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 Welcome
to our first issue of Acceleron Beams into the future.
With this newsletter, we hope to strengthen our working
relationship with you through frequent communications.
In each issue, we will highlight any additional services
taking place within Acceleron. As always, we strive to
stay current with the latest technology in the Electron
Beam and Laser industries. |
In
addition to bringing you the latest in technology, our newsletter
will introduce new Acceleron personnel. We would like to
invite you to share an article of interest that highlights
how Acceleron and your company have worked together to meet
a common goal of success. This article could also discuss
a product or technology that is new to your business.
Acceleron
is dedicated to assisting your company with the best possible
solution for your electron beam and laser requirements. As
a valued customer, your complete satisfaction is very important
to us. Please feel free to call me directly with any suggestions
as to how Acceleron can better serve you. We hope that you
find this first issue of our newsletter both informative
and enjoyable.
Sincerely,
Rory
Montano, President
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| Acceleron
Helps NASA and BAE Systems Launch New Technology |
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| Close-up
of the focal plane assembly, measuring only
2" x 3". |
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In
September of this year, NASA expects to launch an Atmospheric
Infrared Sounder (AIRS) aboard its spacecraft AQUA, as part
of its Earth Observing System mission. AIRS is a 390 lb.
instrument which utilizes satellite remote sensing technology
to provide highly accurate data about the atmosphere, land
and oceans for use in climate studies and improved weather
predictions. Of particular interest to the general population,
AIRS will allow forecasters to significantly improve and
extend weather predictions to seven-day forecasts (now, forecasts
are considered accurate up to 48 hours). AIRS's high resolution
spectrometer precisely samples the Earth's atmosphere from
the ground up to 30 miles. The
AIRS instrument contains a focal plane array which "observes" the
infrared signatures of carbon dioxide and water vapors in
order to determine temperature and moisture profiles.
The
AIRS concept originated more than 10 years ago, in 1990.
The project was contracted by NASA's Jet Propulsion Laboratory
to BAE Systems (then Lockheed Martin Infrared & Imaging Systems).
When BAE Systems moved from the concept phase to the design
and build phase of the project, they realized that the sheer
scope and complexity of the dewar assembly was beyond their
realm of expertise. The detector/dewar assembly is a sealed
vacuum vessel containing the focal plane assembly and infrared
transmitting window and electrical feedthroughs that transmit
the focal plane signals across the dewar wall to the AIRS
system. The technology required to actually build the sensing
device involved a multitude of unusual welds. BAE Systems
did not have this technology in-house, nor could they find
a local source for it. An extensive search for contract welding
firms led BAE Systems to Acceleron. BAE Systems brought some
sample parts to perform sample welds and reviewed all of
Acceleron's capabilities.
"Acceleron
had the capabilities, the equipment, and the knowledgeable
staff that we knew we needed to successfully complete the
AIRS project," said John Talbourdet, Development Engineer
at BAE Systems. "What really put Acceleron ahead of the competition
was their ability to perform different welding methods and
help with the engineering of stress-free welds, along with
the ability to perform Helium leak tests after each weld
to confirm the weld integrity."
As
parts for the focal plane assembly were developed, BAE Systems
solicited recommendations from Acceleron on which welding
techniques to employ. "Stress-free welds were integral to
the assembly of the detector. We relied on Acceleron's strong
engineering background and experience to develop the right
technique," recalled Talbourdet. The focal plane assembly,
or sensing device, measures only 2" x 3" and, therefore,
required very complex workmanship.
Acceleron's
Project Engineer, Bill Ross, particularly remembers one weldment
which was to be located very near a delicate piece of glass.
The material to be welded was Kovar to Kovar. Acceleron was
able to use a laser welding technique that would create a
stress-free weld that would not weaken or crack the glass.
Another
area in which BAE Systems requested our expertise was the
welding of dissimilar metals. One portion of the assembly
required the welding of Kovar to Stainless Steel. The configuration
called for welding from both sides of the piece and, again,
required little or no stress. When faced with what approach
to take, engineers from BAE Systems accompanied AIRS project
manager, Fred O'Callahan, from NASA's Jet Propulsion Laboratory,
to Acceleron to determine how best to proceed. When the final
weldments to the dewar (the vessel actually containing the
focal plane assembly) were performed, we essentially turned
over our lab and operators to BAE Systems for the entire
day. Because the AIRS instrument cost approximately $200
million and the infrared imaging device could not be replaced
without seriously impacting the project schedule, BAE Systems
wanted to ensure absolute success for this final step. By
dedicating our lab completely to the project for one day,
we had no outside distractions and had all of our engineers
on-hand for any troubleshooting that may have been necessary.
