Industrial Heating April 2011

April 2011

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we also manufacture an excellent line of products. These products are created and/or improved using our wealth of knowledge and experience that can only be gained by nearly 100 years in the business. Tradition, integrity, technology, innovation, and dependability are our “beneath the surface” traits that are important to long term success. So, remember us for your next thermal processing equipment needs, and remember that... ...“It’s what’s under SURFACE® that counts”.

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CONTENTS

April 2011 • Vol. LXXIX • No. 4

On the Cover:

A R T I C L E S

This photo by Jack Delano was taken in January 1940, about a decade after Industrial Heating began covering the industry. The shot helps to illustrate how far the magazine and our industry has come in eight decades.

43

Insulating Firebrick – Maximizing Energy Savings Through Product Selection Andy Wynn – Morgan Thermal Ceramics UK Ltd; Bromborough, UNITED KINGDOM

Massimiliano Marchetti and Ermanno Magni – Morgan Thermal Ceramics Italiana s.r.l.; Casalpusterlengo, ITALY Energy prices of recent years have increased the importance of maximizing energy savings in thermal-processing industries. To accomplish this, the equipment designer needs to know which IFB products provide the minimum energy losses. Heat Treating

49

Principles of Gas Nitriding: The Nitriding Process (Part 1) Daniel H. Herring – The HERRING GROUP, Inc.; Elmhurst, Ill. Nitriding 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. In this article, we review the process.

55

F E A T U R E

Ceramics & Refractories/Insulation

Industrial Gases/Combustion

The Ellingham Diagram: How to Use it in HeatTreat-Process Atmosphere Troubleshooting Michael J. Stempo – Air Liquide International U.S. LP; Houston, Texas The Ellingham diagram is not always thought of as a heat-treater’s tool. This article explains its usefulness and demonstrates how to make use of it.

61

Materials Characterization & Testing

Practical Applications of Computational Thermodynamics and Kinetics to Heat Treatment Paul Mason – Thermo-Calc Software Inc.; McMurray, Pa. Heat treating can best be defined as “the controlled application of time, temperature and atmosphere to produce a predictable change in the internal structure (i.e. the microstructure) of a material.” This article describes how computational thermodynamics and kinetics can assist the metallurgist in making such predictions.

IndustrialHeating.com - April 2011 7

14

COLUMNS 14 Editorial Manufacturers Rejoice Has the time finally come for manufacturers to celebrate an upturn in the economy? Will our industry experience better times ahead? We back up last month’s broad comments with more specifics.

16

16 Federal Triangle Carbon Chicanery Congress has failed to pass the cap-and-trade law, but reports of its death might be greatly exaggerated. We are watching a regulatory debacle by the EPA to declare greenhouse gases (GHG) as controlled substances, especially carbon dioxide. Now is the time to act.

18 The Heat Treat Doctor™ Flowmeter Basics Flowmeters are common, but few of us really understand them the way we should. We tend to take them for granted, and this can often lead to serious flow errors and potential process or safety issues that compound themselves over time.

22 Environmental & Safety Demystifying Hazardous (Classified) Areas (Part 2) Last month, we considered some fundamentals of hazardousclassified areas. This column extends the discussion to the exterior areas of high-temperature furnaces.

22

SPECIAL 80TH RY ANNIVERSARY SECTIONS: 66 Hall of Innovators ators 68 Anniversary Logos

24 MTI Profile – Kowalski Heat Treating Company 26 IHEA Profile – Safety Seminar Draws Large Crowd

SPECIAL SECTIONS 64 THERMPROCESS 2011 Preview 73 2011 Aftermarket Directory: Company Listings

DEPARTMENTS 28 Industry News

88 Products

40 IH Economic Indicators

94 The Aftermarket

41 Industry Events

96 Classified Marketplace

83 Literature Showcase

102 Advertiser Index

INDUSTRIAL HEATING Volume 79, Issue 4(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].

8 April 2011 - IndustrialHeating.com

78 2011 Aftermarket Directory: Capabilities Listings 85 HTS insider News from the ASM Heat Treating Society

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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The power wer to know. The power to perform. Solar Manufacturing is the only US-based vacuum furnace OEM affiliated with a major business partner in commercial vacuum heat treating, Solar Atmospheres, with over 25 years of growth and innovation. Everyday our companies co-operate to solve the most difficult heat treating problems. Together we have been able to develop advanced and proven furnace designs. We know how to build them, improve them, repair them and keep them running. We custom engineer and fabricate the right furnace tailored to your specific processing needs. To find out how Solar Ingenuity can customize your solution, call 267.384.5040 or visit solarmfg.com.

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Online Exclusive An 80-Year Legacy of Thermal Processing The legacy of Industrial Heating and its ess predecessor, Fuels & Furnaces (F&F), actually goes lyy beyond the 80-year anniversary we are currently celebrating. From the beginning of F&F in 1924, we were there when many of the key thermalprocessing events occurred in the 20th century. This article pulls quotes and other content from the pages of Industrial Heating as we walk through thermal-processing history and our place in it.

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Everyday Metallurgy

Principles of Gas Nitriding This online exclusive is the second part of a four-part article. The first part appears in this issue on page 49. Nitriding is a case-hardening process in which nitrogen is introduced into the surface of a ferrous alloy by holding the metal at a temperature below that at which the crystal structure begin to transform to austenite on heating. This section discusses techniques for inspection, renitriding, troubleshooting, nitriding tips and economic considerations.

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Doug Glenn Publisher • [email protected] EDITORIAL/PRODUCTION STAFF Reed Miller Associate Publisher/Editor–M.S. Met. Eng., [email protected] • 412-306-4360 Bill Mayer Associate Editor, [email protected] • 412-306-4350 R. Barry Ashby Washington Editor

Dan Herring Contributing Technical Editor Dean Peters Contributing Editor Beth McClelland Production Manager, [email protected] • 412-306-4354 Brent Miller Art Director, [email protected] • 412-306-4356

AUDIENCE DEVELOPMENT Christina Gietzen Audience Development Coordinator Alison Illes Multimedia Specialist Catherine M. Ronan Corporate Audience Audit Mgr. For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected] LIST RENTAL Postal contact: Rob Liska at 800-223-2194 x726 [email protected] Email contact: Shawn Kingston at 800-4094443-828; [email protected] ADVERTISING SALES REPRESENTATIVES Kathy Pisano Advertising Director, [email protected] • Ph: 412-306-4357 Fax: 412-531-3375 Becky McClelland Classified Advertising Mgr., [email protected] • 412-306-4355 Larry Pullman Eastern & West Coast Sales Mgr. 317 Birch Laurel, Woodstock, GA 30188 Toll free: 1-888-494-8480 or 678-494-8480 Fax: 888-494-8481 • [email protected] Steve Roth Midwest Sales Mgr., (520) 742-0175 Fax: 847-256-3042 • [email protected] Patrick Connolly European Sales Representative Patco Media - London, 99 Kings Road, Westcliff, Essex (UK) SSO 8PH, (44) 1-702-477341; Fax: (44) 1-702-477559 [email protected] Mr. V. Shivkumar India Sales Representative, [email protected] Mr. Arlen LUO Newsteel Media, China; Tel: 0086-10-8857-9899; Fax: 0086-10-8216-0061; [email protected] Becky McClelland Reprint Quotes, 412-306-4355 Susan Heinauer Online Advertising Manager, [email protected] • 412-306-4352 CORPORATE DIRECTORS Publishing: Timothy A. Fausch Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Information Technology: Scott Kesler Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Conferences & Events: Emily Patten Clear Seas Research: Beth A. Surowiec BNP Media Helps People Succeed in Business with Superior Information

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Manufacturers Rejoice

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as the time finally come for manufacturers to celebrate an upturn in the economy? Will our industry experience better times ahead? Last month’s editorial touched on the reasons why this is so, but we thought we would add to it with more specifics. The latest reports show that factory orders in January were at the strongest pace in over four years. The manufacturing sector, which is bringing our economy out of the recession, was up 3.1% in January. This was the largest increase since September 2006. Comparing 2011 with a year ago, factory orders were up 10.8%. In February, the U.S. manufacturing sector grew at its fastest rate in nearly seven years. Aerospace was responsible for a large portion of these gains as orders for civilian aircraft and parts jumped 52%. While a more volatile measure, automotive has also been up significantly in early 2011. In January, all of the major car companies reported double-digit gains. The strongest came from GM at 49% and Toyota at 42%. The lack of international trade has been part of the reason for the growth in U.S. manufacturing. As activity has returned, U.S. businesses have increased their demand for equipment and machinery. This domestic demand has, in large part, been satisfied by U.S. production, which has helped to spur the recovery. A measure of this expansion domestically can be seen in the Institute for Supply Management’s February Report on Business®. Issued in early March, it said, “February’s report from the manufacturing sector indicates continuing strong performance as the PMI registered 61.4%, a level last achieved in May 2004.” This number is up 0.6% from January’s 60.8%. An indicator that the U.S. economic recovery is helping U.S. businesses is shown by a comparison with the HSBC China Manufacturing PMI in February. As measured by this indicator, manufacturing activity in

