Industrial Heating May 2011

May 2011

June 28 - July 2, 2011 • Düsseldorf, Germany

Induction Modeling p.41 Selective Laser Melting p.47 All About Gas Nitriding p.53 Heat-Treat Automation p.59

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CONTENTS

May 2011 • Vol. LXXIX • No. 5

On the Cover:

A R T I C L E S

Rex Heat Treat's 15-foot vertical gantry furnace transferring a hardening load into the oil quench. Read more about Rex Heat Treat on p. 28.

41

F E A T U R E

Computer Modeling of Induction Heating: Things to be Aware of, Things to Avoid Dr. Valery Rudnev – Inductoheat, Inc.; Madison Heights, Mich. Computer simulation of induction heating has gone from “useful” to “necessary.” Modern computer simulation is capable of effectively simulating electromagnetic and thermal phenomena for many processes, including those that involve electromagnetic induction. Sintering/Powder Metallurgy

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New Ground in Metal-Powder Additive Manufacturing Rob Snoeijs – LayerWise; Leuven, BELGIUM Selective laser melting (SLM) is a powerful technology that shapes any desired metal part geometry by melting metal powder layer by layer. Digital production of functional metal models yields distinct product improvements and economic advantages.

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4 May 2011 - IndustrialHeating.com

Induction Heat Treating

Vacuum/Surface Treating

Principles of Gas Nitriding (Part 2) Daniel H. Herring – The HERRING GROUP, Inc.; Elmhurst, Ill. This is article is actually the third in a series that included an online exclusive in April. The gas nitriding process, including the applicable equations and other specifics, will be discussed here. Check out all three parts for a full treatment of the process.

59

Process Control & Instrumentation

Implementing Process Controls and Automation in Heat Treating Jim Oakes – Super Systems Inc.; Cincinnati, Ohio In heat treating, automation is approached in categories. The types of processes and equipment may only have certain capabilities when it comes to mechanically automating a process, forcing heat treaters to look at nontraditional types of automation.

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COLUMNS 14 Editorial All About Automotive We review the lightweighting of cars with high-strength steel or aluminum, fuel economy, the impact of the tsunami on the auto industry and the future of automotive materials.

18 Federal Triangle Return of the Small Modular Reactor According to Barry Ashby, America’s nuclear-power future appears healthier than expected. He discusses the small modular reactor (SMR) and why he feels that both the U.S. and the world would benefit from what they have to offer.

20 The Heat Treat Doctor™ The Role of Metallurgical Analysis in Solving Heat-Treat Problems What do heat treaters need to provide to the metallurgist to assure that accurate information and reliable facts result from whatever testing or analysis is performed, upon which we can make informed decisions.

24 Now You Know Bearing Balls, Not Ball Bearings Have you ever wondered how the balls in a ball bearing are made? Although they look simple and are an uncomplicated shape, the production process and requirements are a bit more challenging.

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©2010 Babcock & Wilcox Nuclear Energy, Inc. All rights reserved.

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26 IHEA Profile – IHEA Develops Strategic Plan 28 MTI Profile – Rex Heat Treat

DEPARTMENTS 30 Industry News

66 Products

38 IH Economic Indicators

70 Aftermarket

39 Industry Events

72 Classified Marketplace

63 Literature Showcase

78 Advertiser Index

INDUSTRIAL HEATING (ISSN 0019-8374) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, 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 offices. POSTMASTER: Send address changes to: INDUSTRIAL HEATING, P.O. Box 2147, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, 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 2147, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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Industrial Heating is the official publication of ASM’s Heat Treating Society and official media partner of ASM’s HT Expo & Conference.

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Online Exclusive An 80-Year Legacy of Thermal Processing In case you missed it last month, Industrial Heating’s look back at thermal-processing history is still available online. This article pulls quotes and other content from the pages of past issues.

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Advancements in Gear Hardening

GEAR HARDENING

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Editorial Reed Miller, Associate Publisher/Editor | 412-306-4360 | [email protected]

All About Automotive

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r review of recent automotive news reveals several key k areas to cover. The lightweighting of cars with high-strength steel or aluminum is one important h initiative, which is related to another – fuel econoi my. The third revolves around the impact of the tsunami on the Japanese auto industry. Cut the Fat In just a week or so, the 10th Annual Great Designs in Steel (GDIS) seminar will be held in Livonia, Mich. At that venue, the FutureSteelVehicle (FSV) program presents production technologies and steel grades to the industry’s advanced high-strength steel (AHSS) products. Over the past decade, the use of AHSS by the auto industry has outpaced all other lightweighting options. Making vehicles lighter by using AHSS has an additive effect. As vehicles shed pounds, engines can be lighter because it takes less to power the lighter vehicle. Brakes can be lighter because it is easier to stop a lighter vehicle. Batteries for hybrids or electric cars can also be lighter as the vehicle sheds pounds. Needless to say, all of this trimming of the fat results in a more fuel-efficient vehicle. Experts predict that the use of lightweight steel will save 0.37 quad of energy by 2020. A quad is equivalent to over 8 trillion gallons of gasoline or nearly 300 trillion kWh of electricity. Five new 2011/2012 gas-powered vehicles are professed to reach the 40 MPG threshold by a variety of innovative techniques. Several specifically mention the widespread use of lightweight steel as one of the ways they got there. Obviously, aluminum usage is also important. Development continues on new and improved ways to make metals lighter. Researchers at the Polytechnic Institute of New York University have found a way to make metal lighter while recycling a toxic waste. Metal-foam composites have been created using fly ash – a toxic by-product of coal combustion – as an additive. The metal foam material can be used to replace solid aluminum and magnesium in certain automotive applications. While it’s likely these “inclusions” will not make the steel stronger, tests have found that the lightweight foams absorb more energy than the solid materials. 14 May 2011 - IndustrialHeating.com

What’s Happening? As I write this editorial, Toyota has announced that it is rationing aftermarket parts for dealers in the U.S. They also said that they expect “some production interruptions” at North American factories due to problems obtaining parts from Japan. Similarly, Honda said that it “will begin to adjust production levels, cutting hours at some plants in half.” Subaru cut shifts in half at its Lafayette, Ind., plant to conserve parts, and as of the day of this writing, Nissan is reassessing North American production. The tsunami effect has hurt domestic manufacturers that rely on Japanese-made parts as well. GM was forced to temporarily close a pickup factory in Shreveport, La., and a related engine line in Buffalo due to a lack of imported parts from Japan. Speaking of GM, they recently announced the sale of its share of Delphi Corp. back to its former parts subsidiary for $3.8 billion. This will result in a $1.6 billion gain in its first-quarter financial results. In March, Ford was expected to surpass GM, becoming the top U.S. auto seller. Industry experts say this has more to do with GM falling than Ford gaining. However, with two of the five 40 MPG models – 2011 Fiesta SE SFE and 2012 Focus SFE – Ford has positioned itself well for the higher-priced fuel we are currently experiencing. The Association of Global Automakers, a lobbying group representing Toyota, Honda, Nissan, Hyundai, Kia, Subaru, Mitsubishi, Suzuki and others has petitioned the U.S. government to require the continued availability of E10 fuel – 10% ethanol, 90% gasoline. The feds have approved E15 for 2001 and newer vehicles. Many have expressed concern that the E15 usability tests were not adequate and that prolonged use will damage fuel lines or the engines themselves. The Future A quick glimpse into future technology reveals that materials are a key component. The following list helps paint the picture: honeycomb-shaped, polyurethane-spoked tires; electromagnetic motors to replace shocks and springs; magnesium exoskeleton; graphene-based ultracapacitor for energy storage; aluminum-oxynitride windows, roofs and doors; carbon-fiber composites; lithiumion batteries; integrated solar panels; inflatable metallic structures for better crash protection; and enhanced turbocharger/supercharger technology to name a few. IH Concept car illustration courtesy of WorldAutoSteel www.worldautosteel.org

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Federal Triangle Barry Ashby, Washington Editor | 202-255-0197 | [email protected]

Return of the Small Modular Reactor

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h nuclear disaster in Japan, continued growth in world he electricity demand (projected to rise 77% by 2030) and e aging power-generation infrastructures led to this coma mentary on the best means to satisfy national and inm ternational energy hunger. I attended a small modular reactor (SMR) seminar on March 28 and learned that America’s nuclear-power future appears healthier than expected. It is also headed in the right direction after decades of fear and loathing by a large part of the population. My unofficial count indicates there are 15 light-water designs, 10 liquid-metal-cooled, nine gas-cooled, three molten-salt-cooled and two fusion SMR power producers in development and in varying stages of commercialization. Recall that an SMR was the original – the first nuclear power output of 45 KWe (kilowatts electric) was done at an Idaho laboratory on Dec. 20, 1951, and hundreds of Navy nuclear vessels have since covered the ocean surface and depths for over 50 years. The definition of an SMR is generally accepted as electric output of up to 300 MWe, but the great majority of those cited as in development are in the 10 to 100 MWe range with some field portable units as small as 1.5 MWe output. What distinguishes the modern SMR is greater simplicity of design, economies of factory-built production and dramatically reduced siting costs. What differentiates manufacturing entities from former U.S.-dominated providers is that all have high foreign ownership. For example, GEHitachi is 50% Japanese owned; both Areva and Mitsubishi are 100% Japanese. Over half of those developing SMR concepts are American-owned firms. What this indicates is that participating American industry is concerned about an inhospitable tax and regulatory environment at home and that there’s clear recognition, as expressed by numerous at the seminar, that foreign markets are the preferred (and first) markets of choice. There are many aspects of SMR use that are quite different from other sectors. Previously, all reactors were built on location, were large to achieve economies of scale in financing and operation, and great care was devoted to facility safety and security to prevent theft and improper proliferation of radioactive materials. Today, the trends are to make components in a factory to halve costs and to cut total construction time by half and possibly reduce labor costs eightfold. Reactors housed in a sealed containment can be small enough to ship on a railcar or truck. Installation at many proposed 18 May 2011 - IndustrialHeating.com

sites are underground with all waste materials stored within the containment during a typical 60-year life with refueling every two to 10 years. The reasons for foreign markets being attractive to SMR makers are that many poor countries cannot afford the financing of the large, average-sized plant ($9-11 billion) and, further, that these countries do not have the needed grid infrastructure to distribute power from gigawatt power stations. It is also expected that the anticipated capital cost of these SMRs will be about $5,000 per KWe, or several hundred million dollars, rather than billions for the monolithic power stations. Another overlooked feature of SMRs is that they are indeed “modular” and can be linked together to increase output as demand in a locale changes. Inherent safety of SMR design has been a focus for developers to change the fuel cycles, to do everything from burning other “used fuels” and nuclear waste, and to limit the operating cycle so that “passive” control and cooling means are part of every plant. The object is for no SMR to ever run out of control. An assessment made two years ago by the International Atomic Energy Agency projects that 40 to 100 SMRs will be in operation worldwide by 2030 with the target being 96 units. None of these are predicted to be in the U.S. even though more than 120,000 Americans are in the U.S. civil nuclear workforce and are part of a civilian nuclear power sector that is estimated to reach $500-740 billion during the next decade. For comparison’s sake, 441 large reactors now operate in 35 countries supplying 15% of the world’s electricity. Of course, there is a lack of consensus about the positive outlook offered here. The Institute for Energy and Environmental Research, for example, has a bleak view of future SMRs’ ability to assist electric supply problems. But it is my conviction that SMRs offer an improvement to power-supply needs and that both the U.S. and the world would benefit from what they have to offer. As large consumers of electrical energy, it is in U.S. industry’s best interest to exercise rational support for the SMR avenues that are opening. It is also essential that industry advise the federal government to assist by allowing future opening of these avenues. IH If you would like to ask Barry Ashby a question, e-mail him at [email protected]. You can hear him answer your query, and others, in our Talk Back to Barry podcasts, which are available at www.industrialheating.com.

Conceptual drawing of B&W mPower™ nuclear reactor design. Illustration ©2010 Babcock & Wilcox Nuclear Energy, Inc. All rights reserved.

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The Heat Treat Doctor Daniel H. Herring | 630-834-3017 | [email protected]

The Role of Metallurgical Analysis in Solving Heat-Treat Problems

A

s a young boy growing up in the neighborhoods of Chicago, one of the Heat Treat Doctor’s most trustC ed friends was a mythical conjuror by the name of e Mandrake, The Magician. If a task seemed impossiM ble to accomplish, or when all else failed, all one needed to do was summon Mandrake, and “voila,” the impossible became possible! As heat treaters, we often seek answers to processing problems or component part failures from the metallurgical community without fully understanding what they need to do their job properly. What do we need to provide, whether it be accurate background information, a representative set of samples (good and bad) for comparative analysis, or even something as simple as protecting the surface of the component to be analyzed from further damage? Often, we don’t communicate our expectations in precise terms and thus do not know what to expect from an analysis. It’s time for us to learn what we can do to assure that accurate information and reliable facts result from whatever testing or analysis is performed, upon which we can make informed decisions. Mandrake would be proud. Let’s learn more.

having a confidentiality agreement in place before you start. If it turns out that the component is being returned from the field, extreme care must be taken to ensure a representative sample and to avoid further damage (see “The Do’s and Don’ts of Field Failure Analysis,” Industrial Heating, January 2006). Incoming (Raw) Material Analysis Too often we are forced to begin an analysis making assumptions about the raw material. Provide the laboratory with a copy of the mill’s material certification sheets. In addition to the chemical constituents, the metallurgist will glean information based on the form of the raw material, its grain size, cleanliness and prior mill processing. Doing an actual chemical analysis is not necessarily redundant. For example, trace-element chemistry can play a significant role when investigating certain phenomenon, such as temper embrittlement.

Laboratory Procedures Discuss with your metallurgist or outside laboratory what type of tests will be conducted and in what order. Understand what will be achieved at each step in the analysis process so that you can ask questions or offer suggestions. (This will also help explain the time or expense involved.) In this way, you will be better able to interpret the final results. The Role of Photography Be aware there is nothing more frustrating in the laboratory In this day and age of digital photography, a picture can indeed be worth the legendary 1,000 words (or more). Provide photographs than to work hard on a job only to find out that it is not the right sample or that the damage observed was induced by extraof everything, from multiple angles, and remember to use good neous factors. This translates into lost time and money. Also, be lighting and high resolution. Handle parts carefully so as not to induce damage and resist the temptation to reconscious of the fact that once the investigator has begun to work on your project, it is fit mating fracture surfaces together. Note part best that the analysis move forward uninterorientation and other salient features. rupted. So be sure to define the scope of work and clarify the boundaries of what he or she Processing History/Background Information is allowed to do once the investigation is unDon’t assume that someone knows your process der way. (Oftentimes, a “not to exceed” figure or product, or its intended service application, works well for this part of the investigation.) better than you do. Communicate the history Selecting the proper tests may involve of the part or process; separate assumptions trade-offs due to cost or time. Be sure you unfrom facts; provide necessary drawings, includderstand the cost/benefit relationship of each ing mating components if appropriate as well test and what the expected outcome might be as required specifications; and explain in detail so that the right choices can be made. Insist the design requirements. In other words, take on specificity to avoid open-ended analysis efthe guesswork out of the analyst’s job. Docuforts. Here are some examples of what can be ment anything of importance and give this information to the metallurgist, even if it means Fig. 1. The Doctor’s boyhood companion done in the laboratory. 20 May 2011 - IndustrialHeating.com

QuantumQuench QuantumQuench

Variable Speed Directional Quench There are no moving parts within the vacuum chamber

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rial H

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• Stereomicroscopy • Nondestructive testing • Eddy current • Ultrasonic • Pressure testing (hydrostatic, pneumatic) • Surface finish • Macroetching • Mechanical testing • Hardness/microhardness testing • Tensile testing • Impact testing (e.g., Charpy testing) • Fatigue testing • Torque/torque-tension • Shear and double shear strength • Torsion testing • Creep • Stress rupture and stress durability • Vibratory testing • Sample preparation • Unetched part examination • Etched part examination • Optical microscopy • Microstructural determination • Grain size • Micro cleanliness • Intergranular attack • Inclusion characterization • Alpha case • Image analysis • Plating depth (layer thickness) • Defect measurement • Grain size • Scanning electron microscopy • Fractography • Feature/character recognition • Energy-dispersive X-ray spectroscopy • Qualitative element analysis • Inclusion characterization • Elemental distribution (dot) mapping • Corrosion testing Selecting the Right Laboratory Not all laboratories are created equal, either in the talent of their researchers or in tools available to do the job right. Talk to people you trust in the industry to help in the selection process. Be aware that many labs are better at some things than others and subcontract certain tasks to other labs. Be sure that you understand when and why this is being done and determine if you are better off going direct. 22 May 2011 - IndustrialHeating.com

Machining Pre-Treatment • Parameters • Material Condition (Feeds & Speeds) • Stress State • Material Condition • Fixturing • Machine Factors (Part Support) • Lubricants • Heating • Tooling (Ramp Rate) • Human Factors

• Process • Atmosphere • Equipment • Process Parameters • Metallurgical Factors Hardening

• Part Design • Quench Method • Equipment • Type of Quench • Quench Variables Quenching

Comparative Analysis (Good vs. Bad) If good parts exist, they can be invaluable aids in understanding why a bad part failed. Taking the seemingly extra step (and expense) of testing a good part along with a bad one will yield tremendous insight into the problem at hand. Do this whenever possible. Timing In an effort to get answers, avoid the temptation to push the lab to the point where steps are skipped or time is not taken to investigate secondary factors that may prove to be major contributors. Ask for verbal reports at key milestones in the analysis work, but avoid taking up valuable analysis time by “checking in” too often. Meeting in person to begin a project is always beneficial. Lab Reports Metallurgists tend to write reports for other metallurgists, a noble but often frustrating problem for the heat treater. If you need the report “translated” into layman’s terms, be sure to tell the lab. Yes, there is a delicate balance here between the facts and their interpretation, but this can often be handled by placing the interpretation in a “Discussion” section of the report. The trend today, due to liability concerns, is to simply report the facts and rely on the client to interpret them. If necessary, hire outside experts to put the information in the proper context in order for you to determine the right course of action. There

Material • Chemistry • Metallurgical Factors • Form

Output: Management of Dimensional Variability • Grinding • Straightening • Stress Relaxation • Deep Freeze • Tempering Post Hardening

Fig. 2. Ishakawa diagram – quenching

is nothing worse than paying good money for a report you don’t understand. Root-Cause Determination “What caused the problem, and how can I avoid its reoccurrence” should be the objective of any analysis effort. There are often multiple contributory factors and removing any one of them might avoid a part failure, even though defects may still exist. While it may or may not be possible to establish the root cause, it should always be the goal. The use of Ishakawa (fishbone) diagrams (Fig. 2) or other diagnostic methods listing all of the variables impacting a successful outcome can be a big help. Sometimes it’s the thought process itself and a discussion among various company departments that leads to the solution to be implemented. The Bottom Line: To Analyze or Not to Analyze A cost/benefit analysis should be performed before and after any analysis/ testing work. Knowledge is strength, and assumption is weakness. When in doubt, do the metallurgical analysis. It will amaze you what can be revealed. And remember that Mandrake is alive and well, living within each and every metallurgist! IH

Use this Mobile Tag to see the Field Failure Analysis column referenced in this column.