"Acceleron
was extremely accommodating every step of the way. They provided
many weld samples during the design phase and offered the
experience of their entire staff whenever necessary. We worked
with Engineer Bill Ross, President Rory Montano, Head of
the Laser Department Bob Pride, and many others. Whenever
we encountered a problem, they never hesitated to bring in
an expert from another department," stated Talbourdet.
We
at Acceleron would like to offer our expertise to you. From
the simplest to the most complex, whether your project takes
one day or one decade to complete, we have the knowledge
and equipment to meet your needs.
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Acceleron
Adopts Lean Manufacturing
In
an effort to become more efficient, Acceleron has adopted
the LEAN MANUFACTURING concept.
The
ultimate goal of this system is to produce quality
products through cost-reduction activities and a culture
that focuses on employee involvement through empowerment.
This, in turn, makes Acceleron more competitive, while
also shortening the lead-time for quality products.
Acceleron
will continue to provide high-quality products and
services while retaining employees and fostering a
company-wide culture that promotes continuous improvement
and empowerment.
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| Welding
for the New Millennium: Non-vacuum
Electron Beam |
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Acceleron
has recently been awarded a grant from the U.S. Department
of Energy and will work with Brookhaven National Laboratory
to bring Electron Beam Welding to a new level. Acceleron
has partnered with the Connecticut DEP on this project.
Electron
Beam Welding (EBW) is the highest-quality welding technique
currently in use. It can efficiently join dissimilar
metals without the disadvantages associated with other
methods — a growing necessity in high-tech manufacturing.
Until now, EBW has had a significant drawback that
limited its usefulness in heavy production: standard
EBW must be performed in an evacuated chamber under
vacuum usually at 1 x 10-4 torr. The chamber size is
also a restricting factor when dealing with different
parts in a large variety of sizes.
In
1996, Brookhaven National Laboratory's Dr. Ady Hershcovitch
received a patent for the plasma window. The plasma
window permits an electron beam, which must be formed
in a vacuum, to propagate efficiently into open air.
The plasma "window" is a stabilized gas plasma arc
that can reserve the hard vacuum required inside the
column but is transparent to the beam and allows it
to pass through uninhibited. Deployment of the plasma
window will eliminate the need for an EBW vacuum chamber
and make mobile EBW possible on workpieces of unlimited
size. Eliminating the vacuum chamber will afford a
direct energy savings of 30-40% and eliminate pollutants
associated with large-scale vacuum pumping.
Acceleron
will be the venue providing the working site for this
two-year venture, along with the technical staff to
assist with the assembly and operation of this prototype
machine on an industrial scale. We will be measuring
its performance and increased production levels. Come
back to our Web site for updates on this project.
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| The
Five Most-Commonly Asked Questions About Electron
Beam Drilling |
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Q: What
materials can be perforated by Electron Beam Drilling?
A: Most materials can be perforated by Electron
Beam, however, most of the Electron Beam Drilling
(EBD) performed by En-beaM is on stainless steel
in various grades. We can also perforate copper,
titanium (various grades), D2 steel, duplex stainless
steel and aluminum alloys.
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| .004" dia.
holes drilled in .060" thick 316SS. |
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Q: What
are the limitations in hole size for EB perforating?
A: Material
thickness is the main factor determining the size of the holes
that can be drilled. The smallest holes we have drilled to
date are .003" dia. with our standard tolerance of ± .001".
With some machine modifications and a thinner workpiece, we
could develop smaller holes, if required. The largest holes
we have drilled are .050" dia. (± .001"). It may be possible
to develop even larger holes, if required. The smaller the
hole, the faster we can drill, due to available power beam
density.
Q: What
are the end uses of EB-perforated products?
A: The most common use for these products is filtration.
Most of the products perforated by En-beaM are used by
the paper industry for dewatering pulp, fiber separation,
bleaching of the fibers and removal of inks and dyes in
the recycling process.
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Q: How
does the process of EB perforating work?
A: The workpiece, generally a sheet metal
cylinder, is loaded on to a special fixture on
a lathe, specially designed to rotate the part
in a chamber under the EB gun. The beam is then
pulsed from 1-2000 pulses per second while the
cylinder rotates and is indexed by CNC control.
