H.C. Starck Solutions: Additive Manufacturing for Aerospace & Space 2020

Additive Manufacturing for Aerospace & Space is the premier European conference on additive manufacturing (AM) in air, land, sea, and space applications. Its chief aim is to explore innovative new technologies with a focus on applying emerging additive manufacturing techniques in the aerospace and space industry.

Now into its sixth year, IQPC is bringing the platform to Birmingham UK for another ground-breaking exposition in 2020. H.C. Starck Solutions is happy to announce that we will be attending the exhibit alongside some of the world’s foremost innovators in digital and additive manufacturing.

Additive Manufacturing for Aerospace & Space: A Forum for AM Users

Spanning three days (25 – 27th February 2020), Additive Manufacturing for Aerospace & Space will continue to focus on removing the roadblocks to the industrialization of AM technologies. This involves exploring certification standardization, production cycle assessments, life-cycle costing evaluations, aligning practices with the national additive manufacturing strategy, and many more fascinating topics.

H.C. Starck Solutions is one of the world leaders in additive manufacturing of refractory metals and alloys, with a diverse portfolio of AM technologies enabling us to support two distinct product streams: Semi-finished and finished additively manufactured components. We also offer tailored AM services and powder and wire feedstocks, delivering unique product solutions to original equipment manufacturers (OEMs) in a range of market segments. Our material expertise covers high-performance refractories, including tungsten (W), molybdenum (Mo), tantalum (Ta), and niobium (Nb).

We will be participating in this year’s Additive Manufacturing for Aerospace & Space, leveraging our experience in both aerospace and defense as well as AM technologies. Contact us to let us know if you are registered for the conference, and we will book a time to talk with you about all the latest innovations in additive manufacturing at H.C. Starck Solutions.

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What is 3D Printing?

3D printing, also known as additive manufacturing (AM), refers to a suite of different technologies used to generate components via gradual addition of materials rather than subtraction.

The term subtractive manufacturing is a catchall for engineering techniques that use successive removal of material (cutting, grinding, etc.) to generate shapes and components from a workpiece. Available part shapes are dictated by the practical subtractive manufacturing processes rather than by the shapes that would provide optimum performance.

For example: It is notoriously difficult to machine complex internal geometries into a bulk material and as a result, parts are commonly broken-up into separate individual pieces that can be machined separately.  However, by using some 3D printing techniques, these complex internal geometries can be produced as a single part that eliminates the need for assembly.

3D printing is a novel solution to this problem, opening new avenues of possibility from rapid prototyping up to manufacturing with technical materials.

How Does 3D Printing Work?

Although there are many different forms of 3D printers, most adhere to the same basic principles. The first requirement is a three-dimensional CAD (computer-aided design) file which acts as the digital blueprint for the net workpiece. Dedicated software systems separate this file into vertical slices; extremely thin 2D layers that provide the coordinates for subsequent CNC (computer numerical control) deposition. How this deposition is carried out depends on the type of 3D printing process.

H.C. Starck Solutions specializes in the production of intricate 3D components comprised of high-performance refractory metals like molybdenum (Mo), tantalum (Ta), and tungsten (W), generated using powder metal and wire feedstocks rather than filaments. There are several methods available for creating thin sequential layers from refractory metal powders, but the typical nozzle-deposition technique is unsuitable. Instead, we use a powder bed and a high power laser to fuse individual layers together in-line with the original CAD file. This layer-by-layer fusion technique allows us to generate unique 3D structures that satisfy the various demands of extremely challenging application areas.

This technique is just one of four distinct 3D printing methods that H.C. Starck currently specializes in.

Benefits & Drawbacks of 3D Printing

Since the inception of additive manufacturing at the industrial, and even the domestic scale, reactions to the technology have often verged on hyperbolic. Many have even drawn parallels with comments made by revered futurist Arthur C. Clarke about the forthcoming invention of – what he termed – the replicator; a machine capable of recreating anything based on imagery. While the 3D printer has yet to reach the heights of re-creating “anything”, the technology has matured significantly in recent years.

With vast improvements in the materials and processes available for 3D printing, one of the primary limitations now is scaling the technology to produce consistent quality on a manufacturing scale. Provided sufficient part-to-part quality can be developed, 3D printing can provide numerous benefits to part performance that will improve material efficiency, eliminate unnecessary assembly steps, reduce manufacturing time and improve overall value to the customer.