China fell to a seven-month low (51.7) in February. That’s nearly 10% below the U.S. index. We mentioned this in an earlier editorial, but it bears repeating that the reports of the death of manufacturing in the U.S. have been greatly exaggerated. In every year since 2004, U.S. manufacturing output has exceeded $2 trillion (in constant 2005 dollars). This is twice the factory output of the early 1970s (in constant dollars). Based on this output, U.S. manufacturing would rank as the sixth largest economy in the world, just behind France and ahead of the U.K., Italy and Brazil. For 2009, the most recent year for which international records are available, our manufacturing output of $2.155 trillion (including mining and utilities) is more than 45% higher than China’s. The productivity of the worker is an important reason why the U.S. continues to dominate. According to the U.S. Bureau of Labor Statistics, productivity increased 1.7% over the last four quarters, and annual productivity increased 3.6% from 2009 to 2010. More striking is the fact that manufacturing-sector productivity rose 5.8% in the fourth quarter of 2010. For all of 2010, this measure increased 6.0% – the largest annual increase since 2003. This is also the sharpest increase of all of the 19 industrialized countries in the world. In contrast, Japan experienced the steepest decline – 11.4%. As an example of the trend toward producing more U.S. goods domestically, Caterpillar Inc. is building a $120 million plant in Texas to make excavator machines. Some of the machines produced in this plant had been previously made in Japan. Likewise, Dow Chemical Co. is building an 800,000-square-foot plant near its Midland, Mich., headquarters to make batteries for hybrid and electric vehicles. One caveat that I’ll throw in to this discussion comes from the CEO of Dow Chemical, Andrew Liveris. In spite of their investment, he believes that U.S. manufacturing faces possible decline unless the government comes up with a strategy to boost it, including bigger tax breaks and government support for R&D. A video put together by the U.S. Department of Commerce discusses some reasons why companies choose to manufacture their products in the U.S. To highlight just a few, the U.S. offers a highly educated workforce, strong intellectual property (IP) protections and a business climate that supports and encourages innovation. Check out this five-minute video by using the Mobile Tag or by going to this link (tinyurl.com/4psezh2) to see the discussion and hear some tips for how to take advantage of our current manufacturing “boom.” IH

Use this Mobile Tag to view the five-minute DOC video about building it in America.

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

Carbon Chicanery

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h hank goodness I write this article for readers who work in a very efficient sector of our national econow my m when compared to other sectors that contribute much more to man-made global warming, which is m now called “climate change.” Our political class contributes a lot of hot air. Let me comment on why this is important and give some details relating to whack-jobs who believe all this pseudo-science. We should begin by noting that Al Gore got a D in science at Saint Albans High School in Washington D.C., and that was the last “technical” education he ever had. Peers thought Al would get an F, but kids at St. Albans whose daddy was a U.S. Senator never got Fs, if you know what I mean. Then little Al wrote a book about global warming. But it turns out Al was a hustler. My September 2008 column discussed this “secular science” and the stifling of truth as reported in Congressional testimony by NASA meteorologist Dr. Roy Spencer. Since then, citizens have learned that the UN’s Intergovernmental Panel on Climate Change (IPCC) has fraudulently changed and manipulated data to support a political case for taxing developed, industrial world economies in a thinly veiled “redistribution of wealth” scheme. We have seen the U.S. Congress fail to pass the cap-and-trade law but hear continued political talk of the topic reappearing in this Congress. And we are watching a regulatory debacle by the EPA to declare greenhouse gases (GHG) as controlled substances, especially carbon dioxide. (Incidentally, GHG includes water vapor, CO2, methane or gas from digestive processes and natural fermentations; various nitrogen oxides; halocarbons that are mostly man-made; and various precursor gases like carbon monoxide and volatile non-methane organics.) A new voice has weighed in on this subject. Ian Plimer is professor of earth sciences at Adelaide University in Australia and a serial author on climate. He points out that the recent volcanic eruption in Iceland spewed more CO2 in four days than all reductions in CO2 emissions made worldwide in the past five years. Plimer indicates that the brush-fire season across the western U.S. and in Australia will negate all human efforts to reduce CO2 into the atmosphere for a period of three years. Mount Pinatubo in the Philippines erupted in 1991 and has continued belching CO2 and other GHG since then, emitting more GHG into the atmosphere than all man-made emissions in human history. Yet the world stage continues to tolerate nut-cases and political crooks who want to talk about all this as legitimate. The global carbon cycle is composed of distributed sources and reservoirs (sinks) such as oceans and living biomass that absorb 16 April 2011 - IndustrialHeating.com

carbon. The human contribution to atmospheric CO2 (up to 3% of sources if you believe the nut-jobs*) is primarily supplied (93.8%) by fossil-fuel burning, which makes up 79.2% of the GHG man-made load. Transportation sectors account for 33%, residential 21%, commercial 18% and industrial 27% of CO2 emissions derived from fuel combustion. Electric power generation is the source of 41% of total CO2 emissions. The carbon footprint from all sources (in teragram equivalents) is CO2 (6,089.5 with 5751.2 from fossil fuel burning), methane (539.3) and halocarbons (163.0). The major methane sources are leakage from landfills (132.0), natural gas system equipment (111.0), coal mines (52.4) and manure management (41.3). The idea of a “social cost of carbon” is what liberal politicians want to create; a concept that causes the public to accept a tax as a remedy for this “injustice.” This tax can be directly on fuel use or can be “fuzzed up” with methods such as cap-and-trade protocols. The idea can be more appealing by claiming that carbon is a pollutant and creates “negative externality,” a negative effect on a par-

ty not directly involved in a transaction (the other fellow’s fault), and that the tax should equal the claimed, marginal damage costs. This tax is often called a Pigovian Tax, so named for the socialist economist A.C. Pigou, who defined the idea. This entire issue is as big a distortion of truth and common sense that we will see in our lives, but it is a reality that must be immediately confronted. As industrial people first, but also as American and world citizens, it is essential that you contact your federal elected Representative and both Senators and instruct them to stop all notions that turn this chicanery into our reality. IH *Independent analysis indicated that the oceans contain 37,400 billion tons (GT) of suspended carbon; land biomass contains 2,000-3,000 GT; the atmosphere contains 720 GT; and humans contribute 6 GT (or 0.0146%) of the total. If you would like to ask Barry Ashby a question, please 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.

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

Flowmeter Basics

E

v veryone knows what a flowmeter is, and, yet, few of us really understand them the way we should. The sad r reality is that once flowmeters are installed and operr ating we tend to take them for granted. This can often a lead to serious flow errors and potential process or safety issues that compound themselves over time. Let’s learn more. What is a flowmeter, really? A flowmeter is a device used for measuring the flow of gases or liquids. There are actually two different ways to measure flow – by volumetric means (Fig. 2a) and by mass-flow techniques (Fig. 2b). As heat treaters, we are probably more familiar with the volumetric-flow measurement of gases. The principle involves the displacement of the gas volume over time. Atmosphere furnaces, gas generators and combustion systems typically use these types of devices. Mass flow involves measuring the weight of a gas, and these are commonly found on vacuum furnaces that meter in gases for partial-pressure operation. What types of flowmeters are there? As heat treaters, we typically focus on the measurement of gases. Anyone who has seen a nitrogen/methanol system, however, is aware that liquid methanol must be metered into the furnace. Flowmeters are also used for measuring liquid flow. In addition to flowscopes and mass flowmeters, other common types include: or-

ifices, rotameters, positive-displacement meters, electromagnetic meters, ultrasonic (Doppler-effect) devices, turbine meters, wedge flow devices, impact meters and turbine meters. What are the features and advantages of the most common flowmeter types? Variable-area flowmeters offer: • Mechanical flow measurement with only a single moving part, ensuring measurement reliability • Application versatility and availability of a variety of construction materials, inlet and outlet sizes and types • Easy installation with generally no straight pipe requirements • Low pressure drops • Linear scales, allowing easy flow measurement interpretation • Electronic output availability, preserving the benefits of mechanical flow measurement Tapered-tube rotameters offer: • Low instrument cost (when glass or plastic metering tube is used) • Accuracy at very low flow rates Slotted-cylinder flowmeters offer: • A flow range of 25:1 since flow-measurement accuracy is determined by the precision of the slot manufacturing operation • Instrument specifications can be changed by field replacement of the slotted tube and float, without having to repipe the flowmeter body • Ability to handle high flows and pressures • Improved immunity to the effects of pulsating flows, with no minimum back-pressure Limitations common to both tapered-tube and slotted-cylinder variable-area flowmeters are that vertical mounting is required and that they contain moving parts. The user should also be aware that the accuracy of mass flowmeters and mass-flow controllers is determined by two factors: flow calibration and repeatability. Proper instrument calibration ensures starting-point accuracy. Repeatability is the measure of continuous performance-to-specification over the lifetime of the device. Most mass flowmeters and mass-flow controllers have an accuracy of ±1% of full scale and a repeatability of ±0.25% of full scale.