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WILL. Inductotherm Group: Many companies. One mission. To design and manufacture the most advanced thermal processing systems to help your company succeed. No matter what metal you melt, heat treat, hot forge or process, the Inductotherm Group will put our shared knowledge, global reach and unparalleled technology to work for one company. Yours. INDUCTOTHERMGROUP.COM

Visit us at Thermprocess/GIFA Hall 10, Stand 10B24 June 28th – July 2nd Düsseldorf, Germany

Now You Know Thermal Processing & Metals in Everyday Life

Bearing Balls, Not Ball Bearings

O

ften, when bearings are discussed, people call them ball bearings. In truth, there are several other types of bearings that don’t even use balls. The most common of these is a roller bearing. Also a misnomer is when people refer to the balls in bearings as ball bearings. The balls are just a component of a ball bearing, which may also contain an outer race, an inner race and a retainer (cage). This discussion is all about the balls used in ball bearings. Have you ever wondered how the balls are made? Although they look simple and are an uncomplicated shape, the production process and requirements are a bit more challenging. Balls can be made from a variety of materials, including (but not limited to) tool steel, stainless, brass/bronze, titanium, Stellite, Teflon, and even ceramics such as aluminum oxide and silicon nitride. The material is chosen based on the application of the bearing. Regardless of the material, the manufacturing process is similar for metal balls. We will focus our discussion on through-hardened steel balls. Perhaps surprisingly, balls begin life as a piece of wire. The steel wire is typically annealed coil stock of a diameter appropriate for the final ball diameter being manufactured. The wire is fed into a machine that cuts off a measured piece and smashes both ends toward the middle. This is called cold heading because no heat is used in this process, which leaves a bulge or flash around the middle of the ball. The next step in the process is the deflashing operation. The balls are placed in rough grooves between two cast-iron disks. One disk rotates while the other is stationary. After deflashing, the balls are soft ground. This is a process similar to deflashing, but grinding stones are used to improve the precision. Balls remain oversize so that they can be ground to their finished size after heat treatment. Heat treatment is often performed in a rotary-retort furnace,

24 May 2011 - IndustrialHeating.com

depending on the specification requirements. If an application, such as aerospace or automotive, requires AMS 2750 temperatureuniformity survey (TUS) requirements, heat treatment will generally be performed in a batch furnace. TUSs are very difficult to do in a rotary retort. Small parts, particularly precision parts such as bearing balls, require good heat-treat control. Load sizes are determined by the surface area of the balls based on the maximum surface area that can be quenched in a load. Soak times are determined not by the diameter of the balls in the load, but by the packing height of the balls in the basket. The hardening process typically involves the following: • Preheating • Austenitizing (hardening) • Quenching • Subcooling (deep-freezing) • Tempering (based on final hardness requirement) Following heat treatment, the balls undergo several finishing operations. Descaling is followed by hard grinding, which is a slow and meticulous process that produces diameter tolerances as close as +/-0.0001 inch. Lapping and other finishing operations follow, most of which are proprietary in nature. These are particularly important for high-precision balls, but all balls need to be sized very precisely. Why? Ball bearings are designed with the assumption that all of the balls in the bearing are carrying an equal load, which means they must be the same size. If, for example, one or two balls were slightly larger, the load would be carried only by the larger balls, and the others would be free spinning. This would result in premature bearing failure. Balls are manufactured in accordance with ABMA (American Bearing Manufacturers Association) standards. The ABMA grade is designated by a number, which indicates a specific combination of dimensional form and surface roughness. Grades 3 to 50 are considered “precision” balls, and grades 50 and 100 are semi-precision. The normal range of sphericity for precision balls is +/-0.000003 for grade 3 and +/-0.00005 for grade 50. From here, the grading and specifying requirements get even trickier and are better left for a more detailed treatment of the subject. Bearing ball manufacture was undertaken in space aboard the shuttle. Molten blobs of steel were released into the zero-gravity atmosphere. Because a sphere has the lowest surface area of any form, the molten blobs form perfect spheres while they cool and possibly harden (depending on the material). Since space travel is expensive and the space-shuttle program is coming to an end, it’s likely that bearing balls will continue to be made using the tried-and-true manufacturing method discussed here for years to come. IH

IHEA Profile Industrial Heating Equipment Association | 859-356-1575 | www.ihea.org

IHEA Develops Strategic Plan

D

u uring the past 12 months, IHEA has developed and begun implementing a new strategic plan. Part of b that plan included cultivating knowledge-base ret sources that the industry can rely on for information. s IHEA is pleased to announce that the beginning of its knowledge base can now be found on its website under RESOURCES, where you will find links to a wide variety of content for the following subjects: • Application videos • Energy efficiency • Innovations • Books • Software • Manufacturing careers • Manufacturing-related sites • Furnace market statistics • Government regulations/legislation • Environmental • Business • Social Media • Industry publications • Industry trade associations This will be an ever-expanding section of our website as we locate additional information that is important to the process heating industry. You can help us grow this area by telling us about important resources you use in your business.

the economy and health-care bill; how to attract and keep skilled workers; lengthy discussions on the implementation of IHEA’s strategic plan; and an entertaining motivational presentation on goals, attitude and behavior from keynote speaker Conor Cunneen. In addition, the TC244 Working Group 1 convened. THERMPROCESS 2011 With just a little over two months to go until the start of THERMPROCESS 2011 (June 28 in Düsseldorf, Germany), IHEA and Industrial Heating’s Resource Center has come together. Through the support of IHEA members and industry, this Resource Center will feature a presentation area, meeting rooms and literature from sponsoring companies. It will serve as a gathering spot for IHEA members exhibiting and visiting the show. Sponsorships for the Resource Center are still available. Benefits include access to food and beverage; use of meeting room; company name displayed in the Resource Center; and more. For a complete listing of sponsorships and the benefits included with each level, contact Anne Goyer at [email protected] or 941-373-1830.

Annual Meeting IHEA’s 82nd Annual Meeting recently concluded four solid days of educational presentations, committee and ISO meetings, and networking opportunities at one of the biggest gatherings in years. More than 90 people made the trip to Florida, where members heard updates on

THE DIFFERENCE IS OBVIOUS. The Brightest Solutions Through Ingenuity

Solar stands out from the usual choices. 26 May 2011 - IndustrialHeating.com

Visit www.solarmfg.com to learn more.

PROUDLY MADE IN THE USA

MTI Profile Metal Treating Institute | 904-249-0448 | www.HeatTreat.net

Rex Heat Treat World-Class Heat Treater of Choice

R

ex Heat Treat began as a two-man operation in a two-car garage over 70 years ago. Today, the commercial heat treater based in Lansdale, Pa., employs 90 people at three separate facilities. In 1938, the company’s first job was hardening a pair of chisels. During the late 1950s/early 1960s, what was known as J.W. Rex Company (named after founder J. Walter Rex) built three vertical gantry furnaces ranging in size from 15 to 30 feet tall for the Titan and Minuteman missile programs and became a major source for the heat treatment of ordnance shells. The company name was changed to Rex Heat Treat in 1999. The following year, a 30,000-square foot facility was added in Bedford, Pa. In 2005, the company expanded further with the addition of a facility in Anniston, Ala. Rex Heat Treat’s vertical gantry furnaces (15 and 20 feet high with maximum 65-inch-diameter work zone) are integral to its success. They permit parts to be suspended as required, providing a vertical orientation that takes advantage of gravity and reduces distortion during heat treatment. In addition, the rapid transfer from the furnace to the quench does not allow for any cooling of the load before being submerged in the quench bath. These furnaces offer marquenching, oil, water and air quenching. Rex Heat Treat has vertical capability for parts up to 24 feet long. The company provides a wide variety of other heat-treating services to industries including aerospace, military and power generation. It has large-volume horizontal capacity for annealing and aluminum processing. Rex Heat Treat boasts 19 Nadcap-certified furnaces with surveyed temperatures from 225˚F up to 2200˚F. This long-time MTI member also has pit furnaces from 8 to 25 feet deep and pusher furnaces capable of processing up to 110,000 pounds of parts daily. In addition, the company has substantial integral quench and austempering capacities at its Bedford and Anniston facilities.

28 May 2011 - IndustrialHeating.com

Rex Heat Treat takes pride in its data-acquisition and process control systems (provided by Super Systems Inc.), which support its employees and shows the accuracy of its processes. These systems allow the company’s management team to remotely check, and modify as required, actual furnace runs and witness the quench on a computer, smart phone or tablet device. As a privately owned company, Rex Heat Treat is willing to invest in its employees, equipment and facilities as needed to support viable customer needs. Over the last two years, the company has reinvested $1.5 million back into its three facilities. The vast majority of this investment was new furnaces, major furnace rebuilds and facility infrastructure improvements. The future is bright for Rex Heat Treat. The company has just begun to penetrate the high-end markets it can support, and it will continue to earn opportunities with the global aerospace and defense industries. More importantly, Rex Heat Treat is keeping its options open for the addition of equipment and facilities to support future business levels. For more information, visit www.rexht.com

Celebrating 25 Years of Gears!

Indianapolis, Indiana

Since 1986, Contour Hardening has provided specialized automotive gear components using our patented computer-controlled induction heating technology. Our metal strengthening systems and processes have dramatically altered the traditional methods of manufacturing case hardened gears and other irregularly shaped, complex parts requiring a high degree of dimensional accuracy. This means our treated gears are stronger, more durable, and offer superior quality and better value than the competition.

Silao, Mexico

See you in Cincinnati for the ASM Heat Treat Show. #ONTOUR(ARDENING )NCr.ORTHWEST"LVD)NDIANAPOLIS ). rWWWCONTOURHARDENINGCOM

Industry News

Equipment News

load. The hot zone is an all-metal design incorporating molybdenum/stainless steel shields and molybdenum heating elements with a maximum operating temperature of 1000°C (1832°F). www.solarmfg.com

Vacuum Furnace Ipsen, Inc. shipped a 2-bar TITAN® V6 to the Texas plant of a global energy company. The bottom-loading furnace, with a 60-inch x 60-inch work area, was installed by Ipsen’s field-service team. The TITAN V6 offers energy efficiency and a reduced footprint. It features an easyto-remove hot zone and heat exchanger as well as loadproximity controls. This particular model included several standard options – all-metal hot zone, operator-access platform, 1,000-gallon backfill reservoir tank, controlled cooling using a variable-speed drive and 10-Torr hydrogen partial pressure. www.ipsenusa.com

Carbon-Fiber Process Line

Vacuum Furnace Solar Manufacturing received an order for a car-bottom-type vacuum heat-treating furnace from a major Chinese aircraft manufacturer. It is expected that the furnace will be used for the processing of various titanium aircraft parts and other related products. The Model HCB-120180-2EQ horizontal furnace incorporates a special motorized in/out front-loading system. Solar is modifying the design of its standard car-bottom loading system to uniquely suit the customer’s needs. The furnace work zone measures 99 inches wide x 48 inches high x 180 inches long and has a hearth designed to accommodate up to a 15,000-pound work-

Harper International finalized a contract with the United States Department of Energy’s (DOE) Oak Ridge National Laboratory (ORNL) for a full pilot-scale carbonfiber process line valued at approximately $12 million. The line is a custom-designed conversion process to support ORNL’s lowcost carbon-fiber research and technology transfer. The line incorporates Harper’s proprietary multi-flow oxidation oven technology, advanced LT and HT slot furnaces rated for 1000°C and 2000°C respectively, pre- and post-treatment fiber conditioning, gas treatment and handling, and materialtransport systems. www.harperintl.com

:+$7·6+27)25<285)851$&( 7XWKLOO·V.0%'%\SDVV %RRVWHUFRPSOHPHQWVRXU LQGXVWU\SURYHQ.75RWDU\ 3LVWRQ9DFXXP3XPSLQD V\VWHPGHVLJQHGWRHQKDQFH IXUQDFHDSSOLFDWLRQV³ LQFOXGLQJKLJKYROXPHVDWYHU\ ORZSUHVVXUHV$QG\RXFDQVDYH XSWRRQSXPSGRZQWLPH )HDWXUHV ‡3URYHQSHUIRUPDQFHLQWKHIXUQDFHLQGXVWU\VLQFH ‡/RZPDLQWHQDQFHDQGHDV\LQVWDOODWLRQ³SHUIHFWO\VXLWHG DVDGURSLQUHSODFHPHQW ‡'URSLQNLWVDUHDYDLODEOHIRU6WRNHVŠSLVWRQSXPSV ‡4XLHWHUSHUIRUPDQFHDQGJUHDWHUVWUHQJWKIURPKHOLFDOJHDUV ‡5XJJHGFRQVWUXFWLRQIRUORQJOLIHLQKDUVKHQYLURQPHQWV ‡6WDQGDUGDQGFXVWRPGHVLJQVIRU\RXUDSSOLFDWLRQ ‡0DGHLQWKH86$ 7ROHDUQPRUHFDOOIRU\RXUQHDUHVW UHSUHVHQWDWLYHRUYLVLWYDFXXPWXWKLOOFRP

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Industry News

Finally, a Water-Based STOP-OFF PAINT that Actually Works CONDURSAL 777/i For all forms of Gas Carburizing & Carbonitriding • One coat coverage • Washes off after heat treatment • No Special thinners required • Non-Hazardous

Furnace Controls United Process Controls (UPC) completed a turnkey project for Baldor Electric to upgrade furnace controls and automate heat-treat operations at the company’s Greenville, S.C., plant. To optimize and centralize control, UPC scrapped the old control consoles and replaced them with compact, state-of-the-art control systems based on the Protherm 600 programmable controllers for monitoring and controlling all furnace process parameters. The scope of the control upgrade also included PLCs, VRT controls, supervisory flame pilots, SCR heater controllers and Waukee’s AccuBlendor™ endothermic generator systems

Call or visit our website for more information and pricing. www.duffycompany.com

283 E. Hellen Rd., Palatine, IL 60067-6954 Ph: 847-202-0000 • Fax: 847-202-0004

with turndown control for just-in-time delivery of mixed gases. All controllers and control systems are interfaced with Protherm 9800 production management software, which performs data acquisition, data analysis, alarms and recipe management, and monitoring. The Protherm 9800 also allows live, real-time remote viewing and control of furnace control systems, and it incorporates modules for laboratory documentation and process design. www.group-upc.com

Roller-Hearth Furnace Tenova Core has been contracted by Metallix Refining Inc. to design and supply a custom roller-hearth-type furnace. The furnace will be installed as part of the precious-metal recovery process at Metallix’s Greenville, N.C., refinery. The controlledatmosphere furnace will feature a state-of the-art radiant-tube combustion system for energy-efficient heating, entry and exit vestibules as well as an advanced Tenova Core process-control system. The project scope also includes an afterburner system for environmental control. www.tenovacore.com

Furnace Controls, Software Super Systems Inc. (SSi) installed new controls and software at Stack Metallurgical. The instrumentation included SSi programmable controls for ramp/soak processes with event management and remote recipe maintenance. The controls have been deployed on heat-treatment furnaces in Stack’s vacuum, atmosphere and aluminum departments. One familiar interface across all departments addresses simple and complex recipes and provides the greatest opportunity to run repeatable processes. The equipment also included data acquisition for plant-wide visibility, control and reporting of heat-treatment processes. www.supersystems.com

32 May 2011 - IndustrialHeating.com

Dual-Chamber Furnace Lucifer Furnaces installed a dual-chamber furnace at Amarillo College’s Manufacturing Technologies Department. The Model HS84 furnace has two 12-inch-high x 12-inch-wide x 24-inch-long chambers mounted in a space-saving arrangement. The upper hardening chamber heats to 2450°F, and the lower tempering chamber reaches 1400°F. The upper chamber is insulated with 6.5 inches of dry-fit lightweight ceramic fiber and mineral-wool block for energy efficiency and heated with silicon-carbide elements mounted across the roof and below the hearth. An SCR power supply provides a steady low amperage and voltage supply to the elements for longer life, and a double-pivot horizontal swing door keeps the hot face away from the user at all times. The furnace will be part of the school’s program to teach the principals of heat treating. www.luciferfurnaces.com

Induction Forging System Inductoheat, Inc. shipped a single-module, 500 kW/3 kHz InductoForge® induction forging system and material-handling Continued on page 34

NEW FULL FEATURE

COMBUSTION SAFEGUARD FORM 6642FF

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IndustrialHeating.com - May 2011 33

Industry News

equipment to a supplier of hardware and hand tools. This machine is designed for heating a wide range of billet diameters and lengths to 2250°F. This forging line begins with a 6,500-poundcapacity automatic bin tipper with automatic refill, which dumps carbon steel billets into a rotary feeder. The rotary feeder continuously feeds billets end to end using a start/stop motion sensor and supplies a pinch-wheel in-feed system that precisely delivers billets through the induction coils on heavy-duty skid rails. The power module supplies two in-line forging coils and accurately heats the billets to 2250ºF at a nominal rate of 300 pieces per hour. Process control is enhanced by IHAZ™ (induction heat-affected zone) temperature-modeling software, which allows for customized billet temperature profile to best suit the customer’s ideal billet heating specifications. www.inductoheat.com

Melting Furnaces Brazilian furnace manufacturer Metaltrend sold aluminum melting and holding furnaces for the new casting and rolling line to be installed at Novelis Brasil’s Pindamonhangaba plant. Metaltrend will supply two round top-loading melting furnaces. Each furnace is equipped with six regenerative burners and has a capacity of 140 tons. The line, which will feed a tilting holding and casting furnace, is scheduled to start up in July 2012. www.metaltrend.com.br

Furnace Muffles

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34 May 2011 - IndustrialHeating.com

Merrsen, your partne er to design yourr next generation of high perfform mance furnace !

