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A Publicatio Vol. LXXXIV No. www.industrialheating.com
The International Journal of Thermal Processing OCTOBER 2016
INSIDE
10 IH Connect 30 Vacuum Furnace Control36 Case-Depth Simulation48 Insulating Wools
Rolled, Heat-TreatedRing Distortion 42
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Perfecting your thermal processing operations is paramount to producing high-quality products. By mastering and maintaining control of your equipment, old and new, you can achieve this optimization, which ultimately leads to the ideal performance of your heat-treating equipment. This performance allows you to obtain and replicate desired results, as well as streamline your process, creating time and cost savings.
Advanced controls technology gives you the operational flexibility needed to measure and analyze your equipment and processes with ease. You can then use said analysis to refine and adjust the settings and parameters of your equipment to enhance your process. With advanced controls, this optimization is simple and also ensures less human error in the production process because it eliminates several manual processes, automating them for precise, repeatable control.
Revitalizing older equipment with controls upgrades increases its capabilities and overall flexibility, keeping it up-to-date and in line with your current systems. One example of the benefits of an upgrade to an older system is that many older vacuum furnaces require a manual adjustment of the heating elements via trim pots. With a controls upgrade, one can monitor and adjust the heating elements through the industrial computer’s graphical interface. By eliminating the need for manual adjustments, you rely on the Program Logic Controller (PLC), thus eliminating the potential for …
Optimizing Your Thermal Processing Equipment
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Upgrading and retrofitting your equipment extends the life of your investment, enhances your capabilities and boosts your overall performance through better integration of systems. Ipsen’s CompuVac® controls system features:
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• Real-time and historical trending
Advanced ControlsTechnology
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For over 100 years, Surface Combustion has focused on aplying our technical andpractical experience to the pursuit of moving heat treating and furnace technology forward.
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IndustrialHeating.com OCTOBER 2016 5
42
30
CONTENTS OCTOBER 2016
FEATURESProcess Control & Instrumentation
Automated Control of Vacuum Heat-Treat EquipmentSteven Christopher –
Super Systems, Inc.; Cincinnati, Ohio
Vacuum heat treatment’s requirements are rapidly changing,
with several accreditations influencing how heat treaters
ensure product integrity. As requirements inevitably become
more demanding, equipment must be evaluated
for compliance.
Read it online at www.industrialheating.com/autovac
Industrial Gases/Combustion
CarbTool© – Leading the Way in Case-Depth SimulationsLei Zhang and Richard D. Sisson Jr. –
Worcester Polytechnic Institute; Worcester, Mass.
Heat treaters want an effective simulation tool that predicts
the carburization performance of a variety of steels. At
the Center for Heat Treating Excellence (CHTE) at
Worcester Polytechnic Institute (WPI), researchers are
perfecting carbon-concentration profile predictions through
enhancements to CarbTool©, its simulation software.
Read it online at www.industrialheating.com/carbtool
Heat Treating
Distortion in Rolled and Heat-Treated RingsTaylan Altan, Jose Gonzales-Mendez,
Alisson Duarte da Silva and Xiaohui Jiang –
The Ohio State University; Columbus, Ohio
The rolling and heat treatment of forged rings
sometimes leaves residual stresses that cause
dimensional distortion. Corrective measures are
often based on trial-and-error techniques, but
ongoing research seeks to base corrective actions on
the laws of physics.
Read it online at www.industrialheating.com/distort
Ceramics & Refractories/Insulation
High-Temperature Insulating Wools: Classification (part 1)Rick Sabol – RATH Inc.; Newark, Del.
Back in the 1980s when I first started working in
refractories, an old refractory foreman at Bethlehem
Steel told me, “There are no bad refractories; you
just put them in the wrong spot.” Now all these years
later, I’ve come to realize he was right on both counts.
Read it online at www.industrialheating.com/htwools
30
36
48
42
48
36
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6 OCTOBER 2016 IndustrialHeating.com
INDUSTRIAL HEATING (ISSN: Print 0019-8374 and Digital 2328-7403) is published 12 times annually, monthly, by BNP Media, Inc., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualifi ed individuals. Annual rate for subscriptions to nonqualifi ed individuals in the U.S.A.: $132.00 USD. Annual rate for subscriptions to nonqualifi ed individuals in Canada: $169.00 USD (includes GST & postage); all other countries: $187.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2016, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not
responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offi ces. For SINLGE COPY SALES OR BACK ISSUES ONLY: contact Ann Kalb at (248) 244-6499 or [email protected]. POSTMASTER: Send address changes to: INDUSTRIAL HEATING, P.O. Box 2144, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to IMEX Global Solutions, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to INDUSTRIAL HEATING, P.O. Box 2144, Skokie, IL 60076. For subscription information or service, please contact Customer Service at: (847)763-9534.
CONTENTS OCTOBER 2016
Editor’s PageIndustrial Education
Should everyone go to college? It’s time to question business as usual
and find a way to get more students interested in vocations rather than
professions. How can we do this? Check out this month’s editorial to
find out. Federal Triangle The Ultimate American Problem
What is the ultimate American problem? Barry Ashby contends that it’s
the declining educational competence of citizens. He discusses the subject’s
history and predicts its future, and he also ties it in with the 2016 elections.
The Heat Treat Doctor® The Navy C-Ring Test – A Practical Tool for the Heat Treater
Heat treaters are forever curious about how their furnaces are performing;
in particular the uniformity of properties that will be achieved throughout
the load. There is a simple, yet highly effective, method for quantifying
furnace performance – the Navy C-ring test.
MTI Profi leErie Steel Ltd.
IHEA Profi leWS Thermal Process Technology Inc.
DEPARTMENTS24 Industry News
28 Economic Indicators
51 Products
53 Industry Events
54 Literature Showcase
55 The Aftermarket
56 Classified Marketplace
62 Advertiser Index
SPECIALSECTION10 IH Connect
Connect with advertisers in this
issue through social media.
On the Cover:Forging of a large-diameter, distortion-prone ring is
shown (p. 42).
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20
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MTI & IHEA Associate Member
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16
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8 OCTOBER 2016 IndustrialHeating.com
Manor Oak One, Suite 450, 1910 Cochran Rd., Pittsburgh, PA 15220412-531-3370; Fax: 412-531-3375; Online: www.industrialheating.com
MANAGING DIRECTOR John Schrei [email protected]; 248-786-1637
GROUP PUBLISHER Darrell Dal Pozzo [email protected]; 847-405-4044
EDITORIAL/PRODUCTION STAFFReed Miller Associate Publisher/Editor – M.S. Met. Eng., [email protected]; 412-306-4360 Bill Mayer Managing Editor, [email protected]; 412-306-4350Linda Becker Contributing Editor, [email protected]; 262-564-0074 R. Barry Ashby Washington Editor, [email protected]; 202-255-0197Dan Herring Contributing Technical Editor, 630-834-3017; [email protected] Peters Contributing Editor, [email protected]; 216-570-4537Karen Talan Production Manager, [email protected]; 248-244-6246Brent Miller Art Director, [email protected]; 412-306-4356
AUDIENCE DEVELOPMENTHillary Leman Audience Marketing CoordinatorAlison Illes Senior Integrated Media SpecialistAnna C. Silvestri Audience Audit ManagerFor subscription information or service, please contact Customer Service at:Phone: 847-559-7399 or Email: [email protected]
LIST RENTALPostal & Email ContactsKevin Collopy Sr. Account Manager; Phone: 402-836-6265Toll Free: 800-223-2194, ext. 684; Email: [email protected] Costantino Senior Account Manager; Phone: 402-836-6266Email: [email protected]
ADVERTISING SALES REPRESENTATIVESKathy Pisano Advertising Director and Online Advertising Manager, [email protected]; 412-306-4357, Fax: 412-531-3375Becky McClelland Classifi ed Advertising Mgr.,[email protected]; 412-306-4355Rick Groves Eastern Sales Manager, [email protected]; 248-244-6444; Fax: 248-502-2109Steve Roth West Coast Sales Mgr., [email protected];520-742-0175, Fax: 847-620-2525Hamilton Pearman European Sales Representative, +33 (1) 45 93 0858,[email protected] Mr. Arlen LUO Newsteel Media, China; [email protected];Tel: +86-10-82160060, Fax: +86-10-62150588Becky McClelland Reprint Quotes; [email protected]; 412-306-4355
SINGLE COPY SALESAnn Kalb [email protected]
CORPORATE DIRECTORSJohn R. Schrei PublishingRita M. Foumia Corporate StrategyMichelle Hucal Content DeploymentMichael T. Powell CreativeScott Wolters Events
Lisa L. Paulus FinanceScott Krywko Information TechnologyMarlene J. Witthoft Human ResourcesVincent M. Miconi Production
ONLINE
Pictured left to right
Darrell Dal Pozzo Group Publisher – Industrial Heating; [email protected]
Reed Miller Editorial Director – Industrial Heating; [email protected]
Daniel H. Herring President – The Herring Group, Inc.;[email protected]
Geoffrey Somary President; Ipsen
Herb Dwyer Chief Operating Officer/General Mgr.; Nanmac Corporation
Jonathan Markley Managing Director; SECO/WARWICK
Jim Nagy President; Solar Manufacturing
William J. Bernard lll (B.J.) President; Surface Combustion
Marc Glasser Director of Metallurgical Services; Rolled Alloys
Steve Kowalski President; Kowalski Heat Treating
Jim Oakes Vice President Business Development;Super Systems Inc.
2016 EXECUTIVE COMMITTEE
Web ExclusiveOvercoming the Challenges of 3D Printing with MetalsThe NextManufacturing Center has focused its attention on increasing widespread adoption
of additive-manufacturing technology. The center’s researchers are currently working on
research projects to overcome the current challenges in the field and developing an entirely
new approach to metal additive manufacturing. Read the first part of this two-part series from
Carnegie Mellon University on our website and in October’s 3D Printing Report enewsletter.
www.industrialheating.com/nextmanufacture
VIDEOMetals Production: Iron & Steelmaking with Chris PistoriusChris Pistorius, POSCO Professor of Materials Science & Engineering and Co-Director of
the Center for Iron & Steelmaking Research at Carnegie Mellon University, explains how we
can reduce CO2 emissions from metals production, ironmaking and steelmaking by including
natural gas in the process.
www.industrialheating.com/videos
WHITE PAPERBusch LLCCOBRA dry screw vacuum pumps are highly efficient for use in many industrial applications,
including heat-treatment processes. These models represent many years of experience in dry
vacuum technology and offer key design benefits. The COBRA vacuum pump is reliable,
robust and easy to service. www.industrialheating.com/COBRA
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Phone: 888-988-0899 Email: [email protected] Web: www.AcrossInternational.com
Heat Treatment Solutions from Across International
750°F 2.5 cu ft forced air convectionoven with 28-segment controller
15kW 30-80KHz compact induction heaterwith temperature controller and vacuum kit
1700°C 4” OD vertical tube furnacewith alumina tube & sealing kit
Across International provides a full line of heating equip-ment, including high temperature electric furnaces, drying ovens and induction heaters.
We have more than 20 years of industrial manufacturing experience. We provide quantity discounts and will reply to your requests within the same business day. 100% customer satisfaction is always our first priority.
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More info at www.AcrossInternational.com
500°F 1.9 cu ft vacuumoven with dual-stage pump
500°F 7.5 cu ft 3-zone vacuumoven with heating shelves
20kW 50-250KHz induction heater25kW 1-20KHz induction heater
with tilt-pour melter
1700°C 12x10x10” controlledatmosphere muffle furnace
1200°C 8” OD tube furnace withKanthal® heating element
Visit us at the shows:
Quenching Annealing Melting
ACROSS INTERNATIONALMaterial processing equipment
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10 OCTOBER 2016 IndustrialHeating.com
IH CONNECT
Across Internationalwww.facebook.com/AcrossIntltwitter.com/acrossintlinfo@acrossinternational.comwww.acrossinternational.com
Avion [email protected]
Daniels [email protected]
Custom Electric [email protected]
Gansu Haoshi Carbon [email protected]
Graphite Machining [email protected]
Graphite Metallizing [email protected]
HarbisonWalker Internationalwww.facebook.com/thinkhwiwww.linkedin.com/company/harbisonwalker-
internationaltwitter.com/thinkhwithinkhwi.com
Ipsenwww.facebook.com/IpsenUSAwww.linkedin.com/company/ipsenusatwitter.com/ipsenupdatewww.youtube.com/[email protected]
Jiangsu Fengdong Thermal [email protected]
Kanthal Sandvik Heating Technology USAwww.kanthal.com
Metallurgical High [email protected]
Pillarwww.linkedin.com/company/pillar-inductionwww.youtube.com/user/[email protected]; www.pillar.com
Praxairwww.facebook.com/PraxairIncwww.linkedin.com/company/praxairtwitter.com/praxairincwww.youtube.com/user/[email protected]; www.praxair.com
SECO/WARWICKwww.facebook.com/pages/
SECOWARWICK/149795378426980www.linkedin.com/company/seco-warwick-corp-twitter.com/SECOWARWICKwww.youtube.com/user/[email protected]
Sevenstar [email protected]
Super Systems Inc.www.linkedin.com/company/super-systems-incwww.youtube.com/user/[email protected]
Surface [email protected]
Thermal Product Solutionswww.facebook.com/pages/Thermal-Product-
Solutions/306794196091982www.linkedin.com/company/thermal-product-
solutionswww.youtube.com/user/TPSThermalProductsinfo@thermalproductsolutions.comwww.thermalproductsolutions.com
Welcome to IH Connect. Here’s a quick and convenient way to connect with
leading industry suppliers through social media, website or e-mail. Below is a list
of advertisers in this month’s issue. Connect with them
to stay abreast of the latest technologies in the industry.
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12 OCTOBER 2016 IndustrialHeating.com
As I write this, students are back in
school for the new year, and thoughts
of many of us return to those days.
Thoughts may also focus on your own
children’s post-high school education. If you have
kids who might attend college and want to help
them with the finances, you better be thinking
seriously about this future.
As parents or grandparents, have you
considered an industrial education instead of a
college education for your kids or grandkids? It’s
likely you have wished someone did if you have
ever tried to hire skilled workers for your plant.
When I had this conversation with my son, I
pointed it out in simple math. If you earn $25,000
per year for four years while others are paying
$25,000 per year, you are $200,000 better off
at the end of four years. Needless to say, that’s
probably a low-end estimate of the differences.
I believe we need a cultural paradigm switch,
and we may need to clean house at local high
schools where snobby counselors continue to
encourage everyone to attend college. In his
regular column, Walter Williams, a college
professor from Virginia’s George Mason
University, states simply, “Most college students
do not belong in college.” He and Robert
Samuelson, a Washington Post columnist, assert
that “it’s time to drop the college-for-all crusade.”
Due to the fact that college costs increase
by much more than the cost of living – about
a 450% growth since 1982 – college education
is continuing to lose its value. Add to that the
weak courses such as “Philosophy and Star
Trek” offered by Georgetown University, it’s no
wonder we have a “six-digit number of college-
educated janitors in the U.S,” as reported by Ohio
University professor Richard Vedder, who also
indicates that there are “one-third of a million
waiters and waitresses with college degrees.” In
2012, about 44% of college graduates worked jobs
that did not require a college degree.
It’s time to question business as usual and find
a way to get more students interested in vocations
rather than professions. How can we do this?
Here are a few thoughts from me or greater minds
than mine.
• Provide early exposure to all students to
let them know about job opportunities in
manufacturing. This could/should happen in
the schools, but groups like the Girl Scouts
are another possibility.
• Better utilize existing vocational-training
programs in high school.
• Provide some “diversity training” to high
school counselors to encourage them to
advise kids (particularly those less likely to
excel in an academic setting) that vocational
training is a good option.
• Encourage more women to enter the
manufacturing workforce. Only about 26%
of the manufacturing workforce in the U.S.
is female, compared to 50% of the overall
workforce.
• Companies should provide appropriate
vocational training for new hires.
The facts are that the majority of new
American jobs over the next decade will not
require a college degree, according to the U.S.
Labor Department. A USA Today analysis
estimated that about 2.5 million middle-skill
jobs – requiring high school but not college
training – will need to be filled between 2014
and 2017. Some of this is coming from the
retirement of baby boomers. In our local region
around Pittsburgh, a historically industrial area,
it is expected we could lose about 8% of the
1.2-million member workforce as older
workers retire.
In addition to workforce losses due to
retirements, another issue we are experiencing is
diminishing labor-participation rates. In June,
the Bureau of Labor Statistics reported that
only 62.6% of adult Americans are working or
actively looking for a job. This is the lowest labor-
participation rate in 38 years. A separate White
House report showed something similar. Looking
at prime-age (25-54) males in the workforce,
the report showed that 98% of this group was
employed 60 years ago. Today, this number is 88%.
It’s clear our work is cut out for us. We need to
increase the number of people seeking vocational
training, encourage more women to pursue
manufacturing and get more able-bodied people
working. Consider what part of this challenge you
can invest your resources into. After all, a small
rudder can turn a large ship.
Industrial Education
REED MILLERAssociate Publisher/Editor
EDITOR'S PAGE
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Icontend that the outcome of the 2016 elections
and industrial job futures are interrelated. It
all comes down to the declining educational
competence of citizens. This subject’s history
and predicted future are brief ly discussed here.
Only half of U.S. children were enrolled in
school in 1900, and only 6% of 17-year-olds
graduated from high school. This latter figure
rose to 30% by 1930 and 50% by 1950. Between
1960 and 1990, spending on public-school educa-
tion doubled, but disquiet in the quality of public
schools and the growing lack of focus on results
became issues in the public eye. Concurrently,
from 1960 through today, teacher associations,
unions and government agencies grew in control
and inhibited most public education reforms …
while society was/is being distorted by rapidly
changing social and cultural trends.
Public education, once designed primarily to
impart skills and knowledge, took on political and
social tasks to inculcate objectives about racial
integration, social tolerance and environmental
awareness. President Reagan balked at these
trends and sought to eliminate the Department
of Education, wanting to leave state and local
government in control. Instead, an education
bureaucracy and unions took hold. From 1955 to
1990, the average pupil-teacher ratio dropped by
40%, annual expenditures per pupil exploded by
350% to $5,237 and public-school teacher salaries
rose 45% (adjusted for inf lation).
By 1986, only 6% of 11th graders could
solve multi-step math problems and use basic
algebra; 60% did not know who wrote or why
The Federalist was written; and 75% did not
know when Abraham Lincoln was President.
Meanwhile, teacher unions (with tenure and
salary for mediocre instructors) gained solid
control of public education. Pupil-staff ratios have
dropped from 18 to 1 in 1960 to 8 to 1 in 2010. To
put it nicely, the U.S. federal monopolistic, over-
regulated, bureaucratic system of public schools
is woefully unprepared to meet modern society’s
needs. And it costs far too much.
It is evident that union objectives have been to
raise member wages, grow membership, increase
share of labor force represented, preclude pay
based on performance and eliminate non-union
participation in school operation. Unionization
has increased per-pupil spending 9% relative to
non-union districts. Further, strongly opposed
performance-based pay has succeeded in bloating
budgets – public-school teachers are paid 42%
more than private-sector counterparts, and
performance accountability is nonexistent.