Fig. 1. Typical flow control panel (multiple-zone continuous furnace)

18 April 2011 - IndustrialHeating.com

Is it easier to control a gas or a liquid? Interestingly, liquids are easier to measure and control because of their small compressibility. For most volumetric-flow applications, the incoming pressure in liquid systems does not need to be closely controlled. By their very nature, liquids can be captured

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Furnaces that For more information contact G-M Enterprises 525 Klug Circle, Corona, California 92880 Phone 951-340-GMGM (4646) • Fax: 951-340-9090

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easily and measured to a high degree of accuracy. Gases on the other hand, because of their compressibility, require more complex sensing and control methods. What is the accuracy range of a gas flowmeter? When measuring gas flows in heat-treating applications there is an important distinction between the operating range of a flowmeter and the design range when purchasing a new meter. Plan to operate a flowmeter in a range not below 25% and not above 90% of the flowscope’s scale capacity. In other words, if your flowmeter is rated for 0-2,000 cubic feet per hour (cfh), you can be assured of accuracy when the flow is between 500 cfh and 1,800 cfh. Flows outside these limits are not considered accurate. A good “rule of thumb” for sizing a flowmeter is to purchase your meter “in the middle third.” The flowmeter should be chosen so that the actual flow will be no less than 1/3 and no higher than 2/3 of the scale you select. This gives you the ability in actual operation to compensate for unexpected changes in flow requirements that may occur. Often over the life of a heat-treating furnace, process requirements and operating conditions change – sometimes dramatically – and you want your y ggas measurement to remain accurate.

Should I have my flowmeters recalibrated? If a change of operating conditions is permanent, such as the desire to constantly operate at a different pressure, then recalibration of the flow measurement device is strongly recommended. As a rule, flowmeters used in heat-treating applications are designed for a maximum temperature of 150˚F (66˚C) and an operating pressure up to 50 psig (345 kPa). However, application-specific flowmeters have maximum operating pressures outside these ranges. What affects my gas measurements? If knowing the proper flowrate is important to you, be aware that a change in temperature, pressure or specific gravity of the gas from that for which the meter was calibrated will cause a serious error in the indicated scale reading. (These topics are covered in detail in the online portion of this column.) It is quite common in a heattreat shop to find flowmeters operating at different pressures and temperatures than they have been calibrated for. Do I need to maintain my flow devices? All flowmeters eventually require maintenance. It is a sad truth that some units require more maintenance than others, so this factor should be considered when Electronics

1

Sensor tube Sensor seals

Bypass

Value actuator

Do I really need to learn about my flowmeters to be in control, stay in control, operate safely and keep the cost of my operation as low as possible? Simply stated, yes. Hopefully, this discussion has helped reinforce this idea. Now go out today and check your flow devices! IH This column concludes online.

Valve seal

Valve orifice

Fig. 2. Flowmeter types (a) Endothermic gas FurnaceMeter (Courtesy of Atmosphere Engineering Company); (b) Mass-flow controller (Courtesy of MKS Instruments)

20 April 2011 - IndustrialHeating.com

a unit is selected. However, in most heattreating operations the equipment manufacturer has already made that choice for you, so understanding what maintenance is required and when it should be performed is of paramount importance. Flowmeters have moving parts and require internal inspection, especially if the fluid is dirty or viscous. For example, in furnaces using endothermic gas, the flowmeters often become contaminated with soot (carbon) and must be cleaned by CAREFULLY disassembling the flowmeter and cleaning all internal moving parts as well as replacing the dirty fluid in the flowmeter tube. Caution: This involves isolating the flowmeter, or performing maintenance when the unit is shut down, and must be done in a safe manner as many of the gases involved are asphyxiants as well as being flammable, toxic and possibly life-threatening. Remember also that electromagnetic flowmeters and all flow measurement devices that use secondary instruments such as pressure sensors to actuate a control valve or send a signal to a remote source must be periodically inspected, calibrated, repaired and/or replaced. Improper location of the flowmeter itself, the secondary sensor or readout devices can result in measurement errors and hidden costs.

There was too much good information to contain in this column. Find the rest with this Tag, or go to www.industrialheating.com/meter

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Demystifying Hazardous (Classified) Areas (Part 2)

I

n last month’s column, some fundamentals of hazardousclassified areas were considered. We showed that a “fuel-inevitable” area (e.g., an open dip tank containing a volatile organic liquid) could benefit from hazardous-area classification, but an “ignition-inevitable” area (e.g., the interior of a furnace) must be designated unclassified. This column extends the discussion to the exterior areas of high-temperature furnaces. Furnace Exteriors Unlike the inside of a combustion chamber, the area outside a furnace could be designated hazardous-classified under some circumstances. If there is a non-negligible probability of fuel gas or organic vapor releases into the area, then installation of explosion-proof or purged electrical enclosures might enhance safety for some types of furnaces, as discussed below. According to NFPA 497, the exterior of most furnaces should not be designated Class I, Division 1 because “normal” conditions do not involve releases of fuel gas or organic vapor. Here, normal includes routine releases of fuel due to either normal maintenance or normal operations. Conversely, some furnace exteriors might be designated Class I, Division 2 if fuel gas or organic vapor releases are possible under “abnormal” circumstances (e.g., from infrequent leaks or venting). Here, abnormal excludes major catastrophes but could include gasket and seal leakage. When properly designed, installed, inspected and maintained, steel piping with flanged or threaded connections does not pose a high risk of leakage. The National Fuel Gas Code (NFPA 54) and the ASME Code for Pressure Piping (B31) establish the installation and maintenance requirements for such piping components on ovens and furnaces. Ignition Sources If the exterior of the combustion system presents any surfaces that are routinely “hot,” the boundaries for any classified areas should exclude those hot surfaces. Hot-surface ignition is a complex phenomenon, and, in some circumstances, surfaces above 1000°F will not effectively ignite a gas-air mixture. In the absence of specific information about particular compounds, surfaces above 350°F may be conservatively deemed hot enough to ignite organic gases and vapors in air. Similarly, if the combustion system’s enclosure is “not tight” (i.e. flames or hot gases from the interior can escape or outside fuel vapors can be drawn inside), potential sources of fuel gas should be located far enough away from these openings so the hazardous22 April 2011 - IndustrialHeating.com

classified area ends before the opening begins. Class A, B, C and D Ovens/Furnaces Many electrically heated and gas-fired ovens and furnaces are constructed with tight enclosures and cool exterior surfaces (e.g., Class-D vacuum furnaces). The areas surrounding such systems may be designated either Class I, Division 2 or Unclassified depending on how frequently the vessel or piping connections are unsealed and resealed. Each time a seal is broken, the release of flammable gas is possible, and electrical components that are not rated for Class I, Division 2 service should be de-energized. The surroundings should be sniffed for hazardous concentrations of organic gases before re-energizing unclassified electrical components. Conversely, some industrial heating systems are not constructed with tight enclosures (e.g., Class-A ovens or thermal oxidizers with unsealed joints), and other systems present continuous ignition sources (e.g., Class-C atmosphere furnaces with flame curtains or Class-B furnaces with frequently opening doors). Care should be taken to preclude the release of all flammable gases in the vicinity of such “ignition-inevitable” heating systems to minimize the risk of explosion. Installing Class-I electrical components in ignition-inevitable areas is often pointless, because the areas cannot be designated as hazardous-classified due to the constant presence of ignition sources. In such areas, separation, isolation and ventilation should be employed to prevent fuel gases and vapors from migrating to ignition-inevitable areas. Readers should be cognizant of exceptions to these examples (e.g., a Class-C furnace that is capable of sequentially releasing flammable gases and exposing a burnout pilot) where Class-I, Division-1 electrical components may be warranted. As with all mechanical and combustion systems, good engineering judgment should be employed to ensure actual risks are mitigated appropriately with reasonable controls. IH

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

Kowalski Heat Treating Company “Specializing in those PIA (pain in the #$%) jobs!”