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Less energy > CALCARB® unmatched over 1400°C ! > Monobloc rigid insulation up to Ø 55 inches > Barrel stave construction over Ø 55 inches

Visit us at our booth C38 Hall 9 THERMPROCESS 2011 - www.mersen.com

Industry News

Business News

Lakeside Steel to Build Heat-Treatment Facility in Alabama Lakeside Steel Inc. selected a site in Thomasville, Ala., to build a $7.5 million state-of-theart heat-treatment and end-finishing facility. The new facility will enable Lakeside Steel to upgrade and process the high value-added American Petroleum Institute-certified J, L, N and P grades of OCTG products that it produces and which are required throughout the majority of drilling operations in North America. The plant will be located approximately five miles from the company’s new casing mill currently being constructed in Thomasville. The plant will be located approximately five miles from the company’s new casing mill currently being constructed in Thomasville. Lakeside Steel strongly believes that the Thomasville location will provide the greatest benefit to all stakeholders. The project remains subject to customary conditions and the execution and delivery of definitive agreements.

Carpenter Introduces New Alloy Carpenter Technology Corp. developed a new ultrahigh-strength steel (UHSS) alloy that is a lower-cost alternative to many cobalt-containing precipitation hardenable alloys. TEMPER TOUGH™ alloy is an air-melted, cobalt-free quench-and-tempered alloy that has a unique combination of high strength and high toughness attributes that may allow designers and engineers to achieve an extended cycle life where components are under high loads with constant stress of intense, repetitive motion. The attributes of TEMPER TOUGH alloy make it a candidate for applications in high-demand crankcases, drivetrains, powertrains, structural members, suspensions and industrial tooling, especially when designers are looking for affordable solutions to reduce the weight of parts and/ or components without sacrificing performance. Carpenter Technology currently offers TEMPER TOUGH alloy in bar product forms.

Latrobe Specialty Steel Expands in Ohio Latrobe Specialty Steel was awarded a Contingency Grant from the Ohio Department of Development for creating 31 new full-time jobs and retaining existing jobs at its Wauseon plant. The company will use the grant to purchase new equipment for its growing precision wire manufacturing business at Wauseon. According to Latrobe Specialty Steel, the company will further expand capacity this summer with the installation of technologically advanced hydrogen atmosphere furnaces. The expansion will cost approximately $3 million. At Wauseon, Latrobe makes two product groups: Edgewire and precision stainless steel wire. The industrial bimetal saw market buys Edgewire, an enhanced value-added, small-diameter, rectangular, high-speed-steel wire. Latrobe sources the high-speed steel from its Pennsylvania steel mill. For precision stainless steel wire, Latrobe melts the stainless steel in Pennsylvania, ships it to Wauseon and then draws the wire to the exact standards demanded by its customers in the market for implantable medical devices.

Engineered Sintered Components to Expand Engineered Sintered Components (ESC), a joint venture between Sumitomo Electric and Eaton Corp., announced a $9 million investment in their Troutman, N.C., manufacturing operations. The expansion will include a 20,000-square-foot addition to the company’s second on-site facility and new equipment to support business secured in the manufacturing of powder-metal components for the auto industry. ESC plans to hire 25 staff within the first six months of the project, which is scheduled for completion in late October/early November.

German Manufacturer Chooses Georgia Germany’s Hotset, a heating-element manufacturer, selected Swainsboro, Ga., as the site for its first North American plant. Hotset currently has facilities in Ludenscheid, Germany, and on the island of Malta. Both operations have more than 100 employees. The company plans to establish a sales, warehouse, distribution and manufacturing facility at the Swainsboro location. Hotset has established itself with products such as flexible tubular heaters and hotspring heating elements. The availability of easy access for air and ground transportation was one of Hotset’s primary reasons for selecting Swainsboro.

36 May 2011 - IndustrialHeating.com

Uncovering potential. Changing perspectives. Finding answers.

www.clearseasresearch.com

Industry News

Replace This Tube...

When Hell Freezes Over

Timken Increasing Capacity The Timken Company will increase its annual steelmaking capacity by 120,000 tons across its steel manufacturing facilities in Canton, Ohio. The company is achieving this boost through a series of improvements at its Harrison Steel Plant that build upon and further leverage the $60 million rolling-mill investment completed there in 2008. Additional investments and crew additions being made over the next few months will enable a further increase in output and will allow the company to optimize production loads between its Harrison and Faircrest plants. The changes will effectively create new capacity at both of these steel facilities to support growing demand for finished bar products and billets for tubing product that serve customers in the global industrial, oil and gas, and mobile markets.

It’s hell replacing alloy tubes. INEX your furnace and find something better to worry about.

People in the News Chester J. Mroz will become president and CEO of Yokogawa Corporation of America. Mr. Mroz will be responsible for overseeing all Yokogawa business operations in North America. His professional career covers a broad range of engineering, managerial, consulting and senior executive positions with leading automation, electrical suppliers and systems integrators.

Tubes for Life* Phone: 716-537-2270 www.INEXinc.net [email protected] *A portion of the proceeds from all INEX tubes goes to the American Cancer Society

Economic Indicators REQUEST FOR QUOTE

GRAPHALLOY BEARINGS CAN TAKE THE HEAT. ®

CORPORATION

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38 May 2011 - IndustrialHeating.com

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GRAPHITE METALLIZING

TEL. 914.968.8400 • WWW.GRAPHALLOY.COM/IH

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FEATURE | Induction Heat Treating

Computer Modeling of Induction Heating: Things to be Aware of, Things to Avoid Dr. Valery Rudnev – Inductoheat, Inc.; Madison Heights, Mich. In the last decade, when discussing subjects related to a computer simulation of induction heating, the word “usefulness” has been replaced by the word “necessity.” Modern computer simulation is capable of effectively simulating electromagnetic and thermal phenomena for many processes, including those that involve electromagnetic induction.

B

y combining advanced software with a sophisticated engineering background, induction heating c professionals possess the unique ability to analyze, p in few hours, complex technological problems that could take days or even weeks to solve by running experiments or through physical modeling using the pilot models. Simulation provides the ability to predict how different, interrelated and nonlinear factors may impact the transitional and final thermal conditions. Simulation also helps to determine what must be accomplished to improve the effectiveness of the process, choose the most appropriate process recipes and serve as a comfort factor when designing new systems. In 2007, ASM International began an ambitious undertaking to compile an all-new, comprehensive resource on modeling as it applies to a computer simulation of different metal-processing technologies. Carefully selected world-recognized experts from

Fig. 1. ASM’s new two-volume set on computer simulation of metal processing

leading universities, national research laboratories and industrial corporations from 13 countries were chosen to submit materials. As a result, a brand-new two-volume set was published as a part of the ASM Handbook series (Fig. 1). The first part, “Volume 22A, Fundamentals of Modeling for Metals Processing,” appeared in 2009. The second part, “Volume 22B, Metals Process Simulation,” was published in 2010. This two-volume set covers a wide range of subjects including phase diagrams and transformations, heating and heat treating, casting and solidification, forming, joining, machining, powder metallurgy, integration modeling and equipmentdesign simulation. Among other useful information, Volume 22B contains two articles (listed in the references) that are solely devoted to a computer simulation of induction heating and heat-treating technologies. How it was Done in the Past An estimation of the process parameters based on single-formula “rules of thumb” as well as using the analytical methods and equivalent circuit coil design methods were popular in the 1960s through 1990s.[1,2] Though those techniques were easy to employ, they were very subjective with inherent major restrictions limiting their use for quick estimation of only ballpark parameters of induction systems. There was a danger of obtaining erroneous and inadequate results with such overly simplified estimations. Recent advancements in high-performance computers have improved the cost-effectiveness of the development stage by shortening the learning curve and reducing development time, and computers have significantly restricted the usefulness of simplified formulas. Rather than using computational techniques with many restrictions and disputable accuracy, modern induction heating specialists turned to highly effective numerical simulation methods IndustrialHeating.com - May 2011 41

FEATURE | Induction Heat Treating

Axis of symmetry Hollow shaft Magnetic flux concentrator

Two-turn MIQtype y inductor

Dwelling stage (Fillet pre-heating)

Spray quench

(A)

(B)

(C)

(D)

Fig. 2. Computer simulation of the sequential dynamics of induction scan hardening a hollow shaft using a two-turn machined integral quench (MIQ) inductor with an L-shaped magnetic flux concentrator ring (frequency = 9 kHz) (Courtesy of Inductoheat, Inc.)

such as finite differences, finite element analysis (FEA), edge elements, boundary elements and others. Each of those simulation techniques has certain pros and cons and has been used alone or in a combination with others. In recent years, FEA became a dominant numerical simulation tool for a variety of engineering applications. Though FEA is a very effective modeling technique, it cannot be considered the ultimate computational tool for all induction heating applications. In some cases, a combination of different numerical methods is more effective, while FEA is a preferred choice for others. Case Study: Scan Hardening Numerical computer simulations allow manufacturers of induction equipment to determine comprehensive details of the process that would be difficult, if not impossible, to determine experimentally. As an example, Fig. 2 shows the results of computer modeling the sequential dynamics of induction scan hardening a hollow shaft using a two-turn MIQ (machined integral quench) inductor with an “L”-shaped flux concentrator ring (frequency = 9 kHz). At the beginning (Fig. 2, A and B), a 2.6-second power dwell is applied to properly heat the shaft fillet area. During this stage, an inductor is energized but does not move, and quenching is not applied. Upon completing the dwell stage, the shaft fillet is sufficiently preheated and scanning begins. Scan rate and coil power are varied during scanning to allow proper accommodation of changes in shaft geometry. Computer modeling reveals several important process subtleties: • During scanning, appreciable heating of the shaft begins at a distance a good deal above the top copper turn, creating a preheating effect. Factors responsible for preheating are heat flow in the axial direction due to thermal conduction and propagation of the external magnetic field, which generates heat sources outside of the induction coil. • Presence of an external magnetic field outside the induction coil is also responsible for the post-heating of shaft areas located immediately below the bottom turn and, in some cases, even in regions where the subsequent quenchant impinges the shaft surface. With insufficient quenching, the latter can dramatically reduce quenching severity and potentially create conditions for crossing the nose of the CCT (continuous cooling transformation) curve. 42 May 2011 - IndustrialHeating.com

The result would be the formation of mixed structures with the presence of upper transformation products (e.g., bainitic/pearlitic structures or “ghost” networking). Such microstructures are notorious for scattering and lower hardness readings. • Electromagnetic proximity effect and coil end effect both cause the hot spots appearing on a shoulder near a shaft diameter change. During scanning, the magnetic field preferably couples to the shoulders, leading to a power density surplus at those locations regardless of reduced coil power. The presence of hot spots produced by power surplus necessitates having prolonged cooling to remove excessive heat, which ensures sufficient hardness by martensite formation. At the same time, a heat deficit could occur in the undercut region and transition area near the shaft’s smaller diameter. Comet-Tail Effect It is imperative to take into consideration a “comet-tail” effect when developing a scan-hardening process recipe. Figure 3 shows a magnified temperature pattern of an intermediate process stage (Fig.2, F). The comet-tail effect manifests itself as a heat accumulation in shaft subsurface regions below the scan inductor. This effect is pronounced in the areas of a diameter change.

Fig. 3. The comet-tail effect manifests itself as a heat accumulation in shaft subsurface regions below the scan inductor. (Courtesy of Inductoheat, Inc.)

(E)

(F)

(G)

Upon quenching, the temperature of the shaft surface can be cooled sufficiently below the Ms temperature. At the same time, the heat accumulated in the shaft subsurface might be sufficient for the tempering of as-quenched surface regions and could potentially result in the appearance of soft spots within the case depth. Sufficient quench-out is essential to prevent this undesirable phenomenon. Critical Issues with Computer Modeling of Scan Hardening A limitation of the great majority of commercially available software is that they are not capable of taking into consideration a comet-tail effect when trying to model induction scan hardening. In addition, some software cannot properly handle pre- and postheating effects as a result of external magnetic-field propagation and axial heat flow due to thermal conduction. Make sure that applied software is free of these restrictions and properly models all-important physical phenomena. When designing inductors and developing optimal process recipes, it is imperative to properly model not only heating but the spray-quenching stage as well. Otherwise, crucial aspects of the process might be missed, having a negative impact on modeling accuracy and its usefulness.

300

300

250

250

200

200

150

150

100

100

50

50

100 180 250 640 1300 Magnetic field intensity, A/in.

750

600

450

300

150

10

Temperature, ˚C

Fig. 4. Relative magnetic permeability as a function of magneticfield intensity (range 100-1500 A/in., or 39-590 A/cm) and temperature (range 10-750oC)

(H)

(I)

Before You Hire Somebody to do a Computer Simulation First Step It is important to remember that any computational analysis can, at best, produce only results that are derived from the correctly defined theoretical model, governing equations and boundary conditions. Therefore, before you hire somebody to do computer simulations, make sure that the analyst(s) has a clear understanding of the process specifics and has an appropriate education in the area where you are seeking help. For example, when you are flying an airplane, you expect a pilot to have appropriate training. When you need medical assistance, you expect a doctor to have a proper education and appropriate medical degree. The same principle should be applied when you are choosing a company or analyst to do computer simulations for you. Second Step Make sure that physical properties of heated materials are properly defined. The well-known but rude saying “garbage in – garbage out” clearly indicates a necessity of having accurate physical properties. Experience shows that poorly determined material properties are responsible for an appreciable amount of simulation errors. Only reliable sources should be used when adapting physical properties. Third Step It is important to recognize that the use of modern numerical software (including finite elements, boundary elements, etc.) does not guarantee obtaining correct computational results. It must be used in conjunction with experience in numerical computations, proper education and engineering knowledge to achieve the required accuracy of mathematical simulation. This is especially so because even in modern commercial software, regardless of the amount of testing and verification, a computation program may never have all of its possible errors detected. The engineer must, consequently, be on guard against various kinds of possible errors. The more powerful the software, the more complex it is with a greater probability of errors. Be aware that computer-generated attractive pictures might be misleading if obtained by amateur. Common sense, engineering “gut feeling” and advanced education are always the analyst’s helpful assistants. IndustrialHeating.com - May 2011 43

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Physical Properties Issue Electromagnetic properties of heated materials encompass a variety of characteristics. While recognizing the importance of all electromagnetic properties, two of them – electrical conductivity (its reciprocal electrical resistivity) and relative magnetic permeability – have the most pronounced effect on the induction heating process. Keep in mind that both properties nonlinearly vary with temperature, chemical composition, microstructure, grain size, etc. Relative magnetic permeability, μ r, is not only a complex function of grain structure, chemical composition, microstructure and temperature but also frequency and magnetic-field intensity. The same kind of carbon steel at the same temperature and frequency can have a substantially different value of μ r due to differences in the intensity of the magnetic field. Figure 4 illustrates the complex relationship among μ r, temperature and magnetic-field intensity for carbon steel. Three of the most critical thermal properties of heated material comprise thermal conductivity, specific heat and surface heat losses due to thermal radiation and convection. All these thermal properties are also nonlinear functions of temperature. The interrelated nonlinear nature of the material properties dictates the necessity of developing special computational algorithms that combine electromagnetic and thermal phenomena. There are several ways to couple the electromagnetics and heat transfer when modeling induction heating, including a two-step approach, indirect coupling and direct coupling. Even a cursory look at the behavior of the material properties reveals the danger in using some of these approaches in certain induction heating applications. Critical review of applicability of these coupling techniques is provided in reference 2. Limitation of Some Commercial Codes A great majority of commercial codes used for computer modeling of induction heating processes are all-purpose programs. Regardless of well-recognized, impressive capabilities of modern commercial simulation tools, some generalized programs experience difficulties taking into consideration certain features of a particular induction heating application. This includes, but is not limited to the following: the presence of thermal refractory; heated workpiece can simultaneously move, rotate or oscillate with respect to induction coil; scanning operation that combines heating and quenching; simultaneous use of two frequencies for contour gear hardening; nonuniform initial temperature distribution; etc. Therefore, be aware that some critical feature(s) of a particular induction heating application could be a limiting factor in creating considerable challenges for a majority of presently available generalized commercial software, affecting an accuracy of simulations. This subject has been discussed in detail in reference 2.

