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New 'breathable' rupture disk tech provides overpressure and vacuum relief

To increase equipment safety and reliability, a new rupture disk technology activates at a set burst pressure, but it can also "breathe" to relieve minor pressure fluctuations. The patent-pending, dual-function device from BS&B Safety Systems is ideal for use on low-pressure vessels that are susceptible to ambient temperature changes.
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Engineer's Toolbox: 9 considerations for specifying a slewing ring bearing

In applications that require a bearing to support a structure while it rotates (e.g., cranes, radar, tank turrets), premature bearing failure can put people and equipment at risk. While slewing ring bearings have proven themselves countless times in such applications, designers must consider many factors when specifying them. According to engineers at Kaydon, the bearing's support structure, mounting (including bolt strength, tensioning, and hole patterns), installation, and even storage are all factors in a bearing's success or failure.
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ClampDisk micro fastener is new alternative for automotive and consumer electronics

Designed as a unique alternative in assemblies for the automotive and consumer electronics markets, the ClampDisk Press-on Fastener is a new offering from PennEngineering that delivers a fast, simple way to achieve sheet-to-sheet clamped fastening while replacing the use of standard screws, nuts, and adhesives. The most common challenges that can be eliminated or reduced by using ClampDisk include over installation, cross threading, stripped screw heads, broken screws, and damaged product. This fastener can be removed easily with a sharp-edged tool.
Learn more and see how ClampDisk works.

New nylon constant torque hinge

Southco has expanded its line of E6 Constant Torque Hinges with a compact, nylon version designed for small applications. The newest addition to the company's E6 50 Constant Torque Position Control Hinge series measures 45 mm with a torque range of 4 to 16 in./lb and is 65% lighter compared to the standard E6 50 Hinge. It provides constant resistance throughout the entire range of motion, enabling users to easily position doors, display screens, and other mounted components and hold them securely at any desired angle.
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What injection molding material do I use?

How do you decide what type of plastic to use for your next injection molding project? Xometry can help you narrow your choices. Discover the different strengths and applications for materials that could be ideal for your application by learning about the most common plastic injection molding materials in detail.
Read this detailed Xometry article.

What are carbon composite bellows springs?

The Carbon Composite Bellows Spring (CCBS) from MW Components is a system of carbon fiber elements that combine to work as a high-performance, lightweight, and design-flexible compression spring meant to replace coil springs or metallic Belleville disc springs. A functional spring is made from several individual elements paired and joined to make a stack. The stack spring rate is determined by the number of elements, the base rate of each element, and their series or parallel orientation in the stack. Applications include motorsports, aerospace, and high-performance activities.
Learn more.

Conductive Brush Ring overcomes current leakage in EV powertrains

SKF's new Conductive Brush Ring paves the way to greater reliability and longer life in high-performance electric vehicle powertrain systems. Using pure carbon fiber bristles, it provides a reliable electrical connection between an EV eAxle rotor shaft and its housing. When used in combination with SKF Hybrid ceramic ball bearings, it helps to alleviate parasitic current effects that can lead to premature failure in bearings and other components. Available in different configurations for wet (oil-lubricated) motor designs -- and soon for dry (sealed) applications.
Learn more.

hyperMILL 2024 CAD/CAM software suite

OPEN MIND Technologies has introduced its latest hyperMILL 2024 CAD/CAM software suite, which includes a range of powerful enhancements to its core toolpath capabilities, as well as new functionality for increased NC programming efficiency in applications ranging from 2.5D machining to 5-axis milling. New and enhanced capabilities include: Optimized Deep Hole Drilling, a new algorithm for 3- and 5-axis Rest Machining, an enhanced path layout for the 3D Plane Machining cycle, better error detection, and much more.
Learn more.

One-part epoxy changes from red to clear under UV

Master Bond UV15RCL is a low-viscosity, cationic-type UV-curing system with a special color-changing feature. The red material changes to clear once exposed to UV light, indicating that there is UV light access across the adhesive material. Although this change in color from red to clear does not indicate a full cure, it does confirm that the UV light has reached the polymer. This epoxy is an excellent electrical insulator. UV15RCL adheres well to metals, glass, ceramics, and many plastics, including acrylics and polycarbonates.
Learn more.

SPIROL Press-N-Lok™ Pin for plastic housings

The Press-N-Lok™ Pin was designed to permanently retain two plastic components to each other. As the pin is inserted, the plastic backfills into the area around the two opposing barbs, resulting in maximum retention. Assembly time is quicker, and it requires lower assembly equipment costs compared to screws and adhesives -- just Press-N-Lok™!
Learn more about the new Press-N-Lok™ Pin.

Why hybrid bearings are becoming the new industry standard

A combination of steel outer and inner rings with ceramic balls or rollers is giving hybrid bearings unique properties, making them suitable for use in a wide range of modern applications. SKF hybrid bearings make use of silicon nitride (twice as hard as bearing steel) rolling elements and are available as ball bearings, cylindrical roller bearings, and in custom designs. From electric erosion prevention to friction reduction and extended maintenance intervals, learn all about next-gen hybrid bearings.
Read the SKF technical article.

3M and Ansys train engineers on simulating adhesives

Ansys and 3M have created an advanced simulation training program enabling engineers to enhance the design and sustainability of their products when using tapes and adhesives as part of the design. Simulation enables engineers to validate engineering decisions when analyzing advanced polymeric materials -- especially when bonding components made of different materials. Understand the behavior of adhesives under real-world conditions for accurate modeling and design.
Read this informative Ansys blog.

