Electro Magnetic

Impact

Treatment

Goals and vision

Nomasico’s main activity is the introduction and management of novel industrial services

and products, with the prospect of introducing significant changes in manufacture via the

introduction and establishment its innovative techniques.

Nomasico Strategic goals

Development, management and realization of novel production methods and services.

Clientele selection in accordance to preset selection criteria.

Focus on the client and configuration of novel solutions with regard to the specific needs.

Constant quality improvement of processes, services and methods.

Continuous development on novel technologies and investigation of existing novel processes to

broader fields of application.

Outline

Industrial applications Naval

Crankshaft

Piston Crown

Exhaust Valve Spindle & Seat

Exhaust Valve Housing

Cylinder Cover

Heat Exchanger

Aerospace

Landing gear

Gas turbine engines

Propeller hubs

Hydraulics

Agriculture

Chisel ploughs

Plough shoes

Cultivator disk

Crushers

Blades

Automotive

Gearshift fork

Door locks

Body parts

Brakes

Cylinder liners / sleeves

Construction

Grader blades

Bulldozer components

Trenchers

Drilling

Asphalt and concrete pavers

Defense & homeland security

Blisks

MEMS

Tracked vehicles

Track pins

Hard Chrome replacement

Gas & oil

Rollers

Loaders

Stabilizers

Drill collars

Valve components

Energy production

Turbine blade sand diaphragms

Steam bypass top valves

Pump shafts

Water wall panels

Transport

Ballast sprocket

Skirt plate

Retarder yoke

Axle box

Work hardening, also known as strain hardening or cold working, is the strengthening of a

metal by plastic deformation occurring due to dislocation movements within the crystal

structure of the material.

Many non-brittle metals with a reasonably high melting point as well as several polymers

can be strengthened in this fashion.

Alloys not amenable to heat treatment, including low-carbon steel, are often work-

hardened.

Some materials cannot be work-hardened at low temperatures, such as indium, however

others can only be strengthened via work hardening, such as pure copper and aluminum

Work Hardening

Advantages

No heating required

Better surface finish

Superior dimensional control

Better reproducibility and interchangeability

Directional properties can be imparted into

the metal

Contamination problems are minimized

Work Hardening Advantages & Disadvantages

Disadvantages

Greater forces are required

Heavier and more powerful equipment and tooling

required

Metal is less ductile

Metal surfaces must be clean and scale-free

Intermediate annealing may be required to compensate

for loss of ductility that accompanies strain hardening

The imparted directional properties may be detrimental

Undesirable residual stress may be produced

The technological evolution and the modern composite and complex structures, combined with the

shrinkage of natural resources, demands the strengthening and metal fatigue life extension of components.

Airframe, wing skins and undercarriage

protection from fatigue and stress

corrosion cracking.

Aero-engine or turbine protection by

adding beneficial compressive stresses.

Maximize the fatigue-life of components

which have complex geometries such as

fans, rotors, hub-propeller connector,

impellers, ball bearings.

Fatigue-life maximization of cockpit and

cabin frames, metallic frames and

fastening systems, wheels and brakes,

internal or external metal sheets.

Applications Aeronautics

Applications

Improving life and performance for suspension, gears and transmission including crankshafts, connecting rods,

Valves, pistons, cam shafts, cylinder heads and blocks.

Enhancing fatigue loading of metal components such as aluminum breaks, brake drums, injectors.

Improvements in surface stress and finish in competitive automotive (i.e. F1) that increases the endurance limit

of 20-30% with life extension up to 30 times

Automotive

Maintenance support and quality enhancement in materials such as Ceramic, Steel,

Stainless Steel and Tungsten Carbide, materials used in military applications

Expanding the applications of Aeronautics specifically to Defense Aeronautics

Applications Defense

Protection for energy turbine components against erosion, fretting, fretting fatigue, fatigue and stress corrosion cracking (SCC).

Reproducibility, high uniformity, surface quality for treating high value parts such as low and high pressure blades, disks and bilsks, fans, rotors and stators, gears and gearboxes

Applications Energy

Protection from corrosive and high load conditions –Surgical Instruments

Improved tissue adhesion - Orthopedic prosthesis and implants

Applications Medical

Material integrity against Thermal Fatigue Cracking and Stress Corrosion Cracking.