Conclusion In a fast-paced world economy, the ability of induction heating manufacturers to minimize time between a customer request for quotation and quotation through efficient computer modeling is critical for company’s success. In addition, in opposition to academia, the fast pace of industry does not often allow the luxury of waiting several days in order to obtain the results of modeling. Industry demands the reliable results of computer simulation within a few of hours. Measures should be taken to ensure that a properly educated analyst using proper simulation software conducts a computer modeling. IH References: 1. V. Rudnev, “Simulation of Induction Heating Prior to Hot Working and Coating,” ASM Handbook, Vol. 22B, Metals Process Simulation, D. U. Furrer and S. L. Semiatin, editors, ASM, 2010, pages 475-500 2. V. Rudnev, “Simulation of Induction Heat Treating,” ASM Handbook, Vol. 22B, Metals Process Simulation, D. U. Furrer and S. L. Semiatin, editors, ASM, 2010, pages 501-546 For more information: Contact Dr. Valery Rudnev, FASM, Inductoheat, Inc., An Inductotherm Group Co., 32251 North Avis Dr., Madison Heights, MI 48071; tel: 248-629-5055; fax: 248-589-1062; e-mail: [email protected]; web: www.inductoheat.com

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FEATURE | Sintering/ Powder Metallurgy

New Ground in Metal-Powder Additive Manufacturing Rob Snoeijs – LayerWise; Leuven, BELGIUM Digital production of functional metal models yields distinct product improvements and economic advantages.

S

e elective laser melting (SLM) is i a powerful technology that shapes any desired metal s part geometry by melting p metal powder layer by layer. Using this digital approach, the optimum shape of complex parts can be produced in a single manufacturing step. Such a part not only delivers better performance, it is also more reliable than the complicated assembly it replaces. Furthermore, SLM technology is the right choice for small metal products, of which thousands can be produced simultaneously. In addition to countless industrial applications, the technology can be used for revolutionary orthopedic, maxillofacial and dental implants. The key concept is to produce high-grade parts in any preferred metal alloy using less material and no scrap, reducing unit weight by up to 80%.

Limitations of Metalworking Processes Metal cutting, milling, EDM and other high-quality and efficient metalworking processes have a respectable track record on

Fig. 1. By building up metal parts in layers, the most complex part shapes can be produced, including recesses, ribs, cavities and internal features.

the production floor. Typical for these subtractive methods is that each, in their own way, is limited in removing part material despite many tools and accessories. Design engineers know metalworking processes inside out and take into account their specific limitations up front. They design new parts knowing the limitations of the production method that will be applied. It would be better if they could concentrate on the functionality of the part to be produced. The geometric limitations of successive metalworking processes force designers to make choices that devaluate the functionality of the part or lead to a complicated assembly instead. Building Up Parts in Layers “We reverse the entire process,” said Jonas Van Vaerenbergh, director of the industrial division of LayerWise, a Belgium-based technology firm. “Our core business is selective laser melting (SLM), a technology developed to build up material in layers instead of removing it in different steps. In the meantime, we have optimized the process for a variety of metals and alloys,

Fig. 2. As design rules are packed in, selective laser melting (SLM) removes all obstacles in favor of extreme part optimization.

such as rustproof steel, hardenable steel, titanium, aluminum and Inconel.” In the machine, a high-precision laser is directed to metal-powder particles in order to selectively build up a 20- to 40-micron horizontal metal layer. The metal-powder particles pinpointed by the laser quickly and fully melt so that the new material properly attaches to the previous layer, without glue or binder liquid (Fig. 1). The powerful fiber laser with high energy intensity operating in the inert area inside the machine guarantees that metal parts being built up exhibit a dense and homogenous material structure. CAD directly drives the machine without requiring any programming, clamping or tooling. The SLM approach is capable of simultaneously producing metal parts of different shapes in batches of up to 2,500 pieces, which results in favorable unit pricing and short delivery times. Unlimited Freedom of Shape

In addition to producing small components efficiently and cost-effectively, SLM hardly imposes any limitations in terms of geometry. Van Vaerenbergh explains that the layered approach ensures that the laser gains systematic access to any location while building up parts. In this way, the most complex part shapes can be produced, including recess, ribs, cavities and internal features (Fig. 2). “Usually, the products leaving our facility cannot be produced any other way, van Vaerenbergh said. “This is a different ball game for manufacturers because design rules are packed in, removing all obstacles IndustrialHeating.com - May 2011 47

FEATURE | Sintering/ Powder Metallurgy

Fig. 3. In replacement of a complex assembly, LayerWise produced a single burner component containing nine undercuttings and six internal cavities.

Fig. 4. Usually, the products leaving the facility cannot be produced any other way. Shape complexity is not charged because the production cost is dependent on the weight of the part.

in favor of extreme part optimization.” A specific example is the burner component produced for Diametal. Similar to machine manufacturers for food and pharmaceutical companies, this company is regularly challenged with producing complex circulation pieces such as mixers, inlet and outlet components, dispensers, coupling parts and heat exchangers. The Diametal burner component contains nine undercuttings and six internal cavities (Fig. 3). LayerWise applied SLM to manufacture this component as one

unit in a single production step. This is called function integration, because this SLM-produced component replaces multiple parts manufactured using conventional metalworking processes. Assembling these parts takes time, particularly because they need to be connected hermetically, which reduces reliability. SLM is a fit for resolving miniaturization, leakage and assembly issues. Shape complexity is not a problem because the production cost is dependent on the weight of the part (Fig. 4).

Optimizing Circulation Channels

A perfect example of efficient and flexible design was the production of a component that connects cooling ducts. Firstly, the additive manufacturing process realized 75% weight reduction. Secondly, designers were able to drastically reduce flow resistance by defining channel geometry using free-form surfaces. The part was produced exactly according to the functional CAD design, resulting in an improvement of the circulation properties by 80% (Fig. 5). According to Van Vaerenbergh, the

Focus on Technology Leadership ayerWise is the first production center in Belgium that exclusively focuses on this additive production process for metal parts. The company was founded by Jonas Van Vaerenbergh and Peter Mercelis, both of whom were closely involved in the development of selective laser melting (SLM) at the Katholic University of Leuven. LayerWise intensively collaborates with the university and systematically invests 30% of its resources in research and development to push the boundaries of the technology. “By bringing together technological expertise, production capacity and customer support, we occupy an unique position on a European level,” Van Vaerenbergh said. “Our engineers control SLM to such an extent that they are capable of perfecting the technology and realize the most challenging specifications. Today, we are able to produce with 15-micron geometric accuracy and build up walls as thin as 0.2 millimeters, something that is extremely difficult – if not impossible – using conventional technologies. Also, the implementation of process control tools in and around the melting zone is important to guarantee highest part quality.”

L

48 May 2011 - IndustrialHeating.com

By acquiring full control over the production process, LayerWise achieves a homogeneous microstructure with a relative density of up to 99.98% for an increasing number of metals and alloys. Research shows that the mechanical properties are virtually the same as those of conventional metals. To prove this, LayerWise systematically carries out mechanical tests on the level of density, hardness, elongation and fatigue. The chemical composition of the bulk metal powders are examined in a chemical laboratory in advance.

Growing Along with the Technology Two years after its inception, LayerWise has grown considerably. Recently, the company appointed a number of European distributors. This is part of the strategy to gradually operate on an international scale. “After propagating the SLM technology and its advantages to different industries, companies realize that they can truly benefit from the technology,” Van Vaerenbergh concluded. “Additive metalworking processes change design and production rules completely. By realizing projects together with customers, we offer companies plenty of opportunity to create more added value and produce more cost effectively.”

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FEATURE | Sintering/ Powder Metallurgy

Fig. 5. Injection molding quality and speed can be increased by producing injection-mold inserts with optimal cooling channels.

Fig. 6. Through patented DentWise technology, geometry and surfaceretention-related limitations set by traditionally molded or milled suprastructures no longer apply.

reducing the serial production cycle time of molded plastic parts by 15%.”

manufacture of injection mold inserts also yields impressive results. “Thanks to SLM’s freedom of shape, the cooling channels can be positioned in conformity with the mold shape. This is a major improvement compared to conventionally drilled holes. Optimized channel geometry and location ensure a better-controlled cooling process that delivers higher-quality parts that do not warp and contain fewer hot spots. Imagine the economic advantage of

Production Machines Run Unattended

Production machinery consists of topquality systems that run around the clock. Quickly producing prototypes is possible, but this activity is usually a leg up to serial production. As CAD files are directly converted into three-dimensional geometry, SLM is a cost-effective metalworking pro-

cess that allows for unattended production. After parts are taken out of the production machines, finishing actions start. If desired, conventional metalworking actions (such as drilling, cutting and EDM) can be applied. It is also possible to harden certain component surfaces. As a concluding step, customers can opt for a high-gloss polishing finish. Dental Suprastructures

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Fig. 7. Personalized orthopedic protheses are generally produced in titanium, equipped with a fine surface geometry that actively encourages surface retention (Courtesy of Mobelife).

Fig. 8. An implant for a major maximillan reconstruction integrated a titanium layer structure that stimulates surface retention and strengthens the implant to withstand surgical manipulation.

technology. Implant-supported suprastructures are one example. On the basis of patient-specific geometry data acquired through medical imaging or three-dimensional scanning, the personalized part structure is software-designed and then printed directly in titanium. As a concluding step, the dental technician finishes off the structure and completes the final prosthesis. “Through digital SLM technology, geometry and surface-retention-related limitations set by traditionally molded or milled suprastructures no longer apply,” Peter Mercelis, director of the medical division, said. “In addition, the implant connections are completed with highest precision.” DentWise suprastructures are manufactured using ultrastrong titanium alloy (Ti6Al4V, grade V), which outperforms the commonly used titanium grade II in terms of mechanical properties (Fig. 6). Orthopedic and Maxillofacial Implants

More medical applications exist for SLM technology. During a major maxillofacial reconstruction, sugeons inserted a zygoma manufactured by LayerWise. The complex shape of the implant was digitally derived through medical imaging and produced using SLM technology. This approach offers the ability to restore the facial symmetry of patients nearly perfectly (Fig. 8). Concerning orthopedic implants, the process of building up metal in layers offers the possibility to design porous bone-replacing structures and integrate them into prosthesis. This allows for an excellent long-term fixation. In addition to personalized implants designed on the basis of medical imaging, the SLM technology is used for manufacturing medical instrumentation. A number of biocompatible metal alloys are offered for this purpose. IH

Ipsen delivers flexibility. The Ipsen Vacuum Oil Quench (VOQ) furnace offers the perfect balance of flexibility and quality to meet your most rigorous uptime requirements. The versatile VOQ can handle a multitude of thermal processes for a variety of materials including: • Hardening with gas or oil quench • Carburizing with gas or oil quench • Carbonitriding with oil quench • Brazing • Annealing • Solution annealing • Aging/stress relieving • Tempering The Ipsen VOQ is available in three sizes: 18”x 18”x 24”, 24”x 24”x 36” and 36”x 36”x 48”. For more information, please visit www.IpsenUSA.com.

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FEATURE | Vacuum/ Surface Treating

Principles of Gas Nitriding (Part 2) Daniel H. Herring – The HERRING GROUP, Inc.; Elmhurst, Ill. Editor’s note: This is the third of a four-part presentation, including an onlineexclusive article in April. In an effort to establish a logical order, we will label figures consecutively as they appear, including the online content. Consequently, the numbering of some figures may appear to be missing, depending on your starting point.

N

itriding is a case-hardening process in which nitrogen is introduced into the surface of a ferrous alloy such as steel by holding the metal at a temperature below that at which the crystal structure begins to transform to austenite on heating (Ac1) as defined by the IronCarbon Phase Diagram.

Gas Nitriding Reactions Gas nitriding is typically done using ammonia with or without dilution of the atmosphere with dissociated ammonia or nitrogen (or nitrogen/hydrogen) in the temperature range of 925-1050°F (500565°C). Ammonia (NH3) is allowed to flow over the parts to be hardened. Due to the temperature and the catalytic effect of the steel surface, the ammonia dissociates into atomic nitrogen and hydrogen in accordance with equation 1: 2NH3 A 2N + 6 H

(1)

This is immediately followed by atomic

of ammonia at the steel surface in accordance with equation 4, a modified form of equation 1.

nitrogen combining to form molecular nitrogen per equation 2: 2N + 6 H A N2 + 3 H2

(2)

NH3 A [N] + 3/2 H

During the period in which this nitrogen passes through the atomic state, it is capable of being absorbed into the steel (Fig. 14).

By comparison with gas carburizing, the nitriding atmosphere is not in equilibrium since the flow rate of ammonia is too high to allow equilibrium to be achieved. The amount of ammonia present in the outlet gas is a measure of the degree of dissociation. The higher the flow rates of ammonia, the higher the ammonia percentage in the exiting gas stream and the lower the degree of dissociation. However, a greater percentage of ammonia is present at the surface. Equation 5 provides an explanation of the nitrogen activity in which the activity constant (aN) is directly proportional to the degree of ammonia dissociation and the flow rate.

So, the entire reaction – equation 3, Figure 15 – becomes: 2NH3 A N2 + 3 H2

(3)

Gas Nitriding Activity In accordance with the laws governing diffusion, the degree of nitrogen penetration is governed by the temperature and the amount of nitrogen that can penetrate and diffuse into and away from the outer layer of the steel. In gas nitriding, the nitrogen activity is controlled by the degree of dissociation and the flow rate of the gas (Fig. 16). The nitrogen is supplied by the dissociation

aN _ a · v

H

NH3

H N H N

H

Recombine Fe

N

Atmosphere H

H

H

N2

(5)

where aN is the activity of atomic nitrogen

H N H2

(4)

H N

N N

Cracking H H

Recombine

Diffusion

Top surface layer HH

Underlying layer

Recombine N

Fig. 14. Dissociation of ammonia and nitrogen pickup in steel during gas nitriding[4]

N Diffusion

Fig. 15. Nitriding surface and subsurface reactions[5] IndustrialHeating.com - May 2011 53

FEATURE | Vacuum/ Surface Treating

Ammonia content (Vol.% NH3 in H2 atm) 1 3 10 30 60 80

0

100 V = Furnace volume

Consequently, the nitrogen activity is a function of the number of ammonia molecules dissociated at the steel surface per unit of time. At constant pressure and temperature, the degree of dissociation is reduced as the flow rate increases, but the product (a · v) increases and so does aN. Thus, the nitrogen potential (KN) derived from equation 4 can be expressed as: KN = pNH3 / (pH2)3/2

(6)

The amount of white layer can be controlled by minimizing the nitriding potential. AMS 2759/10 (Automated Gaseous Nitriding Controlled by Nitriding Potential) indicates nitriding potential values (Table 5) for the various classes of white layer. Table 5. K N ranges Class

Nitriding potential ranges, KN 1st Stage

2nd Stage

0

4 – 15

0.2 – 0.8

1

4 – 15

0.4 – 2.6

2

4 – 15

1.2 – 5.5

_

500

800

av

700

400

Ammonia flow

a is the degree of dissociation v is the ammonia flow rate

900

600

300 0.01

Fig. 16. Schematic representation of ammonia dissociation and nitrogen absorption[5]

1000

¡

Fig. 17. Lehrer relationship between nitriding potential and the phases formed within the compound layer[4]

Nitrogen potential is also referred to as the nitriding parameter. At a constant temperature, the nitrogen activity, and consequently the nitrogen content, at the surface of the nitrided surface layer are determined by the nitriding potential. The various phases formed are expressed in the Lehrer Diagram (Fig. 17). It is also important to guarantee that there is an adequate amount of nitrogen available during the process to harden the parts to specification. If there is not enough nitrogen available, the consequence will be low case depths and hardness, with related reductions in physical characteristics. On the other hand, too much nitrogen at the part surface will result in formation of a brittle and excessively thick white layer, resulting in embrittlement of the nitrided case. One of the keys to successful nitriding is controlling the percentage of ammonia available per square area of (work) surface that will supply atomic (nascent)

Case depth, inches (mm)

Time, hours

PD = 25%

40

60

20

80

0 0V

2V

100 4V 6V 8V 10V Flow, scfh

Fig. 18. Percentage dissociation as a function of furnace volume[6]

nitrogen at the surface. It is important to realize that nitriding is due only to the dissociation of ammonia at the part surface, not due to the presence of molecular nitrogen (N2) or dissociated ammonia (N2 + 3 H2). The nitriding reaction (Eq. 1, 2) will ultimately go to completion, but this is a very slow reaction. Empirical work has resulted in a rule of thumb that says if the furnace atmosphere is changed four times every hour, the amount of ammonia that is dissociated is 25±10%. An approximate relationship between ammonia flow rate and percentage dissociation exists (Fig. 18). The general shape of the curve will vary as a function of the furnace style, workload size and surface area. Hence, the best control method for the process is one that measures and controls the percentage of ammonia. When we talk about a 30% dissociation rate, we normally refer to a concentration of 70% ammonia and 30% dissociated ammonia in the exhaust gas. In

Table 7. Typical cycle times for two-stage (Floe process) nitriding – first stage at 975°F (525°C) / second stage at 1050ºF (565ºC)

Table 6. Single-stage nitriding casedepth time at 975°F (525°C)

40

60

600 10

0.1 1.0 Nitriding potential

20

80

1st Stage

2nd Stage

Case Depth, inches (mm)

Time, hours

% Dissociation

Time, hours

% Dissociation

0.005 (0.127)

5

0.005-0.010 (0.127-0.254)

5

15-25%

0

-

0.010 (0.254)

15

0.008-0.012 (0.203-0.305)

5

15-25%

5

83-86%

0.015 (0.381)

30

0.011-0.015 (0.279-0.381)

5

15-25%

20

83-86%

0.020 (0.508)

48

0.013-0.018 (0.330-0.457)

6

15-25%

26

83-86%

0.025 (0.635)

65

0.030 (0.762)

85

0.017-0.022 (0.432-0.559)

8

15-25%

42

83-86%

Note: The single-stage process typically varies from 1-100 hours.