During each pulse, the beam is columnated and
focused by magnetic coils specifically for the
diameter of the workpiece. The power and duration
of each pulse is specific to the particular hole
size selected. |
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Q: Why
is EB perforating utilized when lasers are the cutting
edge of technology?
A: EBD has many advantages over laser drilling
holes at this time. Speed is one major advantage.
Our holes are normally drilled at 500 to 2000 microseconds
(or 1 to 2000 holes per second). The second advantage
is that the drilling is performed under a vacuum,
which limits the amount of recast and microcracking.
The third advantage is that the holes have less of
a taper, so we can drill a tighter hole pattern.
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Personnel
Update
Acceleron
would like you to join us in extending a warm welcome
to two new employees. We are pleased to have them on
our team!
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Bill
Powers — Quality Engineer
Bill comes to Acceleron with extensive experience as a project engineer,
floor inspector, toolmaker, programmer and process engineer. Formerly
employed by a distinguished manufacturing company for over 25 years,
Bill will be working in our Laser Department, setting up processes
and inspection methods with existing and new programs. |
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Sylvain
Beaudoin — Laser Technician
Sylvain joins us from TRUMPF Corporation in Farmington, CT, where
his background as a Laser Service Engineer includes experience in
the areas of laser installation, service technician, programming
and CO2 operator training. He will
be responsible for the operations of our new CO2 laser,
including all programming, production operations and process development. |
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Announcing
a New Addition to Acceleron's Laser Facility
Our
new 5 Axis Hybrid Machine has a working envelope of
41" in X, 18" in Y, and 28" in Z, with a maximum weight
capacity of 1,500 pounds. This additional equipment
will allow us to now service an area of the market
from which we have had many requests. Welding, cutting,
drilling or scribing . . . whatever your laser need
is, Acceleron can assist you!
See
below for more on our improved laser cutting
capabilities.
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| Acceleron
Has the Latest Noncontact Measuring System |
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Acceleron
is proud to introduce the latest in noncontact measuring
technology from the world-class manufacturer Mitutoyo America
Corp. This inline inspection system will measure critical
features concurrently with laser processing to ensure quality
for both our new CO2 flat sheet cutting machine
and our YAG department. "Quick Scope", the CNC
noncontact vision system, is capable of measuring simple-to-complex
parts to within .0002 of an inch, utilizing manual and/or
automatic/cycle mode. This is accomplished with user-friendly,
Windows™-based software. In addition, the Quick Scope's
capabilities range from a magnification of 21x to 147x, ensuring
proper details for accurate measurement.
Included
with the Quick Scope is reporting software to generate custom
reports for process monitoring and improvements and to ensure
customer requirements are met. Another feature of the Quick
Scope is the ability to take snapshots of images which can
be used for training or emailed for customer correspondence.
This is just one of the many ways that we at Acceleron are
demonstrating high quality standards in our ongoing commitment
to customer satisfaction.
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| Above:
The TRUMPF L 2530 is Acceleron's first
flat pattern high-volume production cutting
machine. Right: Cut edge quality, accuracy
and repeatability were the key benefits
offered by TRUMPF. |
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New
Laser Cutting Machine Increases Our Capabilities
Acceleron
recently purchased a state-of-the-art flat sheet laser cutting
machine from our longtime associate TRUMPF Inc., of Farmington,
CT. TRUMPF's Laser Product Manager Peter Bartram and Application
Engineer Dave Turner, along with Sales Engineer Robert Jenks
of Robert E. Morris Company, were instrumental in our decision
to purchase a new TRUMPF machine.
We
chose our first flat pattern, high production cutting machine
based on TRUMPF's reputation and proven track record in building
reliable, high-performance machines, as well as our desire
to go beyond our competitors in offering low-cost, high-quality
sheet metal cutting. Our new 3000-watt laser gives us the
capability to cut up to 0.750 mild steel, 0.500 stainless
steel and 0.312 aluminum at faster speeds than our competition.
The
TRUMPF L 2530 is designed to be effective for R & D low-volume
versions of your latest designs and high-volume production
from thin and thick sheet metal. New technology integrated
into the machine expedites material changeover on short and
long runs. Another feature offered by TRUMPF is ToPs, a special
software package that helps us create faster, more accurate
quotations for customers. These technological features are
another example of how Acceleron is working to lower customer
costs and provide better quality parts. We welcome all new
quotations and the opportunity to show you the impressive
results of our new 3000- watt L 2530.
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