3D Printing Applications

There are now myriad different formats of the technology available for large-scale industry, proprietary market sectors, and even at-home hobbyists. In the industrial space, 3D printing is now serving a key role in markets as varied as:

  • Aerospace & Defence
  • Electronics
  • Medical
  • Industrial Processing

H.C. Starck Solutions: Experts in Technical 3D Printing

H.C. Starck Solutions manufactures high-performance technical materials for demanding areas of application. Our additive-manufactured refractory metals have been used in extremely challenging markets, including aerospace and defense. We pride ourselves on our ability to select the correct technique per application, supporting optimal results acquisition regardless of downstream requirements.

We have dedicated a wealth of resources in expanding our additive manufacturing capabilities to provide unique solutions to the challenges of engineers today. Currently, we are able to provide both semi-finished and finished goods generated via high-precision 3D printing, and powders as feedstocks. If you would like to learn more about our processes, simply contact a member of the H.C. Starck Solutions team today.

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Marketing Specialist – Newton, MA

Marketing Specialist – Newton, MA

We are currently sourcing candidates for a Marketing Specialist in our Newton, MA facility.

Position Summary

The Marketing Specialist is responsible for the collection and preparation of content for our internal and external communication strategies. This includes maintaining and updating information on our products and services for our website, brochures, presentation, and various other marketing tools. The Market Specialist also supports our strategic marketing initiatives through collection and analysis of market relevant data, such as product applications, competition, and industry trends/developments. In this position, he/she reports directly to the Head of Global Marketing & Strategy Development and works closely with various departments in our organization, including Marketing, R&D, Sales, HR, as well as Management.

Essential Functions & Responsibilities

  • Collects, analyzes, and prepares data for internal and external Marketing Communications campaigns
  • Continuously researches and evaluates of market-relevant information (customers, industry, competitors)
  • Is interface to multiple different departments on a global scale (e.g. R&D, Sales, Marketing, Management, HR)
  • Supports our Market Directors in developing their marketing strategies
  • Helps develop, implement, and maintain market intelligence databases and tools to improve analysis of demand and supply trends, predicts industry developments and competitive behaviors
  • Translates findings into concise reports, summarized presentations, and discussion guidelines
  • Supports ad-hoc reporting needs on market positioning and business developments
  • Collaborates with sales teams to support customer opportunities and develop sales enablement tools (e.g. sales presentations, training materials, brochures/flyers, data on technology trends)
  • Supports ongoing project activities with quick turnaround times

Required Experience & Qualifications

  • Bachelor’s Degree in marketing or related degree required

  • Beneficial: 2-3 years of experience in a business-to-business marketing environment for a manufacturing or professional services firm

  • Ability to clearly explain technical and analytical information (verbally, written, and in presentation format)

  • Experience with coordinating integrated marketing activities

  • Analytical, creative, and innovative approach to solving problems

  • Ability to provide total analytic support which includes data extraction, developing reports, and synthesizing data

  • Experienced in Microsoft PowerPoint, Excel, and Word

  • Competencies include: self-driven, creative, analytical, interested in technology and innovation, effective communication, strong team player, sense for structure and quality, interested in learning, excited about developing new best practices

To Apply for this Position

H.C. Starck offers a highly competitive compensation along with excellent benefits, including Medical, Dental, Vision, 401(k) with company match. Please email your resume with your salary expectations to kristen.gasser@hcstarcksolutions.com.

H.C. Starck Solutions is an Equal Opportunity Employer supporting diversity in all our business practices.

Download the full job specification here

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General Electric GEnx Aircraft Jet Engine

Refractory Metals in Aerospace & Defense

Founded on an unparalleled period of innovation, the aerospace and defense (A&D) markets are now among the largest and most lucrative industries worldwide. It is difficult to value the net worth of the global market with any accuracy, but the US aerospace and defense sectors recently logged a record yearly revenue of US $760 billion. This is largely attributed to continued digital transformation and innovation despite mounting geopolitical uncertainties and tensions. Refractory metals are central to these key growth drivers, providing the solutions for low-risk innovations in flight control systems and ballistics.

In this blog post, H.C. Starck Solutions explores the use of refractory metals in aerospace and defense.