54 May 2011 - IndustrialHeating.com

% NH3

a

% Dissociation

KN

700

Temperature, K

Temperature, ˚C

800

Note: Two-stage processes typically vary from 10 hours to over 150 hours, with the second stage time between two and fi ve times longer than the first stage.

FEATURE | Vacuum/ Surface Treating

reality, due to the volume change involved, only 82.3% is ammonia while 17.7% is dissociated ammonia. To nitride successfully, an adequate supply of atomic nitrogen must be available at the part surface. Thus, in gas nitriding, it becomes very important to circulate the ammonia in such a way as to constantly resupply the active nitrogen on all areas to be hardened. Gas Nitriding Cycles and CaseDepth Determination Two types of nitriding processes are used: the single-stage process and two-stage or Floe (pronounced “flow”) process named after its inventor, Dr. Carl Floe. Case-depth and case-hardness properties vary not only with the duration and type of nitriding being performed but also with steel composition, prior structure and core hardness. Case depths are typically

0.008-0.025 inches (0.20-0.65 mm) and take 10-80 hours to produce. Single-Stage Nitriding Process

In the single-stage process, a temperature range of 925-975°F (500-525°C) is typical. The dissociation rate of ammonia into nitrogen and hydrogen ranges from 15-30%. The process produces a brittle, nitrogen-rich layer known as the “white layer” (compound zone) at the surface and is comprised of various iron nitrides (FeN, Fe4N, Fe16N2). Two-Stage Floe Process (U.S. Patent No. 2,437,249)

The two-stage process (Tables 4, 5) was developed to reduce the amount of white layer formed by single-stage nitriding. The first stage is, except for time, the same as that of the single-stage process. In the second stage, however, the addition of a dilu-

tant gas (dissociated ammonia or nitrogen) increases the percent dissociation to around 65-85%. The temperature is typically raised to 1025-1075°F (550-575°C), and the result is the reduction of the depth of the white layer, producing a deeper case of slightly lower hardness. If the two-stage method is used, it is frequently possible to meet dimensional tolerances without any final grinding operation. Dissociated ammonia is generally required for high second-stage dissociation (otherwise erratic control may result), and it is commonly used as a dilutant (to change the percentage per square area that NH3 molecules are exposed to). In some cases, nitrogen is used. However, whitelayer control and porosity can be affected. Loading arrangement and the use of a furnace circulating fan are very important so that a high dissociation level may be achieved. The nitrogen potential varies

Table 8. Typical cycle times for two-stage (Floe process) nitriding Material Designation (SAE/AISI)

P-20

P-20 S

P-20 Ni

DIN

1.2311

1.2312

40CrMnMo7

40CrMnMoS 8·6

1.2738

1.7225

42CrMo4

9840

1.6511

36CrNiMo4

D2

1.2379

X 15SCrVMo12·1

1.2367

Load Equalization[1] (Soak) Time, hrs

Stage 1 Temp[2] ˚C (˚F)

Stage 1 Time (hrs)

Stage 1 % Dissociation Range

Stage 2 Temp[3] ˚C (˚F)

Stage 2 TIme (hrs)

Stage 2 % Dissociation Range

0.076-0.152 (0.003-0.006)

1-4

525 (975)

4

20-30

525 (975)

8

70-80

0.152-0.203 (0.006-0.008)

1-4

525 (975)

6

20-30

525 (975)

24

70-80

0.203-0.305 (0.008-0.012)

1-4

525 (975)

8

20-30

525 (975)

42

70-80

0.076-0.152 (0.003-0.006)

1-4

525 (975)

4

20-30

525 (975)

8

70-80

0.152-0.203 (0.006-0.008)

1-4

525 (975)

6

20-30

525 (975)

24

70-80

0.203-0.305 (0.008-0.012)

1-4

525 (975)

8

20-30

525 (975)

42

70-80

0.076-0.152 (0.003-0.006)

1-4

525 (975)

4

20-30

525 (975)

8

70-80

0,152-0.203 (0.006-0.008)

1-4

525 (975)

6

20-30

525 (975)

24

70-80

0.203-0.305 (0.008-0.012)

1-4

525 (975)

8

20-30

525 (975)

42

70-80

0.203 (0.008)

1-4

525 (975)

8

20-30

525 (975)

24

70-80

0.762 (0.030)

1-4

525 (975)

42

20-30

525 (975)

48

70-80

0.203 (0.008)

1-4

525 (975)

8

20-30

525 (975)

16

70-80

0.762 (0.030)

1-4

525 (975)

42

20-30

525 (975)

48

70-80

Symbol

4140

H10

Case Depth Range mm (inches) (Core + 50 HV)

G-X 40CrMoV5-3

H13

1.2344

X 40CrMoV5-1

420 SS

1.2083

X 42Cr13

0.127 (0.005)

1-4

525 (975)

6

20-30

525 (975)

24

70-80

0.076-0.152 (0.003-0.006)

1-4

525 (975)

3

20-30

525 (975)

6

70-80

0.102-0.203 (0.004-0.008)

1-4

525 (975)

4

20-30

525 (975)

8

70-80

0.203-0.254 (0.008-0.010)

1-4

525 (975)

8

20-30

525 (975)

42

70-80

0.076-0,152 (0.003-0.006)

1-4

525 (975)

3

20-30

525 (975)

6

70-80

0.102-0,203 (0.004-0.008)

1-4

525 (975)

4

20-30

525 (975)

8

70-80

0.203-0,254 (0.008-0.010)

1-4

525 (975)

8

20-30

525 (975)

42

70-80

0.127 (0.005)

1-4

538 (1000)

6

20-30

538 (1000)

24

70-80

56 May 2011 - IndustrialHeating.com

with the composition of the gas mixture that is being sent into the furnace. Crystal (Lattice) Structure Ferrite, or alpha (_) iron, which is a bodycentered cubic (bcc) in crystal structure (Fig. 19), dissolves 0.001% nitrogen at room temperature and 0.115% nitrogen at 1095˚F (590˚C). Gamma prime (a’), or Fe4N, has a face-centered cubic (fcc) crystal structure (Fig. 20) and dissolves 5.76.1% nitrogen. Fe2N and Fe3N are called epsilon (¡), which has a hexagonal closed packed (hcp) crystal structure and dissolves between 8.0% and 11.0% nitrogen. Control of the Nitriding Process There are several methods of controlling the nitriding process based on analysis of the percentage of dissociation. One method involves the use of an ammonia analyzer (Fig. 21), which is tied into ammonia and dissociated ammonia (or nitrogen) flowmeters (for use during the second stage of nitriding). Based on the output from the ammonia analyzer, the process can be accurately controlled. Another method used to measure the degree of dissociation is an analysis of the

Fig. 19. Body-centered cubic (bcc) crystal structure

Fig. 20. Face-centered cubic (fcc) crystal structure

amount of hydrogen in the exhaust gas (Fig. 22). From equation 4 we see:

Instruments for in-situ measurement of the nitriding potential via the hydrogen content (and other methods) are commercially available and under development. These types of continuous-measurement devices are especially important for the short cycles – up to 20 hours. Alternately, a manual method for the control of the nitriding atmosphere involves the use of a dissociation pipette or burette (Fig. 23). Ammonia is completely soluble in water. When water is introduced into the dissociation pipette, any ammonia present dissolves, instantly forming ammonia hydroxide (NH4OH). Water continues to enter until it occupies a volume equivalent

1 volume NH3 A 1/2 volume N2 + 3/2 volume H2 (7) For example, if the measured volume percentage of hydrogen is 30%, the volume percentage nitrogen is 10% (30/3), and the remaining ammonia volume is 60% (100% – 30% – 10%). Given the original volume of ammonia supplied (_) into the furnace chamber, equation 8 allows us to calculate the degree of dissociation (`) in the exhaust gas. 1 – `/100 = (1 – _/100) ÷ [(1 – _/100 + 2(_/100)]

(8)

Zirconia sensor High pressure seal Sensor shield Exhaust gas

_ V

Outside air

+

Housing

Interior platinum electrode (for outside air) Slit

[7]

Fig. 21. Ammonia control system (Courtesy of Super Systems Inc.)

Exterior platinum electrode (for exhaust)

Exhaust manifold

Fig. 22. Anatomy of a hydrogen sensor[5] IndustrialHeating.com - May 2011 57

FEATURE | Vacuum/ Surface Treating

Water 0 N2 + H2 NH3 + N2 + H2

25

0 N2 + H2

50

50

75 A

H2O

100

25

0 N2 + H2

50

75 H2O

100

25

75 H2O

100

Height of water column in graduated chamber (A) for 25%, 50%, and 75% degree of dissociation

Fig. 23. Manual measurement of percentage dissociation[8]

to that previously occupied by the ammonia. The remainder of the exhaust gas, being insoluble in water, collects at the top of the pipette. The height of the water level is read directly from the scale of graduations, and this reading indicates the percentage of non-water-soluble hydrogen-nitrogen gas in the sample. This reading, although not completely accurate, is the degree of dissociation. It should be noted that the dissociation of ammonia involves a twofold increase in volume as shown in equation 3. IH

References available in April’s online exclusive For more information: Dan Herring is president of THE HERRING GROUP Inc., P.O. Box 884 Elmhurst, IL 60126; tel: 630-834-3017; fax: 630-834-3117; e-mail: [email protected]; web: www.heat-treat-doctor.com. Dan’s Heat Treat Doctor columns appear monthly in Industrial Heating, and he is also a research associate professor at the Illinois Institute of Technology/Thermal Processing Technology Center.

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58 May 2011 - IndustrialHeating.com

FEATURE | Process Control & Instrumentation

Implementing Process Controls and Automation in Heat Treating Jim Oakes – Super Systems Inc.; Cincinnati, Ohio Automation can be many different things across many different industries, so it’s hard to have one definition to cover it in its entirety. In heat treating, automation is approached in categories. The types of processes and equipment may only have certain capabilities when it comes to mechanically automating a process, forcing heat treaters to look at nontraditional types of automation.

M

any heat treaters need flexible equipment when it comes to processes and load sizes. Because of economic pressures and competition, costs and capital are being scrutinized. Does it take significant capital to automate a process? In the world of heat treating, it doesn’t have to. What is Automation in Heat Treating? An automated process really needs to start with a plan and goals. For most heat treaters, the main drivers are obvious: quality, documented productivity and cost reductions. “When we started down the path of new controls and software, we envisioned that it was going to be a company-differentiating event,” said Johnathan Rex, plant manager of Rex Heat Treat’s Lansdale, Pa., facility. “That’s exactly what happened, and we have been able to capture

an entirely different market of customers because we focused on the right investment in technology to get us there.” In its simplest form, automation is creating a sequence of steps that flow continuously. Creating a sequence of steps to be automatic doesn’t always require equipment. Simple steps for this to happen can be broken into, operational procedures, preventive-maintenance programs, shared data and smarter controls. Proactive vs. Reactive Maintenance Maintenance is tough and tends to be very reactive. A reactive approach to maintenance bypasses the crucial planning phase of production. The risk is reducing overall equipment utilization as well as any excess capacity, thus having opportunities for higher profit margins on the table. Using SCADA (Supervisory Controls and Data Acquisition) and smart process controls can help with this. Quick access to in-

Access to Information

Resources

Quick decisions

Re

wo

rk

Business plan Spend

Production

La

bo

r

l/ tro on n c s io ces mat Pro auto

Information Process control & information

Seconds

Months

Fig. 1. Investments in automation are driving costs down.

Goal

Fig. 2. Quick access to information provides valuable data for management to shorten decision time.

formation that can be used by personnel throughout the facility enables a better decision-making process. Referencing historical data, questions like these can be answered quickly: Did the load take longer to get to heat than usual? Is the temperature overshooting? Is my carbon percentage oscillating? This information can be valuable when the right person has access to it. The intent is to put yourself in a situation where you have confidence in your ability to produce quality parts. Traditionally, data may have been available on paper charts but was not used effectively because it was not readily accessible. Today, there is more information with the use of open communication standards and plant-wide networks. Access to key data points has to be easy so the right person can analyze it, compare it to historical data and determine if action is necessary. Rework is double trouble in that it results in twice the furnace time, another notification to the customer, a longer delivery time and reduced margins on the job. To avoid it, put people, processes and equipment in place to identify the problem before it happens. With a quick glance at a chart, one can identify if a load coming to heat had a problem. Sure, this information was available before, but comparing two different runs was not easy. With electronic information and tracking of load times, a quick, periodic review can be significant. IndustrialHeating.com - May 2011 59

FEATURE | Process Control & Instrumentation

Fig. 4. Johnathan Rex of Rex Heat Treat uses the latest tools in technology to provide quick access to information from almost anywhere.

