,500 mm) using tracer lasers to meet current market requirements with regard to finding more accurate mechanisms in the entire calibration process with shorter machine downtime.

A significant demand In Spain there is a significant number of CMM’s larger than 1,500 mm that are currently calibrated with standard physical reference patterns. The main problem is related to the complexity of using very long standard physical reference patterns quickly and reliably when a machine is to be calibrated.

IK4-TEKNIKER uses an ETALON AG laser interferometry system called tracer laser that follows a reflector located near the machine’s feeler and also measures linear displacements. This is connected to two major advantages in terms of the processes used nowadays: On the one hand, precision is maintained at an interferometric level throughout the entire calibration process. On the other, machine downtime is significantly reduced, regardless of the size of the CMM. This measuring process was presented at the last edition of the Machine Biennial.

The ETALON AG - IK4-TEKNIKER partnership ETALON AG is a crucial partner in this new service developed by IK4-TEKNIKER as this company is a benchmark in the metrology sector that supplies innovative technology for geometric verification and the monitoring and upgrading of precision of machine tools, coordinate measuring machines and robots.

IK4-TEKNIKER is currently collaborating with ETALON AG as its official distributor in the Spanish market meaning. This means, on the one hand, that cutting-edge and precise know-how related to geomettric verification is readily available and, on the other, that a solid collaboration is underway thanks to the agency agreement signed with this b leading industrial metrology firm. le

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More accurate mechanisms in the entire calibration process with shorter machine downtime.

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PARKE TEKNOLOGIKOA CALLE IÑAKI GOENAGA, 5 20600 EIBAR · GIPUZKOA · SPAIN TEL: +34 943 206 744

www.tekniker.es