This failure in public education has prompted
the Association of American Colleges &
Universities to examine results of education in
terms of surveyed perceptions of students and
employers regarding student’s preparation for
employment. Of 615 interviews, the percentage of
those well prepared for work (applying knowledge
in work settings, critical thinking, written and
oral communications) shows wide perception
difference between students and employers (see
Table). These findings are an embarrassment for
American public education.
What this all means is that a larger and larger
portion of the population over the last 50 years is
less and less able to analyze and determine what
is best for America in a Presidential election or
in House and Senate races (or insist that school
boards relieve or fire non-performing public-
school teachers).
Furthermore, what all this means is that
industrial America needs competent employees for
operation and survival but has an existing and
rapidly growing problem. My advice is to talk to
your local government and require that this
“wrong world” be set “right.” If you don’t, who
will? And if you don’t, America loses.
The Ultimate American Problem
FEDERAL TRIANGLE
BARRY ASHBYWashington Editor
14 OCTOBER 2016 IndustrialHeating.com
Table
Area of Preparation and Competence Students (%) Employers (%)
Work with others and teams 64 37
Staying current with technology 46 37
Judgement in decision-making 62 30
Locating, organizing and evaluating information 64 29
Oral communications 62 28
Work with numbers and statistics 55 28
Written communications 65 27
Analytical thinking 66 26
Creativity 57 25
Solve complex problems 59 24
Apply knowledge to real world 59 23
Staying current with global developments 43 18
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HarbisonWalkerInternationalAT WORK
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16 OCTOBER 2016 IndustrialHeating.com
Heat treaters are forever curious about
how their furnaces are performing; in
particular the uniformity of properties
that will be achieved throughout the load.
We often look to sophisticated tools for answers,
but there is a simple, yet highly effective, method
for quantifying our furnace’s performance – the
Navy C-ring test. Let’s learn more.
Originally designed to study dimensional
changes that occur in the heat treatment of
hardened and/or case-hardened components,
the power of the Navy C-ring test is that it can
be adapted and used while running production
loads to determine both the overall performance
capability (i.e., condition) of the furnace and
the heat-treatment process being conducted in
it. It can also be used to compare in-house heat
treatment with that of outside commercial services.
This test can be structured in such a way
as to aid in the evaluation of atmosphere or
vacuum furnaces. Processes such as normalizing,
hardening and case hardening can be examined
and the performance of oil or high-pressure-gas
quenching methods studied. The test can be
extended from its original purpose to reveal the
following types of information (as a function of
position within the workload) in both the “as-
quenched” and “as-tempered” condition:
• Hardness uniformity (surface, core)
• Dimensional change (distortion)
• Quench system (oil type, agitation,
temperature) effectiveness/uniformity
• Carburizing uniformity (effective and total
case depth plus case variation by position)
• Microstructural uniformity (including
retained austenite levels)
• Material hardenability
• Material surface stress state
• Sensitivity to cracking (as a function of
various quench conditions or media)
One is not limited to a particular material
grade. As such, C-rings are made from both
ferrous (e.g., steel, stainless steel, tool steel) and
nonferrous (e.g., aluminum, titanium) materials.
For steel parts, SAE 1010, 4140, 4340, 8620 and
9310 are typical examples. It is important that the
C-rings are made of the same material (and ideally
from the same heat) as the production parts.
What is a Navy C-ring?Essentially, the Navy C-ring is a short cylinder with
an eccentric hole and open in one extreme (Fig. 1).
The original design (specified to conform to U.S.
Navy Department Specifications for Tool Steels,
No. 47S5c, July 1, 1921)[3] has a thickness of 25 mm
(1 inch). Modifications of this design are common
to mirror the size and thickness of the actual parts
being processed. It is important to run C-rings of
the same physical dimensions within a given load.
The Navy C-Ring Test – A Practical Tool for the Heat Treater
THE HEAT TREAT DOCTOR®
DANIEL H. HERRINGThe HERRING GROUP, Inc.
Fig. 1. Typical Navy C-rings; (a) – (c) Examples of size/type variation in Navy C-ring specimens (a) original design (b) original with hole (c) custom half-size with keyways.
1a) 1b) 1c )13 mm(0.50 in.)
13 mm(0.50 in.)
6.5 mm(0.25 in.)
25 mm(1.00 in.)
4.75 mm(0.1875 in.)
13 mm(0.50 in.)
127 mm(5.00 in.)
127 mm(5.00 in.)
48 mm(1.90 in.)
48 mm(1.90 in.)
74 mm(2.90 in.) 74 mm
(2.90 in.)37 mm
(1.45 in.)
6.5 mm(0.25 in.)
3 mm(0.125 in.)
3 mm(0.125 in.)64 mm (2.50 in.)
24 mm(0.90 in.)
φ6 mm(0.25 in.)
D D AB
BC
C
B
A
E E
A
B
C C
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18 OCTOBER 2016 IndustrialHeating.com
How to Conduct the TestAll parts should be measured before and after heat treatment
using a coordinate measuring system (CMM) to precisely
determine geometrical dimensions. This is critical for
subsequent statistical analysis of the data. The Navy C-ring
samples can then be positioned in a workload in either a vertical
(if an optional hole is drilled in the specimen for hanging) or
horizontal orientation. Typically, a minimum of nine rings is
used, positioned in the corners and center of the load (like a
temperature uniformity survey) along with production parts.
The rings can also be positioned in individual baskets stacked to
make up a load.
Testing of samples in both the as-quenched and as-tempered
condition should be done for surface and core hardness,
microstructure, case depth (via microhardness), retained
austenite and (if desired) residual stress via X-ray diffraction
(XRD) to obtain a complete data set.
Original Test FocusHistorically, the main focus of the Navy C-ring test has been to
evaluate dimensional changes. In simplest terms, distortion of an
engineered component can be defined as a change in its shape or
volume during either manufacturing (including heat treatment)
or in service.
Distortion during quenching is the result of differential
volume changes due to heat extraction and/or phase
transformations. These dimensional changes can dramatically
inf luence manufacturing productivity due to necessity for
post-heat-treatment machining operations. Furthermore, when
distortion is severe, the potential for crack formation becomes a
paramount concern.
The major factors that inf luence distortion[1] are cooling rate,
hardening treatment (e.g., carburizing, ferritic nitrocarburizing),
material hardenability and chemical composition.
Investigating these factors[1] has revealed that the rate of
cooling from carburizing is extremely important. Very fast
cooling rates (e.g., water quenching) completely outweigh the
effects of major changes in composition. By contrast, while the
carburizing process reduces dimensional movement in low-alloy
steels, it has a lesser effect in steels of high hardenability.
Steel composition is more complex, and distinctions must
be made between the effect of composition on increasing
hardenability and the effect on the depression of the martensite-
start temperature in fully hardenable grades. Both aspects
must be fully understood to correlate dimensional movement
over a wide range of compositions. To illustrate this point, the
distortional behavior of boron steels is entirely different from
non-boron steels of comparable hardenability.
The specification of steel chemistry to restricted-
hardenability grades has been reported to reduce the variability
of distortion. Even greater effect has been found by the use of
steels in which the hardenability is greater than that required for
through-hardening for a given section size.
The Navy C-ring has been effectively used to evaluate the
final distortion produced by quenching of steel parts. This
simple specimen can provide distortion information as a
function of heat-treatment condition and position within the
workload with respect to changes in the:
• ID
• OD
• Gap width
• Thickness
• Flatness
• Cylindrical dimensions
• Roundness
• Bore (if an optional hole is machined in the sample)
• Change in size on deep freeze or cryogenic treatment and single
or multiple tempers (as a function of both temperature and time)
In addition, one can understand the effect of material
(composition) and initial microstructure on size and shape
distortion, retained austenite and residual stress.
Furthermore, the test can help evaluate the effectiveness
of prior hardening processes such as (mill) annealing or
normalizing prior to carburizing. Retained austenite evaluation
of carburized components is another parameter of interest,
especially in carburized steels that can contain varying amounts
of retained austenite in the quenched-and-tempered condition –
depending on the material (i.e., alloying elements) and process
parameters used (e.g., carburizing and hardening temperature,
carbon potential, cooling rate). Retained austenite can influence
near-surface hardness and dimensional stability over time.
Heat-treat processes also create residual stress in a material,
which results in dimensional variation (i.e., size and shape
changes) both within a given part and from location to location
within a workload.
SummaryIn this day and age of uncompromising part quality, the
inclusion of Navy C-ring testing on a quarterly basis will
prove an invaluable aid in reducing both equipment- and
process-related variability. Testing of rings for other than
just dimensional change can serve as confirmation of process
stability with regard to such items as temperature variation
throughout the load, quench effectiveness, surface and core
hardness differences as a function of position and overall
material hardenability. The results of these tests can help qualify
process capability, evaluate process (recipe) changes, confirm the
validity of control instrumentation, direct maintenance activities
and act as an invaluable quality-control tool (especially when
statistical data analysis is performed). As they say, “Just do it.”
You’ll be glad you did.
References available online
THE HEAT TREAT DOCTOR®
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SECO/WARWICK Meadville, PA USA814-332-8400 - [email protected]
Call Tom Hart for a Quote or More Information at 814 332 8549 or e-mail [email protected]
™
www.secowarwick.com
What Direction Are You Headed?
0-25 Bar All Purpose Vacuum FurnaceApplications Low Pressure Carburizing, Hardening, Brazing, Annealing, Solution Aging, Sintering, Tempering
Maximum Load Size Up to 5,500 lbs.
Operating Atmosphere Carburizing, Inert, Vacuum, Reducing
Controls Intuitive, User-friendly, Touch Screen HMI
Uniformity Better than ± 10˚F
Hot Zone Graphite or Metal
Convective Heating Up to 1400˚F
Vacuum Up to 10-5 torr
Quenching 2, 6, 10, 15, 20 and 25 Bar, N2, Ar, He
Over 700 furnaces installed worldwide
Brazil China India European Union USA
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MTI PROFILE
In 1961, something special happened in the
16,000-square-foot former home of Chevrolet
Toledo (Ohio) Transmission. That’s when Phil
Flynn, chief metallurgist of Buick Motor, and
Bill Durako, tool steel metallurgist of Crucible
Steel, founded Erie Steel Heat Treating.
The duo knew that heat treating was an
engineering discipline, not a black art, and they
knew they could do it better than most. Today, 55
years later in a modern 70,000-square-foot facility
in Toledo, Erie Steel Ltd. continues that tradition.
The thought that heat treating could be done
better has been transformed and enhanced over
the years to what is now a quest for excellence. A
quest involves inquiry, examination and pursuit,
and it has no endpoint. For Erie Steel, however, it
involves the following attributes.
• People: As Erie Steel’s preeminent resource, its
associates draw upon all other resources, fusing
them together to produce tangible results for
customers. Only people have the ability to com-
pensate for shortcomings in other resources –
making them truly unique. Erie Steel employs
nearly 60 employees from the local community.
• Process: This includes Erie Steel’s current
niche of precision atmosphere carburizing,
high-pressure-quench vacuum hardening,
atmosphere neutral hardening, carbonitriding,
normalizing and annealing, non-atmosphere
annealing and stress relieving.
• Equipment: This includes two vacuum
hardening units, a mesh belt, a four-unit
36-inch x 72-inch batch line with companion
temper and wash capability, two 36-inch square
single-row pusher units, and belt and tumble
blast cleaning with post-blast RP units.
• Integrated business system: Information is the
lifeblood of any organization. Erie Steel’s business
system houses all customer, process, quality and
equipment information. It is web-based, available
to all associates via mobile devices and interactive,
and it provides real-time process documentation
(including video and photo).
• Leadership: The purpose of leadership is to
maximize the efforts of the organization. At
Erie Steel, it not only involves strategic, but
tactical, direction based on knowledge of the
economy, business conditions, customer needs,
governmental regulations and technological
improvements. It also possesses a component of
internal evaluation and provides the organization
with an objective assessment of its condition.
Exemplary of Erie Steel’s quest is new
business involving the carburizing of heavy-truck
steering components. The company engineered,
constructed and installed a single-row pusher and
fixturing specifically for the application. Utilizing
its expertise, Erie Steel was able to successfully
demonstrate the capability of the process.
The future for Erie Steel is bright. The
company was recently awarded the 2016
Commercial Heat Treater of the Year award;
its experienced management team is focused
and stable; and the workforce is knowledgeable
and improving thanks to a corporate training
resource. Erie Steel is prepared to take on many
new challenges.
Visit www.erie.com for more information on Erie
Steel Ltd.
Erie Steel Ltd.2016 Commercial Heat Treater of the Year
MTI Metal Treating Institute
904-249-0448www.HeatTreat.net
20 OCTOBER 2016 IndustrialHeating.com
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T H E S C I E N C EO F V A C U U M
> Manufacturing vacuum furnaces and ovens in our New Jersey facility since 1965
> Unsurpassed temperature uniformity, precision control and data logging
> Easier AMS2750E and NADCAP conformance
> Offering a range of sizes and options to fit your budget
1-856-829-2000 www.tmvacuum.com [email protected] Cinnaminson, NJ USA
T-M Vacuum Products, Inc.
T-
M VACUUM
CELEBRATIN
G
50YEAR S
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IHEA PROFILE
WS is the name; energy-saving gas
burners are its game.
WS Thermal Process Technol-
ogy is the U.S. subsidiary of WS
Wärmeprozesstechnik GmbH, which was founded
in 1982 in Renningen, Germany. The company
manufactures self-recuperative and self-regenerative
gas burners for the heat-treating and steel industries.
WS Thermal Process Technology opened its
doors in Lorain, Ohio, in 1997 and currently has
10 employees for sales, service, training and repairs.
The IHEA member’s signature product is the
REKUMAT® self-recuperative burner, which is
available in both direct-fired and indirect-fired
(radiant tube) versions and is equipped with a
recuperator of either metallic or ceramic (SiSiC)
composition. The latest WS burner innovations
are the REKUMAT® S and REKUMAT® CS
burners. Both burners utilize the so-called “gap
f low heat exchanger” to achieve efficiencies of
80% LHV or higher.
WS is also known for inventing the game-
changing f lameless oxidation (FLOX®)
technology, which enables high air preheat
temperatures (i.e., high combustion efficiency)
with low NOx emissions. The significance of
FLOX did not go unnoticed. Joachim G. and
Joachim A. Wuenning were awarded the German
Environmental Award in 2011 for inventing and
commercializing the technology. All WS burners
can be equipped with FLOX, thus achieving the
lowest NOx emissions with high-efficiency self-
recuperative and self-regenerative gas burners.
Speaking of self-regenerative burners,
REGEMAT® integrates regenerators and
switching valves into one compact unit so that
each burner can act individually. The highest
air preheat temperatures are achieved by using
ceramic honeycomb heat storage material. Both
direct-fired and indirect-fired versions are
available. REGEMAT can achieve efficiencies
up to 88% LHV, which can lead to tremendous
energy savings at high operating temperatures and
in continuously operated furnaces.
WS pioneered the use of ceramic single-ended
radiant tubes in industrial furnace applications,
achieving operating temperatures up to 2300°F,
unmatched temperature uniformity and long
lifetime with low maintenance. With tens of thou-
sands of tubes in operation around the globe, WS
has helped hundreds of customers improve their
processes and drastically reduce their energy costs.
Over the years, WS has proven the importance
of energy-efficient and low-emission combustion
systems in the heat-treating industry. The
company’s goal is to make combustion efficiency
greater than 80% LHV the industry standard
for gas-heated furnaces while maintaining NOx
emissions at a minimum level. This will lead to
significant fuel savings, drastically lower CO2
emissions and improved productivity.
Visit www.flox.com for more information on WS.
WS Thermal Process Technology Inc.Energy-Saving Burners for the Heat-Treat Industry
IHEAIndustrial Heating Equipment Assoc.
859-356-1575www.ihea.org
22 OCTOBER 2016 IndustrialHeating.com
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24 OCTOBER 2016 IndustrialHeating.com
NewsEquipment & Business
EQUIPMENT NEWS
Aluminum Conveyor Forging FurnaceCan-Eng Furnaces International Ltd. has been contracted by Weber
Metals Inc. to design, manufacture and commission an aluminum
conveyor forging furnace. The automated furnace system will heat
aluminum-alloy preforms and billets prior to forging at Weber Metals’
Long Beach, Calif., facility. Can-Eng was selected for this project
because of its demonstrated capabilities in design and development of
large-capacity forging furnaces for the aerospace industry. The furnace
is part of Weber Metals’ 60,000-ton press expansion project, which will
allow the company to manufacture larger and lighter forgings utilizing
more advanced materials for global applications. www.can-eng.com
Nitriding SystemsNitrex Metal supplied three supersized nitriding systems to U.S.
commercial heat treater Nitrex Inc., which recently completed phase
one of a 12,000-square-foot expansion at its facility in Aurora,
Ill. The project has increased the plant’s nitriding capacities to
accommodate parts up to 177 inches (4.5 meters) long and loads
of up to 25,000 pounds (11,300 kg). All systems are equipped with
NITREG nitriding/nitrocarburizing technology, making it possible
to meet AMS 2759/10 specifications for nitriding and AMS 2759/12
specifications for ferritic nitrocarburizing. The expansion also included
upgrades to the company’s metallurgical laboratory. www.nitrex.com
Vacuum FurnaceIpsen shipped a global vertical (GV) vacuum furnace with 6-bar
gas quenching to a commercial heat treater on the West Coast. The
custom-built heat-treating system features a 60-inch-diameter x
60-inch-high (1,524-mm x 1,524-mm) graphite work zone and has
an 8,000-pound (3,629-kg) load capacity. It operates at temperatures
of 1000-2200°F (538-1204°C) with ±15°F (±8°C) temperature
uniformity. The furnace is also equipped with a 35-inch diffusion
pump and Ipsen’s CompuVac controls system. In addition, this GV
furnace is equipped with an argon and nitrogen gas cooling system
with gas injection nozzles located 360 degrees around the perimeter
of the hot zone as well as a variable-frequency drive on the gas
cooling motor for controlled cooling. www.ipsen.com
Heat-Treating OvenJPW Industrial Ovens & Furnaces supplied a northeastern U.S.
manufacturing company with an inert-gas oven capable of reaching
1200°F (650°C). It will be used for heat treating barrels for firearms.