Carbon charts can frequently be evaluated and burner-tube leaks identified when looking at digital charts and identifying saw-tooth trends (i.e. an indication of air in the work chamber when on high fire and the carbon probe trying to compensate for it). It is more common for an out-of-tune burner to be a more reactive maintenance task. With sensor and recording technology today, you can have quick access to current information to allow adjustments to the air-gas ratio that will lead to consistent uniformity and productivity. There are case studies that prove a tuned burner can increase capacity of a furnace tremendously, not to mention the gas savings benefit. Business Process Optimization It’s no secret good labor in heat treating is tough to find. A significant amount of heat-treating experience is retiring from the industry and leaving a large gap in knowledge on the floor. Typically, key personnel can be categorized into operations, maintenance and quality. Aligning priorities across the organization is critical to one’s success. There is no better starting point for making decisions than having information available that can be shared. Whether it is the furnace charts, current customers/jobs running, expected load completed time or planned maintenance, it all collectively feeds the planning process. This information can be accessible using controls and systems, and the data can be used to enable the management team to make more informed decisions that impact resources, equipment, quality and long-term planning. When the infor60 May 2011 - IndustrialHeating.com

Fig. 4. Johnathan Rex of Rex Heat Treat uses the latest tools in technology to provide quick access to information from almost anywhere.

mation is used properly, decision processes become more efficient. Many heat-treating operations have disjointed controls, leaving management to continuously monitor furnaces using personnel and chasing down information. “We have really been able to streamline our processes by using real-time electronic data,” said Scott Wagner, production manager at Rex Heat Treat. “We now have an opportunity to manage production instead of chase information.” Simply put, management can do a better job at planning production and maximizing furnace utilization with the information that is available. Controls and Data Process control can be defined as the ability to meet certain parameters over time using inputs from the process and controlling outputs for desired results. Today’s control and sensor technology makes much of this automation. With technology enhancements come more sophisticated controls to make better decisions. The decisions can be on the process itself, productivity, quality and safety. Traditionally, the inputs for a process were disconnected. Today, more of these are being brought together to provide a more holistic view of the control decision process. PLCs, discrete microprocessor controls and a hybrid of the two are what you see on most heat-treating equipment. Microprocessor controllers typically provide single or multiple PID control loops with expanded features such as event and recipe management. In many cases, the controllers are defined for specific processes or can be programmed to provide function-

ality for a specific process. PLCs can also have PID control loops developed as part of the logic created in the controller. To get full use of the control technology, it is best to create an opportunity for repeatability and allow the level of flexibility that is necessary for the equipment and operation. A foundation for this is recipe control. A recipe gives the steps of the heat-treatment process. It can be a simple ramp to temperature and a timed soak or a more complex process by which multiple temperature inputs, time, atmosphere, pressure and other variables need to be managed. Incremental steps can be taken to put more automation in place and provide better access to information. Using recipe control to automate a nitriding, vacuum carburizing or even a simple temperature ramp/soak leads to greater chances of running the process correctly, resulting in repeatability. Automation of a process using programmable controls eliminates variations in process from shift to shift or operator to operator. A recipe program set up in advance to “step” through the process and automatically advance to the next step upon desired results leaves the controller in charge. Operators can be taken further from the decision process by implementing scanning technology so the recipe is automatically selected based on a shop card or part number. This reduces the chance for the wrong heat-treat cycle and gets the parts heat treated correctly the first time. Controls provide user-defined audible, visual and electronic alarms indicating

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FEATURE | Process Control & Instrumentation

cycle-complete or a deviation from the process. Recipes can be set up so that, upon completion, the heat is turned off. This eliminates unnecessary costs and ensures parts are at heat for the necessary amount of time. Smart alarms capture the attention of operators when a situation needs to be addressed. Again, simple steps automate a process, which positively impacts labor and utilization. With more devices and sensors monitoring the process and a system in place to capture information, data is very easy to access remotely. Whether it is a critical job where periodic remote monitoring is necessary or the ability to tweak a cycle, it can be done. “We have access to our system 24/7 remotely,” Rex said. “I can be ‘eyes on’ critical runs or evaluating a step in a cycle. With the right systems and people in place, we capture every level of the heattreating market by using technology and information to refine our processes and deliver quality parts to our customers efficiently.” Historical information and simulation can lead to more precise control parameters. The more access to these data points, the greater is the opportunity for repeatability. Industry Specifications Advancements in process control and technology have resulted in more industry requirements. Whether it is CQI-9 requiring an endothermic generator to be continuously controlled and monitored or AMS 2759/12 requiring automatic control to produce a continuous compound 62 May 2011 - IndustrialHeating.com

layer with controlled phase composition, both of these requirements can be accomplished utilizing control technology. Using AMS 2759/12 as an example, processing equipment is defined in the document. The method of control is not specified, but it is pointed out that the furnace should be equipped with gas-analyzing equipment capable of measuring the concentration of the reactive gas. This in itself does not specify automation. However, using an integrated process controller that can ensure temperature, time and gas concentration and maintain a safe operating furnace does. In many cases, industry specifications drive a certain amount of documentation, which is required to provide a customer or auditor as proof of the process. This might be required when the parts are completed or on-demand when a customer requests the information. Electronic data and SCADA systems have made this task easier. “The old days of tracking down a chart, copying it and mailing or faxing it are a thing of the past, and I don’t miss them,” explained Sarah Mansuetti, a metallurgist who works in quality control at Rex Heat Treat Lansdale. It is more and more common that information is shared electronically. Whether via email or an attached file, it still gets to the heart of the requirement, which is proof of the heat-treating process. Customer Service There is a whole different level of service that can be provided when smart controls and data acquisition are utilized. “We have opportunities to work with our customers

on product development and process improvements,” Rex said. “We embrace the opportunity to work with customers on special projects or witness processes in real time and produce an information packet upon their departure.” Quick access to information allows an efficient response to a customer requesting data or order status. “With our system in place, I can have an answer for a customer while on the phone with them. I know what to be looking for before I pick up the handset, promptly tell the customer we have two hours left on the final cycle and the parts would be ready by mid-day,” Wagner explained. Prior to having a system, this required “boots on the floor” to find the job, determine the time remaining and getting back to the customer. In Conclusion Today’s heat treater depends on the science of the past but will rely on the technology of the future to stay competitive. Technology moves forward every day and requires that we embrace the technology and automation to remain competitive. Those who resist change will be left behind wondering why their business is declining and will be surpassed by the growing global competition. Those who embrace the opportunity automation and digital documentation provides will grow and prosper. IH For more information: Jim Oakes, VP business development, Super Systems Inc., 7205 Edington Dr., Cincinnati, OH 45249; tel: 513772-0060; fax: 513-772-9466; e-mail: joakes@ supersystems.com; web: www.supersystems.com

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Leading the World in Induction Heating Technologies

Alpha 1 Induction Service Center Alpha 1 Induction Service Center has over 20 years of experience in manufacturing and repairing induction load coils of all types. We specialize in coils for the forging industry. Alpha 1 has the knowledge and experience you can trust to design, build and repair your coils. www.alpha1induction.com

Inductoheat, an Inductotherm Group Co. Inductoheat’s new 12-page brochure discusses how they ignited the innovation of induction power supply design more than 40 years ago and how this was the foundation for the development of new breakthrough technology today. Call 248-585-9393, e-mail [email protected] or visit www.inductoheat.com.

Induction Heating Systems

Inductotherm Group Brochure

CEIA USA CEIA provides induction heating generators, controllers and accessories for use in a wide range of applications, including heat treating, brazing and for aluminum applications. Our induction systems offer unmatched efficiency and precise repeatability. To see what CEIA can do for you, visit our website at www.ceia-usa.com or contact us at [email protected].

Inductotherm Group Inductotherm Group, a global leader in melting, thermal processing and production systems for metals and materials, presents this brochure showcasing its engineering strength and organizational flexibility. Product lines include equipment for heating, air and vacuum melting, and coating and heating systems for steel. For more information, call 609-267-9000, ext. 111 or visit www.inductothermgroup.com.

Induction Hardening System

Combustion Safeguards

Contour Hardening Contour Hardening is a full-service induction hardening system manufacturer, specializing in induction hardening systems, contract processing and application development work. www.contourhardening.com

Protection Controls Inc. Offers this comprehensive Service Manual covering all PROTECTOFIER combustion safeguard units. It provides important and valuable information on installation, service guides, testing and troubleshooting as well as specifications, features and application on Protection Controls’ single and multi-burner units. For a free copy, fax 847-674-7009. www.protectioncontrolsinc.com

Hardening Large Rings and Gears

Data Logger

EFD Induction Seamless induction hardening is the proven cost-saving alternative to thermo-chemical processes. What’s more, induction’s speed and localized heating minimize distortion – reducing subsequent processing costs. Induction is a powerful business tool for companies keen to reduce costs when seamlessly hardening large rings and gears. www.efd-induction.com

Super Systems, Inc. Developed for harsh environments, the SDS 8020/SDS 8040 data logger is the latest in hardware and software technology for portable data acquisition. With operatorfriendly interface and software utilities, a reporting platform compliant with many industry specifications, including AMS 2750D, is provided. Call 513-772-0060 to arrange a demonstration. www.supersystems.com IndustrialHeating.com - May 2011 63

Literature/Website Showcase

Starbar and Moly-D elements are made in the U.S.A. with a focus on providing the highest quality heating elements and service to the global market.

Controls & Power Supplies | Ovens & Kilns Digital Indicating Controllers Yokogawa The UTAdvanced is Yokogawa’s newest controller that combines PID control and ladder logic. The universal flexibility and ample communication protocols makes the UTAdvanced the most efficient and easy-touse hybrid controller. www.yokogawa.com/us

Metal Stress Relieving/Tempering

I Squared R Element Co., Inc.

Pyromaître Pyromaître has developed a process and equipment to stress relieve spring wire at very high speed. It is approved for automotive valve springs in America. The Pyro process is designed to be fast, precise and reject-free. Also developed is the Pyrograph heat-transfer simulation software to better predict and control hardness and residual stress behavior according to given specific alloys. www.pyromaitre.com

Akron, NY Phone: (716)542-5511 Fax: (716)542-2100

Thermal-Processing Systems

Over 40 years of service and reliability

Email: [email protected] www.isquaredrelement.com

Surface Combustion This brochure introduces Surface Combustion and its overall capabilities as a provider of diverse product offering in the thermal-processing industry. Surface’s capabilities also include a wide array of aftermarket services and support activities. Whatever your heat-processing needs, Surface can put its over 85 years of experience to work for you. www.surfacecombustion.com

High-Vacuum Furnaces and Ovens T-M Vacuum Products A pioneer in the high-vacuum heat-treating industry, T-M has been manufacturing highvacuum furnaces and ovens since 1965. Our furnaces come with full computer control, and our ovens come with PLC/color touchscreen interface control. www.tmvacuum.com

Drop Bottom Furnaces

For over 50 years, we have provided Electrical Safety Equipment for Industry. For complete info, contact us at [email protected]. Visit our website at www.protectioncontrolsinc.com.

64 May 2011 - IndustrialHeating.com

Wisconsin Oven Wisconsin Oven manufactures drop bottom furnaces, quench tanks, age ovens and related equipment for solution treatment of aluminum extrusions, sheet metal, castings and other parts. We serve the automotive, aerospace and other industries. Our equipment is designed to the most stringent specifications. Contact: 262-642-3938 www.wisoven.com

“I know that with G-M Enterprises… anything is possible!” eet ain Str 5-2742 ast M 962 E ter, NY 140 s Roche 6-3348 54 (585)

G-M Enterprises works for Rochester Steel Treating Rochester Steel Treating Works, Inc. (RSTW) spent two years researching the purchase of our new single chamber, six bar vacuum furnace. We needed a very flexible furnace that would back up all of our present furnaces as well as give us new capabilities and capacity. We met with many manufacturers but couldn’t find the complete package we were looking for. We finally met with G-M Enterprises. The impression they gave us was that anything was possible. They didn’t have limitations we found with other furnace manufacturers and their instrument packages. G-M listened to our needs and requirements and gave us a package that met those needs without us having to change. The flexibility the furnace has shown from processing simple annealing to six bar quenching of high speed steels and special high heat annealing has been incredible. Initial quench speeds and their repeatability has been great. Hardness achieved in the high speed steels has been beyond our expectations. We have so much confidence in G-M and its systems, we are planning to work with them on our vacuum furnaces as well as atmosphere equipment.

Call G-M Enterprises and let us work for you!

525 Klug Circle, Corona, CA 92880-5452 (951) 340-4646 • Fax (951) 340-9090

Products

SCR Controller

Infrared Temperature Sensor

Control Concepts, Inc. Compact FUSION is built to save panel space and reduce installation costs without compromising reliable power control. Capable of single- or three-phase operation, its modular structure also allows up to four independent zones of control. A smaller footprint is achieved with compact design and onboard, branch-rated protection fusing (Class T) with a blown-fuse indicator for each line. Auto-ranging voltage circuitry enables main supply voltage from 24-600 VAC (45-65 Hz), eliminating the need for hardware jumpers or stocking multiple controllers for international voltages. Optional fieldbus digital interface increases performance and reduces design and installation costs. www.ccipower.com

Omega Engineering The new IR-USB series of infrared temperature sensors provide a reliable and economical method for most PC-based noncontact temperature monitoring. The unit features an IR sensor/signal conditioner installation with a direct USB connection and free user software that converts your PC into a temperature meter, chart recorder or data logger. The emissivity is adjustable from 0.10 to 1.0, and this product measures up to 1000°F. Some typical temperature monitoring applications are where the object to be measured is moving; where the object is surrounded by an EM field, as in induction heating; where the object is contained in a vacuum or other controlled atmosphere; or in circumstances where ere a fast response onse is required. www.omega.com ww.omega.com

Oxidation Oven Harper International The next generation of custom oxidation ovens for the processing of carbon fiber are available at 300-mm to greater than 400-mm tow bandwidths. The design features proprietary atmospheric seals that will reduce fugitive emissions, increase the active volume of the oven and offer reduced energy consumption. The modular construction design has demonstrated a 90% reduction in labor versus similar field erection times into a full line pilot system. www.harperintl.com

Improved Training Prevents Poor Performance ASM will customize any of our heat treating training programs for your applications and your employee needs. Choose from training programs in: • Introductory and Advanced Heat Treating • Heat Treating for the Non-Heat Treater • Induction Heat Treating • Heat Treatment of Carbon and Alloy Steels • And much more Your employees don’t have to travel, resulting in lower training costs. Train employees at all skill levels and stay competitive with better trained staff. We have trained technicians, engineers, R&D, sales, scientists and others at organizations similar to yours, including: • NASA • US Department of Defense • Duke Energy • Los Alamos National Laboratory • Boeing • Honda

66 May 2011 - IndustrialHeating.com

FREE PERIODIC GLASS

Ask for your FREE, no-obligation training assessment and get a FREE Periodic Beer Glass. (Did you know that Carlsberg Brewery was the location of Søren Sorensen’s work on the pH scale?)

Contact John Cerne for complete details. 1.800.336.5152, ext. 5637 Email: [email protected]

Furnace Rollers Sandvik Furnace rollers made from Kanthal APMT will outlast rollers made from conventional alloys by more than four times. Kanthal APMT, an iron-chromium-aluminum (FeCrAl) alloy, is ideal for high-temperature applications up to 1250°C (2280°F). Furnace rollers made from Kanthal APMT remain straight and rigid at these temperatures, reducing the tendency to sag and bend – problems commonly associated with conventional metallic tube materials such as nickel-chromium (NiCr) alloys. In particular, Kanthal APMT is characterized by a unique combination of high creep strength and excellent resistance to oxidation at high temperatures, which is critical for high-performance furnace rollers. The superior performance of these rollers boosts productivity, reduces maintenance costs and contributes to a cleaner environment. www.kanthal.com

Hardness Tester Struers The DuraVision, a new universal and macro hardness tester, is a natural complement to

any production environment testing large or heavy samples in cast iron, steel and aluminum. The DuraVision, designed in four basic models, provides a varying level of automation to suit any production environment need. The unique test load range of 1-250 kgf and 20-3,000 kgf provides a level of versatility and flexibility of performing a diversity of test methods on all types of materials and applications. The load cell technology regulates precise control of the applied load force utilizing an electronic measurement and control system unit, giving technicians a high degree of accuracy and reproducibility during the testing process. Standard features of the DuraVision include a state-of-the-art, high-quality optical system with an integrated optical zoom for image quality and automatic illumination adjustment utilizing an LED light system. www.struers.com

Measurement Instrument Mitutoyo America Corp. The new ROUNDTEST® RA-1600 roundness/cylindricity measurement instrument offers highend precision plus the versatility of ROUNDPAK® data analysis software in a compact footprint. With its robust design and 25-kg capacity, the ROUNDTEST RA-1600 is as well suited for the production floor as it is the quality-control lab. The high rotational accuracy of the unit’s turntable enables measurement of flatness in addition to roundness/ cylindricity. The RA-1600 features a DAT (Digital Adjustment Table) mechanism that makes workpiece centering and leveling simple and ffast. a A high-precision, power-driven Z-Axis column enables evaluation of straightness as well as cylindricity. A detector is included to prevent damaging collisions in the Z-Axis. www.mitutoyo.com

GET CONNECTED www.industrialheating.com/connect

Now it's easier than ever to stay connected to the best source of news and technology in the industry! IndustrialHeating.com - May 2011 67

Products

Professional Support Services to Industry Increase productivity, lower energy and operating costs, improve worker output and satisfaction, and increase company profitability. Let our staff put their practical, engineering, and scientific experience to work for you!

Education/Training

Consulting • HT/Met

Process Analysis

Ceramic Adhesive Aremco Products Ceramabond 569 is a high-temperature ceramic adhesive used in ultrahigh-temperature applications to 3000°F. Ceramabond 569 bonds tenaciously to ceramic, metal and quartz substrates and is applied easily using a brush, syringe or automatic dispensing equipment. Once applied, curing is accomplished by heating at 200°F for two hours or drying at room temperature for 24 hours. Primary applications for Ceramabond 569 include the assembly of platinum resistance heaters, igniters, thermocouples, probes and sensors such as oxygen analyzers, gas chromatographs, mass spectrometers and high-vacuum components. www.aremco.com

Crucible Furnace

Problem Solving

Furnace Diagnostics

Marketing Studies

THE HERRING GROUP, Inc. Home of The Heat Treat Doctor® Phone: 630-834-3017 Email: [email protected] • Web: www.heat-treat-doctor.com

Linn High Therm This high-frequency crucible furnace can be used for the induction melting of metals and metal alloys and for the sintering of powder metals and oxide ceramics. It can operate with or without vacuum. It is possible to use different coils for the applications. The coils are individually height-adjustable to ensure high flexibility for the process. A control unit automatically controls heat, power and gas flow and regulates temperature. Other features include: maximum temperature of 2300°C; effective inner-diameter chamber volume of 84 x 300 mm; maximum inductive power of approximately 6 kW; nitrogen or argon atmosphere. www.linn.de

IFHTSE 19th International Congress 2011 International Federation for Heat Treatment and Surface Engineering 17-20 October 2011, Glasgow Scotland Abstracts are invited under the following themes or other relevant topics: • • • •

Thermal and thermochemical processes Thermomechanical processes Quenching: distortion control Existing and emerging surface engineering processes • Modelling of processes and phenomena

Preference will be given to contributions that include or prioritise the following: • Process economics • Energy management • Design and mangement for improved operation 68 May 2011 - IndustrialHeating.com

The programme will also include special sessions on light metals and on the tribology / surface engineering design interface. The Tom Bell Young Author Award will be available for competition at the Congress. Key Dates Abstract Submission Deadline – Fri. 1st July Early Registration Deadline – Fri. 19th September For further details on the programme and a wide range of sponsorship opportunities please visit the congress website or contact the congress organisers: www.ifhtse2011.org

ASM – 1933

Hold on to your Hats! We’re headed to Cincy! Discover the art and science of heat treating. Register today.

