What's New At Federal!

February/March 2009 – Federal Carbide expands near net shape pressing capabilities with the addition of cold isostatic (CIP) and 60 ton compacting presses.

A Gasbarre Products (Dubois, PA) 60 Ton Die Set Series compacting press was placed in service in February. With a 9” stroke and 6” depth of fill, this press is capable of pressing relatively large and complex forms at rates of up to 40 strokes per minute. The press is designed to allow rapid tool changes and features automatic pick-and-place unit and infinitely adjustable “built in” press controls.

Federal will also complete the installation and startup of a Simac Ltd. 400 Series II Dry Bag Isostatic powder compaction press in March. Capable of isostatic pressures of 30,000 psi, the CIP has a maximum fill diameter of 6”, will produce pressed parts up to 16” in length, and is capable of achieving near net shapes for larger solid and tubular parts.

Gasbarre 60 Ton Press	Simac 400 Series CIP

To support the expansion of its heavy metal alloy and cemented carbide manufacturing capabilities, Federal Carbide has completed the construction of a 12,000 square foot building. The new facility, the third to be located on Federal’s Tyrone, Pennsylvania site, will commence operations in October and represents the company’s most recent effort to further reduce lead times and improve service levels. The facility will primarily house advanced pressing, ISO-pressing, and sinter-HIPing equipment that comprise a series of short lead time manufacturing cells.

August 2008 - Federal Carbide completes the installation of the most advanced sinter-HIP furnace in the world for the sintering of cemented tungsten carbide products.

Further expanding its carbide sintering capabilities, Federal Carbide will place into service a new 12.5 cubic foot working capacity sinter-HIP furnace in August. The new furnace, manufactured by Advanced Vacuum Systems (Ayers, MA), is equipped with an advanced binder removal system and will accommodate loads of 700 kilograms per cycle. The furnace is capable of presintering in hydrogen or vacuum and sintering in vacuum or under isostatic pressure. The hot isostatic pressure (HIP) feature virtually eliminates residual porosity in carbide products, thus guaranteeing the highest level of quality attainable.