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South Florida’s Additive Manufacturing Industry Discussed at FIU Conference
Florida International University (FIU), Miami, Fla., held a conference on January 25–26 titled Pioneering Additive Manufacturing in South Florida. The conference highlighted the region’s advanced manufacturing boom.
“I was struck by a [remark] yesterday stating, ‘You know, often people associate North Florida with defense and South Florida with Mickey Mouse,’ and that’s clearly not the case here,” said Neal Orringer, CEO of Applied Science & Technology Research Organization of America (ASTRO America), a research institute devoted to advancing the public interest through manufacturing technology and policy and organizer of the conference. “There’s a substantial amount of research, development, and investment here, particularly in the Miami area alone.”
The conference actively engaged local businesses and stakeholders in exploring expanding 3D printing capabilities and fostering local innovation ecosystems, shedding light on the significant impact of Florida’s manufacturing sector on the state’s economy. Manufacturing has notably outpaced key industries, including tourism, agriculture, and transportation, solidifying Florida’s standing as a robust manufacturing state.
“Since 2014, the growth rate of GDP [gross domestic product] for manufacturing in the state of Florida has outpaced the growth rate of additive manufacturing in the top eleven states in the U.S.,” said Matthew R. Rocco, president of the South Florida Manufacturers Association.
The event took place just months after the introduction of a new FIU lab dedicated to researching advanced manufacturing techniques. Headed by Professor Arvind Agarwal, the Cold Spray and Rapid Deposition Laboratory explores techniques such as cold spray, plasma spray, and wire arc additive manufacturing. It is funded by a five-year, $22.9 million grant from the U.S. Army Combat Capabilities Development Command Army Research Laboratory.
South Florida’s additive manufacturing industry has transitioned from a once-fringe sector to a strong force, as evidenced by the substantial growth in GDP and the state’s commitment to technological leadership. With a clear trajectory toward becoming one of the top five manufacturing states by 2030, the region’s dedication to innovation ensures a promising future marked by a resilient economy, increased average wages, and amplified global trade opportunities.
Apply for a $2000 ITSA Scholarship
Applications for the International Thermal Spray Association’s (ITSA’s) Scholarship Program will be accepted until August 30. Up to three one-year scholarships worth $2000 each may be awarded. Since 1991, the ITSA Scholarship Program has contributed to the growth of the thermal spray community, especially the development of new technologists and engineers.
To be considered, applicants must meet all of the following criteria:
Be actively pursuing a postgraduate degree in thermal spray processes (plasma, flame, arc, high-velocity oxygen fuel) or materials at an accredited U.S. university,
Have at least one year of studies remaining after this year,
Be recommended by a supervisor/professor of the university they are attending (the student’s financial need must be verified by a professor. The student must also be recommended by at least one industrial source), and
Present an essay about their interest in pursuing a career in thermal spray (maximum of three typed pages).
The application can be accessed at aws.org/About/Industry-Partners/ITSA/ITSA-Scholarship. Winners will be announced in the fall.
SSP Joins SEAM for Peening and Protective Coating Solution
Superior Shot Peening (SSP), Houston, Tex., has partnered with Surface Engineering for Advanced Materials (SEAM), Swinburne University, Melbourne, Australia. The industrial project focuses on developing peening and protective coating technologies for application in inside diameters of pipelines used in oil and gas industries. The collaboration aims to deliver a solution for addressing corrosion and durability issues in the field.
28th Maintenance Group’s Additive Manufacturing Flight Uses Mobile Cold Spray System
The 28th Maintenance Group’s (MXG’s) Additive Manufacturing Flight (AMF) became the first field-level unit to utilize the new Mobile Cold Spray System (MCSS) at Ellsworth Air Force Base, S.Dak., on March 27.
This system is designed to enhance and streamline preventative maintenance of Department of Defense aircraft components. It was developed in partnership with VRC Metal Systems, South Dakota School of Mines & Technology, and the Advanced Manufacturing Program Office from Wright-
Patterson Air Force Base.