Aerospace & Defense: Added-Value with Refractory Metals

Refractory metals are a critical class of materials in high-performance industrial and manufacturing spaces. They comprise a core group of five elements: niobium (Nb), molybdenum (Mo), rhenium (Re), tantalum (Ta), and tungsten (W). While the definition as to what qualifies as a refractory metal varies – with some areas of materials science and metallurgy considering a wider specification than others – these five elements are the definitive refractories.

What unites these materials is their exceptional resistance to extreme temperatures and unique physical and chemical properties. Of the five refractory metals, niobium has the lowest melting point (2750°C) while tantalum has the lowest Vickers hardness rating (873 MPa). These are already extraordinary properties that only improve throughout the refractory metals family, spanning up to a melting point of 3422°C and a maximum Vickers hardness of 4000 MPa.

Vibration_Dampeners,_Balance_Weights-(2)

Tungsten is the go-to refractory metal for aerospace and defense solutions, exhibiting the highest melting point of any metal known to man: 3422°C (6192°F). Combined with its high density (19.3 g/cm3) and extreme hardness, it is routinely used to fabricate critical products that assist in-flight stability or provide powerful penetration for advanced ordinance. Molybdenum and tantalum are also utilized in similarly demanding military and civil aviation applications.

For more information on the materials utilized in aerospace and defense, browse our Products by Industry.

Tantalum is essential in the generation of explosively-formed penetrators (EFP), while molybdenum heating elements and hot zones are used in a range of heat treatment processes designed to elevate the physical properties of components intended for use in aerospace and defense. Niobium is another critical refractory that is taking aerospace to new heights, providing a novel material solution for rocket nozzles and flame shielding applications.

Many financial analysts argue that defense spending and growth in commercial aviation are counter-cyclical, which means the sector often thrives despite economic downturns or recessions. Others believe that there is no such thing as a perceptible periodicity in the sector’s market value. A consistent fact, however, is that innovation in aerospace and defense is often accommodated by new material solutions. Composites were instrumental to the earliest successes of the aviation industry; now refractory metals are providing similar innovations to meet growing global demand.

Among the many innovations in aerospace has been the onset of additive manufacturing (AM) for generating high-performance components. If you would like to learn more about how AM is increasingly utilized in aerospace applications, read the article Additive Manufacturing for Space Applications.

Balance_Weights_5

Refractory Metals from H.C. Starck Solutions

H.C. Starck Solutions specializes in the generation of high purity refractories and alloys for challenging areas of application. We offer a broad range of tried-and-tested products for aerospace and defense, helping manufacturers meet the ongoing demand for high-performance solutions. Our product line includes:

  • WHA Balance Weights for Airplanes and Helicopters
  • Nb C-103 Sheet & Nozzles for propulsion
  • TZM forging dies for engine blade production
  • WHA shielding components for spacecraft
  • Mo, Ta and WHA missile components

If you would like any more information about using refractory metals in aerospace and defense settings, simply contact a member of the H.C. Starck team today.

References:

https://www.wearefinn.com/topics/posts/five-trends-that-will-shape-the-aerospace-and-defence-industry-in-2019/

https://www.forbes.com/sites/lorenthompson/2011/12/05/defense-spending-cycles-are-an-illusion/#674d3deaded0

http://usblogs.pwc.com/industrialinsights/2019/05/16/aerospace-and-defense-industry-hits-record-revenues-and-profits-in-2018/

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H.C. Starck Solutions Expands 3D Printing Capabilities

Press release originally published on PR Newswire.

Coldwater, MI – H.C. Starck Solutions, a global leader in refractory metals, is excited to announce the addition of a powder-bed fusion printing system to its growing list of Additive Manufacturing (AM) capabilities. H.C. Starck Solutions collaborated with Renishaw, a global engineering technologies company, by acquiring one of their Laser Powder Bed Fusion AM systems to optimize the processing of their refractory alloys. Additive Manufacturing, also known as 3D printing, is now being used to produce metal parts and H.C. Starck Solutions is a technology leader in applying AM to refractory metals, including tungsten, tantalum, niobium and molybdenum.