The unit is built to operate with a low-oxygen environment inside the
chamber. By replacing the air with other gases during the process, it
prevents fire hazards and preserves the quality of the products being
treated inside. The oven starts its heat-treating process by purging the
chamber of oxygen. After switching to the process flow meter, heating
begins. www.jpwdesign.com
Laser SystemPreco Inc. received a $1.78 million order for a high-powered,
multi-laser development and manufacturing cell from Brazil’s Senai
Institute of Laser Innovation. The hybrid laser/MIG system, which
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IndustrialHeating.com OCTOBER 2016 25
is being built in Somerset, Wis., includes two high-powered
lasers, one 10-kW disk laser and one 6-kW diode laser. It will
be capable of hybrid laser welding, additive manufacturing, heat
treatment and surface treatment. Preco Inc. is a laser system
manufacturer that also offers contract manufacturing services
for additive manufacturing, heat treating and welding. Senai is
a private non-profit and one of the largest technical training
organizations in the world. www.precoinc.com
Heat-Treatment LineSMS group received an order from TMK subsidiary Seversky
Tube Works for a heat-treatment line for tubes and pipes. The
company’s plant in Polevskoy, Russia, produces seamless and
welded pipe and tube mainly for oil and gas. The line, which is
scheduled to commence operation in the first quarter of 2018,
has a design capacity of 265,000 tons of heat-treated product
per year. Its main components include an austenitizing furnace
with walking-beam transport system, a walking-beam tempering
furnace and a cooling bed. SMS will also supply a complete
water treatment system. The line can perform processes such as
normalizing, quenching and tempering.
www.sms-group.com
Box FurnaceNutec Bickley received an order for a box furnace from a
forging company located in the Chicago area. The equipment,
which has an operating temperature range of 1500-2200°F
(815-1205°C), will be used for heating steel billets before
forging. The furnace has inside dimensions of approximately
7 feet wide x 10 feet high and a maximum capacity of 5,000
pounds of mainly 12-inch billets. The unit includes Allen
Bradley PLC-based instrumentation, pulse-firing combustion
control, pressure control and an assisted vertical opening
door. Insulation is made of a combination of ceramic-fiber
macromodules, IFB and hard refractory.
www.nutecbickley.com
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26 OCTOBER 2016 IndustrialHeating.com
NewsEquipment & Business
BUSINESS NEWSBodycote Acquires Nitrex Metal TechnologiesBodycote acquired Nitrex Metal Technologies of Burlington, Ontario. Nitrex Metal
Technologies, which is not affiliated with Nitrex Metal of Montreal, Quebec, specializes
in precision gas nitriding and ferritic nitrocarburizing in both batch and continuous forms.
Continuous gas nitriding and ferritic nitrocarburizing are unique in the industry and
particularly suited to high-volume automotive work. The acquisition adds to Bodycote’s
thermal-processing services, which already range from conventional atmosphere heat
treatments like batch IQ, vacuum and induction to specialty technologies like LPC,
BoroCote® and Corr-I-Dur®.
GE to Invest $1.4 Billion to Acquire AM CompaniesGeneral Electric plans to acquire Arcam AB and SLM Solutions Group AG, two suppliers
of additive-manufacturing (MA) equipment, for $1.4 billion. Sweden’s Arcam invented the
electron-beam melting machine for metal-based AM and also produces advanced metal
powders. Arcam also operates AP&C, a metal-powders operation in Canada, and DiSanto
Technology, a medical AM firm in Connecticut. Germany’s SLM Solutions Group produces
laser machines for metal-based AM and has sales and application sites worldwide. Both
companies, which will strengthen GE’s existing material science and AM capabilities, will
report to David Joyce, president and CEO of GE Aviation.
GKN Sinter Metals to Expand, Add Jobs in IndianaGKN Sinter Metals, a manufacturer of powder-metal products for the automotive
industry, announced plans to expand its operations in Salem, Ind. The company will invest
approximately $6.9 million to update equipment and renovate its 220,000-square-foot
facility, creating up to 24 new jobs by 2020. The new equipment will allow GKN Sinter
Metals to increase production of eight-speed and 10-speed transmissions. The first round
of enhanced equipment was installed this year, with the second phase scheduled to begin in
2017. The company also plans to make interior and exterior enhancements to its existing
building, including a room to showcase current advanced-manufacturing technologies.
Atlas Copco Completes Acquisition of Leybold VacuumEffective Sept. 1, 2016, Atlas Copco AB owns the former Oerlikon Leybold Vacuum GmbH,
renamed Leybold GmbH and now part of the Vacuum Solutions Division. The deal, worth
approximately $514 million, was first reported in November 2015. Leybold, headquartered
in Cologne, Germany, develops and delivers vacuum pumps, systems and customized vacuum
solutions and services for various industries. The company offers sustainable solutions for
industrial processes such as secondary metallurgy. Leybold’s product portfolio includes
rough-, medium-, high- and ultrahigh-vacuum pumps; vacuum systems; vacuum gauges; leak
detectors; components and valves; and consulting and engineering services.
Zhongwang USA LLC to Acquire Aleris for $2.33 BillionGlobal aluminum rolled products producer Aleris Corp. entered into a definitive agreement
to be acquired by Zhongwang USA LLC for $2.33 billion. Aleris will continue to be
headquartered in Cleveland, Ohio, and will be operated as an independent entity. The
company will retain its name and management team and continue to serve its customers
Induction Brazing with eldec.
Member of the EMAG Group
eldec, LLC3355 Bald Mountain Road, Unit 30Auburn Hills, MI 48326 USAph: +1 248 364 47 [email protected]
www.eldec-usa.com
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IndustrialHeating.com OCTOBER 2016 27
For More Information Contact Us Today Tel: (845) 651-6600 Email: [email protected]
Alumina Fiber Thermal Insulation That Outperforms All Others.
Breakthrough Technology
Built upon four decades of cost effective 1700oC high performance!
Introducing PATI
Reinforced - Resists Cracking Like No Other!Microwave Transparent!
Avion Manufacturing Company2950 Westway Drive, Suite 106Brunswick, OH 44212
Phone: 330-220-2779Fax :330-220-3709Web: www.avionmfg.come-mail: [email protected]
Boronizing is a thermochemical surface treatment in which Boron atoms diffuse into the steel substrate for a very hard Borocoat-layer. Boronizing easily tops the performance of commonly used methods such as carburizing and nitriding.
High hardness 1400-2600 HV, even on non-alloyed steels Diffusion depth 10-250 μm High abrasion resistance, resistance against cold welding Excellent thermal stability Self-lubricating effect at high temperatures Superior bonding strength, no coating but diffusion layer Good resistance against molten metals (Al, Zn)
with no changes to current operations, contracts or commitments. It
will continue with the implementation of all strategic growth projects,
including its major expansion project in Lewisport, Ky., which will
enable Aleris to meet the North American automotive industry’s
growing demand for aluminum auto-body sheet.
JV to Produce Titanium Powder for Additive ManufacturingGKN Hoeganaes agreed to enter into a joint-venture agreement with
TLS Technik to manufacture titanium powders in North America
for additive-manufacturing (AM) applications. TLS of Bitterfeld,
Germany, has 20 years of experience manufacturing titanium powder
for the AM market. The joint venture complements GKN’s previously
announced powder R&D efforts in Cinnaminson, N.J., and provides
a North American source for titanium powders, especially for the
aerospace and medical markets. A new facility for the joint venture is
scheduled to open in 2017.
University Creates 3D Printing ConsortiumCarnegie Mellon University’s NextManufacturing Center in
Pittsburgh, Pa., created a consortium to bring together major
companies and organizations in industry, the nonprofit sector and
government to unlock the potential of 3D printing in the U.S. The
consortium’s founding members include: Alcoa, ANSYS, Bechtel
Marine Propulsion, Bosch, Carpenter Technology, Federal Aviation
Administration, General Electric, Ingersoll Rand, National Energy
Technology Laboratory, SAE International and United States Steel.
NextManufacturing Center, which includes faculty and students
from the College of Engineering, School of Computer Science and
Mellon College of Science, is committed to developing new ways of
thinking to make 3D printing a mainstream manufacturing process.
The center also is developing new tools for a wide range of complex
manufacturing processes.
Refractory Companies Enter into AgreementSeven Refractories of Slovenia entered into an agreement with the
refractory business of Dalmia Bharat Group to develop and supply a
wide range of monolithic refractories for the Indian market. Dalmia
Bharat Group supplies refractory bricks and solutions to steel plants
in India, while Seven Refractories supplies monolithic refractories to
the European market. The cooperation agreement is intended to lead
to a joint venture between the companies.
CORRECTIONThere was an error in our August 2016 article “New Approach to
Material Handling Within the Heating, Heat-Treatment Cell.”
The word “patented” in the deck of the article should have read
“patent-pending.”
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28 OCTOBER 2016 IndustrialHeating.com
ECONOMIC INDICATORS
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REQUEST FOR QUOTE
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ORDERS
Values above 50 indicate growth or increase. Values below 50 indicate contraction or decrease.To participate in this survey, please contact Bill Mayer at [email protected]
When you need reproducibility, precision, andreliability, choose Praxair.With more than 100 years of experience in the useof industrial gases, Praxair can help you improve yourmanufacturing process. We offer a full range ofindustrial gases and services for heat treating andcombustion applications including:
• Heat treating atmosphere gases• Purging and inerting process gases• Award winning oxy-fuel combustion applications• Gas quenching• Thermal spray coating services• Furnace audits and process evaluations• Integrated gas supply capability• On-site evaluation, design, testing, and installation• Start-up and process support
For more information on how we can help your business, call 1-800-PRAXAIR or visitwww.praxair.com/heattreating.
Quality Stainless Fabrications • For all types and styles of industrial furnaces
All alloys incl. 304, 316, 309, 310, 330, RA253ma, 600, 601, RA602ca, Hast. C+X • Fabricated to customer specifications • Highest quality at a reasonable cost • High tech support available
Also Specializing in:
Radiant Heater Tubes Furnace Rolls Serpentine Trays Corrugated Boxes
Specialty Fixtures RetortsRecuperatorsAll Alloy Fabrications
34250 Mills Road, Avon, OH. 44011 (440) 327-5000 phone; (440) 327-5599 fax
Web: www.Qual-Fab.netEmail: [email protected]
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Address: 2821 Old Route 15 | New Columbia, PA 17856 | USA Phone: (570) 538-7200 | Fax: (570) 538-7380
www.thermalproductsolutions.com
DESIGN THE PERFECT PRODUCTCustomize our thermal processing ovens and furnaces to fit your application needs, in any environment.
Call our Engineering Design Center 570-538-7200
Or email [email protected]
Applications Military and aerospace
Consumer product testing
Clean room applications
Explosive environments
Inert gas atmospheres
High temps and vacuums
Small footprint designs
Robotic load/unload
Web-based management
Pollution control
Aftermarket service Start-up and training
Installations
Temperature uniformity
Preventative maintenance
Retrofits
Refurbished equipment
Rental equipment
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30 OCTOBER 2016 IndustrialHeating.com
PROCESS CONTROL & INSTRUMENTATION
Vacuum heat treatment is evolving as quickly as any
of the other subsets within the industry. Changes
are ushered into the industry as customers, end users
and governing bodies (AMS, Nadcap, etc.) press for
increased visibility of both production and available historical
data. Production and labor costs also significantly inf luence
how equipment is evaluated as heat treaters look to increase
utilization and reduce operational, rework and maintenance
costs. As requirements become more demanding, many heat
treaters are faced with a difficult question: Do we buy new
equipment or upgrade what we have?
Considerations for Replacing the Entire FurnaceOnce disassembled, a seemingly complex vacuum furnace
consists of relatively few components: the shell, hot zone, VRT
heating system, diffusion pump, vacuum pumping system and
various plumbing/valves.
Once isolated, all of these components become much simpler
to maintain. Cooling jackets can be cleaned, and specialized
instrumentation determines weak points. Degrading hot zones
and failing diffusion/vacuum pumps can be easily repaired,
rebuilt and replaced. Working with one of the industry’s
many specialized contractors allows for equipment to be
well maintained, serviced and repaired – greatly extending
equipment life.
With routine maintenance, furnace replacement can be
determined largely from production requirements. One example
is a larger certified work zone, which can be difficult to increase
even by a few inches. Production demands may exceed the
throughput of a furnace, requiring a larger model. A new
customer may require a positive-pressure quench process when
the facility only offers atmosphere-rated equipment. Any of
these scenarios may limit one’s options, leaving a new purchase
as the best choice.
Considerations for Upgrading ControlsIf a new furnace is not inevitable, upgrading controls may provide
all the needed functionality at a fraction of the cost. During any
upgrade, it is important to review or work with your contractor to
develop a modern and safe control package. “NFPA86 Chapter 14:
Class D Furnaces” outlines what considerations need to be made
when performing such work (Fig. 1).
New Panel vs. “Swapping” Out HardwareThe first question every heat treater considers: Do we replace
the entire panel or just the outdated hardware? With a new
panel significantly increasing the retrofit’s price, the return on
investment must justify the expense. New panels provide a clean,
documented solution that certainly “shows better” to existing
and potential customers. If space is of concern, the footprint can
also be reduced with modern, smaller instrumentation allowing
older two- to three-door enclosures being replaced with
single-door equivalents (Fig. 2). In addition, new panels may
significantly reduce unplanned downtime, offsetting the initial
expense over the course of several years. Some considerations
that may reduce downtime include:
Steven Christopher – Super Systems, Inc.; Cincinnati, Ohio
Vacuum heat treatment’s requirements are rapidly changing, with several accreditations infl uencing how heat treaters ensure product integrity. As requirements inevitably become more demanding, equipment must be evaluated for compliance. Heat treaters often fi nd themselves questioning whether they should replace or retrofi t equipment.
PROCESS CONTROL & INSTRUMENTATION
Fig. 1. Design view
Automated Control of Vacuum Heat-Treat Equipment
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32 OCTOBER 2016 IndustrialHeating.com
PROCESS CONTROL & INSTRUMENTATION
• What is the condition of the motor starters, relays,
transformers and other components within the control
panel? As these components fail, each failure will result
in some type of downtime, perhaps impacting product –
potentially resulting in liability or rework costs.
• What is the availability of a programmable logic
controller (PLC), silicone-controlled rectifier (SCR),
vacuum instrumentation and other complex components?
Some of the components within a control panel may have
become obsolete or have lead times exceeding four to
six weeks. PLC failure from obsolete processors can be
the single-most disruptive failure, resulting in extended
downtimes. To help estimate the exposure to component
failure, it is recommended that you routinely audit
hardware, calling your local distributor to determine
which are still offered. If offered, what is the lead time?
This proactive approach can also help determine what
needs to be stocked as spare parts.
• Are electrical schematics available for the control panel?
If so, how accurate are they? Inaccurate schematics often
extend unplanned downtime. Before beginning repairs,
maintenance crews must trace and re-label wires to
understand how a furnace is wired.
Uniformity Improvement via Heating-Circuit RedesignMany furnaces struggle with passing both low- and high-
temperature uniformity survey (TUS) ranges. Even with
routine hot-zone maintenance, this may be
inevitable. Minor modifications to the
heating system can result in drastic
improvements.
Traditionally, heat chambers have
three to five distinct zones with the
same number of variable reactance
transformers (VRTs). Each VRT’s out-
put is proportional to a command signal
and generates from a single silicone-con-
trolled rectifier (SCR), split into three
to five distinct signals. Each is manually
trimmed via adjustable rheostats.
Unfortunately, ideal rheostat settings
often vary between temperature ranges.
Improvements are achieved by replacing
the original SCR and rheostats with a
dedicated SCR for each VRT.
The loop controller must also be
evaluated because it will require the same
number of isolated analog outputs as SCRs.
Another desired feature is the ability
to uniquely scale each output at various
temperatures, improving uniformity and
“centering” the load TC delta at setpoint.
Many controllers and PLCs can have
expansion outputs added or replaced with an equivalent model
supporting the appropriate number of outputs.
Recipe/Loop Controller ConsiderationsControllers have seen significant advancements in recent years,
gaining f lexibility from historically basic ramp/soak profiles.
Modern PLCs and controllers offer a wide range of custom
features focused solely on vacuum heat treatment. When
evaluating one’s current controller, the following questions
should be asked. Does my current controller:
• Provide all of the functionality required by my customers
and accreditations?
• Allow for customization?
• Allow for a sufficient number of recipes?
• Provide complete visibility as to furnace
operation, valve position and motor status?
• Allow for selectable load TC evaluations for
guaranteed soaks?
• Generate and maintain an alarm history for
all applicable alarms?
• Offer built-in PID tuning assistance?
• Load custom PIDs for various temperature
ranges? Or by recipe?
• Automatically provide vacuum and outgas
interlocks?
• Accommodate for expansion should
additional analog outputs; load TCs; and
diffusion pump, dew point or vacuum
sensors be added?
• Communicate with a data-acquisition
(SCADA) system and any external
instrumentation via industry-standard
protocols (RS232, RS485, Modbus TCP)?
• Include a built-in maintenance program?
• Allow for remote access for support?
Is my current controller still offered by the
manufacturer? Is it available “off the shelf,” or
is it an obsolete item?Fig. 2. Vacuum control panel
Fig. 3. Open control panel with prints
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IndustrialHeating.com OCTOBER 2016 33
Built-In Maintenance ProgramsModern controllers also offer built-
in maintenance programs. Simple
maintenance programs record motor run
times and valve and production cycles.
Complex maintenance programs may
utilize a database allowing specific users
to track routine maintenance dates,
downtime and costs.
Custom reports and searches then
help shift from reactive to proactive
maintenance schedules. Preventive
maintenance reminders allow facilities
to reduce unplanned downtime, which
increases productivity. Plant-wide
maintenance costs can further be
reduced by performing maintenance on
actual run times rather than estimated
monthly intervals.
Vacuum Instrumentation ConsiderationsSeveral industry leaders have long
provided extremely accurate, robust
vacuum controllers to the heat-treating
industry (Fig. 3). Recent developments
in built-in communications may
inf luence the decision to replace
vacuum instrumentation. Does my
instrument support communications?
Communications are important because
they eliminate the inherently greater
error of analog signals. This not only
increases data accuracy but reduces the
need to calibrate chart recorder inputs.
Certain instruments allow
communication modules to be added to
the original design at a fraction of the
cost of a new controller. Others have to
be replaced with an equivalent model
supporting communications.
High-Limit Controller ConsiderationsSeveral specifications now require that
the high-limit controller’s temperature
be charted during production. Similar
to that of vacuum instrumentation, the
most accurate way to record data is to use
a controller with communications.
Certain models allow communication
modules to be added to the original
design, while others have to be replaced
with an equivalent model supporting communications.
Dew-Point MonitoringMany heat treaters are required to record each furnace’s inert gas dew point. Common
practices require an operator to manually sample gas into a handheld analyzer. This
requires the operator’s time and necessitates a handwritten log. Combined with the
trend chart, this creates two pieces of production documentation.
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34 OCTOBER 2016 IndustrialHeating.com
PROCESS CONTROL & INSTRUMENTATION
Modern controls integrate in-situ dew-point sensors that can
be trended 24/7, eliminating the need for paper logs. SCADA
and process controllers allow the operator or recipe to define
alarm thresholds, alerting the operator should the dew point
rise above a specified temperature.
Increased Visibility via SoftwareAs electronic SCADA has become more common, the
requirements have also become more stringent. Customers and
governing bodies have organized to formalize what type of
electronic data is acceptable. At minimum, a SCADA system
must be of non-modifiable, read-only, write-once format.
Storage in a non-encrypted database has the potential for post-
process manipulation and is considered unacceptable.
When evaluating any SCADA system, it is important to
understand today’s requirements, as well as consider that new
requirements may develop in the future. Leading software
offers secure, web-based updates, allowing industry compliance
for not only the year of purchase but the life of the software.
Historically, SCADA systems have recorded data in one-
to two-minute intervals. As computer memory becomes less
expensive, many now offer logging intervals as short as one
second, sometimes mandated for shorter-cycle processing.