K

o owalski Heat Treating (KHT) was founded in 1975 by b Robert S. Kowalski. A 3,000-square-foot facility used salt-bath technology to service the needs of the u tool and die industries in northern Ohio. Since its t inception, KHT has grown to encompass over 30,000 square feet of processing capacity in four facilities. The company’s business model is built on its motto: “Specializing in those PIA (pain in the #$%) jobs!” KHT, which celebrates its 36th anniversary this year, is committed to a philosophy of continual improvement with the support of its highly trained and motivated staff. KHT offers solutions by combining the optimal use of state-of-the-art technology with a world-class staff that understands the need to solve problems with the highest level of quality and service. The current management team includes second-generation Kowalski family members Stephen Kowalski (president), David Lorenz (VP of operations-metallurgist), Nancy Vermilye (corporate controller) and Susan Lorenz (quality manager). Even during these recent “exciting” economic times, KHT made substantial investments in the expansion of its K-Salt Division, which specializes in rack salt-tosalt processing. By doubling its capacity, KHT has been able to continue to service the growing requests for rack salt-tosalt austempering and marquenching of distortion-sensitive components up to 38 inches in diameter. These increased capabilities have allowed KHT to take over the processing

24 April 2011 - IndustrialHeating.com

of components previously done in-house, enabling its customers to focus their resources on core business competency and reduce bottom-line costs by eliminating the need for equipment maintenance, capital expenditures and energy costs. Construction is currently under way that will dramatically expand KHT’s K-Flat division. Scheduled to be completed in the second quarter of 2011, the project will bring an additional 10,000,000 pounds of heat-flattening capacity online. This is the answer for close tolerance, specialty flatwork, allowing for the heat flattening of parts up to 53 inches in diameter with tolerances of .002 TIR. In addition to its K-Salt and K-Flat divisions, KHT’s wide range of services includes K-Glow (pulsed plasma ion-nitriding/ferritic nitrocarburizing), K-Vac (HPQ 10- to 20-bar vacuum processing), K-Life (deep cryogenics to -320°F) and K-Labs (fully integrated metallurgical laboratory). Together these divisions serve the medical, wind energy, outdoor power equipment, military, agriculture, power transmission, oil field, transportation, construction equipment and aerospace industries. Over the last 12 months, highly engineered process solutions have come directly from KHT operators that have resulted in over 50% increases in production. These kinds of process improvements will continue to drive Kowalski Heat Treating’s growth and are fundamental to the company’s success. For more information, call 888-KHT-HEAT or visit www.khtheat.com.

Quality for generations... Founder of Metal Treaters in St. Paul, Minnesota, Thomas Roberts, standing next to his first Ipsen furnace purchased in 1967, and it’s still running today! Metal Treaters currently runs five generations of Ipsen furnaces.

Ipsen delivers… More than 60 years of thermal processing excellence — Quality, Reliability, Innovation, Expertise, Versatility. Since 1948, Ipsen has provided the solutions heat treaters need to be successful. Choosing Ipsen brand furnace technology means choosing a partner you can count on for generations to come. www.IpsenUSA.com Scan the QR code to visit and “Like” us on Facebook

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

Safety Seminar Draws Large Crowd

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ducating industry on the vital role of safety has always been of utmost importance to the Industrial Heating Equipment Association (IHEA). That’s why IHEA has sponsored its annual Safety Seminar for over 20 years. Years like this, when NFPA releases revisions to NFPA 86, it’s even more important for those in our industry to have a chance to learn about the revisions from experts. More than 60 people attended the 20th IHEA Safety Standards Seminar on March 7-8 in Chicago. Nine speakers, all members of the NFPA 86 Technical Committee, covered selected sections of the new 2011 edition of NFPA 86 Standard for Ovens and Furnaces. Changes between the prior 2007 edition and the 2011 edition were highlighted. An overview of the new NFPA 87 Recommended Practice for Fluid Heaters was presented by the chair of the NFPA 87 technical committee, Algirdas Underys. In addition, selected sections of NFPA 54 National Fuel Gas Code regarding fuel supply line purging and NFPA 68 Explosion Protection by Deflagration Venting regarding explosion relief requirements were discussed. Seminar chairman Ted Jablkowski of Fives North American Combustion said, “This seminar was the largest yet and comprised of attendees from a wide range of equipment users, consultants, suppliers and manufacturers from the U.S., Italy and Mexico.” But an even better way to gauge the success of the seminar was from the attendees themselves. Comments on their evaluation forms included: • “It is a great seminar. I feel that anybody that works in the furnace industry (operator, maintenance and engineer) should take this class.” • “Excellent format, content and expertise and knowledge of speakers” • “A really great, very informative, very instructional seminar. Very glad to have been a part of it.” IHEA’s Safety Seminar will be offered again in 2012. Visit www. IHEA.org for a complete schedule and registration information.

Ray Ostrowski kicks off IHEA’s 20th annual Safety Seminar, which was held March 7-8 in Chicago.

26 April 2011 - IndustrialHeating.com

IHEA, Industrial Heating to Launch Resource Center at Thermprocess 2011 With support from member companies, IHEA and Industrial Heating will launch its first Resource Center at Thermprocess June 28-July 2. Visitors from around the world will gather in Düsseldorf, Germany, for one of the largest trade shows for industrial furnace and process-heating professionals. The 48-square-meter Resource Center will feature a presentation area, meeting rooms, literature from sponsoring companies and serve as a gathering spot for exhibiting IHEA members and visitors. To date, the following companies are Resource Center sponsors: Platinum Eclipse Gold Fives North American Combustion Selas Heat Technology Co. Surface Combustion Silver Dry Coolers Supporting Elster Kromschröder Hauck Vulcan Catalytic Wellman Furnaces It is not too late to become a sponsor of the Resource Center. 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.

Glen Mortensen of Zurich Services Corp. speaks to a large group of attendees at IHEA’s Safety Seminar.

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Industry News

Equipment News Electroslag Remelting System

Furnace Controls

Consarc Corporation shipped a 150-ton electroslag remelting (ESR) system to the Japan Steel Works (JSW). The ESR furnace system consists of two furnace heads with two melt stations and is capable of melting a single 150-ton electrode, or multiple smaller electrodes simultaneously, under complete inert-gas cover. It utilizes proprietary power systems designed and built by Consarc specifically for this large-scale ESR application. JSW plans to put the ESR furnace system into production in August 2011. The furnace system was designed, manufactured, preassembled for test and shipped from Consarc’s world headquarters in Rancocas, N.J. It gives JSW unmatched ESR capabilities and enables the company to maintain its position as a premier supplier of large forged rotor shafts. www.consarc.com

Super Systems Inc. (SSi) supplied Bodycote North America with an automated nitriding control system at its Highland Heights facility outside of Cleveland, Ohio. Highland Heights upgraded the controls on a gas nitriding pit furnace to provide automated process control for precise metallurgical results and a traceable, repeatable nitriding process. The SSi nitriding system includes a complete electrical and flow-control system that provides the furnace with the ability to run recipes for one- or twostage gas nitriding cycles and control all the necessary parameters to achieve precise metallurgical results. According to Bodycote, the new controls give Highland Heights the ability to automatically control Kn, temperature, back pressure, soak time, gas flows and data log everything for complete traceability. www.supersystems.com

Quality Endures Time Tested Innovation Since 1916

F

air weather is no test of navigation. Almost any craft will survive smooth seas, but it takes a stout ship and seasoned skill to weather rough gales and dangerous waters.

The user of Furnaces and Ovens today must have equipment that can be depended upon to stand the gaff of high production demands and hard going. “Built by Holcroft” is his assurance of dependable quality. Holcroft installations are designed and built to withstand extreme emergency demands and to insure economical, successful operation without costly interruption. Holcroft advertisement, April 1929

Manufacturer of Thermal Processing Equipment 28 April 2011 - IndustrialHeating.com

IQF, Temper Furnaces

Batch Oven

BeaverMatic sold an internal-quench furnace (IQF) and a temper furnace to Nevada Heat Treating Inc. for enhanced acceleration of product development cycles in growth industries. The IQF furnace has a work area of 30 inches wide x 48 inches long x 26 inches high for hardening 1,500 pounds of small- to mediumsize parts. In tandem, the temper furnace – with identical workload capacity – will relieve the internal stresses and reduce brittleness of parts after hardening. BeaverMatic constructs the temper furnace with six indirect straightthrough radiant-tube burners, alloy radiant tubes and spark ignition system with a 400,000 BTU/hour total output. For precision control of temperature and furnace operations, Super Systems Inc. will be used for software and process control. The 9205 controller will provide all the necessary temperature and atmosphere control. Complementing the process control is the SuperDATA SCADA system, which will provide Nevada Heat Treating with quick access to real-time and historical data throughout the plant. www.beavermatic.com

Lucifer Furnaces delivered a large tempering batch oven to an East Coast manufacturer of precision grinding equipment. Key features of this unit include a vertical airflow pattern and wire-on-rod heating elements. A roofmounted stainless steel belt-driven fan with a heavy-duty motor provides vertical airflow for uniform heat. Coilwound heating elements mounted on ceramic rods on all sidewalls provide rapid, energy-efficient heat, and a stainless steel liner serves to baffle the fan and elements so that air is circulated past the heating elements then upward through the chamber. The furnace is lined with 6.5 inches of multilayered lightweight insulating firebrick and mineralwool block for maximum heat storage and minimum heat loss. Powered with 42 kW, this heat-treating oven reaches 1400°F. The 18-cubic-foot chamber is complete with cast alloy roller rails to accommodate a large, heavy load. www.luciferfurnaces.com

