What are Advanced Metals?

Advanced Metals, also known as high-performance metals or advanced materials, refer to a class of metallic materials that possess exceptional mechanical, physical, and chemical properties compared to traditional metals. These metals are engineered to exhibit superior strength, hardness, corrosion resistance, heat resistance, electrical conductivity, and other desirable characteristics. They are used in a wide range of industries and applications where standard metals may not meet the specific requirements. Some examples of advanced metals include:

• Titanium alloys
• Nickel-based alloys
• Stainless steel alloys
• Aluminium alloys
• High-strength steel
• Refractory metals
• Shape memory alloys
• Magnesium alloys

The development and utilisation of advanced metals have revolutionised various industries by enabling the creation of innovative products and technologies. These materials offer improved performance, durability, efficiency, and functionality compared to traditional metals, opening up new possibilities in engineering design and manufacturing.

Process Cooling and Advanced Metals

Process cooling equipment plays a crucial role in advanced metals research and production by controlling and maintaining specific temperatures during various stages of the manufacturing process. Some examples of how process cooling equipment is utilised in relation to advanced metals include:

Heat removal during metal casting

• In metal casting processes, molten metals are poured into moulds to obtain the desired shape. Process cooling equipment is used to rapidly cool the moulds after casting. This helps in solidifying the metal and achieving the desired microstructure and mechanical properties. Efficient heat removal ensures proper solidification and minimises defects like porosity or shrinkage.

Heat treatment during annealing

• Heat treatment and annealing processes are commonly employed to improve the mechanical properties of advanced metals. These processes involve heating the metal to specific temperatures and then cooling it at controlled rates. Process cooling equipment is used to control the cooling rate during quenching or annealing. Precise temperature control is critical to achieve the desired material properties and prevent unwanted transformations.

Cooling in metal forming processes

• Advanced metals often undergo various forming processes, such as rolling, extrusion, or forging, to shape them into the desired forms. Process cooling equipment is used to remove the heat generated during forming, preventing excessive temperature rise that can lead to material defects or reduced dimensional accuracy. Heat exchangers or cooling systems help to maintain the metal at an optimal temperature, ensuring proper formability and dimensional stability.

Welding and joining operations

• Welding and joining operations are common in advanced metals research and production. These processes generate significant heat, which can affect the metallurgic properties of the joined materials. Process cooling equipment is used to cool the welded joints rapidly. This controls the cooling rate, preventing the formation of undesirable microstructures or cracks, and ensures proper joint stability.

Control of process temperatures

• Process cooling equipment is used to control and maintain precise temperatures during various stages of advanced metals research and production. Cooling systems help to achieve the desired temperature range for specific processes like heat treatment, annealing, or material testing. Consistent temperature control is essential for obtaining reproducible results, ensuring quality, and meeting stringent specifications.

Environmental control:

• In some advanced metals research and production processes, maintaining a controlled environment is crucial. Process cooling equipment can help to regulate the temperature and humidity levels in the production area. This ensures stable process conditions and minimises the impact of ambient variations on material properties or process stability.

 

Recirculating Chillers

Recirculating chillers are widely employed in advanced metals research and production. These self-contained units circulate a heat transfer fluid to remove heat from the process. Recirculating chillers offer several benefits in advanced metals research and production, including:

Precise temperature control:

• Recirculating chillers provide precise temperature control, allowing researchers and manufacturers to maintain a consistent and controlled temperature environment during various stages of advanced metals processing. This level of temperature control is crucial for achieving the desired material properties, optimising process conditions, and ensuring repeatability in experiments or production runs.

Efficient heat removal:

• Advanced metals processes often generate significant amounts of heat that need to be efficiently removed to maintain optimal working conditions. Recirculating chillers excel at heat removal, efficiently transferring heat away from the process equipment or components. The chillers circulate a heat transfer fluid which absorbs heat from the process and then cools it down before recirculation. This efficient heat removal helps to prevent overheating, minimises the risk of material deformation or damage, and enhances overall process efficiency.

Wide temperature range:

• Recirculating chillers offer a wide temperature range, allowing researchers and manufacturers to cool their processes to specific temperature setpoints. Whether the application requires sub-ambient temperatures, room temperature, or elevated temperatures, recirculating chillers can be adjusted to accommodate the desired temperature range. This flexibility is particularly valuable in advanced metals research and production, where different materials and processes may have specific temperature requirements.