SCADA systems should offer data in both graphical and
tabular views, allowing heat treaters, customers and auditors
to have valuable, irrefutable evidence of processing parameters
such as load tracking, utilization and job status.
Load TrackingPlant-wide software can effortlessly integrate production
with a load-tracking database. Sophisticated databases allow
management to:
• Restrict which recipes furnaces can process
• Maintain recipe revision history
• Access data from multiple computers
• Search production history via key information
• Produce trend charts and custom reports
• Reduce audit time
UtilizationModern software also determines equipment utilization,
calculating daily, weekly or monthly efficiencies. Shifts and
departments can be compared to allow visibility during off
hours. Utilities (gas and electricity) can be monitored to
calculate per-lot and monthly costs.
E-mail and Phone-Based AlertsFacilities requiring 24/7 visibility can utilize web-based alert
software. Programming distinguishes which alarms warrant
alerts, sending emails (or text messages) to mobile phones.
Critical alarms can escalate so that an alert is immediately
sent to a supervisor, followed by an email to engineering if the
alarm is not resolved in a specified time.
Alerts can be used to notify production of job status,
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IndustrialHeating.com OCTOBER 2016 35
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allowing them to reduce gap time. Example alerts include:
• Furnace alarms (high-limit condition, motor starter
tripped, process deviation)
• Monitoring (poor inert-gas dew point, warming water
temperatures)
• Maintenance alerts
• Production alerts (30 minutes remaining in cycle, end
of cycle)
SummaryWhen considering major equipment changes, the ideas
discussed within this article coupled with a practical,
production-minded and financially sound approach allow one
to answer the difficult question: Do we buy new equipment or
upgrade what we have?
Today’s technology can provide significant advantages for
equipment automation – increasing productivity, reducing
operating costs and maintaining compliance with the
constantly evolving industry that is vacuum heat treatment.
For more information: Contact Steven Christopher at Super Systems Inc.; 7205 Edington Dr., Cincinnati, Ohio 45249; tel: 513-772-0060; e-mail: [email protected]; web: www.supersystems.com
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36 OCTOBER 2016 IndustrialHeating.com
INDUSTRIAL GASES/COMBUSTION
Researchers at CHTE have been working on gas
and vacuum carburizing models that can be used to
optimize industrial carburizing-parameter processes,
eliminating much of the trial and error currently
happening in the industry. This report will focus on gas
carburization. As part of the research process, CarbTool®
predictions were compared with industrial experimental results
of four types of steels heat treated by gas carburization.
CarbTool® – Carburizing Simulation ToolThe solution algorithm used in CarbTool is based on the finite-
difference method (FDM), and the code is developed using
Microsoft Visual C++ in Window OS. Users can specify the
carbon potential or a f lux at the surface between gas and steel.[1]
The output of CarbTool is the carbon-concentration profile.
Users input carburization parameters, such as temperature, time
and carbon potential or f lux. After a quick simulation, the carbon
profile along the distance below the surface can be plotted, with
the case depth determined according to a user-defined value.
CarbTool has two modules: gas carburizing and vacuum
carburizing. Gas carburization functions include:
• Variable operating temperature
• Constant mass-transfer coefficient
• Variable carbon potential
• Single boost-diffuse process
• Data export of carbon profile at certain interval and final time
• Effective case-depth indication at 0.35 wt.% carbon or
other user-defined condition
Gas Carburizing ModelGas carburizing is a complex phenomenon that involves three
distinct stages: 1) carbon transport from the atmosphere to
the steel surface; 2) surface chemical reactions and absorption;
3) diffusion of the absorbed carbon atoms toward the bulk of the
steel down the chemical-potential gradient.[2]
Total carbon transfer from the atmosphere to the steel is
thus determined by a rate-limiting process, which kinetically
becomes the rate-controlling stage of carburizing. Figure 1
INDUSTRIAL GASES/COMBUSTION
CarbTool© – Leading the Way in Case-Depth SimulationsLei Zhang and Richard D. Sisson Jr. – Worcester Polytechnic Institute; Worcester, Mass.
Heat treaters want an eff ective simulation tool that predicts the carburization perfor-mance of a variety of steels. At the Center for Heat Treating Excellence (CHTE) at Worcester Polytechnic Institute (WPI) in Massachusetts, researchers are perfecting carbon-concentration profi le predictions through enhancements to CarbTool©, its simulation software.
Fig. 1. Schematic of gas carburization process[1,2]
Cp
Cs
Dc
Co
Boundary layer
Vapor-solid interface
Gas atmosphere Metal
J = β (Cp – Cs ) Chemical reaction at surface
β
J=-Dc dc—
dx
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38 OCTOBER 2016 IndustrialHeating.com
INDUSTRIAL GASES/COMBUSTION
shows the mechanisms of carbon transfer during carburizing and
the primary control parameters: the mass-transfer coefficient ( )
defining carbon atoms, f lux (J) from the atmosphere to the steel
surface and the coefficient of carbon diffusion in steel (D) at
austenizing temperatures.[1]
Mass-Transfer CoefficientA constant value for the mass-transfer coefficient is applicable
for most cases because once the carbon potential approaches
the near-solubility limit in austenite with carbon content
greater than 0.5 wt.%, the value of becomes consistent with
temperature and has little relation with gas compositions.[4]
The carbon potential of the carburizing atmosphere is set as
the boundary condition, which defines the physical problem.
The mass balance of the steel is:
β(Cp–C
s)=-D
c dc—
dx
[1]
Diffusivity DevelopmentDiffusivity data of 10XX, 51XX, 86XX and 48XX series
steels in the current version of CarbTool was experimentally
measured by O.K. Rowan.[1] Diffusivities of other alloys were
built-in based on the experience reference data. The comparison
of different alloys’ diffusivity is presented in Figure 2. These
curves are almost parallel to each other, so the diffusivity of
one alloy should be proportional to that of another alloy. For
example, 10XX and 51XX can be expressed as k in the following
equation; k is dependent on carbon concentration.
D51xx = k
51XX —D
10xx
From the f lux balance condition at the steel interface and the
continuity equation of the mass accumulation within the solid,
the rate at which the total f lux over the carburizing time is:
⌠⌡
x
xοC(x,t) dx =⌠
⌡
to
tf
Jdt
where x0 is the initial condition of the interface between the
two components of the diffusion couple, x∞ is the depth beyond
which no concentration gradient exists and t is the diffusion
time.
Assuming the isotropic media, based on Fick’s first law:
J(xo)=–D(x
o) dC
(x
o,t)
–dx
By equating the previous two equations, the expression of
diffusion coefficient from the carbon profile can be derived.[7]
D(xo)=-
⎛dC(xo,t)⎞ -1
•d ⌠
xo
Cdx– – ⎝ dx ⎠ dt ⌡
x∞
Based on this equation, two carbon profiles treated in the
same carbon potential and temperature but different time are
required. There are two parts: the negative inverse of the slope
Table 1. Chemical composition (wt.%) at room temperature
C Cr Fe Mn Mo Ni P S Si
8620 0.18-0.23 0.40-0.60 Bal 0.70-0.90 0.15-0.25 0.40-0.70 0-0.035 0-0.040 0.15-0.30
5120 0.17- 0.22 0.70-0.90 Bal 0.70-0.90 0 0 0-0.035 0-0.040 0.15-0.30
4320H 0.17-0.23 0.35-0.65 Bal 0.40-0.70 0.20-0.30 1.55-2.00 0-0.035 0-0.040 0.15-0.30
Table 2. Comparison between objective and experimental results
4320 8620 5120
Surface carbon (wt.%)
Target 0.7 ± 0.05 0.8 ± 0.05
Experiment 0.65 0.80 0.82
Simulation 0.69 0.83 0.83
Effective case depth (mm)
Target 0.89 ± 0.05
Experiment 0.87 0.82 0.84
Simulation 0.89 0.89 0.89
Fig. 3. Geometry of sample
Fig. 2. Carbon diffusivities as a function of alloy and carbon concentration
2.8E-07
2.4E-07
2.0E-07
1.6E-07
1.2E-07
8.0E-08
10XX
51XX
86XX
48XX
0.2 0.4 0.6 0.8 1
Carb
on d
iffus
ivity
, cm
2 /s
Carbon concentration, wt.%
Φ9.525 mm
76.2 mm
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40 OCTOBER 2016 IndustrialHeating.com
INDUSTRIAL GASES/COMBUSTION
of any position on the carbon profile and the differentiation
in terms of time-integrated area under the corresponding
section.[2]
To develop the diffusivity, samples of each alloy can be
treated in a carbon potential of 1.1 wt.% at three different
temperatures. Samples were kept for 1 hour, 2 hours and 3 hours
separately at each temperature.
Case StudyChallengeIn one study, a series of steels were to be carburized for
mechanical testing. The carbon profiles were achieved by gas
carburizing in endogas. CarbTool modeling was used to revise
the processes to achieve the same surface carbon concentration
and effective case depth.
Three materials are selected for the gas carburizing process.
Table 1 shows the chemistries (AISI and UNS). The carburizing
objectives are as follows:
• Case depth: 0.035 inch (0.9 mm) at C = 0.35 wt.%
• Surface carbon: 0.80 ± 0.05% for 8620 and 5120
• 0.70 ± 0.05% for 4320
Test samples were gas carburized in an industrial furnace
using a boost-and-diffuse method. Samples were heated up
to 1700°F and held 3.5 hours in endothermic gas at carbon
potential of 0.95%, then diffused at 1550°F for one hour in
carbon potential of 0.8%, quenched in oil at 140°F and tempered
at 350°F for two hours. Figure 4 shows the process schematic.
SolutionThe carbon depth-profile measurements of the carburized
parts were performed using an optical emission spectrometer
(OES). Modeling was calculated by inputting the parameters of
boost-and-diffuse cycles. Figure 5 shows the measured results
and model predictions from CarbTool. These results agreed very
well, which verified the effectiveness of CarbTool on predicting
gas carburizing.
The accuracy of CarbTool was demonstrated in Table 2.
CarbTool’s calculated surface concentration is compared with
the measured result. The effective case depth is also compared
for experimental and simulation results. They match each
other well.
Key Conclusions and Benefits• CarbTool is effective in predicting the carbon profile for gas
carburizing and vacuum carburizing.
• Carburization modeling helps heat treaters better
understand the effects of process parameters on the
diffusion process, distribution of carbon concentration, and
effective case depth and hardness.
• Effective modeling saves time and money over
experimental trials.
Fig. 4. Process schematic of gas carburizing
Tem
pera
ture
1700˚F1550˚F 1700˚F
Cp=0.95 wt.%
1550˚FCp=0.8wt.%
210 min 60 min
Time
Time
4.5 hours
Carburizing
TemperingQuenching
Cooling
2 hours25˚C
350˚F
140˚F
Fig. 5. Comparison of measured and predicted carbon profile of three alloys
0.80.70.60.50.40.30.20.1
0
0.90.80.70.60.50.40.30.20.1
0
0.90.80.70.60.50.40.30.20.1
0 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
CarbToolExperimental
CarbToolExperimental
CarbToolExperimental
Carb
on c
onte
nt, w
t. %
Carb
on c
onte
nt, w
t. %
Carb
on c
onte
nt, w
t. %
Depth, mm Depth, mm Depth, mm
4320 8620 5120
Tem
pera
ture
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IndustrialHeating.com OCTOBER 2016 41
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• The model will give engineers the ability to optimize
material, process and design for best results.
AcknowledgmentsCHTE member Timken Inc. provided the raw materials and
intellectual support for this research project. Carburization
heat treatments were performed at Bodycote Inc. and Surface
Combustion Inc. All are CHTE members. Their support is
greatly appreciated.
Lei Zhang is a graduate student and CHTE researcher at
Worcester Polytechnic Institute. Richard D. Sisson Jr. is the
George F. Fuller Professor of Mechanical Engineering and
technical director of CHTE at WPI.
For more information: If you are interested in learning more about this research study or about CHTE and its other projects, please visit www.wpi.edu/+chte, call 508-831-5592 or e-mail Richard Sisson at [email protected] or Lei Zhang at [email protected]
References available online
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42 OCTOBER 2016 IndustrialHeating.com
HEAT TREATING
After being rolled at forging temperature, most rings are
heat treated (i.e. normalized, quenched and tempered; see
Fig. 1). Because of this processing, some rings, especially
those with a large outer-diameter to wall-thickness ratio,
distort and become ovular (out of tolerance). This distortion is not
the only problem resulting from this phenomenon. Even if the
finished rings meet dimensional tolerances and are shipped to the
customer, residual stresses resulting from heat treatment may be-
come a problem during subsequent machining, causing additional
deformation and distortion.
A study on control of distortion and residual stresses in rolled
and heat-treated rings is being conducted by the Engineering
Research Center for Net Shape Manufacturing (ERC/NSM) in
partnership with the Forging Industry Association (FIA/FIERF),
Education and Consulting LCC and four forging companies
supplying the energy and aerospace industries. Understanding and
ultimately solving this problem is a challenging task considering
the three triggering mechanisms (thermal, metallurgical and
mechanical) that affect the ring during heat treatment and cause
the undesired results.
In light of the complexity of the problem, most ring-rolling
companies approach it with corrective rather than preventive
measures. Some manufacture the ring with large tolerances so
it can be machined to final dimensions. Others correct the ring
distortion by a mechanical method (compression or expansion),
which also partially relieves the residual stresses. However,
mechanical methods are fairly empirical, and there is a need for a
physics-based understanding and methodology to produce rings
with minimal distortion at an acceptable cost and lead time.
The ProcessRing rolling is conducted at a temperature around 2200°F
(1204°C). This leads us to an important assumption: The high
temperatures at which the ring is being formed will not create any
major residual stresses unless the rolling process itself is not well
controlled and leads to nonconcentric rings. Consequently, the
scope for this project does not include the finite element analysis
(FEA) of the ring-rolling process and focuses only on the heat-
treatment steps.
Before heat treatment, the rings are either arranged individually
or stacked in groups of four to six units. Then they are normalized
at approximately 1700°F (925°C) for two hours and air cooled.
Distortion in Rolled and Heat-Treated Rings
Forged rings with high outer-diameter to wall-thickness ratios are most prone to stresses from manufacturing and heat-
treating processes (courtesy of Scot Forge).
Normalizing(~925˚C, ~2 hours)
Air coolingQuenching tank
(54˚C)Air cooling
Austenitizing(~850˚C, ~2 hours)
Tempering(~590˚C, ~2 hours)
Fig. 1. Commonly used procedures in heat treatment of hot-rolled rings.
HEAT TREATING
Taylan Altan, Jose Gonzalez-Mendez, Alisson Duarte da Silva and Xiaohui Jiang – The Ohio State University; Columbus, Ohio
The rolling and thermal treatment of forged rings sometimes leaves residual stresses that cause dimensional distortion. Corrective measures in industry are often based on trial-and-error techniques. Ongoing research seeks to base corrective actions on the laws of physics.
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44 OCTOBER 2016 IndustrialHeating.com
HEAT TREATING
Industry experience indicates that, although ring stacking
will cause nonuniform cooling, the observed distortion is not
significant due to the slow cooling rate. Furthermore, the residual
stresses developed will vanish in the next heating stage.
Prior to quenching, austenitizing is typically carried out at
1515°F (850°C) with the same stack used during normalizing.
After exiting the furnace, the rings are submerged into a
quench tank. The cooling rate at which the rings reach the
bath temperature should be fast enough to generate martensitic
microstructure that will harden the ring material.
Microstructural IssueA microstructural change takes place during quenching. Ideally,
the ring has a homogeneous austenitic microstructure at the
beginning of this step. Depending on the cooling rate, the
microstructure will change to pearlite, bainite or martensite
(Fig. 2). The amount of transformation will not be the same
along the cross section of a ring.
How will this affect the distortion and residual stresses
development?
The strain and stress fields vary with time depending on
the thermal and mechanical properties of each phase, which
are, in turn, functions of temperature and cooling rate. Also,
the volume change at each phase and transformation plasticity
during phase transformation should be taken into account. All
these factors act together and cause the undesired phenomena,
namely that the stresses may
exceed the yield point at various
locations in the ring. Thus, non-
homogeneous plastic flow occurs,
causing distortion.
Heat-Treatment FEAThe commercial modeling
program used for this project
is DEFORM from Scientific
Forming Technologies of Columbus,
Ohio. This software allows us to conduct a thermomechanical
and metallurgical analysis to predict microstructural changes
and geometrical variations. The phase-transformation model
of the material is determined by the cooling rate and phase-
transformation kinetics. Since each phase carries particular thermal
and mechanical properties, these factors are integrated into
the model and calculated accordingly. The thermal component
considers the heat transfer between the ring and the environment,
whether it is air or a quenchant. Finally, the calculation of stresses
and strains through each phase constitutes the mechanical model.
For this project we selected an AISI 4140 ring that is
geometrically similar to rings produced and heat treated by the
sponsoring companies. The dimensions are given in Table 1. To
simplify our calculations, we assumed that a single ring is heat
treated. In actual industrial settings, only large rings are thermally
treated individually, while smaller rings are heat treated in stacks.
Normalizing and Austenitizing Heating StagesThe heating operations for normalizing and austenitizing were sim-
ulated for two reasons. First, volumetric expansion of the ring prior
An operator in a control room oversees the ring-rolling line (courtesy FRISA Industries).
100
80
60
40
20
0
Austenite
Martensite
Bainite
Ferrite
0 200 400 600 800 1000 0 200 400 600 800 1000Temperature, ˚C Temperature, ˚C
Austenite
Martensite
Bainite
Pearlite
Ferrite
100
80
60
40
20
0
Phas
e vo
lum
e, %
Phas
e vo
lum
e, %
Fig. 2. Microstructure evolution in 4140 steel during cooling at: a.) 20°C/s and b.) 5°C/s.
a. b.
Table 1. Ring dimensions
Dimensions in mm
Outer diameter (OD) 1,296
Inner diameter (ID) 1,164
Height (H) 163
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THANK YOU FNA 2016 SPONSORS
AFC -Holcroft
Chemtool Incorporated /Tenaxol
Dry Coolers
Dubois Chemicals/Heatbath
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Industrial Heating
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Ipsen
J.L. Becker
Metal Treating Institute
Radyne / EMSCO / Lepel
Solar Manufacturing
Super Systems Inc.
Surface Combustion
Wirco
I would like to personally thank each and every sponsor,
I would also like to say we’re hard at work preparing
Patrick McKenna
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46 OCTOBER 2016 IndustrialHeating.com
HEAT TREATING
to cooling was captured. Second, to corroborate that the heating
time is sufficient to achieve homogeneity at the desired temperature,
we assumed that austenite was formed with volume fraction 1.0 in
the ring at the end of every heating stage and before quenching.
Air CoolingConvection, conduction and radiation are the heat-transfer
mechanisms that act during air cooling. The finite element
(FE) simulation conducted considers that after heating for
normalizing, two rings are individually placed one next to
another on a resting surface. The heat-transfer coefficient
with the environment was selected assuming still air, while the
conduction coefficient was chosen upon free resting conditions
on the surface. The radiation phenomenon was modeled by the
Boltzmann equation, considering also the proximity effect of an
adjacent cooling ring that emits heat.