UBQ Furnace AFC-Holcroft sold a UBQ (universal batch quench) furnace to Belgium-based VCST Industrial Products for installation at the company’s plant in Leon, Mexico. The gas-fired furnace has effective working dimensions of 36 x 48 x 36 inches and will be used to process various precision-machined gears for automotive and off-road powertrain applications. This furnace will be equipped with AFC-Holcroft’s new high/low endo gas-flow design, which reduces operating costs. AFC-Holcroft partner MATTSA will be building the furnace and installing on site. www.afc-holcroft.com

Our Legacy— A Lasting Commitment To Quality, Built One Innovation At A Time. AFC HOLCROFT AFC-Holcroft 49630 Pontiac Trail Wixom, MI 48393-2009 Tel: 248-624-8191 Fax: 248-624-3710 [email protected] www.afc-holcroft.com IndustrialHeating.com - April 2011 29

Industry News

High-Temperature Oven

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30 April 2011 - IndustrialHeating.com

Despatch Industries completed an order for a custom-built, hightemperature PTD oven for a customer in the petroleum industry. The customer plans to utilize the PTD oven to cure a coating on tools that would significantly extend the durability and life expectancy of the tool. The custom PTD features a larger chamber size and increased weight capacity, specifically designed for the customer’s distinct load requirements. The oven has a maximum temperature of 343°C (650°F) to meet the conditions of the curing application. Prior to shipping, completed factoryy testing pp pp g Despatch p p g and the oven achieved ±3°C end-to-end uniformity. www.despatch.com

Industry News

Nitriding System Nitrex Metal delivered a turnkey nitriding system to China’s Chongqing Hongjiang Machinery Co. Ltd., a producer of engine fuel-injection systems. The NX-1015 includes Nitreg® nitriding and Nitreg®-C nitrocarburizing technologies to automatically control treatments for fuel-injector assembly parts as well as transmission parts made of Nitralloy, tool steels, high-grade steels and other specialty steels. The system also houses an ammonia dissociator for just-in-time delivery of process gases and a neutralizing system to eliminate residual ammonia and meet local environmental targets. Chongqing Hongjiang chose this nitriding system to meet the need for more tightly controlled nitriding/nitrocarburizing. www.nitrex.com

Business News Renco to Purchase Severstal North America Facilities

North American Cronite Better by Design

North American Cronite 37162 Sugar Ridge Road • North Ridgeville, Ohio 44039 Phone 440-353-6594 • Fax 440-353-6599 E-mail: [email protected] • Website: www.afegroup.com 32 April 2011 - IndustrialHeating.com

AFE Cronite

The Renco Group, Inc. signed a definitive agreement to purchase Severstal North America operations at Warren, Ohio; Wheeling, W.Va.; and Sparrows Point, Md. The deal will provide Renco’s newly created RG Steel LLC subsidiary with about 7.5 million tons of annual steel production capacity, making it the fourth-largest steel producer in the U.S. The sale will leave the remainder of Severstal North America focused on its Dearborn and Columbus facilities.

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Industry News

AK Steel Melts First Heat in New EAF

Ipsen delivers support. Count on Ipsen’s responsive Aftermarket Support to help you get winning performance from your heat treating equipment. From parts and service to retrofits and training, we can provide you with everything you need to be successful. • Parts and service for atmosphere and vacuum furnaces • Hot zones, retrofits and upgrades • Thermal processing and furnace operation/maintenance training • Global service and support • Installation and start-up services Visit www.IpsenUSA.com to learn more about our Aftermarket Support.

AK Steel said that the first heat of steel was melted on March 4 in the company’s new 175-ton-capacity electric arc furnace (EAF) at its Butler (Pa.) Works. A new ladle-metallurgy furnace (LMF) at the Butler plant has also begun processing molten steel. The addition of the new EAF and LMF to the Butler melt shop is part of a modernization of the company’s specialty-steel operations during the past several years totaling more than $180 million. The new EAF is capable of melting 1.4 million tons/year, which is about 40% more than the total capacity of the previous three-furnace operation. According to AK Steel, the new furnaces will enable the company to lower production costs, increase steelmaking capacity and improve the quality of all of Butler Works’ products. They also give AK Steel greater flexibility in adjusting production levels and product mix of electrical, stainless and carbon steels, depending upon market conditions.

Gerdau to Invest in Brazilian Steel Mill Brazil’s Gerdau S.A. plans to expand steel production capacity at its Santa Cruz-based Cosigua mill by 50% to 1.8 million tons/year. In addition, a new wire rod and rebar rolling mill with an annual capacity of 1.1 million tons will be installed. The investment project, which will create 550 direct and 3,000 indirect job opportunities, will be executed in two phases. The first phase will involve expansion of production capacity at the melt shop, which is expected to be operational by 2012, and start-up of the new wire rod and rebar rolling mill in 2013. A new rebar fabricating facility will also be installed during the first phase. In the second phase, the rolling mill will start operating at an installed capacity of 1.1 million tons, which is expected to reach 2.6 million tons by the end of the phase.

Lakeside Adding Thermal Processing to Ontario Facility Lakeside Steel Inc. is adding additional thermal-processing capabilities, including normalizing, to the Welland, Ontario, facility of its wholly owned subsidiary, Lakeside Steel Corporation. This refurbishment will create 12 new jobs and will enable the modernized operation to ship fully end-finished and normalized tubing products to oil-country customers in the U.S. and Canada. Normalization processing involves the application of heat treatment to products in order to realign grain structure, enhance properties and strengthen the product. Lakeside has already begun refurbishing equipment to enable this value-added processing for its tubular products.

Rio Tinto Alcan to Invest in Kentucky, Retain Jobs

SPEED UNIFORMITY EFFICIENCY 34 April 2011 - IndustrialHeating.com

Rio Tinto Alcan will invest $37 million to improve the electrode department at the Sebree aluminum smelter in Kentucky. The project will include installation of a new bake furnace for the fabrication of anode blocks for the smelter’s potlines. As a result, the facility will be able to operate at its current capacity for the next 15-20 years. The investment project, which is expected to be complete by August, will also help retain the jobs of nearly 500 employees. The anode bake furnace will be utilized to bake 1,600-pound green anodes that are used in the aluminum smelting process.

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Industry News

Air Products to Supply Industrial Gases to Solar Atmospheres Air Products has been selected by Solar Atmospheres to provide industrial gases for its new plant in Fontana, Calif. Air Products will supply Solar Atmospheres with nitrogen, argon and helium for use in the vacuum processing of metals. With this latest contract, Air Products continues to supply all of Solar Atmosphere’s nitrogen, argon and helium needs at each of the company’s five plants, including four locations in Pennsylvania.

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AMG Acquires Aluminum Master Alloy Producer AMG Advanced Metallurgical Group N.V. acquired 100% of the LLC interests of KB Alloys, LLC for $23.5 million. KBA produces aluminum master alloys and grain refiners and has production sites in Kentucky and Washington. AMG, through its Advanced Materials division subsidiary London & Scandinavian Metallurgical Co. Ltd., is a market leader in Europe and South America for aluminum master alloys, grain refiners and aluminum powder technologies with production sites in the U.K. and Brazil. The combination of KBA with AMG’s aluminum master alloys businesses establishes AMG as one of the world’s largest producers of master alloys for the aluminum industry.

Minnesota Foundry Set to Expand ME Elecmetal announced a $10 million expansion to its Duluth, Minn., foundry that will increase production capacity by 25% and add 30 permanent jobs, mostly in production. The company, which produces high-quality iron and steel castings for the mining industry, has outgrown its current capacity because of domestic and foreign demand. According to ME Elecmetal, this is the largest capital investment at the Duluth facility, which opened in the early 1980s and currently employs 150. The expansion project should be completed by fall.

Praxair Expands Tennessee Air Separation Plant

Take Advantage of the Clemex CMT.HD Hardness Testing Solution Use Your Tester as a Powerful Quantitative Microscopy Instrument See More Details with a High-Resolution Camera Position Indents Accurately using Annotation Tools Get Automated Measurements and Results www.clemex.com

36 April 2011 - IndustrialHeating.com

Praxair, Inc. will double the capacity of its Memphis, Tenn., air separation complex to produce oxygen and nitrogen in order to supply Nucor Corp. and Valero Energy Corp. Praxair completed construction of a pipeline capable of serving multiple customers in the Riverport area. A new plant is expected to start up in the third quarter of 2011. As part of the expansion, Praxair will add 400 tons/day of new liquid production to serve growing customer requirements.