Fatigue-life improvement of Primary Pump Shaft, Pipes for reactor cooling, Partition

plates, J-weld

Applications

Nuclear

Enhancing the fatigue life performance of metal critical components used in Oil & Gas Implementations

Applications Oil & Gas

Typical applications of shipping construction and repair

Diesel Engine Fatigue sensitive parts

Cam shafts

Crank shafts and counterweights

Connecting rods

Propulsion Turbine Fatigue sensitive parts

Shafts

Gears

Propeller

Applications Ship Const. & Repair

Typical applications of Transportation

Frogs

Switch blades

Welded railways structures

Boggies

Chassis parts

Applications Transportation

The market of Work Hardening seems to be a niche market.

All the competitive companies rely on their know-how and patented methods to attract

specific costumers.

The cost of services per application is very expensive due to the expensive equipment and

utilities.

Industry innovation will lead to application expansion.

Market Analysis

Competitors Pfeifer: High Frequency Impact Treatment

Curtiss-Wright Surface Technologies: Shot Peening, Laser

Peening, Coating Surfaces

Empowering Technologies: Ultrasonic Shot Peening, Ultrasonic

Impact Treatment

Lambda Technologies Group: Low Plasticity Burnishing,

Controlled Impact Burnishing

Applied Ultrasonics: Ultrasonic Impact Treatment

Laser peening

Competitors

Laser peening is a mechanical surface enhancement process. Using a high energy pulsed

laser beam, shock waves which are generated and propagate through the material are

responsible for inducing cold work into the microstructure and contributing to the

increased performance of the material. The laser peening process requires

a laser beam

a target

confining media.

The application of the overlays is crucial to the performance of the process and thus requires

time and extreme attention from certified technicians. Furthermore as any laser related process,

it is expensive.

The currently most popular available treatments include:

• Laser peening

• Ultrasonic Impact Treatment

• Low plasticity burnishing

By introducing a certain amount of plastic deformation these techniques produce a level of residual stress so as to

improve damage tolerance and fatigue or stress corrosion performance.

Competitive technologies In Ultrasonic Impact Treatment, ultrasonic waves are produced by an electro-

mechanical ultrasonic transducer, and applied to a workpiece.

An acoustically tuned resonator bar is caused to vibrate by energizing it with an

ultrasonic transducer. The energy generated from these high frequency impulses is

imparted to the treated surface through mandatory contact of specially

designed tools for impact treatment with freely movable strikers that are mounted

in a holder.

Ultrasonic Impact Treatment

Low plasticity burnishing is a method that provides surface

compressive residual stresses. The basic tool is a ball that is supported in a

spherical hydrostatic bearing. The tool is usually held in a CNC. The machine

tool coolant is used to pressurize the bearing with a continuous flow of fluid to

support the ball. The ball rolls across the surface of a component in a pattern.

The tool path and normal pressure applied are designed to create a distribution

of compressive residual stress.

Low Plasticity Burnishing

Competitive technologies

The nondestructive inspection of complex geometries and novel materials e.g.

sandwich structures has always been a challenge, leading to new techniques

based on laser‐induced resonant frequencies. These are based on excitation and

measurement of structural resonant frequencies thus determining characteristic

signatures of healthy structures. Possible defects alter or destroy the expected

frequency signatures, leading to their detection. The excitation is offered by

lasers which add great cost to the process.

As far as surface polishing and oxide removal is concerned, most treatments

involve the implementation of dangerous chemicals and ultrasonic vibrations.

The combination of ultrasonics, heat, and cleaning solutions is usually the

preferred strategy.

Such applications present several disadvantages such as the necessity for tanks (in

which the process takes place) and the use of solvents (subject to law limitations).

Aqueous solutions are also used, nevertheless are far less efficient.

VISAR

acid solution cleaning operation

Technical aspects This novel technological approach resolves problems encountered in critical elements in industrial systems. It is known that in the

competitive industrial environment a component is to operate under:

Elevated loading

Thermomechanical fatigue

Hostile environment

Furthermore, a failure can trigger a spiral of negative consequences ranging from economic losses to environmental disasters and even

loss of life. Conclusively, an approach with the capability to innovatively improve the condition in all types of metals is bound to be

greeted by the industry.