QuenchingThe heated rings are submerged in a quenching tank with
agitated solution (Fig. 3). In order to simulate the quenching, heat
conduction of the ring with the quenchant should be carefully
modeled. A computational fluid dynamics (CFD) tool depicts the
heat-transfer conditions for a particular quenching system. This
approach, developed for academic purposes, has some limited
commercial application.
On the other hand, from an industrial point of view, the
number of possible quenching settings and ring geometries
make the CFD analysis impractical and expensive. Therefore,
we adapted a FE tool to achieve a close-to-reality and practical
quenching simulation.
The most critical parameter during quenching is the heat-
transfer coefficient, which depends on temperature, agitation
and stacking conditions. Some companies participating in this
project conducted temperature measurements on the ring during
quenching. This data was later analyzed to calculate the heat-
transfer coefficient. It is noteworthy that this calculation depicts
the specific quenching conditions (location in the tank and in the
stack, propeller proximity and orientation) for this ring and cannot
be standardized for any given ring that is quenched in this tank.
Figures 4 and 5 show examples of the distortion evolution
through time during quenching and the final estimated
distortion after heat-treatment simulation, respectively. Here,
different values of the heat-transfer coefficient were assumed at
various locations in the quenched rings.
The reliability of a quenching simulation is conditioned to
mostly two things. The first is the precision with which the
quenching tank conditions are emulated (in other words, how
reliable the heat-transfer calculations are). The second is the
accuracy of the mechanical (elastic and plastic), thermal and
metallurgical properties of the material to be simulated.
Fig. 3. Typical arrangement of ring stacks in the quenching tank.
Fig. 4. Example of distortion evolution during quenching (diameter comparison between X and Y direction).
Quenching tank with agitated solution X-dimension
Difference between X and Y dimension
0 5 10 15 20Quenching time, min.
Initial volumetric expansion due to heating prior to quenching1.61.41.2
10.80.60.40.2
0
A zero value would mean that the ring has returned to nominal diameter
Y-di
men
sion
Location of propellers (agitation) varies
according to tank design.
Y
YZ
XX
X dimensionY dimension
6.15mm
Fig. 5. Resulting geometrical distortion and residual stresses after FE simulation of heat treatment (original ring dimensions are given in Table 1).
570
499
428
356
285
214
143
71.3
0.000
Reference geometry
Maximum deviation from circumference: 6.15 mm Nominal outer diameter 1296 mm Geometry with magnified displacement X10
Y
OX
Fig. 6. Preliminary results for FEA of mechanical correction method (compression): a.) FE setup; and b.) residual stress distribution after corrective method.
Effe
ctiv
e st
ress
, MPa
570
499
428
356
285
214
143
71.3
0.000Compression stroke
Distorted geometry
Targetgeometry
a) b)
Flattools
Effe
ctiv
e st
ress
, MPa
Y Y
O OX X
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IndustrialHeating.com OCTOBER 2016 47
SummaryAs progress is made, the ERC/NSM
is building its knowledge in heat-
treatment simulations and recognizing the
importance and intricacies of an integrated
metallurgical, mechanical and thermal
analysis. We can summarize our progress
as follows:
• Different steps of heat treatment (up
to quenching) have been simulated
in a commercial FE code in order
to predict ring distortion and
distribution of residual stresses.
• According to FEA results, air
cooling will not create any significant
distortion (ovality).
• Heat-transfer variation during
quenching as a function of
temperature, tank and stack location,
and quenchant agitation is the key
factor in calculating distortion, hence
the importance of correctly modeling
the heat-transfer coefficient.
• Through FEA, distortion and
residual-stress distribution have been
predicted assuming certain quenching
conditions.
Our ongoing work focuses on the
mechanical methods (e.g., compression or
expansion) used by ring-rolling companies
to correct geometrical distortion and
relieve residual stresses. Our goal is to
establish a physics-based methodology
that will optimize the procedure used for
mechanical correction (i.e., minimum
time and best achievable tolerances in
concentricity).
To this end, we considered the distorted
ring geometries obtained from quenching
simulations to investigate the compression
method by corrective tools already in
use. These, in our opinion, are not well
understood, since most of this experience
is built on trial and error. Our intent is to
find a relationship between the distortion-
to-diameter ratio and the compression
stroke needed to achieve the geometrical
tolerances for the ring.
Preliminary results (Fig. 6) show that a
number of compression steps at different
locations of the ring will correct ovality,
and residual stresses are relieved through
this plastic strain. Further work needs to be conducted to optimize the process.
For more information: Contact Taylan Altan, professor and director of ERC/NSM, The Ohio State
University, 339 Baker Systems, 1971 Neil Ave., Columbus, Ohio; tel: 614-292-9267; web:
www.ercnsm.org. Co-authors Jose Gonzalez-Mendez, Alisson Duarte da Silva and Xiaohui
Jiang are graduate research associates.
www.AjaxTocco.com
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48 OCTOBER 2016 IndustrialHeating.com
CERAMICS & REFRACTORIES/INSULATION
Every refractory material has both technological and
economic advantages and disadvantages relative to
the specific application. For the correct selection, it
is important for the plant operator, the kiln/furnace
supplier and the refractory supplier to work in partnership to
achieve the optimum technical and economic solution. The
solution presented is based on using high-temperature insulating
wool (HTIW) products, which boast significant advantages
compared to traditional refractory products on investment cost,
operating expenses, reliability, overall efficiency and the fast
availability of the equipment following relining or maintenance
and repair work.
What is high-temperature insulating wool (HTIW)? HTIW
in the form of alumino-silicate fiber (ASW; Rath ALSITRA)
and mullite polycrystalline fiber (PCW; Rath ALTRA® 72)
provide excellent chemical, physical and thermomechanical
properties and belong in this group of high-temperature
insulating wools along with alkaline-earth silicate fiber (AES).
For our North American colleagues, refractory ceramic fiber
(RCF) and polycrystalline fiber are called HTIWool in most of
the world.
As a result of increased requirements on industrial furnaces
with application temperatures above 900°C (1652°F), the
use of HTIW has increased greatly in the last decade.
Much of this demand is where the insulation is exposed to
high thermomechanical (temperature shock), mechanical
or chemical stresses. Considering this general demand,
special ultra-lightweight products made of HTIW with
their outstanding thermal, thermomechanical and chemical
properties are particularly suitable for application in modern
industrial furnaces.
The advantages of these materials are obvious.
• Optimized specific energy consumption (with up to 50%
energy savings compared to conventional dense/heavy linings)
• Increase in the overall efficiency of high-temperature
furnaces
• Reduction of greenhouse-gas emissions
• Excellent chemical stability
CERAMICS & REFRACTORIES/INSULATION
High-Temperature Insulating Wools:Classification (part 1)
Rick Sabol – RATH Inc.; Newark, Del.
Back in the 1980s when I fi rst started working in refractories, an old refractory foreman at Bethlehem Steel told me, “There are no bad refractories; you just put them in the wrong spot.” Now all these years later, I’ve come to realize he was right on both counts. There are no bad refractories, and 50 isn’t old.
Refractory Materials
Wool
Mats/blankets
Modules
Paper
Boards
Functional products and shapes
Vacuum-formed products
Plastic mixes and foams
Ropes, textiles
Heat-insulating and insulatingrefractory bricks
Other heat-insulating materials
Materials made from high-temperature insulation wool
Heat-insulating materials
Dense shapedrefractory products
Unshapedrefractory materials
Functionalrefractory products
Fig. 1. Classification of refractory materials
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IndustrialHeating.com OCTOBER 2016 49
• Outstanding thermomechanical properties (e.g., almost
unlimited thermal shock resistance)
This paper presents an overview and examples of the use of
HTIW products in thermal-process engineering in the steel
industry. Examples include:
• Module lining (combined systems) in forging furnaces
• Ultra-lightweight burner blocks
• Ultra-lightweight insulation for water-cooled rollers in
roller-hearth furnaces (e.g., continuous for casting/thin
casting compact-strip production – CSP/thin-slab casting)
Refractory Materials and Products of HTIWRefractory materials can be classified into four main groups in
accordance with Fig. 1:[1]
• Dense, shaped refractory products
• Unshaped refractory materials (monolithic)
• Functional refractory products
• Heat-insulating materials
The main group of heat-insulating materials includes HTIW
products, heat-insulating and insulating refractory bricks
and other heat-insulating materials (e.g., calcium-silicate and
microporous materials, etc.).
An overview of the HTIW products is also shown in Fig. 1.
The range of products formed from these ultra-lightweight
materials extends from wool through mats/blankets and
modules to vacuum-formed products in the form of boards,
functional products and shaped components.
HTIWs used as raw materials for the above-mentioned
ultra-lightweight refractories are part of the group of
inorganic, man-made mineral wools. An overview of HTIWs
is shown in Fig. 2.
The products made from alumino-silicate wool
(ALSITRA) and polycrystalline wool (ALTRA) are
undoubtedly most important in the group of HTIW for
thermal-processing installations and industrial furnace
construction. Thanks particularly to their outstanding
technical properties, these products are now indispensable
for a wide range of industrial applications in the temperature
range of 600-1800°C (1110-3270°F).
Products made of AES, another form of high-temperature
insulation wool, exhibit lower chemical resistance and are more
prone to recrystallization, thereby limiting their potential
application in thermal-process engineering. The main
application for these AES materials is in the domestic appliance
industry and in industrial processes for temperatures to a
maximum of 900°C.
Alumino-silicate wool (ALSITRA) and the AES wools
are produced in a melting process and a subsequent blowing
or spinning process. Crystallization, shrinkage and sintering
processes limit the application temperature of these products to
below 1300°C (2370°F).
In contrast, HTIWs on the basis of alumina (PCW, e.g.,
ALTRA 72) are produced with sol-gel technology and heat-
treated at temperatures up to 1400°C (2550°F) during the
production process. The materials produced in this way have
classification and application temperatures up to 1650°C
(3000°F). Application-specific and optimized delivery forms
(vacuum-formed components ALTRAFORM) ensure the
suitability of these products up to temperatures of 1800°C.
Table 1 lists the most important physical and chemical
Fig. 2. Overview of high-temperature insulation wools
High-temperature insulation wool (HTIW)
Wool alkaline-earth-silicate (AES)
Calcium-magnesium-silicate-wool
Aluminumsilicate-wool
Aluminum-zirconium-silicate-wool
Calcium-magnesium-zirconium-silicate-wool
Magnesium-silicate-wool
Aluminum silicatewool (ASW/RCF)
Polycrystalline wool alumina-wool (PCW)
Fig. 3. Temperature ranges for the application of synthetic mineral and high-temperature insulation wools
Tem
pera
ture
, ˚C
1600
1400
1200
900
600
300
20
Polycrystallinewool
Alumino-silicatewool
The width of the cone indicates the frequency
of application of thermal insulation materials in
specifi ed temperature range
AES-wool
Mineral wool(glass and rock wool)
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50 OCTOBER 2016 IndustrialHeating.com
CERAMICS & REFRACTORIES/INSULATION
properties for the evaluation of HTIWs.[2] The classification
temperature of HTIWs is defined as the temperature at which
a permanent linear change (shrinkage) of 4% is not exceeded
after 24-hour heat treatment in an electrically heated laboratory
furnace in a neutral atmosphere.[3]
The actual maximum application temperatures of amorphous
HTIW (ASW and AES wool) are generally at least 150-200°C
(safety allowance) below this classification temperature. This
is because, in contrast to the determination of the classification
temperature in ideal, neutral-firing conditions with a relatively
short exposure (24 hours), the products used in the field are not
only exposed to high temperatures but to additional chemical
and physical stresses that often deviate far from ideal conditions
and therefore limit the application temperature.
In contrast, products made of polycrystalline high-
temperature wool (PCW; e.g., ALTRA) can be used without a
safety allowance up to the actual classification temperature, even
in industrial applications.
Besides the typical chemical compositions and the resulting
classification temperatures, the actual application temperatures
under process conditions, chemical resistance to acids and bases
and apparent density are important for the use of the materials
in industrial furnaces. These conditions differ widely in the
field of thermal-process engineering applications in which
HTIW is used.
The most suitable materials, and especially the most
appropriate high-temperature insulation wool for the respective
application, can be selected based on the specifications in
TRGS 619 (Technical Rules for Hazardous Substances).[4]
This technical guideline is a valuable aid to all involved with
thermal-processing installations – plant operators, furnace and
refractories suppliers – in the selection of a suitable refractory
material.
At the same time, TRGS 619 provides an excellent possibility
for the documentation of the furnace lining concept for
regulatory agencies and/or for those responsible for occupational
health and safety and environmental protection.
The competent user and furnace supplier will, in
consideration of this directive, opt for the use of HTIW
as refractory lining material for a thermal-processing plant
providing this material proves technically suitable in an
objective analysis.
Figure 3 shows, in simplified and clear form, the possible
temperature ranges for the application of HTIW products,
with indication of the frequency of application in the respective
temperature window.
ConclusionWith regard to the enormous technical developments in the
construction of industrial furnaces and the energy savings
that have only been made possible thanks to the application
of high-temperature insulation wool products in different
industrial sectors, thermal insulation for progressive
companies with state-of-the-art processes and temperatures
exceeding 900°C would be unthinkable without these
materials.[7,8]
In part 2, we will continue our discussion of the benefits of
HTIW and cover some specific applications such as burner
blocks and roller-hearth furnaces.
For more information: Contact Rick Sabol, business development manager, RATH Inc., 300 Ruthar Drive, Newark, DE 19711; tel: 302-294-4458; e-mail: [email protected]; web: www.rath-usa.com
References available online
Table 1. Physical and chemical properties of high-temperature insulation wool
Product
Chemical properties Physical properties
Chemical composition
Acid/ alkaline
Classification temperature
Typical service temperature
Softening point
Bulk density
Thermal shock sensitivity
Mean fiber length
˚C ˚C ˚C kg/m3 μm
AES wool
CaO
-/+ 1000 <1000 ~~1280 96-128 + 1-3MgO
SiO2
MgOSiO2
-/+ 1250 <1100 ~~1360 96-128 + 1-3
Aluminum silicate wool
Al2O2 (48%); SiO2 (52%) +/- 1250 <1150 ~~ 1700 96-160 ++ 1-3
Al2O2 (54%); SiO2 (48%) +/- 1400 <1300 ~~1750 96-160 ++ 1-3
Al2O2 (35%); SiO2 (50%)ZrO2 (15%)
+/- 1400 <1300 ~~1570 96-160 ++ 1-3
Polycrystalline wool Al2O2 (72-80%); SiO2 (20-28%) +/+ 1850 <1850 ~~2000 80-120 ++ 2-4
Al2O3 (97%); SiO2 (3%) +/+ 1850 <1850 ~~2000 80-120 ++ 2-4
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IndustrialHeating.com OCTOBER 2016 51
Silicon Carbide CeramicsSGL Group – The Carbon CompanySIGRASIC® Performance, which is produced from the carbon fiber
reinforced carbon (CFC) material SIGRABOND® Performance
by means of a special infiltration process, is used for charging
elements and systems. With its hi gh fiber content and low porosity,
this material combines the benefits of ceramic with the favorable
characteristics of carbon fiber material. For CARBOPRINT® Si,
the basic structure made of carbon
is established in a 3D printing
process. By infiltrating the
printed component with silicon, a
carbon-reinforced silicon carbide
ceramic is created that offers a
high ductility in combination
with resistance against corrosive
atmospheres and a high abrasion
resistance. www.sglgroup.com
Vacuum PumpBusch USAThe COBRA NX vacuum pump is ideal for industrial applications
and for wherever gases and vapors need to be pumped reliably and
without contamination. The pump provides dry screw technology,
which allows the compression chamber to be completely free
from operating fluids. This prevents condensation and deposits
from the pumping medium and stops the medium from becoming
contaminated with oil. The pump design allows for high, stable
pumping speed in the common operation pressure range. COBRA
NX is equipped with direct water cooling, which ensures optimum
cooling, and all functions required for maintenance are located on
one side of the pump. www.buschusa.com
Bearing AssembliesMetallized Carbon Corp.Cast iron pillow blocks and flange blocks with self-lubricating,
carbon-graphite bearing inserts can be used for applications where
oil/grease lubrication cannot. These bearing assemblies provide low
friction and long maintenance-free wear life in high-temperature
applications. They are ideal for high-temperature conveyors for
annealing and heat treating.
Three carbon-graphite grades are
supplied: Metcar Grade M-11,
carbon graphite, for light loads
at temperatures up to 700°F;
Metcar Grade 1515, copper-
impregnated carbon graphite,
for higher loads at temperatures
up to 750°F; and Metcar Grade 2500, high-temperature electro-
graphite, for temperatures up to 1000°F. www.metcar.com
Modular Vacuum ControllerThe Fredericks CompanyThe TELEVAC MX200 modular vacuum controller is suited for
use in heat-treating and vacuum furnaces, laboratories and research,
cryogenics, leak detection, and coating processes. An upgrade of the
TELEVAC MM200, it includes the addition of USB and enhances
existing RS-232/485 communications protocols for more efficient
interfacing. The device, which controls any TELEVAC vacuum
sensor, provides a 10-millisecond response time, which is 20 times
faster than the previous version. Users can access all features through
a new display panel, and the front panel shows up to eight sensors.
www.frederickscompany.com
ProductsThermalProcessing
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52 OCTOBER 2016 IndustrialHeating.com
ControllerBartlett Instrument CompanyThe Genesis touchscreen temperature controller features
a user-friendly display, WiFi communications, improved
diagnostics, data collection and real-time graphing. It is a
direct replacement for Bartlett-manufactured controllers,
and no extra wiring is necessary. Software upgrades can be
done via a WiFi connection, and users will soon be able to
monitor their kilns from a smartphone app.
www.bartinst.com
Fluid Monitor and Control SystemHoughton InternationalThe GREENLIGHT™ continuous concentration monitor is a completely self-contained
measurement system. Its small, modular design enables easy, reliable and low-cost
continuous monitoring of fluid concentration using state-of-the art refractive index
sensor technology with a user-friendly interface. The ACTS™ fluid monitor and control
system is a fully integrated system that measures pH, temperature, conductivity or other
fluid properties in addition to concentration via refractive index. It provides automatic
concentration control capability by independently controlling six separate programmable
relay outputs for additions of water, fluid concentrates or additives. www.houghtonintl.com
Gas-Fired FurnaceGrieveNo. 1042 is a 2000°F (1093°C), gas-fired heavy-duty furnace
designed for heat-treating applications. Workspace dimensions
measure 30 inches wide x 60 inches deep x 30 inches high, and
750,000 BTU/hour are installed in four modulating natural gas
burners with a floor mounted combustion air blower. The unit’s
insulated walls are
comprised of 5-inch-
thick 2300°F ceramic
fiber and 4-inch-
thick 1900°F block
insulation. It features
two lanes of roller
rails supported by
firebrick piers and an
air-operated platform
with roller rails to
bridge from loading
table to workspace.