AISI Launches New Websites The American Iron and Steel Institute (AISI) launched a new network of websites that included a redesign of its flagship steel.org, a new face for North American steel recycling at recycle-steel.org and launch of smdisteel.org, which is dedicated to the steel markets. The Steel Market Development Institute (SMDI), which is a

September 2007

Heat Treat SHOW ISSUE Coverage Starts on p.38

Furnace & Process Optimization p.83 Lightweight & Strong Tubular Goods p. 89 New Vacuum-Furnace Hot-Zone Design p. 95 Infrared Technology for Induction p. 101 Wear- & CorrosionResistant Steel St eel pp. 109 The “Idealized” “Idealized” ” Radiant Tube p. 115 115

From Sept. 2007

Phone: 905-827-4171 www.vacaero.com

Literature Showcase: e:  Heat Treating Furnaces & Accessories  Alloy & Specialty Metals nching Systems  Heat Exchangers & Quenching A

This Vintage Cover shows a bottomloading vacuum furnace from VAC AERO International. The furnace was installed at a U.S.-based turbine engine component manufacturing facility. Contact VAC AERO International Inc. at: 1371 Speers Road, Oakville, Ontario L6L 2X5 Phone: 905-827-4171 E-mail: [email protected] www.vacaero.com

Publication • www.industrialheating.com • 23,030 Circulation • The Largest And Most Preferred Industry Publication

Industry News

business unit of AISI created in 2008, unveiled its new website as part of the launch, while the Steel Recycling Institute (SRI), also a business unit of AISI, features a redesign of its website, including expanded content on sustainability and life-cycle analysis.

In Brief • February 2011 sales for the Metal Treating Institute (MTI) reached $74.7 million, a 24.3% increase over February 2010 sales, which totaled $60 million. All nine MTI districts reported higher sales in February 2011 compared to a year ago. • California Brazing announced its official accreditation to the AS9100 international aerospace quality standard. The scope of this accreditation includes heat treating, machining, brazing and contract manufacturing. • Germany’s Elino Industries – a manufacturer of high-temperature and custom-engineered furnaces – has a new location in the U.S. Equipment will be manufactured, assembled and tested at the company’s new facility in Wisconsin and fully supported in the field by Elino Inc. USA employees. • BNP Media, parent company of Industrial Heating, received the 2010 Virtual Event Excellence Award for Best Social Media Integration, which was jointly sponsored by ON24 and the Social Media Academy.

38 April 2011 - IndustrialHeating.com

From Oct. 1989

Phone: 585-889-9000 www.ameritherm.com

Economic Indicators

Eternal Tubes... REQUEST FOR QUOTE

Wouldn’t it be heavenly to never have to install another failed alloy tube?

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Can y our c ontrols stand u p t o the d emands o f p ulse f iring? Pulse f iring requires c ont rols w hich c an m eet t he demands o f repeatability o ver m ill l i o nss of c ycles.

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To t ak e a dvant age o f t hese b enefit s, i nvest i n h igh quality K romschröder c ontrols f rom H auck. Hauck M an uf act uring C ompany , PO Box 90, Lebanon, PA 17042 Phone: 717-272-3051 Fax: 717-273-9882

40 April 2011 - IndustrialHeating.com IH06084Hau.indd 1

www.hauckburner.com 5/6/08 10:14:51 AM

Industry Events www.thermprocess-online.com

MAY 2-5 AISTech 2011 – The Iron & Steel Technology Conference and Exposition; Indianapolis, Ind. www.aist.org

Düsseldorf, Germany June 28 – July 2, 2011

3-5 Interwire 2011; Atlanta, Ga. www.wirenet.org 17-21 Aluminium Two Thousand – 7th World Congress; Bologna, Italy www.interall.it 18-21 PowderMet 2011 – International Conference on Powder Metallurgy and Particulate Materials; San Francisco, Calif. www.mpif.org 19 Free Webinar, hosted by Industrial Heating – “Induction Success or Failure: Optimum Frequency for Your Process” www.industrialheating.com 23-26 Metallurgy-Litmash/Tube Russia/Aluminium Nonferrous 2011; Moscow, Russia www.metallurgy-tube-russia.com 25-27 2011 Heat Treat China Show; Beijing, China [email protected]

JUNE 6-10 ASME Turbo Expo 2011; Vancouver, B.C. www.asme.org 14-15 Aluminum Extrusion Conference & Exhibition 3; Essen, Germany [email protected] June 28-July 2 Thermprocess 2011 – International Trade Fair for Thermo-Process Technology; Düsseldorf, Germany www.thermprocess-online.com Industrial Heating is the Official North American Media Co-Sponsor

AUGUST 18 Free Webinar, hosted by Industrial Heating – “Temperature Sensing/Control: The Right Tools Save You Money” www.industrialheating.com

SEPTEMBER 19-21 2011 Die Casting Congress & Tabletop; Columbus, Ohio www.diecasting.org/congress

OCTOBER 16-21 MS&T 2011, in conjunction with ACerS 113th Annual Meeting; Columbus, Ohio www.matscitech.org

Welcome to the 10th International Trade Fair and Symposium for Thermo Process Technology! Industrial furnaces, heat treatment equipment, components, testing and refractory technology on display together with the symposium for thermo process technology will bring you up to speed with the latest developments for successful business. The focus will be on innovations for energy and resource efficiency as well as sustainability, especially highlighted by the exhibitors in the ecoMetals segment.

Oct. 30-Nov. 4 AVS 58th International Symposium and Exhibition; Nashville, Tenn. www.avs.org Oct. 31-Nov. 2 ASM Heat Treating Society Conference and Exposition; Cincinnati, Ohio www.asminternational.org IndustrialHeating.com - April 2011 41 thp1102_85x241_4C_US.indd 1

15.07.2010 11:18:01 Uhr

From January 1961

Phone: 609-267-9000 www.inductotherm.com

FEATURE | Ceramics & Refractories/Insulation

Insulating Firebrick – Maximizing Energy Savings Through Product Selection Andy Wynn – Morgan Thermal Ceramics UK Ltd; Bromborough, UNITED KINGDOM NGD DOM Massimiliano Marchetti and Ermanno Magni – Morgan Thermal Ceramics Italiana s.r.l.; Casalpusterlengo, ITALY Insulating firebricks (IFBs) are well-established products for solving many problems of high-temperature heat containment in industries ranging from ceramicproduction kilns to anodes for primary aluminum. The volatile energy prices of recent years have increased the importance of maximizing energy savings in these industries. In order to optimize energy savings, the kiln designer needs to know which IFB products provide the minimum energy losses.

T

also presents further consequences of the manufacturing method on performance in terms of heating and cooling rates and reduction in CO2 emissions.

h purpose of this work is to he quantify the differences in perq formance that can be achieved f by studying a wide range of IFBs b currently available on the market. This is accomplished through laboratory-based measurements of energy losses from standard kiln arrangements constructed with a variety of test bricks. Since different suppliers manufacture IFBs by different techniques (casting, slinger, extrusion, foaming, pressing), the brick microstructures produced can be very different. This leads to a wide variety of thermal conductivities in the market within the same class of product, which in turn leads to a wide variation in the ability of the different types of IFBs to control energy loss from the kiln. This work demonstrates that IFBs can display up to 37% difference in the energy savings achievable, depending on their method of manufacture. The article

Background IFB Manufacturing Methods Table 1 lists the physical properties of four commercially available class-23 IFBs, representing the main manufacturing processes used by manufacturers. The “Cast” process uses gypsum plaster as a rapid-setting medium for a high-water-content clay mix containing some additional burnout additives. The “Slinger” process is a form of low-pressure extrusion of a wet clay mix containing high levels of burnout additives with the additional processing step that the semi-extruded material gets “slung” onto a continuous belt to generate additional porosity before drying and firing. The “Extrusion” process forces a

Table 1. Physical properties of class-23 IFBs

damp clay mixture containing burnout additives through an extrusion nozzle, where the extrudate is subsequently cut into bricks, dried and fired. The “Cement” process is a form of casting using cement instead of plaster, which leads to a much slower set. Further details concerning these manufacturing processes are available in the literature.[1] The density data reported in Table 1 is the average of measurements recorded on six bricks selected at random from a larger batch of product. The remainder of the physical-property data is generally an average of three measurements, while the thermal-conductivity data shown in Fig. 1 is measured on one sample selected at random from the batch. IFB Thermal Conductivity The different manufacturing methods for IFBs produce products with differing struc-

Cast

Slinger

Extrusion

Cement

Density (kg/m3)

483

611

569

520

MOR (MPa) ASTM C-93

1

0.7

0.9

1.2

CCS (MPa) ASTM C-93

1.2

0.9

1.1

2.0

PLC (%) after 24hrs @ 1230˚C ASTM C-210

-0.2

0.0

-0.2

0.0

Reversible linear expansion (%)

0.5

0.6

0.6

0.6

Hot load deformation % after 90 mins; 1100˚C @ 0.034 MPa ASTM C-16

0.1

0.0

0.2

0.1

Thermal conductivity, Wm-1K-1

0.35

Manufacturing Process

0.3 0.25 0.2

Cement Extrusion 0.15 Slinger Cast

0.1 0.05 0

0

200

400

600

800

1000

1200

Fig. 1. Thermal conductivity for class-23 IFBs IndustrialHeating.com - April 2011 43

FEATURE | Ceramics & Refractories/Insulation

Fig. 3. IR thermograph of muffle kilns during 1000˚C firing test (cast IFB-lined kiln on the left)