Powder-bed fusion is a revolutionary tool in enhancing the performance of many refractory metal parts for demanding applications in medical imaging, biomedical implants, space propulsion and chemical processing. The Renishaw equipment will be used to produce complex metal parts in support of H.C. Starck Solutions’ customers in the aerospace, defense, medical, and industrial markets. The powder-bed fusion printer will be located in their manufacturing facility in Coldwater, Michigan, which is the same facility that produces their AM powders.

Renishaw’s powder-bed fusion system offers the best combination of high precision and geometric flexibility of any current AM technique,” says Andreas Mader, Chief Executive Officer of H.C. Starck Solutions. “Combining our knowledge of AM technologies with our expertise in refractory metals will provide our customers with superior solutions to their business needs. The addition of the powder-bed fusion technology from Renishaw is only one of many steps H.C. Starck Solutions is taking to expand its AM portfolio in support of this growing sector.

An AM-manufactured molybdenum (Mo) pump impeller.

H.C. Starck Solutions and Renishaw continue to share their respective knowledge and expertise to process the materials efficiently and with superior metallurgical performance.

About H.C. Starck Solutions

H.C. Starck High Performance Metal Solutions (H.C. Starck Solutions), a leading global manufacturer of metal powders, complex metal parts and additively manufactured parts made from refractory metals, is an independent business unit of H.C. Starck Group with operations in the United States, Europe and Asia. H.C. Starck Solutions supplies its fabricated products to growing industries, including electronics, aerospace, medical, chemical processing, glass melting and commercial heat treating. They deliver product solutions to original equipment manufacturers (OEMs), end-users and aftermarket manufacturers.

About Renishaw

UK-based Renishaw is a world-leading engineering technologies company, supplying products used for applications as diverse as jet engine and wind turbine manufacture, through to dentistry and brain surgery. It has 5,000 employees located in the 36 countries where it has wholly-owned subsidiary operations.

Throughout its history, Renishaw has made a significant commitment to research and development, with historically between 13 and 18% of annual sales invested in R&D and engineering. The majority of this R&D and manufacturing of the company’s products is carried out in the UK.

The Company’s success has been recognized with numerous international awards, including eighteen Queen’s Awards recognizing achievements in technology, export and innovation.

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Process Engineer – Coldwater, Michigan

Process Engineer – Coldwater, Michigan

We are currently sourcing candidates for a Process Engineer in our Coldwater, Michigan facility.

Position Summary

Responsible for the development, monitoring and improvement of all manufacturing processes within the Coldwater Hot Works production areas. Ensures that all processes accurately reflect the documented production practices, costing is adequate and quality requirements meet or exceed customer specifications.

Essential Functions & Responsibilities

  • Develop, document, and oversee the manufacturing process for respective product lines in cooperation with manufacturing and quality control to ensure that all applicable standards are met or exceeded
  • Evaluate new processes, manufacturing methods and equipment, as required, to improve process capabilities, material yields, and develop new products
  • Provide technical support to customers in an effort to define product/process requirements or troubleshoot existing materials or applications
  • In conjunction with quality control and quality assurance to resolve nonconforming material issues, customer complaints, complete and implement corrective and preventative measures, perform FMEA or other statistical analyses to support all quality initiatives.

Required Experience & Qualifications

  • 3-5 years’ experience in a similar or related metals manufacturing environment

  • Experience with project management

  • Thermo-Mechanical processing of metal mill products, Combustion systems and process equipment control systems preferred

  • Bachelor’s Degree in metallurgical or mechanical engineering

  • 5 years’ experience in a similar or related metals manufacturing environment

  • Working knowledge of MRP/ERP planning tools

  • Experience with SPC, Lean Manufacturing and SAP

  • Proficient in using MS Office software Ability to communicate proficiently both orally and in writing using the English language

  • This position may require the applicant to be licensed under certain United States laws and regulations

  • Competencies: results orientation, entrepreneurial orientation, analytical thinking, taking initiative, effective communication, influencing others, self-confidence

Note: This position will involve access to export-controlled technical data and/or technology and the position requires either U.S. Person status or the ability to obtain an export license from the appropriate government agency for Non-U.S. Persons.

To Apply for this Position

H.C. Starck offers a highly competitive compensation along with excellent benefits, including Medical, Dental, Vision, 401(k) with company match. Please email your resume with your salary expectations to kelly.cline@hcstarcksolutions.com

H. C. Starck Solutions is an Equal Opportunity Employer supporting diversity in all our business practices.

Download the full job specification here

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