“With mobile cold spray, we can take this technology to the warfighter,” said AMF Director and Chief Dr. Brian James. “We’re very excited and honored to work with VRC Metals Systems and the South Dakota School of Mines and Technology to make Ellsworth the first to implement the Mobile Cold Spray System for our airmen.”
The MCSS is built from a convex box equipped with various workstations necessary to conduct cold spray techniques and other material testing procedures remotely from a conventional rooted laboratory. Due to its compact design and outfitted dimensions when resting on its trailer platform, the MCSS meets continental United States roadway and cargo plane transportation requirements.
The AMF currently conducts cold spray operations to support preventative maintenance on B-1 aircraft; however, transporting cold spray equipment from the laboratory to the flightline when necessary is not simple.
“Cold spray involves hoses, nozzles, and gas, which can take a significant amount of time to assemble,” said Staff Sergeant Chynna Patterson, 28th MXG additive manufacturing lead technician. “Having the mobilized cold spray system accessible means that we can reduce equipment setup time when we need to perform on-site maintenance of the parked aircraft.”
With the MCSS being designed, fabricated, and implemented at Ellsworth Air Force Base, the number of mission-capable aircraft will increase. — Airman 1st Class Dylan Maher, Ellsworth Air Force Base 28th Bomb Wing
Rice University Students Build Low-Cost Cold Spray Metal 3D Printer Prototype
A team of students from Rice University, Houston, Tex., has developed a cold spray metal 3D printing device that relies on pressure and velocity rather than temperature to create a metal part. Their work could help expand the repertoire of metal additive manufacturing techniques, reducing costs and enhancing the quality of making or repairing one-off complex metal parts.
Team AeroForge members — Eli Case, Julianna Dickman, Garrett French, Galio Guo, Douglas Hebda, Grant Samara, Davis Thames, and Aasha Zinke — used the device to successfully deposit copper, demonstrating the viability and potential of their prototype. The project won an Excellence in Capstone Engineering Award and first place in the Willy Revolution Award for Outstanding Innovation at the annual Huff OEDK Engineering Design Showcase. The project is also the recipient of this year’s Hershel M. Rich Invention Award.
Applications for the device include the manufacture and repair of metal parts with a complex structure, such as components used in industrial assembly lines or vehicles or aircraft. Industries that rely on metal components — automotive, oil and gas, defense — can incur significant losses due to supply chain disruptions, so the team hopes its device can provide a viable, low-cost alternative for making or repairing parts on demand.
The device consists of a gas tank that feeds high-pressure nitrogen gas into the system; controls that regulate valves and monitor pressure and temperature; a pressure vessel that heats the gas to 842°F; a powder feeder designed to dispense metal powder into a nozzle at a precise rate; and a custom nozzle.
Many of the team’s efforts focused on reducing costs, because most metal 3D printers can cost over $1 million. Team AeroForge built its device for less than $5000.
“One of our big innovations here is making the system so much cheaper,” Samara said. “A lot of our parts were machined in house, for instance the pressure vessel, because that’s potentially a very dangerous thing. Other parts, like the nozzle, are proprietary, so it’s not something that you can find elsewhere. The nozzle is a very difficult part to manufacture; we had to develop new processes to make it.”
Case, who worked on the nozzle and heater design and on the software, said that one of the main takeaways from the project for him was the importance of having people with different areas of expertise working together. Another takeaway was how critical it is to build more room for contingency in the project timeline. Hebda confirmed that for the team, it had been “pedal to the metal trying to fix the designs that were not going to work.”
French, who had a lot of hands-on hardware design experience as part of the engineering design minor, emphasized that “this team is just very motivated — it is a handpicked team, and this is also a student-pitched project . . . We are all people that signed up for a particularly hard project.” — Rice University
Integrated Global Services Credited for Role in Mega Turnaround
Integrated Global Services (IGS), Richmond, Va., has been recognized as a major contributor to the successful Ras Tanura Refinery (RTR) 2024 mega turnaround and inspection (T&I) for Saudi Arabian Energy Co. (Aramco). The RTR complex is Aramco’s largest refinery and the biggest in the Middle East.