This novel technology aims at a contactless mechanical treatment of metallic and non-metallic surfaces

including:

• impact treatment

• cyclic deformation

• surface polishing

by tensile and/or compressive stresses with the ability of adjusting the direction and the

amplitude of the applied force vector in a:

• Faster

• Better

• Cheaper way

Technical aspects

Electric current passes through the body of the under treatment material. The waveform of this current is pulsed with the ability of controlling parameters including

Duty cycle

Period

Amplitude

A conductor is set on top of this thin insulating film, so as to transmit pulsed electric current during the duty of the pulsed current passing through the under treatment area.

The direction of the current on this conductor is either parallel or anti-parallel to the electric current passing through the under treatment material, thus causing tensile or compressive forces between the electric current conductor and the under treatment material respectively, and always vertical to the surface of the under treatment material. The waveform of these two simultaneously transmitted currents is pulsed. Thus, the force acting on the surface of the under treatment material, F, is either tensile or compressive to the surface of the under treatment material, following the Ampere’s law:

𝐹

𝐿= 2𝜇𝜇0

𝐼1𝐼2

𝑡 (1)

In case that currents I1 and I2 are equal in amplitude the force becomes:

𝐹

𝐿= 2𝜇𝜇0

𝐼2

𝑡 (2)

The sign of the force F indicates the character of the applied force, being either tensile or compressive, for parallel and anti-parallel current directions respectively.

The main principle-Set up I

The under treatment material is coated by a thin insulating film, which in turn is covered by a conductor.

Passing pulsed current through the under treatment material and the conductor results in tensile or compressive

forces on the surface of the under treatment material. Auxiliary conductors may be used to control the angle

(from -90 to +90 degrees with respect to the electric current conductor)

of the transmitted tensile and compressive forces on top of the surface of the under treatment material by

transmitting pulsed current of the proper amplitude and direction.

In this way, a contactless push-pull multidirectional

electromagnetic hammer is provided that can be

used for impact or cyclic deformation treatment.

The main principle-Set up II

The said forces are proportional to the product of the applied pulsed currents and

inversely proportional to the thickness of the thin insulating film. Large amount of

transmitted pulsed current may result in heavy deformation of the surface of the

under treatment cylinder, resulting even in polishing of its surface. In this case, the

applied forces are applied due to the short gap between the under treatment

cylinder and the surrounding tube.

An under treatment metallic cylinder is covered by a thin insulating film (2),

which in turn is covered by a surrounding metallic tube (7). the cylinder (6) is

treated by means of tensile or compressive forces, vertical to its surface, by

passing pulsed current through its body as well as through the surrounding

metallic tube (7).

The main principle-Various set ups

Specific Area coverage

Point focused coverage

Further applications Similar treatment can be also provided in non-conducting materials by means of covering them with

conducting elements. In this case, only compressive stresses can be applied on the surface of the under

treatment material.

Another implementation of the invention will be the removal of on surface oxides and polishing. The

difference in function is fundamental and based on the alteration of current parameters.

The specified device will also serve as a Non Destructive investigator by means of generating much

smaller forces, which, instead of treating the under treatment material, generate elastic waves, their

shape and size determining the stress level of the corresponding area of elastic wave generation,

propagation and detection.

Apart from that, the current use of electromagnetic forming and electromagnetic welding with

inductive counter-acting response requires elevated amounts of energy to properly operate in

electromagnetic forming and welding processes.

Analysis of results

Aluminium substrate treated with ferrite layer at 2000V-150kA

Aluminium substrate treated with ferrite layer at 2000V-150kA

Bronze substrate treated with ferrite layer at

2000V-150kA

Conclusions

We have presented a new method by which non-contact push and/or pull multidirectional electromagnetic

forces, applying tensile and/or compressive forces in metallic surfaces and compressive stresses in non-

metallic surfaces, are able to deliver non-contact mechanical treatment including impact treatment, cyclic

deformation, surface polishing, as well as contactless and efficient removal of surface oxidation, oxide

removal, electromagnetic forming and electromagnetic welding, advantageously possessing the ability of

adjusting the direction and the amplitude of the applied force vector.