Fig. 2. Muffle kilns built for the energy-use study

ture and chemistry, which in turn deliver different performance properties.[2] The primary performance parameter for IFBs is their ability to insulate, which, in terms of measureable properties, is assessed by the thermal conductivity of the product. Density is sometimes used as a rule-of-thumb indicator of the insulating ability of an IFB, but this can be misleading. The difference in thermal conductivity between the different types of IFBs is shown in Fig. 1. It can be seen from this data that the thermal conductivity of the IFBs studied is not directly related to the density. For example, the highest-density product (slinger) has an intermediate set of thermal-conductivity values, but the IFB with the highest thermal conductivity (cement) actually has one of the lowest densities of the products studied. So, to maximize the insulating abilities of IFBs, product selection should not be made on density values. Commercially published thermalconductivity data varies in quality and accuracy with some datasheets omitting the test method, which makes the data

misleading when comparing and selecting products. The thermal-conductivity data quoted in this work was measured independently to ASTM C-182, but what is not normally published is how the thermal-conductivity data translates to real conditions in service. If one IFB has lower thermal conductivity than another, how does that translate to heat loss in real applications in terms of energy costs? This work serves to answer this question by measuring actual energy use under controlled conditions using different IFBs. Experimental We commissioned a kiln builder to manufacture two electrically heated laboratory muffle kilns of identical design and power rating (Fig. 2). One was lined with the cast IFBs as characterized in Table 1, and the other was lined with the cement IFBs. We selected these two IFBs for the study as these represented the IFBs with the lowest and highest measured thermal conductivity. For each kiln, power meters were set up

Table 2. Results of 800˚C firing tests with class-23 IFBs IFB Type

Cast

Results The results of the energy-usage tests are shown in Tables 2 and 3. By monitoring the kilns during the tests using an infrared camera (VarioCAM, FPA detector 320x240 pixel, 25 mm FOV 32°x25°), the kiln surface temperatures could be measured. Figure 3 illustrates how much heat is wasted through the body of the kiln lined with the higher thermal-conductivity IFB and how the surface temperature of the kiln becomes overheated. This behavior has the combined effect of wasting energy costs and presenting health and safety issues in terms of hazardous working temperatures.

Table 3. Results of 1000˚C firing tests with class-23 IFBs Cement

Test 1 (800˚C for 15 hours): IFB thermal conductivity at hold (Wm-1K-1)

between the power source and the kiln in order to measure the energy usage during the controlled test firings. Two test firings were conducted. Test 1 was a ramp at 3˚C/ minute from ambient to 800˚C, hold for 15 hours, natural cool back to ambient. Test 2 was a ramp at 3˚C/minute from ambient to 1000˚C, hold for 15 hours, natural cool back to ambient.

IFB Type

Cast

Cement

0.19

0.33

Test 2 (1000˚C for 15 hours): IFB thermal conductivity at hold (Wm-1K-1)

0.17

0.28

Door temperature during hold (˚C)

59

69

Door temperature during hold (˚C)

71

91

Roof temperature during hold (˚C)

52

90

Roof temperature during hold (˚C)

88

123

Energy used during ramp up (kWh)

2.0

2.9

Energy used during ramp up (kWh)

3.3

4.7

Energy used during hold (kWh)

9.2

14.4

Energy used during hold (kWh)

12.7

20.7

Total energy used (kWh)

11.2

17.3

Total energy used (kWh)

16.0

25.4

35

-

37

-

% Energy saved by using cast IFB

44 April 2011 - IndustrialHeating.com

% Energy saved by using cast IFB

Cast

Cast

Cast

Cement

Cement

Cement

Fig. 4a. Microstructure of IFBs (50x)

Fig. 4b. Microstructure of IFBs (100x)

Fig. 4c. Microstructure of IFBs (200x)

Discussion The results of the monitored test firings have demonstrated that there can be considerable differences in energy requirements to heat up kilns constructed using different types of IFB. With the IFB types studied under our test firing conditions, ~37% less energy was needed to run the test kiln through a 1000˚C (1832˚F) firing cycle with the cast IFB compared to the cement IFB. This difference in energy usage is a consequence of the different thermal conductivities, which are due to the differences in microstructure and pore size created by the manufacturing processes.[2] Figures 4a to 4c show the microstructure of the cast and cement IFBs used in the study as observed under an electron microscope. Figures 4a-4c show that the cast IFB has a much finer microstructure. The cement IFB has large quantities of relatively large holes in the structure, ranging from 700-1300 micron. Such large pore sizes are formed when combustible materials are added to the mix for the cement-based casting process and are burned out during the firing process. Typically, expanded polymer spheres of ~1 mm diameter are used by manufacturers to create such high levels of porosity in the fired product. This has the effect of reducing density and making the brick light in weight, but it

does not contribute so much toward the insulating properties of the IFB. Both the cast and cement IFBs display similar pore sizes in the mid-size range, around 50 micron diameter. This is again due to use of burnout additives. But the cast IFB has a much higher proportion of pore sizes in the <10 micron range. Mercury porosimetry studies [2] indicate a significant presence of even finer porosity than this in the cast IFB. It is this combination of ultrafine pore structure, coupled with an absence of very large pore sizes that affords the cast IFB with lower thermal conductivity compared to the cement IFB. IFBs are normally used in applications >1000˚C because, at these temperatures, they provide the most cost-effective insulation available compared to alternative insulating refractories (Fig. 5). The structural nature of the products also means that they offer resistance to abrasion in high-temperature environments, coupled with chemical resistance (when the chemistry is tailored to cope with specific gases). At application temperatures above 1000˚C, the most important heat-transfer mechanism becomes radiation rather than conduction and convection, which are the more significant heat-transfer mechanisms at lower temperatures. The large pore sizes in the cement IFB are inefficient

at retarding energy transfer at the infrared wavelengths involved, so this type of IFB displays a higher thermal conductivity compared with the cast. Conversely, the microporous structure of the cast IFB, with its small pore sizes, is much more efficient at interfering with energy transfer at infrared wavelengths, so this type of IFB displays low thermal conductivity. This is why the microstructure of the cast IFB provides superior insulation compared to the cement IFB. Energy Savings The laboratory test results demonstrate the potential to minimize energy usage by appropriate selection of IFB for a kiln lining. To understand how this affects real, Table 4. Assumptions for heat-transfer calculations Roller kiln operating conditions: Heating section area (m2)

150

Working temperature (˚C)

1300

Ambient temperature (˚C)

25

Working weeks per year

48

Kiln efficiency (%)

80

Lining arrangement: Layer 1: Class 26 ‘Slinger’ IFB thickness (mm)

114

Layer 2: Class 23 ‘Test’ IFB thickness (mm)

114

Layer 3: Back-up insulating board

50

IndustrialHeating.com - April 2011 45

Thermal conductivity, Wm-1K-1

FEATURE | Ceramics & Refractories/Insulation

0.50

Sol Gel continuous fibre

A

0.40 26 Class SLINGER IFB

Layer Cast Layer 1 (Layer 2) 3 79˚C

B

Layer Cement Layer 1 (Layer 2) 3 88˚C

0.30 Superwool board

1300˚C

725 W/m2

0.20

877 W/m2

1300˚C

Vermiculite board 23 Class cast IFB 0.10 Microporous board 0.00 700

800

900

1000 1100 1200 Temperature, ˚C

1300 1400

Fig. 5. Thermal conductivity for various refractories

full-size kiln installations, we ran heattransfer calculations (using the same cast and cement IFB types in the laboratory studies) to assess energy running costs for a typical roller kiln used by ceramic ware manufacturers (Table 4). The hot-face model of the standard lining arrangement (layer 1) was set up based on data from commercially available class-26 IFBs (JM26, Thermal Ceramics). The backup insulation (layer 3) was set up using data from commercially available bio-soluble fiber board (Superwool 607, Thermal Ceramics). To assess the effect on energy consumption of using different IFB types in the lining arrangement, layer 2 was designated the test layer into which the data from different IFB types were input. The results of the heat-transfer calculations are shown in Fig. 6. The heat-transfer calculations show that the lining arrangement with the cement IFB requires 152 W/m2 more energy o to maintain the 1300 C kiln temperature than the lining arrangement with the cast IFB in layer 2. So for the 150 m2 heating area, the difference in energy consumption between the two simulated roller kilns is 22.8 kW. This equates to a savings of ~230,000 kW/year energy using the cast IFB compared to the cement IFB. Assuming a gas price of 0.035€/kWh, this equates to an annual savings of ~€8,000/ year. Since the average life of a kiln lining is about 10 years, the total savings over the life of the kiln lining would be ~€80,000. A 150 m2 heating area in the kiln would need ~8,500 standard-sized IFBs. Although the cast-IFB price is higher than cement in this example, this higher price would be paid back in only four months. After the initial four-month payback pe46 April 2011 - IndustrialHeating.com