New FATH T-slotted rail components in black from AutomationDirect

Automation-Direct has added a wide assortment of black-colored FATH T-slotted hardware components to match their SureFrame black anodized T-slotted rails, including: cube connectors (2D and 3D) and angle connectors, joining plates of many types, brackets, and pivot joints. Also included are foot consoles, linear bearings in silver and black, cam lever brakes, and L-handle brakes. FATH T-slotted hardware components are easy to install, allow for numerous T-slotted structure configurations, and have a 1-year warranty against defects.
Learn more.

Weird stuff: Moon dust simulant for 3D printing

Crafted from a lunar regolith simulant, Basalt Moon Dust Filamet™ (not a typo) available from The Virtual Foundry closely mirrors the makeup of lunar regolith found in mare regions of the Moon. It enables users with standard fused filament fabrication (FFF) 3D printers to print with unparalleled realism. Try out your ideas before you go for that big space contract, or help your kid get an A on that special science project.
Learn more.

Break the mold with custom injection molding by Rogan

With 90 years of industry experience, Rogan Corporation possesses the expertise to deliver custom injection molding solutions that set businesses apart. As a low-cost, high-volume solution, injection molding is the most widely used plastics manufacturing process. Rogan processes include single-shot, two-shot, overmolding, and assembly. Elevate your parts with secondary operations: drilling and tapping, hot stamping, special finishes, punch press, gluing, painting, and more.
Learn more.

Green steel made from toxic red mud in new economical process

The production of aluminum generates around 180 million tons of toxic red mud every year. Scientists at the Max Planck Institute for Iron Research (Dusseldorf, Germany), a center for iron research, have now shown how green steel can be produced from aluminum production waste in a relatively simple way.

In an electric arc furnace similar to those used in the steel industry for decades, they convert the iron oxide contained in the red mud into iron using hydrogen plasma. With this process, almost 700 million tons of CO2-free steel could be produced from the 4 billion tons of red mud that have accumulated worldwide to date, which corresponds to a good third of annual steel production worldwide. As the Max Planck team shows, the process would also be economically viable.

According to forecasts, demand for steel and aluminum will increase by up to 60% by 2050. However, the conventional production of these metals has a considerable impact on the environment. Eight percent of global CO2 emissions come from the steel industry, making it the sector with the highest greenhouse gas emissions. Meanwhile, the aluminum industry produces around 180 million tons of red mud every year, which is highly alkaline and contains traces of heavy metals such as chromium.

In Australia, Brazil, and China, among others, this waste is at best dried and disposed of in gigantic landfill sites, resulting in high processing costs. When it rains heavily, the red mud is often washed out of the landfill, and when it dries, the wind can blow it into the environment as dust. In addition, the highly alkaline red mud corrodes the concrete walls of the landfills, resulting in red mud leaks that have already triggered environmental disasters on several occasions, for example in China in 2012 and in Hungary in 2010. In addition, large quantities of red mud are also simply disposed of in nature.

Potential to save 1.5 billion tons of CO2 in the steel industry
"Our process could simultaneously solve the waste problem of aluminum production and improve the steel industry's carbon footprint," says Matic Jovicevic-Klug, who played a key role in the work as a scientist at the Max Planck Institute for Iron Research. In a study published in the journal Nature, the team shows how red mud can be utilized as a raw material in the steel industry. This is because the waste from aluminum production consists of up to 60% iron oxide.

The Max Planck scientists melt the red mud in an electric arc furnace and simultaneously reduce the contained iron oxide to iron using a plasma that contains 10% hydrogen. The transformation, known in technical jargon as plasma reduction, takes just 10 min., during which the liquid iron separates from the liquid oxides and can then be extracted easily. The iron is so pure that it can be processed directly into steel.

The remaining metal oxides are no longer corrosive and solidify on cooling to form a glass-like material that can be used as a filling material in the construction industry, for example. Other research groups have produced iron from red mud using a similar approach with coke, but this produces highly contaminated iron and large quantities of CO2. Using green hydrogen as a reducing agent avoids these greenhouse gas emissions.

"If green hydrogen would be used to produce iron from the four billion tons of red mud that have been generated in global aluminum production to date, the steel industry could save almost 1.5 billion tons of CO2," says Isnaldi Souza Filho, research group leader at the Max Planck Institute for Iron Research.

An economical process, including with green hydrogen and electricity
The heavy metals in the red mud can also be virtually neutralized using the process. "After reduction, we detected chromium in the iron," says Jovicevic-Klug. "Other heavy and precious metals are also likely to go into the iron or into a separate area. That's something we'll investigate in further studies. Valuable metals could then be separated and reused." Additionally, heavy metals that remain in the metal oxides are firmly bound within them and can no longer be washed out with water, as can happen with red mud.

However, producing iron from red mud directly using hydrogen not only benefits the environment twice over; it pays off economically too, as the research team demonstrated in a cost analysis. With hydrogen and an electricity mix for the electric arc furnace from only partially renewable sources, the process is worthwhile, if the red mud contains 50% iron oxide or more. If the costs for the disposal of the red mud are also considered, only 35% iron oxide is sufficient to make the process economical.

With green hydrogen and electricity, at today's costs -- also taking into account the cost of landfilling the red mud -- a proportion of 30 to 40% iron oxide is required for the resulting iron to be competitive on the market.

"These are conservative estimates, because the costs for the disposal of the red mud are probably calculated rather low," says Souza Filho. There's another advantage from a practical point of view: Electric arc furnaces are widely used in the metal industry, including in aluminum smelters, as they are used to melt down scrap metal. In many cases, the industry would therefore need to invest only a little to become more sustainable.

"It was important for us to also consider economic aspects in our study," says Dierk Raabe, director at the Max Planck Institute for Iron Research. "Now it's up to the industry to decide whether it will utilize the plasma reduction of red mud to iron."

Source: Max Planck Institute for Iron Research

Published February 2024

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