Engineering Service Solutions

Engineering Service Solutions

H.C. Starck Solutions understands market trends and the latest cutting-edge technologies are providing us the opportunity to create value added solutions for complex applications. To this, we created our Engineering Solutions Services that provide customized engineering services for all furnace applications. From engineering design assistance to furnace products and applications, H.C. Starck Solutions can craft the solution to fit your company’s furnace needs.

LevelServices Included
LEVEL 1: Basic EngineeringBasic layouts in 2D and bill of materials
Selection of the number of sheets and calculations of the temperature in the individual layers;
Calculations:
• Heating elements – resistance (ohms)
• Surface loading (W/cm2) and a secondary voltage (Volt)
• Heat loss and heating power
• Furnace hearth-supports inside the heating chambers/zones
LEVEL 2: Proof EngineeringComplete drawings in 3D/2D and bill of materials;
Selection of the number of sheets and calculations of the temperature in the individual layers;
Calculations:
• Heating elements – resistance (ohms)
• Surface loading (W/cm2) and a secondary voltage (Volt)
• Heat loss and heating power
• Furnace hearth-supports inside the heating chambers/zones
LEVEL 3: Finite Element Method (FEM)/Computational Fluid Dynamics(CFD)Preparation FEM/3D model of current design
Preparation CFD/3D model of current design
FEM simulations of current design: static stress, modal frequencies, thermal stress, thermal calculations, structural buckling, nonlinear static stress, event simulations and sharp optimization
CFD simulations of current design
Analysis of the result

SUPPORT OR ANY QUESTIONS?

Please reach out with specific requests of materials that are not listed and a member of our team will get back to you.

Brochure Download

REQUEST A QUOTE

Please fill in the boxes on the contact form and a member of the team will contact you directly for a quotation.

Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


Read More

Spray Drying

Spray Drying

Spray drying is a critical process in the generation of high-performance thermal spray powders for various end-use applications. It is key in ensuring the homogeneity and uniformity of metal powders intended for deposition onto a wide range of substrates in a semi-molten state. Each of these properties is a vital metric in the eventual functionality of deposited coatings. The performance of automotive components, heat management systems, and numerous other products can stem back to this preparatory stage of raw material processing.

H.C. Starck Solutions has succeeded in synthesizing the highest quality refractory powders from a broad range of technology metals, including molybdenum (Mo) and tungsten (W). These advanced thermal sprays serve the purpose of fixing non-uniform surfaces and protecting against the destructive effects of erosion and general wear-and-tear.

The success of H.C. Starck Solutions thermal spray powders depends on the quality of the underlying raw material, which can be compromised by spray drying. H.C. Starck Solutions spray drying capabilities support the generation of highly-engineered products with tight control of particle morphology, size distribution, and mechanical strength. The result: Thermal sprays with outstanding sphericity and flowability, ensuring even coatings of myriad substrate materials, even for contiguous layers.

Spray-Drying Services from H.C. Starck Solutions

H.C. Starck Solutions has expanded this unique capability, offering customers the benefit of their expertise in the processing of advanced thermal spray powders at the earliest stage. Numerous refractory powders can be dried with tight control of particle properties by adjusting the drying parameters and feedstock characteristics.

With almost 100 years’ experience in powder metallurgy and a worldwide network of research and development (R&D) laboratories and manufacturing facilities, H.C. Starck Solutions occupies the cutting-edge of powder processing for demanding areas of application. Combustion engine components and high-density high-power electronics are merely two examples of the various components that H.C. Starck Solutions spray-drying capabilities can optimize and revolutionize.

If you would like more information about the materials available for H.C. Starck Solutions powder spray-drying services, please do not hesitate to contact a member of the team today.

SUPPORT OR ANY QUESTIONS?

Please reach out with specific requests of materials that are not listed and a member of our team will get back to you.

REQUEST A QUOTE

Please fill in the boxes on the contact form and a member of the team will contact you directly for a quotation.

Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


Read More

Plating

PLATING

Material processing for challenging applications often requires a novel solution. H.C. Starck Solutions highly qualified process engineers and developers have long been collaborating with customers to meet unique industry requirements with value-added resolutions. This has culminated in one of the core services on offer from H.C. Starck Solutions. Using high-purity molybdenum (Mo) as a base material, H.C. Starck Solutions routinely generates composite plates using a choice of electrodeposited metals, including:

  • Precious metals like gold (Au) and silver (Ag).
  • Transition metals like nickel (Ni), rhodium (Rh, and ruthenium (Ru).

H.C. Starck Solutions plating service exploits the exceptional thermodynamic properties of molybdenum, including its high strength and stiffness under refractory conditions. It is one of the highest performing substrate materials for plating in aerospace and defense, electronics, and industrial processing applications, benefitting from exceptional adherence with deposited metal coatings. H.C. Starck Solutions molybdenum plates can withstand extremely high temperatures without softening or expanding, enabling the functional coating to retain its desired characteristics throughout operating conditions.

The challenge of electroplating on molybdenum substrates is the material’s relatively high reactivity with other metals. This can result in the generation of undesirable oxides that inhibit adhesion between the substrate and the coating material. H.C. Starck Solutions has a wealth of experience in design and engineering with challenging refractories, including molybdenum and its alloys. These problems can subsequently be overcome with confidence, ensuring uniform functional coatings of high-performance molybdenum substrates for sectors as challenging as semiconductor and chemical processing.

If you would like any more information about H.C. Starck Solutions electroplated coatings and electroless nickel coating services, please contact a member of the team today.

REQUEST A QUOTE

Please fill in the boxes on the contact form and a member of the team will contact you directly for a quotation.

Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


Read More

Design, modelling, simulation

H.C. Starck operates a proprietary range of design, modeling, and simulation services founded on over 100 years’ experience in materials processing and custom engineering. This development process bridges the company’s unmatched expertise with customer design and manufacturing processes. Industry needs can be addressed with absolute confidence, with enhanced modeling and simulations providing quantitative insights into material properties under processing conditions. This feeds back to the design process, providing actionable insights to optimize quality assurance and control processes.

This world-class research and development (R&D) chain is supported by a worldwide network of state-of-the-art laboratories and testing facilities. The primary focus of H.C. Starck laboratories is the continual refinement of the core product and material portfolio. This singular drive is in keeping with the company’s commitment to quality and innovation. That same sense of constant fine-tuning is also applied to customer needs and requirements.

H.C. Starck Design, Modelling & Simulation Services

H.C. Starck R&D facilities routinely conduct a broad range of material tests to glean the best possible understanding of technical materials in various conditions. These include, but are not limited to:

  • Finite element analysis (FEA).
  • Grain size analysis.
  • Hydro testing.
  • Helium leak analysis.
  • Metallographic characterization.
  • Particle count.
  • Ultimate tensile strength (UTS) testing.
  • Ultrasonic testing.

Using advanced modeling and simulation software, H.C. Starck can reliably predict the performance of products as complex as glass melting components and rotary sputter targets. The stress-strain distribution of plates during rolling processes can be characterized. Fatigue analysis, crystallographic deformation, thermodynamic properties under extreme use conditions. Myriad complex material properties can be reliably explored, evaluated, and optimized without expending significant materials or time on costly R&D that can now be accurately conducted using modeling and simulation.

If you would like to learn more, simply contact a member of the H.C. Starck team today.

REQUEST A QUOTE

Please fill in the boxes on the contact form and a member of the team will contact you directly for a quotation.

Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


Read More

Rotary Forging

ADVANTAGES

High fabricating efficiency and the lowest possible reject rate are essential when working with expensive, high-performance materials. H.C. Starck has an advanced process for precision forging that saves costs, materials, waste, and time.

Our CNC rotary forging machine can make precision-forged bars, tapers, and steps for near-net-shape products. Each second, its state-of-the-art control system regulates power, forging force, temperature, and other processing parameters for high workpiece uniformity. Precise control of the forging process results in consistently high product quality.

We work with a wide range of materials, including soft metals such as copper, and materials that are difficult to forge such as cobalt and nickel alloys. From material procurement and the blank to forging and finishing processes, we provide everything from a single source.

REQUEST A QUOTE

Please fill in the boxes on the contact form and a member of the team will contact you directly for a quotation.

Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


Read More

Recycling

Accountability and sustainability are entrenched in H.C. Starck’s company values, with a commitment to resource conservation and ethical manufacturing processes. H.C. Starck is consistently ahead of the curve with regards to recycling technology. Almost half of the company’s raw materials come from in-house recycling processes, including demanding refractory metals and technical ceramics.

Using specialist processes, H.C. Starck can reliably re-process powdered metals, semi-finished goods, and unfinished compounds even after they have served standard and proprietary customer purposes. These can be channeled back into the material cycle with limited quantity losses and little-to-no detrimental impact on quality.

Recycling is one of H.C. Starck’s core competencies, falling in line with the company’s overarching commitment to environmental protection, energy savings, and waste avoidance. Alongside these unmatched re-processing capabilities, H.C. Starck continually strives to optimize all production processes to improve overarching energy-efficiency and reduce the company’s environmental footprint.

Industrial Recycling Expertise

H.C. Starck runs a “closed-loop” recycling program based on decades of expertise in material development and application. This enables practically all materials generated and supplied by H.C. Starck to be recycled through a closed reuse loop. Blanks, components, powders, and compounds can be re-processed and finished, retaining their as-reclaimed properties, often through multiple recycling cycles.

There are myriad benefits to H.C. Starck’s closed-loop recycling concept. It is economically and environmentally beneficial, providing high-quality parts with comparable properties to their virgin counterparts. This is a cost-effective technique for refractory metal powders, reducing the reliance on raw materials with volatile supply chains and fluctuating prices. Supply chain security is assured, with H.C. Starck’s closed-loop recycling services.

H.C. Starck offers fair and reliable recycling services, with transparent assessments of reclaimed materials and a fully-compliant approach to waste processing with respect to international and European legislation. If you need any more information about H.C. Starck’s closed-loop recycling service, please do not hesitate to contact a member of the team.

REQUEST A QUOTE

Please fill in the boxes on the contact form and a member of the team will contact you directly for a quotation.

Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


Read More

Hot and Cold Rolling

ADVANTAGES

Material processing can often be challenging, especially when working with refractory metals. H.C. Starck’s expertise in powder metallurgy and material processing make us excellent partners for assisting you with your material processing.

H.C. Starck’s highly qualified Process Engineers and Production Developers are available to help resolve material processing issues with our hot and cold rolling technology.

These engineers are experienced in a wide spectrum of metals and alloys, and can assist with specifications for your material process and design needs.

Our toll rolling services offer the capability of converting material into varying flat material sizes of gauge, length and width. H.C. Starck has the expertise to walk with you every step of the way, from the concept phase through high volume manufacturing.

Through a tolling team approach, customers benefit from H.C. Starck’s dedicated personnel of research engineers. This collaborative effort facilitates new and improved product designs along with providing access to extensive in-house state-of-the-art laboratory facilities equipped with the latest in analytical tools, testing equipment, modeling, and simulation software for evaluating product performance in your particular application.

H.C. Starck is a premier global supplier of refractory and technology metals, advanced ceramic powders, and a recognized leader in recycling of refractory metals. H.C. Starck’s expertise includes 100 years of product development, powder metallurgical, and advanced metal and ceramic powders experience. We have a vast product portfolio – from molybdenum, tungsten, niobium, tantalum, copper, nickel pure and alloyed materials to complex, fabricated assemblies.

REQUEST A QUOTE

Please fill in the boxes on the contact form and a member of the team will contact you directly for a quotation.

Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


Read More

Fast Track

High Performance Metal Solutions

Fast Track Service Offering

  • Refractory metals in sheet and rod form, cut to customer requirements, at competitive pricing, excellent quality and customer service.
  • A dedicated Sales and Materials prep team for quotations and shipments.
  • Stock items and material dispatched within 3 days of order.
  • One of the largest inventories of refractory materials supported by H.C. Starck‘s global supply chain.
  • Enquiries quoted within 24 hours for stock material. Non-stock items quoted using our global supply chain.
Fast Track_service offering_material
Fast Track_service offering_forms

H.C. Starck Certifications

  • ISO 9001 and ISO 14001
  • EICC Approved Conflict-Free Materials: Tantalum and Tungsten

H.C. Starck, a global supplier of technology metals – molybdenum, tungsten, tantalum and niobium pure and alloyed materials, serves growing industries in electronics, chemicals, automotive, medical technology, aerospace, energy, and environmental technologies.

