Savings can be achieved by improving energy efficiency, which reduces the amount of electricity consumed. Savings can also be easily achieved by making slight changes to the timing of this consumption, thereby reducing the peak electricity demand.

Large heat-treating facilities are substantial electricity consumers. Specializing in vacuum heat treating and brazing for aerospace and other high-technology industries, VAC AERO International’s Oakville, Ontario, plant operates more than 24 vacuum, air and controlled-atmosphere furnaces. Included are three very large vacuum oil-quench furnaces, all of which result in substantial electricity consumption. Indeed, the company’s electricity costs have increased by more than 30% in recent years, thereby driving an effort to find lower-cost solutions. by Mark Passalent

For maximum fuel efficiency, many gas turbine engine designs depend on sacrificial coatings to tighten internal clearances between moving parts. An extra gap of .005" between the rotating blades and the engine casing can increase fuel consumption by as much as 0.5%. As fuel comprises more than half of direct operating costs, this waste can be significant. Engine efficiency largely depends on close clearance between blades and casing. Clearance can be affected by a number of engine operating variables, including casing expansion and contraction, loading due to maneuvering, thrust, gust, stall, vibration and manufacturing tolerances. An industrial turbine engine manufacturer was experiencing unsatisfactory results with the ring segment coatings used to maintain rotor-shroud clearance. Because of poor abradability, the coatings caused excessive wear on the tips of the turbine blades. The engine manufacturer and VAC AERO agreed to work cooperatively to develop an improved abradable coating for these applications.

When joining aluminum for aerospace electronics, brazing often is the most practical choice for creating a continuous all-metal joint interface. Because of its light weight and excellent thermal conductivity, aluminum often is the material of choice for assemblies that house or cool airborne electronics. These complex assemblies often are manufactured from numerous individual components that must be joined. There are many ways to join aluminum including mechanical fastening (screws, rivets, etc.), adhesive bonding, welding and brazing. The selection of a joining process must be based on a careful analysis of the service requirements and the materials involved. 

Because of its light weight and good thermal conductivity, aluminum is often the material of choice for assemblies that house or cool electronics. These complex assemblies often are manufactured from numerous individual components that must be joined. There are many ways to join aluminum including mechanical fastening (screws, rivets, etc.), adhesive bonding, welding and brazing. The selection of a joining process must be based on a careful analysis of the service requirements and the materials involved.