Compact and self-contained design:

• Recirculating chillers feature a compact and self-contained design, making them easy to install and integrate into existing research or production setups. They typically include a pump, compressor, evaporator, condenser, and control system, all housed within a single unit. The compact design saves valuable space in laboratories or production facilities and allows for convenient placement near to the process equipment or workstations where cooling is needed.

Low maintenance requirements:

• Recirculating chillers are designed for long-term operation with minimal maintenance requirements. They often incorporate features such as built-in filters and self-diagnostic systems that help to ensure the reliable and efficient functioning of the equipment. This low-maintenance nature allows researchers and manufacturers to focus on their core activities without significant downtime or maintenance-related disruptions.

Safety and environmental considerations:

• Recirculating chillers offer enhanced safety features, including temperature and pressure controls, safety alarms, and automatic shutdown mechanisms. These features help to prevent system failures, protect the equipment, and mitigate potential risks associated with temperature fluctuations or abnormal operating conditions. Furthermore, recirculating chillers are designed with environmental considerations in mind. They may use eco-friendly refrigerants, feature energy-saving modes, and may incorporate insulation or noise reduction measures.

Versatility and compatibility:

• Recirculating chillers are versatile and compatible with a wide range of advanced metals processes and applications. They can be used in various research or production scenarios, including heat treatment, annealing, welding, casting, machining, or material testing. Recirculating chillers can be easily integrated into existing setups, and their temperature and flow rate can be adjusted to suit specific process requirements.

 

Heat Exchangers

Heat exchangers are devices that transfer heat from one fluid to another without direct contact. They are used in advanced metals research and production to control temperature during processes like heat treatment, annealing, or welding. Heat exchangers offer several benefits in advanced metals research and production, including:

Efficient heat transfer:

• Heat exchangers are designed to efficiently transfer heat between two fluids, typically the process fluids and a heat transfer fluid. They provide a large surface area for heat exchange, allowing for effective heat transfer and efficient cooling of the advanced metals process. This efficient heat transfer helps to maintain precise temperature control, prevent overheating, and optimise process conditions.

Temperature control:

• Heat exchangers enable precise temperature control by adjusting the flow rate and temperature of the heat transfer fluid. This control allows researchers and manufacturers to maintain a specific temperature range required for different stages of advanced metals processing, such as heat treatment, annealing, or welding. Accurate temperature control is critical for achieving the desired material properties, ensuring consistent results, and meeting stringent specifications.

Scalability:

• Heat exchangers are scalable, meaning they can be designed and sized to accommodate the cooling demands of various research or production setups. Whether it is a small-scale laboratory experiment or a large-scale industrial operation, heat exchangers can be customised to match the heat load and cooling requirements of the specific application.

Customisable configurations:

• Heat exchangers can be customised to meet specific requirements in advance coatings research and production. They are available in various configurations which can be tailored to the specific needs of the coating process. Customisable configurations ensure compatibility with different coating equipment and enables optimal heat transfer performance.

Space efficiency:

• Heat exchangers are designed to be compact and space-efficient, making them suitable for installations where space is limited. Their compact size allows for easy integration into existing coating systems or equipment, optimising the use of available space in research laboratories or production facilities. Heat exchangers can be installed in confined areas or mounted directly onto coating equipment, minimising the footprint, and maximising operational efficiency.

Process safety:

• Heat exchangers enhance process safety in advanced coatings by providing a reliable and controlled method of heat transfer. They help to prevent overheating of the coating material, which can lead to quality issues or safety hazards. Heat exchangers ensure that the coating process remains within the desired temperature range, minimising the risk of thermal damage, material degradation, or equipment failures.

Compatibility with high-temperature applications:

• Advanced metals processes often involve high temperatures that require efficient cooling solutions. Heat exchangers are capable of handling high-temperature applications, making them suitable for use in heat treatment, casting, or other processes where temperatures can reach extreme levels. They are designed to withstand the temperature and pressure requirements of advanced metals research and production.

Improved process control and product quality:

• The precise temperature control provided by heat exchangers ensures consistent process conditions and material properties in advanced metals research and production. Maintaining a stable temperature environment reduces the risk of material defects, improves dimensional accuracy, enhances metallurgic transformations, and leads to high-quality finished products. Heat exchangers play a crucial role in achieving the desired material characteristics and meeting strict industry standards.

The selection of process cooling equipment depends on various factors, including the specific requirements of the advanced metals process, cooling capacity needed, temperature range, and environmental considerations. Different cooling equipment options can be employed individually or in combination to meet the cooling requirements of the specific research or production setup.