REQUEST A QUOTE

Please fill in the boxes on the contact form and a member of the team will contact you directly for a quotation.

Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


Read More

Extrusion

ADVANTAGES

Our range of flexibility encompasses almost any size and near-net-shape in almost any metal you can imagine. One of the few suppliers worldwide able to extrude pipe with integral flanges. Efficient use of materials, close attention to quality and a flexible production program mean that we can often deliver a first class product precisely to customer specifications in as little as two weeks after receipt of order. integrated supply package, where we can procure the material, make the billet, extrude it and finish it for market.

SUPPORT OR ANY QUESTIONS?

Please reach out with specific requests of materials that are not listed and a member of our team will get back to you.

In the fabrication of technology metals, H.C. Starck is well ahead of the field. Our extensive and growing expertise in metal and alloy extrusion out paces the competition. Whether forming complex profiles, cross-sections or simply making tubes, H.C. Starck’s core competencies are well-known in the marketplace. Our range of flexibility encompasses almost any size and near-net-shape in almost any metal you can imagine.

Together with our many other strengths, we have garnered a special position in the manufacturing world. With piping, for example, we are one of the few suppliers worldwide able to extrude pipe with integral flanges.

Efficient use of materials, close attention to quality and a flexible production program mean that we can often deliver a first class product precisely to customer specifications in as little as two weeks after receipt of order.

Our customers derive great benefit from our integrated supply package, where we can procure the material, make the billet, extrude it and finish it for market. So whether it’s heat treatment, cleaning, straightening or simply cutting, the customer receives everything from a “single source”.

Extrusion Technology and Capabilities

H.C. Starck is unique in its ability to extrude almost any metal in any size range. From concept to production, from small 6 inch diameter to large scale 17 inch diameter billet, we provide extrusion services to deliver specified material, size and shape to your specific needs. H.C. Starck’s extensive extrusion capabilities allow us to provide extrusion services with as little as two weeks lead-time.

At H.C. Starck we utilize our 5,000 metric ton (5,500 ton) extrusion press to extrude rods, tubes and shapes from difficult to extrude materials, including:

Copper and Copper Alloys

C10100 | C15000 | C16200 | C17200 | C17500 | C18200
C63000 | C70600 | C71500 | Copper and Niobium

Stainless Steels

300 series | 400 series | 15-5 PH | 17-4 PH | Duplex

Nickel Base Alloys

C276 | 400 | 625 | 718 | 800H | 925

Titanium and Titanium Alloys

CP2 | 6AI | 4V

Refractory Metals

Molybdenum and Molybdenum Alloys
Tantalum and Tantalum Alloys
Niobium | Chrome

Aluminum Metal Matrix Composites

Composite Billets

Superconductor Materials

Clad Materials

Pipe Matrix

Pipe capability at 20 feet (6 m) minimum extruded lengths.
Please inquire for other sizes and metals.

REQUEST A QUOTE

Please fill in the boxes on the contact form and a member of the team will contact you directly for a quotation.

Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


Read More

Electron Beam Melting

ADVANTAGES

A number one priority for H.C. Starck Solutions is our contribution to the environment. To advance our sustainability development, we offer customers the unique service of recycling spent or used products through our electron beam melting (EBM) furnace.

Electron beam melting technology at H.C. Starck Solutions uses recycled molybdenum, tantalum and niobium as part of its raw material input. The process employs electrons to bombard the material in the EBM furnace, so the material melts and falls into a water-cooled copper mold where it solidifies into a round ingot. The ingot is then forged and formed into the desired shape.

Electron beam melting is carried out under high vacuum in the EBM furnace. In the instance of molybdenum, the elements with melting points lower than molybdenum volatilize which leaves the molybdenum more than 99.95 % pure and 100 % dense.

H.C. Starck Solutions continues to improve its electron beam melting processes to offer customers the most efficient and cost saving alternatives.

REQUEST A QUOTE

Please fill in the boxes on the contact form and a member of the team will contact you directly for a quotation.

Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


Read More