Controls include a
digital indicating
temperature controller
and manual reset
excess temperature
controller with
separate contactors.
www.grievecorp.com
ProductsThermalProcessing
Quality Heat Treat Equipment & Atmosphere Generators
THERMO TRANSFER INC.
Radiant Tube Heated Roller Hearth Furnace
Our Gas Fired Roller Hearth Furnaces incorporate the latest features in furnace design including atmosphere, temperature and PLC controls.
We offer complete design, manufacturing, installation and service for all of your heat processing equipment needs.
Roller Hearths Tip-UpsMesh Belts Atmosphere EquipmentBox Furnaces Replacement PartsCar Bottoms Complete Rebuild ServicesCatalyst Repairs
For more information, write or call: Thermo Transfer Inc. 1601 Miller Ave. Shelbyville, IN 46176 (317) 398-3503; Fax (317) 398-3548 Website: www.thermotransferinc.com
CUSTOM HIGHEFFICIENCY
COMBUSTIONSYSTEMS
We custom design our 300O to 2300OF systemsto our customers’ specifications and offer
turnkey manufacturing and installation.
Call 704.814.9221www.AirAndEnergyInc.com
State Of The Art Design
Heavy Steel Construction
Highest Quality Materials
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IndustrialHeating.com OCTOBER 2016 53
INDUSTRY EVENTSOctober 10-1212th China International Heat Treat and
Furnace Expo; Shanghai
www.cihtexpo.com
October 18-20European Brazing School, hosted by Wall
Colmonoy; Pontardawe, Wales
www.wallcolmonoy.com
October 23-27MS&T 16 – Materials, Science and
Technology 2016; Salt Lake City, Utah
http://matscitech.org/
October 26-28Heat Treatment Congress 2016;
Cologne, Germany
www.hk-awt.de/en
October 26-28TMP 2016 – Thermo-mechanical
Processing International Conference;
Milan, Italy
www.aimnet.it/tmp2016.htm
November 6-11AVS 63rd International Symposium and
Exhibition; Nashville, Tenn.
www.avs.org
November 15-17Fundaments of Brazing Seminar, hosted by
Kay & Associates; Simsbury, Conn.
www.kaybrazing.com
November 17-18Nitriding Symposium, hosted by Nitrex
Metal and United Process Controls; Las
Vegas, Nev.
www.nitriding.info
Nov. 29-Dec. 1Aluminium 2016 – 11th World Trade Fair
and Congress; Düsseldorf, Germany
www.aluminium-messe.com
Heat Treating Systems
Forging & Forming Systems
Tube & Pipe Systems
Brazing & Joining
Specialty Heating
Retrofits & Rebuilds
Field Service & Coil Repair
Induction Heating Equipment Solutions
If you would like to submit a thermal-processing
event to appear on our online calendar, visit www.
industrialheating.com/events and click the “Submit
an Event” button. You can also check out a full list
of industry events, including those coming in 2017.
SUBMIT AN EVENT
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54 OCTOBER 2016 IndustrialHeating.com
LITERATURE & WEBSITE SHOWCASE
Thermal Insulation MaterialHaoshi Carbon Fiber Co.We manufacture all of our own carbon and graphite thermal insulation materials under the strictest quality standards. We supply carbon fiber, carbon felt, graphite felt, rigid graphite board, hot zones and CFC for vacuum furnaceswww.hscf-group.com
AtmospheresPraxair Inc.Based on the proven benefits of nitrogen/hydrogen processes with customers who previously used disassociated ammonia or exothermic gas, Praxair has made advances in atmosphere use and pressure control for improved furnace operations.www.praxair.com
High-Temperature LensingMarshall ElectronicsMarshall Electronics Optical Systems Division is the global OEM leader of high-temperature lensing used worldwide in hot industrial process environments for real-time imaging. Our high-temperature pinhole to 1000°C lens products are used in thermal processes for temperature measurement monitoring; and vacuum processing, heat treatment, leak detection and industrial furnace applications.www.marshall-usa.com/electronics
Hexoloy Silicon CarbideSaint-Gobain CeramicsSaint-Gobain Ceramics' new brochure offers a comprehensive overview of its line of ceramic materials for high-performance applications, including Hexoloy® sintered silicon carbide, Norbide® hot-pressed boron carbide and Noralide® NBD-200 hot-pressed silicon nitride. Content includes technical information and fabrication processes. Call 716-278-6233 for more information. www.refractories.saint-gobain.com
InsulationUnifrax I LLCFoamfrax™ insulation offers exceptional energy savings, installation speed and lining performance for upgrades of existing fiber linings, lining over refractory, and furnace lining patches or refits. It can be gunned directly onto metal, refractory or fiber surfaces and installed at rates in excess of 1,000 board feet/hour. www.unifrax.com
Cooling TowersDelta Cooling TowersDelta Cooling Towers manufactures a complete line of corrosion-proof engineered-plastic cooling towers. The towers carry a 15-year warranty on the casing, which is molded into a unitary leak-proof structure of engineered plastic. All models are factory assembled and simple to install.www.deltacooling.com
Carbon Atmosphere AnalyzerSuper Systems Inc.The CAT-100 atmospheric carbon potential analyzer provides a measurement of carbon potential in a furnace with a carbon-bearing atmosphere. The easy-to-use product provides a fast reading based on analysis of a metal coil soaked in the furnace for about 30 minutes. The CAT-100 has a color touch screen with features that include logging stored readings and furnace settings.www.supersystems.com/cat.html
Heat-Processing EquipmentThermo Transfer Inc.Thermo Transfer Inc. provides complete design, manufacture and installation of new equipment. We also provide repairs and modifications to your existing heat-processing equipment. Thermo Transfer Inc. can provide replacement parts for the equipment it builds and for other manufacturer’s furnace and generator equipment. www.thermotransferinc.com
High-Temperature Ceramic MaterialsZIRCAR Ceramics Inc.ZIRCAR Ceramics Inc. manufactures ceramic-fiber-based high-temperature thermal and electrical insulation products for use at temperatures up to 1825°C (3317°F). We offer boards, cylinders, blankets, papers, textiles, coatings and adhesives. In addition, we provide furnace insulation assemblies and resistance heated modules.www.zircarceramics.com
Carbon Bonded Carbon Fiber (CBCF) InsulationGraphite Machining Inc.We specialize in elements, injection nozzles, connectors, hearth assemblies, furnace fixtures and our American-manufactured HEATGUARD insulation board. HEATGUARD is moisture- and gas-resistant, allowing rapid pump-down to deep vacuums. Superior insulating properties result in greater energy savings. www.graphitemachininginc.com
Downloaded from "www.sholehsanat.com"
IndustrialHeating.com OCTOBER 2016 55
PARTS • SERVICE • CONSULTINGContact: Becky McClelland Phone: 412-306-4355 Fax: 248-502-1076 [email protected] Rates: Just $145 per month for a single card, $290 for a double card. We’ll post your ad online for an additional $30.
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Call: 248-624-8191Fax: 248-668-9604
AFTERMARKET SERVICES Field Service Installation Vacuum Leak Testing/Repair Preventative Maintenance Used/Rebuilt Furnaces
55 Northeastern Blvd., Nashua, NH 03062Ph: 603-595-7233 Fax: 603-595-9220
Alan Fostier: [email protected] Demers: [email protected]
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for current inventoryJohn L. Becker, II Ph: 734-331-3939
Fax: 734-331-3915 Cell: 734-516-2814
PROFESSIONAL SUPPORT SERVICES TO INDUSTRYTHE HERRING GROUP, INC.
Home of “The Heat Treat Doctor”®
Education/Training - Consulting - Product/Process Analysis - Problem Solving -
Furnace Diagnostics
Ph: 630-834-3017; Fx: 630-834-3117email: [email protected]
Web: www.heat-treat-doctor.com
YOUNGMETALLURGICALCONSULTING
Training and expertise that make a difference
Young Metallurgical Consulting will work
with your staff to teach the day-to-day
processes necessary to manage and improve
your organization. Your employees will
learn the aspects of heat treating that are
not taught in the classroom and can only be
gained through direct hands on experience.
Production Scheduling Quality Procedures, Control Plans, Written Instructions, PFMEA &
CQI-9 compliance
Customer Service Essentials
www.youngmetallurgicalconsultinginfo@youngmetallurgicalconsulting.com
248-909-0038
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THE AFTERMARKET
www.pillar.com
Induction Heating For more information
contact us at
800-558-7733 Used Heat Treating Furnaces and OvensContact: Michael J. Kay
30925 Aurora Road Solon, OH 44139
Ph: 440-519-3800 Fax: 440-519-1455Email: [email protected]
Website: www.whkay.com
42056 Michigan Avenue. Canton, MI 48188Phone: 734-331-3939 Fax: 734-331-3915
E-mail: [email protected]
Batch Temper FurnacesC0048 Sunbeam Batch Temper Furnace (24”W x 36”L x 24”H, 1400ºF,
electric)C0049 Can-Eng Batch Temper Furnace (30”W x 48”L x 30”H, 1400°F,
gas-fired)C0052 Surface Combustion Batch Temper Furnace (30”W x 48”L x 30”H,
1200°F, gas-fired)C0068 Despatch Box Furnace (48”W x 48”D x 72”H, 395ºF, electric)C0069 Enviro-Pak Drop Bottom Furnace (48”W x 48”D x 48”H, 500ºF,
electric)C0070 BeaverMatic Batch Temper Furnace (36”W x 48”D x 36”H, 0000ºF,
gas-fired)V1010 Dow Batch Temper Furnace (30”W x 20”H x 48”L, 1250ºF, gas-fired)V1024 PIFCO Batch Temper Furnace, Skid Hearth (36”W x 48”L x 30”H,
1300ºF, electric)V1049 Surface Combustion Batch Temper Furnace (87”W x 36”H x 87”L,
1350°F, gas-fired)V1064 Seco Warwick Batch Temper Furnace (48”W x 48”H x 72”D,
1250°F, electric)V1081 Lindberg Batch Temper Furnace (20”W x 30”D x 18”H, 1250ºF,
electric)V1090 Lindberg Nitrogen Batch Temper Furnace, 24”W x 36”D x 18”H,
1350ºF, electricV1095 Surface Combustion Temper Furnace (30”W x 48”D x 30”H,
1250°F, gas-fired)V1099 Surface Combustion Temper Furnace (30”W x 48”D x 30”H,
1400°F, electric, 81kw)V1106 Dow Batch Normalizer Furnace (43”W x 80”D x 34”H, 1800°F,
gas-fired)
Batch High-Temp FurnacesC0007 JL Becker Batch High-Temp Furnace with atmosphere (72”W x
72”H x 72”L, 1650ºF, gas-fired)C0041 Park Thermal Batch High-Temp Furnace (36”W x 24”H x 60”L,
1850°F, electric)C0042 Can-Eng Batch High-Temp Furnace (8’W x 22’4”L x 6’H, 1850°F,
electric)U3556 Pacific Industrial Batch High-Temp Furnace (24”W x 18”H x 36”L,
2800ºF, electric)V1013 Thermolyne Batch High-Temp Furnace, Front Door Loading (10”W
x 9”H x 14”L, 2000ºF, electric)V1067 Seco Warwick Batch High-Temp Furnace (24”W x 24”H x 36”D,
1800°F, electric)V1110 Holcroft Batch Temper Furnace (36”W x 48”D x 30”H, 1400ºF,
gas-fired)
Batch Oil Quench FurnacesC0058 Despatch Quick Quench Furnace (5’W x 20’L x 8’H, 1200°F, electric)V1068 Surface Combustion Batch/Oil Quench Furnace (30”W x 30”H x
48”D, 1800°F, electric)
Car Bottom FurnacesV1070 HeatTek Car Bottom Furnace (8’W x 17’D x 6’6”H, 1650°F, gas-
fired, radiant tube)V1079 Johnston Car Bottom Furnace (30’W x 40’D x 15H, 1800ºF,
gas-fired)
Drop Bottom FurnacesC0065 (2) Heat Processing Drop Bottom Furnaces with shared Quench
(68”W x 120”L x 84” H, 1100ºF, gas-fired)U3543 Despatch Drop Bottom Furnace (4’W x 4’H x 6’L, 1200ºF, electric)
Internal Quench FurnacesC0064 Lucifer IQ Furnace (18”W x 24”D x 18”H, 1900ºF, electric)U3569 Surface Combustion IQ Furnace (24”W x 18”H x 36”D, 1750ºF,
gas-fired)U3606 Dow/AFC IQ Furnace (30”W x 48”L x 24”H, 1850°F, gas-fired)U3620 Ipsen Straight-Thru IQ Furnace (24”W x 18”H x 36”D, 1850°F,
gas-fired)V1046 Surface Combustion IQ Furnace (87”W x 36”H x 87”L, 1850°F,
gas-fired)V1047 Surface Combustion IQ Furnace (62”W x 36”H x 62”L, 1850°F,
gas-fired)
V1048 Surface Combustion IQ Furnace (62”W x 36”H x 62”L, 1850°F, gas-fired)
V1062 Surface Combustion Super IQ Furnace (36”W x 36”H x 72”D, 1950°F, gas-fired)
V1082 Holcroft IQ Furnace with Top Cool (36”W x 48”D x 30”H, 1850ºF, gas-fired)
V1083 Holcroft IQ Furnace, Top Cool (36”W x 48”D x 30”H, 1850ºF, gas-fired)
V1093 Surface Combustion Allcase IQ Furnace (30”W x 48”:L x 30”H, 1850ºF, gas-fired)
V1111 Surface Combustion IQ Furnace (30”W x 48”D x 30”H, 1850ºF, gas-fired)
Mesh Belt Brazing FurnacesC0044 CGS Moore Mesh Belt Curing Oven (22”W x 20’L x 10”H, 500°F,
gas-fired)U3529 CI Hayes Mesh Belt Brazing Furnace (18”W X 6”H, 2100ºF,
electric)U3580 JL Becker Mesh Belt Brazing Furnace (14”W x 6”H, 2100ºF,
electric)U3592 JL Becker Mesh Belt Brazing Furnace (12”W x 6”H, 2100ºF,
electric)V1035 Seco Warwick Mesh Belt Brazing Furnace (18”W x 12”H, 2100ºF,
electric)
Mesh Belt Tempering FurnacesC0010 Despatch Mesh Belt Tempering Furnace (57”W x 14”H x 20’ L,
1000ºF, gas-fired)V1022 Surface Combustion Mesh Belt Tempering Furnace (42”W x 36’D
x 12”H, 1350ºF, gas-fired)
Pit FurnacesV1088 Leeds & Northrup Pit Furnace (24” ID x 30” deep, 750ºF, electric)
Roller Hearth & Rotary FurnacesC0025 Park Thermal Batch Temper Roller Hearth Furnace (36”W x 30”H
X 72”L, 1250ºF, gas-fired)U3550 PIFCO Powered Roller Hearth Temper Furnace (21”W x 16”H x
10’L, electric)V1009 Ipsen Continuous Temper Roller Hearth Furnace (24”W x 18”H x
10’L, 1350ºF, electric)V1091 Finn & Dreffein Rotary Hearth Furnace (13’3” ID x 5’3” ID x 4’ W
x 2’8” H, 2275ºF, electric)
Steam Tempering FurnaceU3616 Degussa Durferrit Steam Tempering Furnace (24” dia x 48”D,
1200ºF)
Tip Up FurnacesC0043 Industrial Furnace Tip-Up Furnace (36”W x 60”L x 24”H, 1850°F,
electric)
Vacuum FurnacesC0013 CI Hayes Oil Quench Vacuum Furnace (24”W x 18”H x 36”D,
electric)C0019 Surface Combustion Vacuum Temper Furnace (36”W x 24”H x
48”L, 1350°F, electric)C0027 Pacific Scientific Vacuum Temper Furnace (24”W x 24”H x 36”D,
1450ºF, electric)U3612 AVS Vacuum Annealing Furnace (18”W x 12”H x 24”D, 2400ºF,
electric)V1004 CI Hayes Vacuum Furnace, Oil Quench (18”W x 12”H x 30”L,
2400°F, electric)V1080 Ipsen Vacuum Furnace (18”W x 32”D x 12”H, 2100ºF, electric)V1108 Surface Combustion Vacuum Furnace, 2-Bar (36”W x 48”D x
36”H, 2250ºF, electric)
Endothermic Gas GeneratorsU3594 AFC-Holcroft Gas Generator (3,000 CFH Endo)U3614 Lindberg Gas Generator (1,000 CFH Endo)V1021 Surface Combustion Gas Generator (2,400 CFH Endo)V1075 Lindberg Gas Generator (3000 CFH Endo)V1105 Surface Combustion Gas Generator (5,600 CFH Endo, 1950°F)
Exothermic Gas GeneratorsU3581 CI Hayes Gas Generator (4,000 CFH Exo)U3593 JL Becker Exothermic Gas Generator (2,500 CFH with gas dryer)V1036 Seco Warwick Gas Generator (3,000 CFH Exo)
Material Handling - ConveyorsU3565 Conveyor - Roller (48”W x 20’L)
Ovens - CabinetC0037 Grieve Cabinet Oven (36”W x 36”L x 36”H, 650°F, electric)U020 Blue-M Oven/Ref (20”W x 20”H x 18”D), (-4°F/400°F)U3625 Lindberg Atmosphere Oven (38”W x 38”D x 38”H, 800ºF, electric)U3629 Cabinet Oven (30”W x 30”D x 36”H, 1200ºF, electric)
Ovens - Walk-InC0035 Park Thermal Walk-In Oven (48”W x 60”L x 48”H, 500°F, electric)C0036 Grieve Walk-In Oven (48”W x 48”L x 60”H, 500°F, electric)C0038 Despatch Walk-In Oven (54”W x 108”L x 72”H, 500°F, electric)C0039 Gehnrich Walk-In Oven (72”W x 96”L x 72”H, 400°F, electric)U3630 Michigan Oven Walk-In Oven (6’W x 10’D x 4’H, 950ºF, gas-fired)V1040 Despatch Walk-In Oven, Dual-Door, Straight-Thru (12’W x 12’D x
5’H, 1100ºF, gas-fired)
BlowersU018 Twin City Blower (20 HP, RBA-SW, Class 22)
Charge CarsU3621 Dow Charge Car, DEDP (66”W x 54”H x 60”D)V1043 Surface Combustion Charge Car (DEDPER, 30”W x48”L)V1051 Surface Combustion Charge Car (DEDPER, 87”W x 87”L)V1076 Surface Combustion Charge Car (30”W x 48”L, DEDP)V1085 Holcroft Charge Car (DE/DP, 36”W x 48”D)V1112 Surface Combustion Charge Car, SE, 30”W x48”D
CompressorsU019 Spencer Turbo Compressor (1.5 HP)U023 Spencer Turbo Compressor
Scissors Lifts & Holding StationsMany other holding stations - ask for detailsV1086 Holcroft Scissors Lift & (2) Holding Tables
Heat Exchanger SystemsU030 Graham Systems Heat Exchanger - PlateV1104 SBS Heat Exchanger
Holding & Cooling StationsV1107 (5) Holding Stations (36”W x 48”D)V1113 Forced Cool Station (30”W x 48”D x 30”H)
Water Cooling SystemsU3404 JL Becker Cooling Tower with Tank (Tower: 51”W x 64”H x 36”L,
Tank: 72”W x 66”H x 84”L)U3595 JL Becker 2-Tank Water Cooling System (2 Dayton 1HP Motors)V1038 Bell & Gossett Shell & Tube Heat Exchanger with Tank
WashersU3564 Holcroft Spray/Dunk Washer (36”W x 72”H x 36”L, gas-fired,
rebuilt)V1052 Surface Combustion BIQ Washer (87”W x 36”H x 87”L, 180°F,
gas-fired)V1077 Park Thermal Spray/Dunk Washer (30”W x 48”L x 30”H, 190°F)V1084 Holcroft Spray/Dunk Washer (36”W x 48”D x 30”H, 190ºF, gas-
fired)V1101 Surface Combustion Spray Washer (36”W x 48”D x 30”H, 180ºF,
electric, 58kw)
TransformersExtensive inventory of all types of transformers for any and all
applications
Baskets & BoxesExtensive inventory of heat treat baskets and boxes
For Miscellaneous Parts Inventory and Complete Equipment Listings visit www.heattreatequip.com
CLASSIFIED MARKETPLACE
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http://twitter.com/IndHeat or www.industrialheating.com/FB-UsedEquip
offers high-impact packages so you canfind the most qualified job candidates!