The award was presented to IGS at a ceremony on May 7 for its support and efforts in helping lead the RTR 2024 mega T&I.
The RTR turnaround involved over 8000 workers, 6.9 million labor hours, and 5000+ scope items over a multiweek period. It is projected to yield over $26.7 million in benefits for the energy company through enhanced efficiency, optimized fuel consumption, reduced emissions, and other improvements.
IGS’s high-velocity thermal spray cladding technology and Cetek fired heater efficiency coating were highlighted as key innovations deployed during the turnaround. IGS’s metal spray technology enhanced the integrity and lifespan of the crude unit desalination column overhead line, while the Cetek coating enhanced efficiency and optimized fuel consumption by 1 million standard cubic feet per day. The coatings also reduced greenhouse gas emissions by 19,722 metric tons per year.
Al Muhannad Al Johani, general manager of IGS Saudi Arabia, said, “At IGS, we believe that true sustainability in the energy sector is achieved through partnership. Our collaboration with Aramco on the Ras Tanura Refinery’s 2024 mega turnaround is a prime example of how combining our expertise with our client’s objectives leads to groundbreaking results. Together, we’ve not only enhanced operational efficiency but also set new benchmarks in environmental conservation. This project underscores our commitment to working alongside our clients to forge a more sustainable and efficient future.”
Aramco credited proper planning, collaboration, and innovation as critical factors allowing the mega turnaround to be completed safely, ahead of schedule, and with top results compared to global refinery benchmarks.
The incident-free project is being celebrated as a major achievement for Aramco’s largest asset and a model for future turnarounds across the company’s operations.
Kennametal Enhances Turning Platform with Coated Inserts
Kennametal Inc., Pittsburgh, Pa., has expanded one of its turning platforms with additional inserts. The KCP25C platform features advanced coating technology KENGold™, which improves toughness, abrasion resistance, and consistency.
“The KCP25C turning platform has set a new standard with its performance, achieving higher metal removal rates and improved wear resistance,” said Scott Etling, Kennametal’s vice president of global product management. “Growing the portfolio allows us to support customers’ ever-evolving needs and address their toughest machining challenges.”
The turning platform now includes additional ISO turning inserts to complete the portfolio, Top Notch™ profiling inserts, and railroad turning inserts.
Leveraging advanced pressing and honing technologies, the company has achieved consistently tight tolerance levels with KENGold, the advanced coating technology introduced last year.
“This next-generation coating technology is multilayer to not only protect against wear but act as a strong thermal barrier and resist chipping for more reliable, increased cutting speeds, higher metal removal rates, and consistent tool life,” added Etling.
KCP25C is ideal for roughing, finishing, and medium finishing in general engineering, automotive oil and gas, and wind and solar industries.
Höganäs Honored as Partner of the Year by Mitsubishi Heavy Industries
Höganäs, Höganäs, Sweden, a metal powders producer, received the Partner of the Year award from the gas turbine combined cycle (GTCC) business division of Mitsubishi Heavy Industries (MHI), Tokyo, Japan.
The Partner of the Year award signifies the collaboration between the two companies, highlighting the synergy, trust, and mutual respect that have defined the relationship between them. Höganäs received the award for its performance regarding quality and supply and the stable supply of thermal spray powder for MHI’s gas turbine.
“We are immensely honored to be named Partner of the Year 2023 from the GTCC business division of Mitsubishi Heavy Industries,” said Hans Keller, president of coating and brazing technologies. “This award is a reflection of the hard work, dedication, and passion exhibited by every member of our team. It reaffirms our commitment to forging strong partnerships and exceeding the expectations of our customers.”