October 31-November 2, 2011 Duke Energy Convention Center • Cincinnati, Ohio USA

Gear Up for Success and join innovators, influencers and decision makers in the heat treating industry from around the world for the 26th ASM Heat Treating Society Conference and Exposition – Heat Treat 2011. Be sure to plan to attend and support this global event. Visit www.asminternational.org/heattreat for the latest conference and exposition information. Sponsored by:

Media Sponsor:

Heat Treating for the Non-Heat Treater This course is for the NON-heat treater (part designers, material specifiers, purchasing agents and technicians) who need a basic education in heat treating and need to learn how to “speak the language”. The focus will be on the “value added” by heat treating. The effects that heat treating process parameters (time, temperature and atmospheres) have on the final Instructor: Scott Mackenzie properties of a product and the links between microstructure and mechanical properties are discussed, as well as reasons for distortion, cracking and part rejections. Dates: June 20-22, 2011 Location: Homewood Suites, Beachwood, OH, USA To register, visit www.asminternational.org/education or call ASM Member Service Center, 440-338-5151 ext. 0

IndustrialHeating.com - May 2011 69

The Aftermarket Parts, Services & Consulting Resources

THE AFTERMARKET

$

125 pparts arts

2011 Rates Just $125 perservice Month for Single B/W Cards

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Induction Heating

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Forging

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Induction Coil & Transformer Repair, Spare Parts, Flux Concentrator Sean Buechner – Coil Sales - East Coast Tom Learman – Concentrator Sales; Coil Sales – Mid-West Gil Traverse – Spare Parts & Handling Equipment Frank Veno, President – CEO www.alpha1induction.com

AFTERMARKET C E N T O R R SERVICES Vacuum Industries Field Service Installation Vacuum Leak Testing/Repair Preventative Maintenance Used / Rebuilt Furnaces

55 Northeastern Blvd. Nashua, NH 03062 Ph: 603-595-7233 Fax: 603-595-9220 www.centorr.com/ IH [email protected]

Alan Fostier: [email protected] s Dan Demers: [email protected]

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41150 Joy Rd., Plymouth, MI 48170 The Best Single Source For All Your Heat Treating Requirements

Lone Star Induction, Inc. Specializing in Induction: Heating – Forging – Melting

• Standard 3 to 4 week delivery • Performing quality after market repairs • Preventative maintenance • 24 hour emergency service All of our repairs are performed on site at our centrally located repair facility in Texas. Lone Star Induction offers over 30 years experience in the heating and melting industry.

Electric Heating Elements For a broad range of applications Find out more at… www.Duralite.com 70 May 2011 – IndustrialHeating.com

We Guarantee Our Work! Lone Star Induction, Inc. 5610 SECR 2010 Corsicana, TX 75109 Phone: 866-403-5744 www.LoneStarInduction.com [email protected]

The Aftermarket Parts, Services & Consulting Resources Hot Zone Rebuild & Upgrade Vacuum Furnaces Controlled Atmosphere Furnaces Hydrogen Retort Furnaces

Ipsen’s Aftermarket Support team offers the most comprehensive vacuum furnace support: ‹ Worldwide Service & Support ‹ 7HY[Z:LY]PJL<WNYHKLZ9L[YVÄ[Z Training and more!

525 Klug Circle, Corona, CA 92880-5452 Phone: 951-340-4646 Fax: 951-340-9090 Emaill: [email protected] or [email protected]

Aftermarket Support: 800-727-7625 Engineered Components: 815-332-2625

PROFESSIONAL SUPPORT SERVICES TO INDUSTRY THE HERRING GROUP, INC. Home of “The Heat Treat Doctor” ® Education/Training - Consulting Product/Process Analysis - Problem Solving Furnace Diagnostics

Used Heat Treating Furnaces and Ovens

Ph: 630-834-3017; Fx: 630-834-3117 email: [email protected] Web: www.heat-treat-doctor.com

Ph: 440-519-3800 • Fax: 440-519-1455 Email: [email protected] Website: www.whkay.com

Contact: Michael J. Kay 30925 Aurora Road • Solon, OH 44139

Aftermarket Services for Induction Equipment s s s s s s s s

Coil Repair, Design, and Replacement Retrofits of Existing Systems Replacement Parts for most OEM’s Preventative Maintenance Service Development Laboratory Commercial Induction Processing Complete Heating Systems All Induction OEM’s Serviced

New/Rebuilt Furnaces – Vacuum Pumps Leak Detection/Field Services MufÁe and Alloy Fabrication Equipment Relocation • Replacement Parts

Ó£™äxÊ>ÌiÜ>ÞÊ,`ÊÊUÊÊ ÀœœŽwi`]Ê7ÊxÎä{x

Phone: (909) 622-1091 Email: [email protected] • Website: www.mangoldengineering.com

ÜÜÜ°«ˆ>À°Vœ“ÊÊUÊÊÃiÀۈViJ«ˆ>À°Vœ“

PARK THERMAL INTERNATIONAL (1996) CORPORATION New / Reconditioned Ovens Furnaces - Quenching Oils – Heat Treating Salts – Component Parts – Stainless Steel Foil – Refractory Products 62 Todd Road Georgetown ON L7G 4R7 Tel: (905) 877-5254 Toll Free: (877) 834-4328 (HEAT) Fax: (905) 877-6205 Email: [email protected] Web Site: www.parkthermal.com

THERMO TRANSFER INC. 1601 Miller Avenue Shelbyville, In 46176 317-398-3503 317-398-3548 fax E-Mail: [email protected]

NEW/ USED/ REBUILT FURNACES AND GENERATORS FURNACE TROUBLE SHOOTING AND REPAIR SERVICE

Induction O.E.M. for

Pillar Induction

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Qual-Fab Inc. Quality Stainless Steel Fabrications for the Heat Treat Industry • Radiant Heater • • • • •

Tubes Retorts Corrugated Boxes and Baskets Serpentine Trays Muffles Stainless Fixtures

• • • • • • •

Furnace Fans Furnace Rolls Diffusers Retorts Repairs All Alloys Stainless Steel and High Nickel

Contact Gary Vanek Phone: (440) 327-5000 Fax: (440) 327-5599 Email: [email protected]

Visit Industrialheating.com/ helpwanted to find out how the

Industrial Heating

Classified Marketplace can help you target qualified job candidates!

REPLACEMENT ALLOY ROLLS AND RADIANT TUBES

www.thermotransferinc.com

VACUUM FURNACE REBUILDS • • • •

Hot Zones Pumps Leak Detection Service

Vacuum Engineering Services Co. P.O. Box 694, East Windsor, CT 06088 Phone 860-627-7015 • Fax: 860-627-9964 Website: www.vacuumengineering.com

www.qual-fab.net WONDER WELD INDUCTION GUARANTEED WORK FOR 33 YEARS

HEAT TREATING MELTING FORGING • 3 To 300 KW Power Supplies • • Complete Coil Design & Repair • • Closed Loop Cooling Systems • • Controls & Complete Automation •

Tel: 614-875-1447 Fax: 614-870-0236 www.wonderweld.com IndustrialHeating.com – May 2011 71

Classified Marketplace Rates Per Column Inch

Fax Your Ad To: Becky McClelland at 248-502-1076

1x=$125; 3x=$115, 6x=$100 and 12x=$95. No additional charge for bold print Blind box numbers available = $15 per issue

Or Mail To: Industrial Heating Manor Oak One, 1910 Cochran Road, Suite 450, Pittsburgh, PA 15220 Or Call (412) 306-4355 • Email: [email protected]

HELP WANTED

HELP WANTED

HEAT TREATING BUSINESS MANAGER

SUPERVISOR/ OPERATOR

Well-established NW PA firm seeks high-caliber, experienced P/L manager for commercial heat treating business. Must have strong related technical background. Must have strong customer interaction success record. Plenty of corporate staff and systems support available. Firm has excellent equipment, facilities, and reputation. Growth oriented. Not a position for rookies or mild credentials. Generous compensation. Relocation assistance. Long term sought, but Interim-only interests considered as well. Please send confidential resume to: [email protected] attn: mht manager now Modern Industries, Inc. www.modernind.com

Precision Die & Stamping, Inc. (Tempe, Arizona) has an opening for a Supervisor Operator of a high capacity austempering belt furnace. Must have a minimum 5 years heat treating experience. Please send resume to [email protected]

HELP WANTED

Always Online at: www.industrialheating.com

Immediate Openings Available for: Plant Quality Assurance • Knowledge of heat treat, heat treat laboratory and pyrometry operations. Min of 5 years Quality System Management (ISO 9001:2008/AS 9100 or equivalent) • Nadcap process management • Heat treat process management • Internal audit experience (process and QMS auditing) • RCCA experience • Creating and implementing process control plans • Basic Statistical Process Control • General knowledge of Corner Stone software (Visual Shop) • Computer skills (word, excel, PowerPoint, Adobe) • Team builder and team attitude • College degree preferable

Experienced Maintenance Personnel • Qualified candidates shall be skilled in the following areas: • Vacuum furnaces / Mechanical pumps • Welding / Pipe Fitting • Combustion Systems • Reading mechanical and electrical blueprints • Motor Wiring and Troubleshooting • PLC operation and Ladder Logic Diagrams

Resumes only! Forward all resumes to: [email protected]

industrialheating.com/ helpwanted to find out how the Industrial Heating Classified Marketplace can help you target qualified job candidates! 72 May 2011 – IndustrialHeating.com

HELP WANTED

SALES MANAGER American Heat Treating, Inc., is in need of a Sales Manager to Identify, Develop, and Maintain current and future customer base, and to develop marketing programs such as Websites, Brochures, and Internet sales. The ideal candidate will possess excellent communications skills, as well as good management and interpersonal skills; knowledge of CQI-9 heat treat standard; blueprint reading; and problem analysis and resolution. Business or Engineering degree and 3+ years experience in manufacturing sales, OR 5 to 10 years experience in commercial heat treating, with 3 to 5 years in management required.

Online Video! 16 Commerce Drive, Monroe, CT 06468 Ph: 203-268-1750; Fax: 203-452-9925 [email protected] CertiÀed ISO 9001/2000

Check out the latest Used Equipment Listings on Facebook and Twitter – #IHUsedEquip

FOR SALE

FOR SALE New Design

SPARK IGNITER

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Used for the automatic ignition of recuperative burner systems.

FOR SALE Singleton Corrosion Test Cabinet

*Diff erent Leng ths A vailab le

Working Dimensions: 18"W x 30"H x 29" D 115 V • Complete with control panel, 2 temperature controllers and water level gauge on tank.

AFC Mesh Belt Austemper Furnace System NEW DESIGN • Improved Performance • Longer Life • Larger Gap • Floating Spark • Direct Replacement Call for model/ pricing information

*We offer both designs

750 Lbs/Hr, 1700ÝF, 30" W x 6" h x 120" long includes loader, furnace, salt tank, wash, exit conveyor & control panel.

Seco Warwick Mesh Belt Austemper Furnace System 1000 lbs/hr, 1550ÝF, 36" w x 14' L, 2 zone, includes loader, furnace, salt tank, wash, exit conveyor & control panel.

Surface Combustion Atmosphere Gas Fired Rotary Hearth Furnace 22" dia. (Fibre) c/w Mesh Belt 60'L Temper

283 East Hellen Road • Palatine, IL 60067 Tel: 847.202.0000 • Fax: 847.202.0004 www.duffycompany.com

EQUIPMENT FOR SALE

Mowry Enterprises, Inc. New

Used

Rebuilt

Solutions

For Sale VFS 6 BAR, 36 x 36 x 48: graphite hot zone, high vacuum, internal quench, 2650 F, PLC/ touch screen controls Ipsen 224, 15” x 10” x 24” , 2002 control panel, rebuilt pump, graphite elements, mech pump/ diffusion pump

Canefco Direct Gas Fired Draw Furnace 11' wide x 75' long (in heat) x 13" high. Max temp 900 ÝF, net capacity 15,000 lbs, 3 zones of control. Comes with re-circulating fans and free standing control panel. For more information, please call your sales representative at 1-877-834-4328 (HEAT).

Park Thermal International (1996) Corp. 62 Todd Road, Georgetown, Ontario L7G 4R7 Toll Free: 877-834-4328 • Fax: 905-877-6205 [email protected] • Web: www.parkthermal.com

FOR SALE

VACUUM OIL QUENCH CARBURIZER: C.I. Hayes: 24” x 24” x 24”, Still installed, 2 chamber with isolated oil quench, complete with water recirc system and alloy grids. Heat Chamber is 24 24 36. Quench chamber can be modiÀed for this larger load. VFS HL 36: 2500 F, 24” x24” x38” graphite hot zone, High vacuum, PLC/ touch screen controls, Pressure Quench VFS HL 50: 36” x 30” x 48”, graphite hot zone, high vaucum, 1200 CFM external quench, 2650 F 2 BAR: 10” x 10” x 20” hot zone, Graphite. Mech pump and blower, built in 1999. TM 12 x 12 x 20: graphite hot zone, high vacuum, internal quench, 5 psig positive quench ABAR 48 x 48 bottom load: graphite hot zone, high vacuum, external quench, PLC/ touch screen controls

www.mowryenterprises.com email: [email protected] Phone: 978-808-8634 Fax: 508-845-4769

HEAT TREATING SALTS • Austempering and Martempering • Neutral Hardening Salts • High Speed Hardening Salts • Liquid Nitriding • Quenching and Tempering Salts

Insist on the the red oval – your assurance that products are Genuine Park Metallurgical. ISO 9001:2008 certified

www.heatbath.com ph: 413.452.2000

POLYMER QUENCHANTS • OIL QUENCHANTS IndustrialHeating.com – May 2011 73

Classified Marketplace

Check out the latest Used Equipment Listings on Facebook and Twitter – #IHUsedEquip

FOR SALE

FOR SALE

FOR SALE

Brazing Furnace For Sale Seco Warwick 18"W x 9"H x 10'L x 30'L, 2150-F, 175 kW, Includes New Alloy Muffle

PROCESS HEAT

The Next Generation

LHS Air Heater

Built-in thermocouple with digital temperature readout

Upgrade your LE to a Next Generation LHS air heater today www.leisterusa.com Toll-free: (855) Leister [email protected]

Furnaces, Ovens & Baths, Inc. 4790 White Lake Road, Clarkston, MI. 48346 248.343.1421 – Phone 248.625.4030 - Fax Email: [email protected]

Industrial Heating REPRINTS December 2010

Induction Quenching p.36 MIM Furnace Uniformity p.41 Thermocouples for AMS 2750D p.45 Fixture Design for Efficiency p.51

ASM HTS insider p.54 Cover: Rescue in Chile p.20 Insert: 2011 Industry Calendar A

Publication Official publication of ASM‘s Heat Treating Society • www.industrialheating.com i lheating com

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 ProÀles, 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

Hot Zone Rebuild & Upgrade Vacuum Furnaces Controlled Atmosphere Furnaces Hydrogen Retort Furnaces 525 Klug Circle Corona, CA 92880-5452 Phone: (951) 340-4646 Email: [email protected] or [email protected]

Visit industrialheating.com/ helpwanted to find out how the Industrial Heating Classified Marketplace can help you target qualified job candidates!

FOR SALE Diffusion Bonding

SVLXQLIRUPO\GLVWULEXWHGSODWHQSUHVVXUH &)0RO\KHDWHUVVKLHOGV SODWHQV [7RUU+LJK9DFXXP'LIIXVLRQ3XPSV )PLQ)DVW&RROLQ$UJRQIURP)WR) SRXQGORDGFDSDFLW\ %DWFKRU6HPLFRQWLQXRXV 8VHGIRUKLJKYROXPHSURGXFWLRQRIGLIIXVLRQERQGHG7LWDQLXP :HFDQFXVWRPL]HWKLVV\VWHPWRPHHW\RXULPPHGLDWH QHHGV /RFDWHGLQVRXWKHUQ1HZ(QJODQG

74 May 2011 – IndustrialHeating.com

Densification

FOR $25.00 WE WILL POST AND LINK YOUR AD ONLINE Visit industrial heating online at www.industrialheating.com

Check out the latest Used Equipment Listings on Facebook and Twitter – #IHUsedEquip

FOR SALE

FOR SALE

VACUUM PUMPS

FOR SALE

SALES AND SERVICE

CASHVAC INC. • • • • •

Classified Marketplace

25 years experience Guaranteed rebuilding Warrantied service OEM replacement parts New and used pump sales All makes and models

• FREE ESTIMATES AND DELIVERY

Surface Combustion Gas Fired Integral Quench Furnaces. (4 Available) With washers, tempers and generators. Working dimensions: 30" w x 30" h x 48" d; Rated: 2500 lbs./hour; c/w controls

Factory Trained Stokes Pumps/Blowers

Park Thermal Gas Fired Mesh Belt Furnace

Specializing in Stokes Vacuum Pumps

1250ÝF, 65" w x 27' long x 4" high, natural gas, complete with free standing control panel.

