1. Improving Competitiveness Using Sub-Harmonic Vibrations By Thomas E. Hebel Bonal Technologies, Inc.

2. New Way to Become More Competitive

3. Using Sub-Harmonic Vibrations

4. How to Be More Competitive 1.Reduce Costs (without sacrificing quality) 2.Reduce Time 3.Improve Quality

5. Areas of Focus 1.Stress Relief 2.Welding

6. 1.Stress / Stress Relief Mechanical Stress is caused by forcibly changing shape of grains (can be calculated) Thermal Stress caused by thermal shock (is vague, hard to calculate)

7. Problems Caused by Thermal Stress Distortion After Machining Delayed Distortion Premature Fatigue

8. Solution Stress Relief – Thermal stress relief – Natural aging – Cryogenics – Stretch – Compression – Vibration stress relief (sub-harmonic)

9. Caution: Not All VSR Systems Work Resonant-vsr is inconsistent * Resonant-vsr may cause fatigue ** * US Dept of Energy ** US MIL Spec 810B

10. Successful VSR ( Meta-Lax®) is Unique to Industry SUB-Harmonic vibrations Can “certify” stress relief Meta-Lax ® developed by Bonal Technologies, Inc.

11. Sub-Harmonic Processing is Not Heat (weldment has ¼-in wall thickness next to 7-in block)

12. No Concern for Heat Side Effects (improve MPG)

13. Sub-Harmonic Stress Relief Find harmonic curve Set frequency in leading portion Dwell for 15-60 minutes

14. Certification Sheet with 1 st Scan

15. How Stress Relief is Certified Take periodic scans Curve shifts over slightly Curve “stabilizes” in new location to signify stress relief is complete

16. Complete Certification Sheet

17. Sub-Harmonic SR vs. TSR Similarities Optimum zone Dwell period Consistent results Differences No distortion No scaling / discolor. No change in M echanical P roperties

18. Neutron Diffraction Comparison (stress levels before and after sub-harmonic treatment)

19. Ex. 1 – Autobody Carrier (better distortion control than TSR, saved $150,000)

20. Ex. 2 – Bulkhead for Lock and Dam (480,000-lbs., note equipment in upper left corner)

21. Ex. 3 – Airplane Wing Checking Fixture (50-ft., machine stability and eliminate delayed distortion)

22. Ex. 4 – Press Base (80,000-lbs., machine distortion equal to TSR)

23. Ex. 5 – Vibration Screen Decks (eliminated cracking for four years)

24. Ex. 6 – Surface Plate (0.002-inch flatness over 12 x 19-ft area)

25. Increase Stress Relief Capability Semi-finished / near net finished parts Finished parts / assembled parts Hardened materials Thick/thin sections

26. 2.Welding – Advantages Reduce Weld Distortion (50-95%) Reduce Weld Cracking (50-95%) Improve Weld Quality

27. Vibrate “Base” Metal (Sub-Harmonic Weld Conditioning) Apply sub-harmonic stress relief during welding

28. Reduce Weld Distortion Molten metal stays molten longer Able to reduce weld amps

29. Reduce Weld Cracking and Improve Weld Quality Preheat Pulsate “weld” metal Vibrate “base” metal (sub-harmonic)

30. Metallurgical Changes More uniform weld grain Higher ductility (up to 400%)* Higher impact (up to 75%)** *Wayne State University ** Charles Bronson

31. Photomicrograph Comparison NormalWith Sub-Harmonic

32. U.S. Dept. of Energy Report “The 4140 plates not [sub-harmonic] vibrated during welding were cracking at the weld crater at the end of each pass made. This did not occur when [sub- harmonic] vibrating.”

33. Ex. 1 - Automotive Checking Fixture (81% less distortion than normal)

34. Ex. 2 – Aluminum Bonding Fixture (69% less distortion than normal)

35. Ex. 3 – Edge of Loader Bucket (400% longer service life)

36. Ex. 4 – Life Boat Adaptor (0.003-inch distortion in 12-feet after welding)

37. Ex. 5 – Wind Tunnel Part (0.032-in distortion in 32-ft, stainless steel)

38. Ex. 6 – Platen (eliminated cracking upon cooldown)

39. Competitive Summary from Using Sub-Harmonic Stress Relief Reduce Mfg. Costs and Time Match TSR for Effectiveness and Consistency Increase Stress Relief Capacity

40. Competitive Summary from Using Sub-Harmonic Weld Conditioning Prevent Distortion (50-95%) Prevent Cracking (50-95%) Improve Service Life (up to 400%)

41. Special Thanks to NASA-Langley, Advex, McDonnell-Douglas, Woodward-Governor, General Motors, State Fab, U.S. Army Corps. of Engineers, Steward Machine, Boeing, J&J Burning, Danly,Corrosion Engineering, K&M Machine, Grumman Aerospace, U.S. Steel-GLS Div., NASA-Edwards, Purdue University, and Build- A-Mold for photos of their parts.

42. Direct Technical Questions to: Bonal Technologies, Inc. (developers of Meta-Lax technology) Thomas E. Hebel, President Royal Oak, Michigan (248) 582-0900 THebel@Bonal.com www.Bonal.com