2016 Print Rates: $145 per column inch for 1x frequency; $135 for 3x; $120 for 6x; $115 for 12x. Print ad PLUS online posting: Add $49.00 Print ad, Online Ad PLUS IH Daily News Brief Eblast: Add $75.00. ALL of the above PLUS a job listing in the Industrial Heating’s group on : Add $149.00
Web ONLY! Need Maximum Exposure Right Away? Online Ad Posting, IH Daily Newsbrief Listing, and : Listing in the IH Group: $250.00.
Contact Becky McClelland at: 412-306-4355 or [email protected]
PHONE TABLET COMPUTER
IT’S ALL ONLINE
2015 Buyers GuideOnline at: www.industrialheating.com/buyersguide
FIXTURE DESIGN We require the freelance services of
an experienced vacuum furnace fixture designer who is thoroughly familiar with
carbon/carbon composite material. This is a profit-sharing opportunity. Please reply in confidence to: Becky McClelland –
email: [email protected].
Heat Treat Equipment 42056 Michigan Ave.Canton, MI 48188 John L. Becker, II Ph: 734-331-3939Fax: 734-331-3915 Email: [email protected]
(3) V1096 Surface Combustion Temper Furnaces (30"W x 48"D x 30"H, 1250°F, gas-fi red)
(3) V1097 Surface Combustion Temper Furnaces (30"W x 48"D x 30"H, 1400°F, electric)
(1) V1049 Surface Combustion Temper Furnace (87"W x 87"L x 36"H, 1350°F, gas-fi red)
(1) V1111 Surface Combustion IQ Furnace (30"W x 48"D x 30"H, 1850ºF, gas-fi red)
(1) V1068 Surface Combustion IQ Furnace (30"W x 48"D x 30"H, 1800°F, electric)
(2) U3569 Surface Combustion IQ Furnaces (24”W x 36”D x 18”H, 1750ºF, gas-fi red)
(1) V1046 Surface Combustion IQ Furnace (87"W x 87"L x 36"H, 1850°F, gas-fi red)
(2) V1047 Surface Combustion IQ Furnaces (62"W x 62"L x 36"H, 1850°F, gas-fi red)
(1) V1062 Surface Combustion Super IQ Furnace (36”W x 72”D x 36”H, 1950°F, gas-fi red)
(3) V1092 Surface Combustion Allcase IQ Furnaces (30"W x 48":L x 30"H, 1850ºF, gas)
(1) V1021 Surface Combustion Gas Generator (2,400 CFH Endo)
(1) V1105 Surface Combustion Gas Generator (5,600 CFH Endo, 1950°F)
(1) V1043 Surface Combustion Charge Car (DEDPER, 30"W x 48"L)
(1) V1051 Surface Combustion Charge Car (DEDPER, 87"W x 87"L)
(1) V1076 Surface Combustion Charge Car (DEDP, 30"W x 48"L)
(1) V1112 Surface Combustion Charge Car (SE, 30"W x 48"L)
(1) V1052 Surface Combustion BIQ Washer (87"W x 87"L x 36"H, 180°F,
gas-fi red)
(1) V1077 Surface Combustion Spray/Dunk Washer (30"W x 48"L x 30"H)
(2) V1101 Surface Combustion Spray Washers (36"W x 48"D x 30"H, 180ºF, electric)
(1) V1113 Surface Combustion Forced Cool Station (30"W x 48"D x 30"H)
(2) V1113 Surface Combustion Holding Stations with rails (30"W x 48"D)
(1) V1113 Surface Combustion Holding Station with rollers (30"W x 48"D)
Surface Combustion Spring Cleaning All Equipment at Reduced Prices
EQUIPMENT FOR SALE
MECHANICAL ENGINEER/TECHNICAL SUPPORT
Lindberg/MPH in Riverside, MI is now
accepting applications for a mechanical
engineer and technical support
individual. Lindberg/MPH offers
competitive pay and benefit packages.
Please reply in confidence to:
ELECTRICAL ENGINEER–––– AND ––––
MECHANICAL ENGINEERSWisconsin Oven Corporation
in East Troy, WI is now accepting applications for an electrical engineer and mechanical engineers. Wisconsin
Oven offers competitive pay and benefit packages. Please reply in confidence to: [email protected].
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Check out the latest Used Equipment Listings on Facebook and Twitter – #IHUsedEquip
Moist Creamy Putty Just Apply and Let DryBonds Most Materials
Resists Chemicals, Electricity, Molten Metals
and Abrasion
High TemperatureAdhesive & Sealant
[email protected] 718-788-5533
2300˚F
FOR SALEEQUIPMENT FOR SALEINTEGRAL QUENCH FURNACES
NEW INVENTORYGASMACGas Fired Car Bottom Furnace, 96” W x 168” D x 93” H, 1150°F Max Temperature, 3,000,000 BTUH, Free Standing Control Panel w/ Chart Recorder, Re-Circ. Fan and Powered Car.
IPSENVacuum Furnace, Model VFC-224R, 18” x 12” x 32” Chamber, 2 Chart Recorders, Stokes model 149-111 Vacuum Pump c/w New Chamber Basket, Load Cart and Controls. HUBERGas Fired Car Bottom Furnace, 10’ 4” W x 12’ 8” L x 14’ H, 1,800°F, 1,300,000 BTUH, fi ber lined with 4 Power Flame JD130 burners, power driven car, digital controls and recorder. WILSONWilson BP3002 Digital Hydraulic Bench Type Brinell Hardness Tester. BLOWERNew Combustion Blower, SMJ, Engineered Product, SMJ 8823-15, 85,000 CFH, suitable for 6,500,000 – 7,000,000 BTUH Furnace.
IMMACULATE EQUIPMENTSECO/WARWICKElectric Box Furnace, 48” W x 48” H x 72” L, Max Temp 1250°F, Powered Rollers, Load/Unload Table and Controls.
SECO/WARWICK High Temperature Electric Furnace, 24” W x 24”H x 36” L, Max. Temp. 1,800°F, Powered Rollers, Load/Unload Table & Controls.
SURFACE COMBUSTIONElectric Batch/Oil Quench Furnace,30” W x 30” H x 48”L, Max. Temp. 1,950°F, System 1 Rear Handler, 3500 Gal. Quench Tank, 2 Agitators & Controls.
Visit us online at:www.parkthermal.com
We have all the ancillary equipment available for the above such as Tempering Furnaces, Washers, Charge Cars and Endo Generators.
Park Thermal International (1996) Corp. 62 Todd Road, Georgetown, ON L7G 4R7257 Elmwood Avenue, Suite 300, Buffalo NY 14222-2249Tel: (905) 877-5254 | Fax: (905) 877-6205Toll Free: (877) 834-HEAT (4328)Email: [email protected]: www.parkthermal.com
2 Locations to Better
Serve You
MEDIUM INTEGRAL QUENCH FURNACESSURFACE COMBUSTION(3) INTEGRAL QUENCH FURNACES, 30”W x 30”H x 48”L, 1,750°F, 1,000,000 BTUH, Trident Tubes, Endo/Natural Gas/Ammonia, SSI Atmosphere Controllers, SSI Gold Probes, Oil Filters And SBS Coolers. System Comes Complete with a Gas Fired Temper, Washer and Charge Car.
LARGE INTEGRAL QUENCH FURNACESAFC - HOLCROFT(2) INTEGRAL QUENCH FURNACES, 36”W x 30”H x 48”L, 1,800°F Max, Recuperated with Top Cool, Rear Handler, Oil Heaters (54kW), Re-Circ. Fan, Control System.
SURFACE COMBUSTION(3) INTEGRAL QUENCH FURNACE, 5000 lb. Payload Each, 36”W x 36”H x 72”L, Recuperated Rear Handler And Controls.
KING SIZE INTEGRAL QUENCH FURNACESURFACE COMBUSTIONINTEGRAL QUENCH FURNACE, 10,000 lb. payload, 87” W x 87” L x 36” H, 1,850°F, 4,600,000 BTUH, 12,500 Gallons, 6 Agitators, Eclipse Burners, 3 Rear Handlers & Controls with PLC.
THE ECONOMY FOR 2016 SEEMS TO BE: IMPROVING NOT IMPROVING
Note: We have over 500 pieces of equipment in stock. If your needs are not listed above, please let us know and we will locate a furnace/oven to suit your needs.
PHOENIXINDUCTION CORPORATION
Qualified Induction Specialists with over 90 years of combined experience, providing on site:
Troubleshooting “down” equipment Quality preventative maintenance Acid flushing, thermal imaging & analysis Large inventory of OEM parts, as well as other manufacturers, AJAX*, AIH*, Bone Frontier*, IEH*, and Robotron*
24/7/365 days a year emergency phone support
Call: [email protected]*Registered trademarks of their respective companies
Build your brand and stay in front of prospective
customers by building on traditional print advertising
with one of IH’s many online options.
www.industrialheating.comContact Becky McClellan for Details @ 412-306-4355
ADVERTISE ONLINEWITH
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http://twitter.com/IndHeat or www.industrialheating.com/FB-UsedEquip
––––– ATMOSPHERE GENERATORS –––––750CFH Endothermic Ipsen Gas1000CFH Exothermic Gas Atmos. Gas1500CFH Endothermic Lindberg (Air) Gas2000CFH Ammonia Dissoc. Drever (3) Elec3000CFH Endothermic Lindberg (3) - Air Gas3600CFH Endothermic Surface (2) Gas5600CFH Endothermic Surface (3) Gas6000CFH Gas Atmos. Nitrogen Generator Gas
–––––––––– BOX FURNACES ––––––––––12" × 24" × 10" Lindberg (Atmos.) Elec 2000°F12" × 24" × 10" Lindberg (Atmos.) Elec 2500°F12" × 24" × 12" Hevi Duty (2) Elec 1950°F12" × 32" × 12" L&L (Retort) Elec 2000°F13" × 24" × 12" Electra Up/Down Elec 2000°F16" × 24" × 15" C/K (Atmos) Elec 2300°F16" × 20" × 28" Nabertherm (New) Elec 2444°F17" × 14.5" × 12" L&L (New) Elec 2350°F18" x 30" x 13" Hevi-Duty Elec 1850°F18" x 36" x 18" Lindberg (Fan) Elec 1850°F18" x 48" x 18" L&L Mfg. Elec 2350°F20" x 48" x 12" Hoskins Elec 2000°F24" × 42"× 14" Hevi-Duty Elec 2300°F24" × 48"× 24" Hevi-Duty Elec 2350°F30" × 48"× 30" Lindberg (Atmos-Fan) Elec 1850°F36" × 48"× 30" Surface (Atmos.) RTB Gas 1800°F36" × 72"× 42" Eisenmann (Car Bottom) Gas 3100°F60"×216"×48" IFSI (Car Bottom) Gas 2400°F60"×156"×60" Lindberg Car Bottom Gas 1850°F64"×180"×68" Swindell-Dress. Car Bottom Gas 2350°F96"×360"×48" Sauder "Autotilt" Elec 1400°F126"×420"×72" Drever "Lift-Off" (2) (Atmos.) Gas 1450°F
–––––––––– PIT FURNACES ––––––––––14" Dia × 60"D Procedyne Fluid Bed Elec 1850°F42" Dia x 50"D Sunbeam Nitrider Elec 1200°F72" Dia x 72"D Flynn + Dreffein (2) Elec 1400°F
––––––––– VACUUM FURNACES –––––––––15" × 24" x 10" Ipsen - VFC 224 Elec 2400°F24" × 36" x 18" Hayes (Oil Quench) Elec 2400°F24" × 48" x 24" GCA (Vac. Indust) Elec 2400°F36" × 48" x 24" Surface (Temper) Elec 1350°F48" x 48" x 24" Surface(2-Bar) Elec 2400°F48" × 60" Ipsen Bottom Load Elec 2400°F
–––– INTEGRAL QUENCH FURNACES ––––24" × 36" × 24" AFC (Top-Cool-Line) Elec 1850°F30" × 48" × 20" Surface Gas 1750°F30" × 48" × 30" Surface Elec 1750°F
––––––– BELT FURNACES/OVENS –––––––12" × 120" × 15" Grieve (Solvent) Elec 450°F 30" × 15' × 18" Despatch Elec 500°F 32" × 24' × 12" OSI Slat Belt Gas 450°F 36" × 18' × 6" OSI Gas 1250°F 36" × 28' × 22" Lewco (2) Elec 350°F 60" × 40' × 14" GE Roller Hearth (Atmos) Elec 1650°F 60" × 40' × 14" Wellman Roller Hearth (Atmos) Elec 1650°F
–––––––––– MISCELLANEOUS –––––––––Combustion Air Blowers (All sizes)24" × 36" Lindberg Charge Car (Manual)36" × 48" × 30" Holcroft "D&S" Washer Elec30" × 48" Surface Charge Car (SE-ER)24" × 36" × 24" Salt Quench Tanks (2) Elec 1000°FWilson Hardness Testers (Superfi cial)(2) Bell & Gossett "Shell & Tube" Heat Exchangers24" x 36" x 24" Lindberg "Cooldown" Chamber36" x 48" AFC Charge Car (DE) ElecAFC Pusher Line (Atmos.) Gas 1750˚F 48" x 48" x 48" TSI Alum: Drop Bottom Elec 1100˚F 36" Wide Table – Rotary Hearth (Atmos.) Elec 1850˚F30" x 48" Surface Roller Table36" x 48" Holcroft Charge Car (DE)
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Since 1936
CELE
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G OUR 80TH ANNIVERSARY
W.H. KAY COMPANY 1936 -2
016
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Professional SupportServices to Industry
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Phone: 630-834-3017 Email: [email protected]
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An excellent marketing opportunity! If it’s been printed in Industrial Heating, you can have it reprinted by Industrial Heating. Feature Articles, Technology Spotlights, MTI or IHEA Profi les, Literature Features, and much more. Customize your reprints with your company’s ad, special message or even the cover of Industrial Heating. Contact Becky McClelland at 412-306-4355
14 JANUARY 2015 IndustrialHeating.com
nce upon a time, in a science class far,
far removed, the subject of pH was
discussed. Little did we know at the
time how important these two simple
consonants, combined in such an odd way, were
to the water systems that cool our heat-treating
equipment. Let’s learn more.
The Water MoleculeAll substances are made up of millions of tiny
atoms. These atoms form small groups called
molecules. In water, for example, each molecule
is made up of two hydrogen (H) atoms and one
oxygen (O) atom (Fig. 1). The formula for a
molecule of water is H2O (there are two hydrogen
atoms needed for each oxygen atom to form a
stable compound).
Introduction to pHThe term pH is used to describe a unit of measure
to indicate the degree of acidity or alkalinity of
a solution. It is measured on a scale of 0-14. The
term pH is derived from “p” (the mathematical
symbol of the negative logarithm) and “H” (the
chemical symbol of hydrogen).
The formal definition of pH is the negative
logarithm of the hydrogen-ion activity. It is
expressed mathematically by the formula:
(1) pH = - log [H+]
Thus, pH provides a way of expressing the degree
of the activity of an acid or base in terms of its
hydrogen-ion activity.
The pH value of a substance is directly
related to the ratio of the hydrogen ion [H+]
and the hydroxyl ion [OH-] concentrations. If
the hydrogen ion concentration is greater than
the hydroxyl ion concentration, the compound
is acidic and the pH value is less than 7. If the
hydroxyl ion concentration is greater than the
hydrogen ion concentration, the compound is
basic with a pH value greater than 7. If equal
amounts of hydrogen ions and hydroxyl ions are
present, the material is neutral with a pH of 7.
Acids and bases have, respectively, free
hydrogen and hydroxyl ions. Since the
relationship between hydrogen ions and hydroxyl
ions in a given solution is constant for a given set
of conditions, either one can be determined by
knowing the other. Thus, pH is a measurement
of both acidity and alkalinity, even though
by definition it is a selective measurement of
The Importance of pH
THE HEAT TREAT DOCTOR®
DANIEL H. HERRINGThe HERRING GROUP, Inc.
O
Table 2. Typical water requirements for open systems[2]
Description Value
Hardness (calcium carbonate)
7-10 grains/gallon[a] (120-170 ppm)
Total suspended solids 10 ppm
Total dissolved solids 200 ppm
Iron 0.3 mg/liter
Aluminum 0.05-0.2 mg/liter
Copper 1.0 mg/liter
pH 7.0-8.0
Odor 3 threshold odor number
Conductance ≤ 300 μS/cm
Maximum water temperature (inlet) 31°C (88°F)
System drain pressure ≤ 3.5 psig
Notes: [a] Grains per gallon is defined as 64.8 mg (1 grain) of calcium carbonate per 3.79 liters (1 U.S. gallon) or 17.1 ppm.[b] For best cooling efficiency and component longevity, the water supply should be treated to prevent corrosion and scale (controlled by phosphonate test; range 15-20 ppm), scum formation, algae and other biological agent buildup and the like.
Table 1. pH chart[2]
Concentration of hydrogen ions compared
to distilled waterpH level Examples of solutions at this pH
10,000,000 pH=0 Battery acid, Strong hydrofl uoric acid
1,000,000 PH=1 Hydrochloric acid secreted by stomach lining
100,000 pH=2 Lemon juice, gastric acid, vinegar
10,000 pH-3 Grapefruit, orange juice, soda
1,000 pH=4 Acid rain, tomato juice
100 pH=5 Soft drinking water, black coffee
10 pH=6 Urine, saliva
1 pH=7 "Pure" water
1/10 pH=8 Sea water
1/100 pH=9 Baking soda
1/1,000 pH=10 Great salt lake, milk of magnesia
1/10,000 pH=11 Ammonia solution
1/100,000 pH=12 Soapy water
1/1,000,000 pH=13 Bleaches, oven cleaner
1/10,000,000 pH=14 Liquid drain cleaner
The International Journal of Thermal Processing MAY 2015
32
AUTOMOTIVEIndustry Overview
3D Printing, Sintering and More
e
A Publication Vol. LXXXIII No. 5 www.industrialheating.com
INSIDE
36 Understanding Jominy40 Maintaining Vacuum Pumps44 Purchasing Induction48 Corporate Profi les 28 JANUARY 2015 IndustrialHeating.com
VACUUM/SURFACE TREATING
In order to establish a basis for projecting the future
of the heat-treating industry in North America, it is
important that we analyze the industry over the past
20 years.