FOR SALE

Elnik Systems Vacuum Furnace

TOLL FREE: 1-800-397-1600

12”wide x 22”long x 12” high; Electric 480V; 3 phase; 60 cycle Complete with control panel, pumping system, cooling water system and nitrogen tank. For more information, please call your sales representative at 1-877-834-4328 (HEAT).

Park Thermal International (1996) Corp. 62 Todd Road, Georgetown, Ontario L7G 4R7 Toll Free: 877-834-4328 • Fax: 905-877-6205 [email protected] • Web: www.parkthermal.com

FOR SALE

Industrial Heating

REPRINT PLAQUES ARE NOW AVAILABLE

Contact Becky McClelland at 412-306-4355 or [email protected]

• 30” x 48” x 30”H, Lindberg Batch Tempers, 1250°F, 3 Available • 72"W x 6"H x 24' , Holcroft, Atmosphere, 1600-F, Mesh Belt • 36” x 48” x 30”H, Vac Aero, 6 Bar Vacuum Furnace, 2500°F • 36” x 72” x 36"H, Surface Combustion Integral Quench w/Top Cool • 102” x 72” x 16”H, Holcroft Slot Forge, 2200°F, Gas, UNUSED • 21” x 42” Tray Size, Holcroft 2 Row Pusher, 1750°F, Direct Fired, Cooling • Lean Fume Afterburner, Surface Combustion, 1800°F, 2000 SCFM • Progressive Technologies Rotary Index Shot Peeners • Induction Heating, 7.5 kW to 750 kW, 1 kHz to 450 kHz, 21 In Stock • 36” x 48” x 30”H, Surface Combustion Batch Tempers, 1400°F, Gas • 59”W x 67”H x 50”L, Despatch, 1000°F, Atmosphere w/Forced Cooling, 2 Available • 8 Cubic Feet Jet Wheel Blast Multi Tumble Shot Blast Machines w/ Loader, 2 Available • Dual Rotary Drum Washer, 2 Stage w/Blow Off, 23” Diameter x 15’L, Stainless Drums • SBS Air to Oil Heat Exchangers – 2 Available Contact: Jeffrey D. Hynes 248.343.1421 or [email protected]

FURNACES OVENS & BATHS For a complete inventory listing with photos visit www.fobinc.com

IndustrialHeating.com – May 2011 75

Classified Marketplace

Check out the latest Used Equipment Listings on Facebook and Twitter – #IHUsedEquip

FOR SALE Since 1936

(2) Car Style Batch Kilns ––––– ATMOSPHERE GENERATORS ––––– 750CFH Endothermic Ipsen (Air) Gas 1000CFH Ammonia Dissoc. Drever Elec 1000CFH Ammonia Dissoc. Hayes (1994) Elec 1000CFH Exothermic Gas Atmos. Gas 1500CFH Endothermic Ipsen Elec 3000CFH Endothermic Lindberg (3) Gas 3000CFH Ammonia Dissoc. Drever Elec 3600CFH Endothermic Becker (1995) Gas 5600CFH Endothermic Surface (5) Gas 6000CFH Gas Atmos. Nitrogen Generator Gas 10.000CFH Exothermic Seco/Warwick (2) Gas –––––––––– BOX FURNACES –––––––––– Huppert Elec 2000˚F 8" × 12" × 6" 9" × 14" × 9" Lucifer Up/Down Elec 2000/1250˚F 9" × 18" × 9" Lucifer Up/Down Elec 2000/1250˚F 12" × 24" × 8" Lucifer Up/Down (Muffle) Elec 2100˚F Hayes (Atm) Elec 1800˚F 12" × 24" × 8" 13" × 24" × 12" Electra Up/Down Elec 2000˚F 12" × 24" × 8" Fce. Works (Muffle) Gas 2000˚F 14" × 24" × 12" Lindberg H2 Retort Elec 2150˚F Elec 2350˚F 17"×14.5"×12" L&L (New) 24"×36"×18" Lindberg Elec 2000˚F 24"×36"×24" Lindberg Elec 2100˚F 30" × 48" × 30" Surface (RTB-Atmos.) Gas 1750˚F 39" x 144" x 56" Nabertherm Kiln (2) Elec 2450˚F Gas 2000˚F 72" x 72" x 48" R&G (2) 72"×72"×48" R&G Elec 2000˚F –––––––––– PIT FURNACES –––––––––– 22" Dia × 26"D L&N Elec 1400˚F 22" Dia × 26" L&N Nitrider Elec 1200˚F 28" Dia x 48" Lindberg Elec 1400˚F 40" Dia × 60"D L&N (steam) (2) Elec 1200˚F 48" Dia × 72"D Surface Gas (R.T.) 1850˚F 60" Dia × 144"D Lindberg Elec 1400˚F ––––––––– VACUUM FURNACES ––––––––– Elec 2450˚F 24" × 36" × 24" ALD - 6 Bar (1997) 24" × 36" × 24" ALD - 6 Bar Elec 2450˚F –––– INTEGRAL QUENCH FURNACES –––– 8" × 18" × 8" Ipsen Gas 1850˚F 15" × 24" × 10" L&N Tricarb Elec 1850˚F 24" × 36" × 24" Lindberg (Top Cool) Elec 2000˚F 24" × 36" × 24" Surface Gas 1750˚F 30" × 48" × 30" Surface Elec 1750˚F 30" × 48" × 30" Surface Gas 1850˚F ––––––– BELT FURNACES/OVENS ––––––– 24" × 5' × 6" Darvon (New) Elec 400˚F 12" × 15' × 4" Sgt. & Wilbur (1994) Muffle Gas 2100˚F 16" × 24' × 4" Abbott (Atmos.) Muffle Elec 2400˚F Gas 500˚F 24" × 17' × 28" Jensen – Dual Belt 24" × 19' × 30" Jensen Gas 500˚F 24" × 30' × 30" Jensen Gas 500˚F 24" × 40' × 18" Despatch Elec 500˚F 24" × 40' × 18" Despatch Gas 650F 28" × 18' × 12" Hayes Elec 800F 32" × 21' × 18" Sunbeam Elec 1450˚F 36" × 108" × 34" Process Heating Elec 300˚F 42"× 24'× 30" Jensen Gas 500˚F 60"×45'×12" W-House Roller Hearth Gas 1700˚F

76 May 2011 – IndustrialHeating.com

–––––––––– MISCELLANEOUS –––––––––– 30” × 48” Lindberg Charge Car (double-ended) 4000# Accurate — Skip Hoist (NEW) 30"× 48"× 30" Dow Washer (D&S) Elec New Carbon Probes 36" × 48" Surface Roller Tables 30" × 48" Surface Charge Car (System I) 30" × 120" × 12" Ransohoff Belt Washer/Dryer Gas 60" Diam Surface Rotary Hearth (RT) Gas Wilson Hardness Testers (RC) SBS Air/Oil Coolers ––––––– OVENS/BOX TEMPERING –––––– 12" × 18" × 12" Surface Gas 1250˚F Elec 1250˚F 12" × 18" × 12" Lucifer 12" × 16" × 18" Lindberg (3) Elec 1250˚F 14" × 14" × 14" Blue-M Elec 1300˚F 14" × 14" × 14" Gruenberg (solvent) Elec 450˚F 15" × 24" × 12" Sunbeam (N2) Elec 1200˚F 15" × 24" × 18" Lindberg Elec 1250˚F Gas 1200˚F 18" × 36" × 18" Surface 18" × 48" × 18" Lucifer Elec 1400˚F Elec 400˚F 20" × 18" × 20" Blue-M 20" × 18" × 20" Blue-M Elec 650˚F 20" × 18" × 20" Blue-M (3) Elec 800˚F 20" × 20" × 20" Gruenberg (Solvent) Elec 450˚F Elec 500˚F 20" × 18" × 20" Despatch 20" × 24" × 20" Despatch Elec 1350˚F Elec 850˚F 24" × 24" × 24" Grieve 24" × 26" × 24" Grieve Gas 500˚F 24" × 24" × 36" New England Elec 800˚F Elec 600˚F 24" × 24" × 48" Blue-M (2) 24" × 36" × 24" Demtee (N2) Elec 500˚F 24" × 36" × 24" Paulo Gas 1250˚F Elec 650˚F 25" × 20" × 20" Blue-M 25" × 20" × 20" Blue-M Elec 1300˚F 26" × 26" × 38" Grieve (2) Elec 850˚F Gas 1250˚F 30" × 48" × 54" Lindberg 36" × 24" × 24" Young & Bertke Elec 400˚F Elec 600˚F 36" × 24" × 48" Blue-M 36" × 36" × 36" Grieve Elec 500˚F 36" × 36" × 36" Trent Elec 1200˚F Elec 600˚F 36" × 36" × 48" Blue-M 37" × 19" × 25" Despatch Elec 850˚F 37" × 25" × 50" Despatch (3) Elec 500˚F Elec 650˚F 36" × 60" × 36" CEC (2) 36" × 36" × 60" Hevi-Duty Elec 850˚F 36" × 36" × 120" Steelman Elec 450˚F Elec 850˚F 38" × 20" × 26" Grieve 38" × 26" × 38" Grieve Elec 1250˚F 48" × 24" × 48" Blue-M Elec 600˚F Gas 850˚F 48" × 30" × 42" Despatch 48" × 30" × 48" P-Quincy Elec 500˚F 48" × 48" × 72" Lydon Bros. Elec 450˚F Elec 450˚F 48" × 48" × 84" Gruenberg 48" × 72" × 72" Mich. Oven Elec 500˚F Gas 850˚F 50" × 50" × 50" Grieve 54" × 30" × 60" P-Quincy Elec 350˚F 55" × 30" × 60" P-Quincy Elec 550˚F 54" × 68" × 66" Despatch (Solvent) Elec 500˚F 60" × 64" × 72" Poll. Cont. Burn-off Gas 850˚F 72" × 48" × 89" Grieve (S.S.) Elec 500˚F Gas 750˚F 72" × 96" × 72" Despatch (2) 72" × 72" × 72" Mich. Oven Gas 500˚F 72" × 120" × 72" Grieve Gas 450˚F Gas 1000˚F 72" × 144" × 42" Bowman (Car) Gas 750˚F 84" × 96" × 72" Despatch (2) 96" × 120" × 96" Poll. Cont. Burn-off Gas 850˚F

Nabertherm - (2002) • ID: 39"W x 144"D x 56"H • Electric – 1340ÝC • 480/3/60 – 235 KW • Multiple Cars + Spares

+“Like New” Condition + Cleveland, OH Ph: 440-519-3800 Email: [email protected]

FOR $25.00 WE WILL POST AND LINK YOUR AD ONLINE Visit industrial heating online at www.industrialheating.com FOR SALE

FOR OVER 45 YEARS, specializing in buying and selling used Heat Treating, Heat Processing and Metal Finishing Equipment worldwide.

   

Heat Treat Furnaces (Batch & Continuous) Heat Processing Ovens • Parts Washers Shot Blast Cleaning/Peening & Vibratory Finishing Machines • Dust Collectors

“Featured Equipment” • Surface Combustion 6000 Endo, Gas Air Cooled • Vac Aero 6 bar, 2400ÝF, 36"x 48"x 30" • Surface Combustion 36"x72"x36" Top Cool I/Q Line • Lindberg 24 " x 36 " x 18" Vacuum Furnace • Various pieces of Induction Equipment Enterprise Equipment Co., Inc. 6000 Caniff Ave.,Detroit, MI 48212 Ph: 313-366-6600 • Fax: 313-366-6603 Web: www.eecoinc.com Email: [email protected]

Check out the latest Used Equipment Listings on Facebook and Twitter – #IHUsedEquip

AMIC R E C . BLE T PA M T E S T A IGH C EALAN

Classified Marketplace

FOR SALE

FOR SALE

& SMoist Creamy Putty E V I S ADHE Just Apply and Let Dry

FOR SALE

H

Bonds Most Materials Resists Chemicals, Electricity, Molten Metals and Abrasion

2300 F

Park Thermal Electric Re-Circulating Furnace 120 KW, 52" W x 50" H x 9' long, 1400ÝF. Complete with Digital Controls. Mint Condition.

AFC Mesh Belt Tempering Furnace

O

FREE MATERIALS HANDBOOK

COTRONICS CORP. www.cotronics.com - [email protected] 718-788-5533

60" W x 18' heated length x 6" h, natural gas, 1250ÝF. Complete with controls.

Lindberg Electric Rotary A-1 Condition 18” wide x 9” high x 60” diameter 72 kW; 1500ÝF. Complete with control system

Industrial Heating

Lightnin Mixers (9) Available

REPRINT PLAQUES ARE NOW AVAILABLE

5 HP, 1725 RPM, Complete w/ propellers and agitators. Shaft length 46" L, Small Propellers 8"W - Large Propellers 19"W

An excellent marketing opportunity

FOR SALE

For more information, please call your sales representative at 1-877-834-4328 (HEAT).

Park Thermal International (1996) Corp. 62 Todd Road, Georgetown, Ontario L7G 4R7 Toll Free: 877-834-4328 • Fax: 905-877-6205 [email protected] • Web: www.parkthermal.com

FOR $25.00 WE WILL POST AND LINK YOUR AD ONLINE Visit industrial heating online at www.industrialheating.com

Contact Becky McClelland at 412-306-4355 for details IndustrialHeating.com – May 2011 77

Advertiser Website Index Page

Company

Phone

Website

34

AEC Inc.

847-273-7703

www.aecinternet.com

13

Ajax TOCCO Magnethermic Corp.

800-547-1527

www.ajaxtocco.com

36

Alpha 1 Induction

800-991-2599

www.alpha1induction.com

66, 69

ASM International

800-336-5152

www.asminternational.org

40

Buehler Ltd.

847-295-6500

www.buehler.com

55

Can-Eng Furnaces Ltd.

905-356-1327

www.can-eng.com

44

CEIA USA Ltd.

888-532-CEIA

www.ceia-usa.com

29

Contour Hardening

317-876-1530

www.contourhardening.com

39

DMP CryoSystems

915-351-8500

www.CryoSystems.com

32

Duffy Co., The

847-202-0000

www.duffycompany.com

39

EFD Induction, Inc.

248-658-0700

www.efd-induction.com

21,65

G-M Enterprises

951-340-4646

www.gmenterprises.com

38

Graphite Metallizing Corp.

914-968-8400

www.graphalloy.com/IH

58

H.C. Starck Inc.

617-584-9322

www.hcstarck.com

68

Herring Group, The

630-834-3017

www.heat-treat-doctor.com

64

I Squared R Element Co., Inc.

716-542-5511

68

IFHTSE Congress, Scotland

32

Induction Tooling Inc.

440-237-0711

16,17

Inductoheat®, Inc.

800-624-6297

www.inductoheat.com

23

Inductotherm Group

609-267-9000

www.inductothermgroup.com

38

INEX Incorporated

716-537-2270

www.INEXinc.net

51

Ipsen, Inc.

800-727-7625

www.ipsenusa.com/titan

35

Mersen

01 46 91 54 00

www.mersen.com

www.isquaredrelement.com www.ifhtse2011.org www.inductiontooling.com

10

Metallurgical High Vacuum Corp.

269-543-4291

www.methivac.com

25

Nanmac Corp.

508-872-4811

www.nanmac.com

19

National Element

800-600-5511

www.nationalelement.com

31

North American Cronite, Inc.

800-243-4123

www.afegroup.com

52

Oerlikon Leybold Vacuum USA

724-327-5700

www.oerlikon.com/leyboldvacuum

Inside Front Cover

Omega Engineering, Inc.

203-359-1660

www.omega.com

12

Orton Ceramics

614-818-1338

www.temptab.com

Inside Back Cover

Plansee USA LLC

800-782-6659

www.plansee-usa.com

33, 64

Protection Controls Inc.

847-674-7676

www.protectioncontrolsinc.com

3,5

Pyromaitre Inc.

418-831-2576

www.pyromaitre.com

34

Qual Fab, Inc.

440-327-5000

www.qual-fab.net

61

Seco/Warwick Corp.

814-332-8400

www.secowarwick.com

49

SGL Carbon, LLC

800-727-4474

www.sglcarbon.com

26

Solar Manufacturing

215-258-3350

www.solarmfg.com

37

Southern California Gas

800-847-5497

www,socalgas.com/incentives

46

Struers, Inc.

888-787-8377

www.struers.com

33

Super Systems Inc.

513-772-0060

www.supersystems.com

8,9

Surface Combustion Inc.

800-537-8980

www.surfacecombustion.com

50

Thermalloys

46-248-12577

www.thermalloys.com

7

T-M Vacuum Products, Inc.

856-829-2000

www.tmvacuum.com

30

Tuthill Vacuum & Blower Systems

800-825-6937

www.tuthill.com

11

Unifrax LLC

716-278-3800

www.unifrax.com

45

VAT, Inc.

781-935-1446

www.vatvalve.com

15

WIRCO, Inc.

800-348-2880

www.wirco.com

27

Wisconsin Oven Corp.

262-642-3938

www.wisoven.com

Back Cover

Yokogawa Corp. of America

800-258-2552

www.us.yokogawa.com

78 May 2011 - IndustrialHeating.com

High Quality Work Begins with Exceptional Furnace Control!

For more information:

www.utadvanced.com

800-258-2552

AD51 1102

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