Heat Treating: Past and Future The Metal Treating Institute (MTI) produces monthly records
of sales from its members and provides a Heat Treating (HT)
Index to cover up-to-date current and historical performance.
This index highlights the past ups and downs of the industry
and tends to ref lect market trends.
Using the above historical data and trends as well as
additional data from other sources qualified to analyze and
make future projections, we have determined the following:
• Major downturns seem to occur approximately every 10
years as seen in 2000 and 2009-2010.
• The HT Index growth from 1994 to 2004 was
approximately 18.5%.
• The HT Index growth from 2004 to 2014 was
approximately 17.0%
• We are projecting growth from 2014 to 2024 will
be approximately 15.5%. Although this might seem
conservative, we foresee a small downturn in 2016 and a
more serious downturn in 2020.
• The major downturn in 2009 was approximately 33%. We
predict the major downturn in 2020 may be on the order of
18-19%.
The historical HT Index and our projection for the next 10
years are shown in Figure 1.
Comparing the HT Index to the S&P 500 IndexIt is interesting to compare the industry past-performance
index with an established financial index. We selected the
S&P 500 as a major financial index to illustrate the relative
performance of the two indices and created the chart shown in
Figure 2. Notice how closely they follow each other.
North American Furnace MarketsThe North American furnace market continues to grow, with a
trend away from atmosphere-type equipment toward increasing
use of vacuum furnaces.
Atmosphere FurnacesAs is illustrated in Figure 3, atmosphere furnaces can be very
dangerous to operate and control. They are rarely shut down and
Futuristic LookAat the North American Heat-Treating World
COVER FEATUREVACUUM/SURFACE TREATING
120
100
80
60
40
20
0
HT monthly index actualHT monthly index projectedLinear (HT monthly index projected)
2008 2018
-33%-18.5%
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
2016
2018
2020
2022
2024
Inde
x va
lue
Index year
120
100
80
60
40
20
0
2500
2000
1500
1000
500
0
Heat treat index
S&P index
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
Hea
t tre
at in
dex
S&P
inde
x
YearFig. 1. (above) Heat Treating (HT) Index history and projection
Fig. 2. (right) Comparison of the HT Index to the S&P 500 index
William R. Jones and Réal J Fradette – Solar Atmospheres Inc.; Souderton, Pa.
The objective of this paper is to highlight the heat-treating markets of North America with respect to equipment and processing, comparing current 2014 status and projecting expectations for 2024. Historical growth and industry expectations for the future will be discussed.
IndustrialHeating.com JANUARY 2015 29
therefore consume excessive process gas when not in use. This is
inefficient from an operating standpoint. From an environmental
standpoint, they are becoming more and more challenged.
From a process standpoint, they do not have the capacity for
close monitoring of work temperature.
Vacuum FurnacesThe vacuum furnace is an environmentally friendly piece of
equipment (Fig. 4). It is typically easy to load and unload, and
an operator can view the work positioned in the furnace prior to
closing the furnace door. Thermocouples can be attached to the
work for exact processing temperatures to ensure accurate cycle
performance and satisfactory resulting metallurgy of the parts.
NFPA StandardsFurnace manufacturers must comply with standards that have
been established by the NFPA committees. These are recom-
mended guidelines that are not necessarily enforceable by law
but will be recognized by the “Authority Having Jurisdiction”
(AHJ), who may rule on such things as zoning codes and occu-
pancy permits, meeting local fire codes, and possibly insurability.
The following NFPA standards apply:
• NFPA 86 and 86D (Furnace Standards)
• NFPA 55 (Compressed gases and 29 CFR 1910.103
hydrogen systems)
• NFPA 70 (National Electrical Code [N.E.C.])
Furnace Sales and Market Share 2014Figure 5 illustrates the North American total furnace market as
established for 2014. These annual sales numbers are based on
various financial reports and other multipliers, such as sales per
employee, and represent as accurate an estimate as possible.
As shown in Figure 5, the atmosphere furnace market is
approximately 1.69 times that of the vacuum furnace market.
However, this ratio is continually decreasing as processing
changes occur. These changes lean toward vacuum processing.
Projected Furnace Sales and Market Share 2024Based on projected HT Index growth and other factors, we
are able to create a chart (Fig. 6) highlighting furnace sales
projected for 2024.
Figure 6 ref lects the growth of the vacuum furnace market
and its acceptance by the heat-treating world. We expect this
trend to continue in future years.
The pie charts (Fig. 7) ref lect the projected growth of the
vacuum furnace industry comparing furnace sales of 2014
versus 2024.
In-House/Captive vs. Commercial Heat-Treating MarketsBased on financial information from MTI and other
sources, we are able to state the approximate current sales
volume for commercial heat treaters in North America
Fig. 3. Atmosphere furnace Fig. 4. Vacuum furnace
Fig. 6. Projected furnace sales for 2024
Type of equipment 2024
Number of
manufacturers
Numberof
employees
Estimated total annual
sales
Percent of
total
Atmosphere 45 1,940 $ 306,825,000 48%
Salt bath 5 192 $ 32,285,000 4%
Vacuum 22 862 $ 306,375,000 48%
Totals for North America 2024 72 2,994 $ 645,000,000 100%
Fig. 5. North American 2014 total furnace market
Type of equipment2014
Number of
manufacturers
Number of
employees
Estimated total annual
sales
Percentof
total
Atmosphere 44 2,012 $ 332,000,000 60%
Salt bath 5 187 $ 31,000,000 5%
Vacuum 20 653 $ 196,000,000 35%
Totals for North America 2014 69 2,852 $ 559,000,000 100%
44 FEBRUARY 2015 IndustrialHeating.com
CERAMICS & REFRACTORIES/INSULATION
Engineering design and the lining materials chosen
are key factors in controlling the efficiency and
energy usage of equipment used in iron and steel
applications. As a result, it is critical that industrial
designers understand the advantages and disadvantages of the
materials they choose. For example, it is especially important
to select insulating firebricks (IFBs) that minimize energy
losses. Recent studies conducted on IFBs produced using the
three most common manufacturing methods – cast, slinger and
extrusion – show that the cast process offers the lowest thermal
conductivity and provides the greatest energy savings.
IFB Manufacturing Techniques Vary Widely in Ability to Control Energy LossesThe versatile IFB is used in numerous iron and steel
applications, including: blast furnaces, ductwork in direct-
reduction processes and reheat furnaces, backup insulation in
coke ovens, and in tundishes and ladles. They are also used
extensively to form the sidewalls, roofs and hearths of a wide
variety of heat-treatment, annealing and galvanizing lines.
Figure 1 shows their use in a coke oven stack (top) and in a
tunnel kiln (bottom).
IFBs are manufactured using a variety of techniques, the
most common of which are casting, slinger and extrusion. The
cast process uses gypsum plaster as a rapid-setting medium for
a high water-content clay mix containing additional burnout
additives. The slinger process is a form of low-pressure extrusion
of a wet clay mix containing high levels of burnout additives.
It includes an additional processing step in which the semi-
extruded material gets “slung” onto a continuous belt to generate
additional porosity before drying and firing. The extrusion
process forces a damp-clay mixture containing burnout additives
through an extrusion nozzle, where the extruded material is
subsequently cut into bricks, dried and fired.
The brick chemistries and microstructures produced can
differ widely among these methods, leading to a extensive
variety of thermal conductivities within products of the same
temperature rating. This variation, in turn, has an effect on the
ability of different IFB types to control energy loss.
Comparing Manufacturing MethodsTo understand the effect of the three main IFB manufacturing
methods on thermal conductivity and energy-loss behavior,
researchers conducted a study to quantify the differences in
energy usage that can be achieved within Class 23 and Class 26
IFBs.
Figure 2 shows the thermal conductivity of the IFBs
tested, a critical property since IFBs are primarily used for
their insulating abilities. In each class of IFB, cast brick has
the lowest thermal conductivity, followed by the slinger-
produced brick, with the extruded brick displaying the highest
conductivity.
Researchers designed two identical electrically heated
laboratory muffle kilns (Fig. 3) and conducted energy-usage
studies comparing the IFB bricks. They lined the first kiln with
Class-23 cast IFBs, and this formed the benchmark since they
had the lowest thermal conductivity in the class. Test results are
Using Insulating Firebricks to
Maximize Energy Savings
Steve Chernack – Morgan Thermal Ceramics; Augusta, Ga.
Selecting products made with the right manufacturing process makes the diff erence.
Fig. 1. IFBs are widely used in iron and steel applications.
The International Journal of Thermal Processing FEBRUARY 2015
INSIDE
6 IH Connect34 Combustion Resources44 Firebricks Save Energy48 Cutting-Edge StainlessA Publication Vol. LXXXIII No. 2www.industrialheating.com
The Other White Metal 38
38 FEBRUARY 2015 IndustrialHeating.com
COVER FEATURENONFERROUS HEAT TREATING
The downside, however, is that plant specialization
can lead to a false sense of security based on a
single market focus and tentativeness to broaden
the company’s capabilities and services. While
specialty houses will separate ferrous heat treaters from those
of the nonferrous variety, broadening processing services can
protect the company from the loss of key clients and business
that occurs in changing markets. This is most evident in the
steel versus aluminum processing arena.
Aluminum is a completely different animal than steel. A
simple comparison is that when steel is quenched, it becomes
hard and brittle, whereas aluminum becomes soft and ductile.
Hopefully, this article will demystify aluminum processing to
a degree and encourage you to consider adding aluminum to
spread your economic risks across different industrial markets.
Why is this important? As I see it, the heat-treating industry is
entering a theater of change. Adapting to this change could re-
quire adding new services and client types to position the com-
pany as more diversified and capable to meet future demands.
To know aluminum, you first must be able to decode the
way different aluminum conditions are defined. There is no
basic qualification statement such as “harden, quench and
temper” to conform to a certain HRC. Instead there are
defined conditions that are more like landing zones as opposed
to re-temper zones that steel processing so kindly affords. You
will become more familiar with the various conditions as you
read on. Knowing these key properties allows us to navigate
the zones that are defined by process steps as well as minimum
mechanical properties. I have also included a few actual
case studies written in layman’s language to help clarify the
processing of aluminum.
Condition OThe full-annealed condition is the softest, most ductile
and most easily workable of all aluminum conditions. This
condition in age-hardenable alloys (2000, 6000 and 7000
series) is arrived at by soaking at a setpoint below the solution-
treating temperature followed by a controlled slow cooling
Peter Hushek – Phoenix Heat Treating, Inc.; Phoenix, Ariz.
While many heat-treating companies have moved from general processing to selective processes, the trend has been mainly to one of specialization. The thinking is that specializing will simplify focus on process improvement, enhance productivity and increase profitability.
The Other White Metal
(above) Workers push the auxillary liquid-nitrogen tank from under
a drop-bottom solution heat-treat furnace on a track to where the
aluminum components can be removed. The furnace is designed for
solution treating of small batches of aluminum parts to large forgings
and castings. PHT operates two identical solution-treating systems,
primarily to serve the aerospace industry. The systems quench with
liquid nitrogen, glycol and glycol/water.
IndustrialHeating.com FEBRUARY 2015 39
typically to 500°F (260°C). The ductility can be enhanced
by reducing the descent in temperature as a function of time.
Soak time at the high-temperature phase of the cycle must be
carefully controlled to prevent grain growth.
Condition AQ or WThis condition is extremely unstable and will vary based on the
degree with which the maximum solubility of the alloying agent
has been brought to complete solid solution by the soak and
quench steps (commonly called the solution-treating process). In
order for this condition to maintain its maximum formability,
it must be quickly stored at 0°F or lower. Many alloys will
continue to naturally age at temperatures as low as 0°F (-18°C),
which is why the use of dry ice for storage and transport is
encouraged. The 2000- and 7000-series alloys are especially
vulnerable to this low-temperature natural-aging process.
Condition T-4T-4 is the condition typically referred to as the “natural age”
since it occurs at room temperature. The standard timeframe
associated with the natural-aged condition is 96 hours. When
the degree of complete solid solution is high, the reaction
time for reaching this condition can be reduced. While the
minimum hardness may be met in less time than the 96-hour
standard, the material will continue to transform itself until the
maximum hardness (for the combination of alloy composition),
degree of solid-solution attained, rate of the quenching and
room temperature of the surroundings are met.
Condition T-3T-3 condition is very similar to T-4 with one slight variation – it
receives a cold working, stretching or rolling after the quench
phase and prior to the natural age hardening. The bonus of the
T-3 over the T-4 is the increased yield strength. This provides the
designer with a greater range of applicable uses but comes at the
loss of ductility. The reduced ductility and general formability
make it useful for large surface-area parts with limited bend radii.
Gentle bends are OK, squared corners are not.
Condition T-6T-6 is the highest-strength condition for most alloys that have
not received cold working (work strengthening) after the quench
phase. It is extremely stable in its mechanical properties and can
be subjected to lower-temperature stress-relief processes without
degradation of these properties. This state is achieved by an
artificial-age process after the solution-treat and quench steps.
It is referred to as “artificial” since it requires setpoints greater
than room temperature. The cycle times can range from four
hours all the way to 36 hours followed by an air cool.
Condition T-7-3, T-7-4, etc.These conditions are often referred to as the “over-aged”
condition. This means that the material will be lower in
mechanical properties than T-6 but have unique properties
based on the alloy. In some cases, it will allow for use at
elevated service temperatures without loss of strength. For
example, the corrosion resistance of 7075 is increased due to
this over-age process, which increases its service life. T-7-3
is often used in aerospace manufacturing, where corrosion
resistance on nonflying structural components is critical
TerminologyFinally, there is much confusion about the correct wording in
the processing of aluminum, specifically that caused by the
Close-up image of the large Brinell testing equipment that PHT modified to test large aluminum
forgings and castings.
6061 aluminum forging of a physical vapor
deposition (PVD) vacuum chamber that is
used in the semiconductor industry. PHT built
specialized tooling to lift and move large
forgings, such as this, of varying shapes
and sizes. The Brinell mill bed will support
components weighing up to 600 pounds.
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For $30.00 We Will Post and Link Your Ad Online at www.industrialheating.com
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62 OCTOBER 2016 IndustrialHeating.com
INDEX OFADVERTISERS IN THIS ISSUE
ADVERTISER NAME PAGE PHONE WEBSITE
Across International LLC 9 888-988-0899 www.acrossinternational.com
Air & Energy Systems Inc. 52 704-814-9221 www.airandenergyinc.com
Ajax TOCCO Magnethermic Corp. 47 800-547-1527 www.ajaxtocco.com
Avion Manufacturing Co. 27 330-220-2779 www.avionmfg.com
Daniels Fans, A Cincinnati Fan Company Inside Back Cover 800-628-1200 www.danielsfans.com
Delta Cooling Towers 34 800-289-3358 www.deltacooling.com
Dry Coolers Inc. 7 800-525-8173 www.drycoolers.com
Eldec Induction U.S.A. 26 248-364-4750 www.eldec-usa.com
Fengdong 31 086-515-83282811 www.fengdong.com
Forge Fair 2017 11 216-781-6260 www.forgefair.com
G-M Enterprises Back Cover 951-340-4646 www.gmenterprises.com
Graphite Machining, Inc. 35 610-682-0080 www.graphitemachininginc.com
Graphite Metallizing Corp. 41 914-968-8400 www.graphalloy.com/IH
HaoShi Carbon Fiber Co., Ltd. GanSu 37 0086-931-8893573 www.chinahaoshi.net.cn
Harbison Walker International 15 800-492-8349 www.thinkhwi.com
INEX Incorporated 35 716-537-2270 www.INEXinc.net
Ipsen Inc. 3 800-727-7625 www.ipsenusa.com
Kanthal Sandvik Heating Technology USA 33 716-691-4010 www.kanthal.com
L & L Special Furnace Co., Inc. 34 910-459-9216 www.llfurnace.com
Lindberg/MPH 17 269-849-2700 www.lindbergmph.com
Marshall Electronics 51 310-333-0606 www.marshall-usa.com/optical
Metal Treating Institute (FNA 2016) 45 904-249-0448 www.furnacesnorthamerica.com
Metallurgical High Vacuum Corp. 41 269-543-4291 www.methivac.com
Neturen 43 86(0)515-83857909 www.neturen.com.cn
Pillar Induction 53 800-558-7733 www.pillar.com
Praxair 28 800-PRAXAIR www.praxair.com
Qual-Fab Inc. 28 440-327-5000 www.qual-fab.net
SECO/WARWICK Corporation 19 814-332-8400 www.secowarwick.com
Sevenstar Electronics Co., Ltd. Industrial Furnace 39 8610-84572692 www.sevenstar.com.cn
Solar Manufacturing 13 267-384-5040 www.solarmfg.com
Super Systems Inc. 25 513-772-0060 www.supersystems.com
Surface Combustion Inc. 4 800-537-8980 www.surfacecombustion.com
T-M Vacuum Products, Inc. 21 856-829-2000 www.tmvacuum.com
Thermo Transfer Inc. 52 317-398-3503 www.thermotransferinc.com
Thermal Products Solutions (TPS) 29 570-538-7200 www.thermalproductsolutions.com
Unifrax, LLC Inside Front Cover 716-768-6500 www.unifrax.com
Wisconsin Oven Corp. 23 262-642-3938 www.wisoven.com
ZIRCAR Ceramics Inc. 27 845-651-6600 www.zircarceramics.com
Get Connected with Facebookwww.facebook.com/IndustrialHeating
Twitterwww.industrialheating.com/twitter
LinkedInwww.industrialheating.com/linkedin
YouTubewww.youtube.com/industrialheating
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ALL WET?
No Problem.Daniels Fans can replace your water cooled high temperature fan with our
proven air cooled shaft design. No water cooling required up to 2,200°F.
World leading manufacturers of high temperature industrial fans since 1977.
A Cincinnati Fan Company
Now in North [email protected] | www.danielsfans.com | 800.628.1200
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Furnaces that work
Vacuum Furnaces - Atmosphere Furnaces - Replacement Parts - Hot ZonesLocations: East Coast, Midwest & West Coastwww.gmenterprises.com phone (951) 340-4646 fax: (951) 340-9090
G-M Model HVF 401-XSFQ (20-BAR) “State-of-the-art” Vacuum Furnace commissioned at one of the Leading US Commercial Heat Treat Plants.Having a free work area of 36”W x 36”H x 60”L and a 8,000 lbs. gross loading capacity, Equipped with
externally mounted 600 HP motor with Allen-Bradley Variable Frequency Drive (VFD) to provide controlled
cooling with externally mounted 14,000,000 BTUs/hour primary heat exchanger and a 300,000 BTUs/
Hr. post cooler to provide maximum quenching capabilities for various types of loads and large cross-
sections. Furnace controls equipped with Honeywell HC900 and Wonderware Computer Control.
Contact G-M ENTERPRISES for
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