114

114 50

114

114 50

Fig. 6. Heat-transfer calculations on A (cast IFB) and B (cement IFB)

riod, the rest of the 10-year service life delivers continuous cost savings due to the lower energy requirements. Additional Impact of IFB Selection Another important consequence of the energy savings achieved using the lower thermal-conductivity IFB is the reduction in CO2 emissions. Using the cast IFB instead of the cement IFB reduces the environmental impact of running the kiln. In the current kiln scenario, as the savings in this example using cast IFB is ~230,000 kW/year, a natural gas-fired roller kiln will require 22,000 m3/year less gas to fire it. As natural gas produces 37.8 MJ/m3, then 830,000 MJ/year will be saved. Since 1 m3 of natural gas produces ~1 m3 of CO2, there is a potential reduction in CO2 emissions of ~22,000 m3/year. The equivalent of 1 m3 of CO2 is 1.96 kg, which equates to ~43 tons/year reduction in CO2 produced or 430 tons over the life of the kiln lining. A further benefit of using the lower thermal-conductivity cast IFB against the cement IFB is that the outer temperature of the kiln is lower. In the example calculated in this work, the skin temperature of the kiln utilizing cast IFB in layer 2 is o 79 C, whereas the skin temperature of the kiln utilizing cement IFB in layer 2 is o 88 C. The lower surface temperature obtained using the cast IFB produces a more comfortable working environment for operators and minimizes the risk of burns due to operators coming into contact with the surface of the kiln compared to the higher thermal-conductivity cement IFB. The choice of IFB in the kiln lining will also impact other practical aspects of using the kiln in a production environment. Selecting the cast IFB rather than

the cement IFB will allow faster heating and cooling rates in the kiln, because the lower-density cast IFB has a lower thermal mass. This effect was observed in the energy studies reported in this paper. During both the 800˚C and 1000˚C test firings, the cast IFB reached the programmed dwell temperature faster than the cement IFB. Conclusions The work reported in this paper has demonstrated the following points: • Differences in energy use as large as 37% were measured, under controlled laboratory conditions, between IFBs manufactured by different methods. • When selecting insulating refractory products for furnace linings, close attention should be paid to the reported thermal conductivity of IFB products. • The density of the products should not be used as a criterion to assess insulation ability, as this may lead to incorrect product selection. • To minimize energy consumption in the kiln, the published thermal conductivity needs to be measured to a recognized international standard (e.g., ASTM C-182) and be as low as possible. Selecting an IFB due to price alone can turn out to be a false economy and a costly mistake in the long run. • IFBs manufactured by the cast process offer the lowest thermal conductivity available today at application temperatures and, therefore, provide the greatest energy savings. This paper has quantified the energy savings that are possible when using cast IFBs. The benefits of using the lowest

thermal-conductivity IFBs available are: 1. Large cost-saving potential due to reduced energy usage 2. Lower CO2 emissions due to reduced energy usage 3. Reduced kiln surface temperatures offer operators safer working conditions IH For more information: Contact Dr. Andy Wynn, Morgan Thermal Ceramics, Tebay Road, Bromborough, Merseyside, CH62 3PH, U.K.; tel: (+44) 151 482 7483; fax: (+44) 151 482 7426; e-mail: andy.wynn@morganplc. com; web: www.morganplc.com or Lance Caspersen, Morgan Thermal Ceramics, 2102 Old Savannah Rd, Augusta, GA 30906; tel: 706-796-4200; fax: 706-796-4328; e-mail: [email protected]

REFERENCES 1. Moody KJ, Street JP, Magni E. Insulating Firebrick: Manufacturing Processes and Product Quality. In Alafar Conference, Guatemala, Nov. 7-11, 2004. 2. Wynn A, Marchetti M, Street JP, Yin T. Insulating Firebrick – Effect of Manufacturing Method on Product Performance. In UNITECR 09 Conference, Brazil, Oct. 13-16, 2009.

From Oct. 1982

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IndustrialHeating.com - April 2011 47

FEATURE | Heat Treating

Principles of Gas Nitriding: The Nitriding Process (Part 1) Daniel H. Herring – The HERRING GROUP, Inc.; Elmhurst, Ill. Editor’s note: This is the first of a four-part presentation, including an online-exclusive 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 out of order, depending on your starting point. Photo courtesy of Nitrex Metal Inc.

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 Iron-Carbon Phase Diagram (Fig. 1). The material typically is placed in contact with ammonia, which allows the transfer of nitrogen to the surface during its thermal decomposition to nitrogen and hydrogen. Other special nitriding processes are also used for certain types of stainless steels involving the decomposition of nitrogen gas at high temperatures, but these will not be the focus of this discussion. Several unique features of nitriding are: • Nitriding is a (relatively) low-temperature process compared to other casehardening processes (Fig. 2). • Quenching is not required for a hard case. • Part distortion is typically less than

other case-hardening processes. • Nitriding is relatively easy to control in terms of process parameters. • In the gas nitriding process, a crystal structure that is ferritic rather than austenitic is highly desired. Purpose of Nitriding Nitriding is a diffusion-related surface treatment (Fig. 3) with the objective to increase surface hardness (among other properties) by the creation of a case on the surface of the part (Fig. 4). One of the appeals of this process is that rapid quenching is not required. Therefore, dimensional changes are kept to a minimum. It is not suitable for all applications. For example, one of its limitations is that the extremely high surfacehardness case is more brittle than that produced by the carburizing process. A typical manufacturing sequence for gas nitriding (Fig. 5) consists of several

Temperature, ˚F 572 752 932 1112 1292 1472 1652 1832 2012 2192 2372 2552

2100 1100

2000

Ac1 (Fe-C)A

1900

Austenite

1000

heat-treatment steps, including pre-treatments and (optionally) stress relief between machining steps. Nitriding creates a component that has the following properties: • High surface hardness (typically > 67 HRC) • Resistance to wear • Anti-galling properties (for applications in poor lubrication conditions) • A minimum of distortion and deformation (less than, for example, carburizing/hardening) • Resistance to tempering (that is, resistant to softening) • Stability of the nitrided case • Improved fatigue life and other fatiguerelated properties • Reduction in notch sensitivity • Resistance to corrosion (except for 300series stainless steels) • Small volumetric changes (some growth does occur)

900 800

1700

Ferrite Austenite + cementite

Accm

Ac3

1500

Ferrite + austenite

1400

Ac1

700 600 0.0

1600

Temperature, ˚F

Temperature, ˚C

1800

Carbonitriding Nitriding Nitrocarburizing (austenitic) Nitrocarburizing (ferritic)

1300 Ferrite + pearlite

0.4

0.6

Cementite + pearlite

0.8 1.0 1.2 Carbon, wt%

1.4

1.6

Boronizing

1200 1100

0.2

Carburizing

1.8

1000 2.0

300 400 500 600 700

800 900 1000 1100 1200 1300 1400 1500 Temperature, ˚C

(Left) Fig. 1. Simplified iron-iron carbide phase diagram[1] (Above) Fig. 2. Temperature for typical case-hardening processes[2] IndustrialHeating.com - April 2011 49

FEATURE | Heat Treating

Properties that are considerably improved by nitriding are fatigue strength (resistance to dynamic loading), friction and resistance to wear, and corrosion resistance. Types of Nitriding Three methods of nitriding are commonly used in the industry today: gas nitriding (Fig. 6), plasma nitriding (Fig. 7) and salt-bath nitriding (Fig. 8). Each method is unique and has both advantages and limitations. Only gas niriding will be discussed here. Prerequisites for Nitriding To ensure the best nitriding results, the following precautions and recommendations should be followed. First, the steel should be hardened, quenched and tempered prior to nitriding so as to possess a uniform structure. Tempering temperature has an influence on the hardness of the case as well as the depth of nitriding (Fig. 9). The tempering temperature must be sufficiently high to guarantee structural stability at the nitriding temperature. The minimum tempering temperature should be 50°F (10°C) higher than the maximum temperature to be used for nitriding. In addition, the following is recommended: • Before nitriding, the steel must be free from decarburization. Precleaning is mandatory; residue on the parts will result in spotty cases. • If freedom from distortion is of paramount importance, the internal stresses produced by machining or heat treating should be removed before nitriding by performing a stress-relief operation,

•

•

•

•

that is, heating to and holding at a temperature of 1000-1300°F (538-705°C) followed by slow cooling. Since some growth takes place on nitriding, this should either be allowed for in the final machining or grinding operation prior to nitriding or removed by lapping or careful grinding. If required, the removal of a slight amount of the nitride case should be anticipated in the nitriding case-depth calculation. If maximum resistance to corrosion is desired, the parts should be used as processed (with white layer intact). Nitrided steels of the Nitralloy type should not be used where resistance to the corrosion of mineral acids is encountered or where resistance to sharp abrasive particles at high velocities is required (as in sand nozzles). If straightening is required after nitriding, it should be done hot, if possible, in the temperature range of 1200°F (650°C). Cold-straightening techniques should be carefully reviewed as microcracking is a concern.

• If maximum hardness and maximum resistance to impact are desired, and the question of maximum corrosion resistance is not of vital importance, the removal of 0.001-0.002 inch (0.0250.050 mm) of the nitrided case is desirable. The amount to be removed depends on the original case depth. This operation will remove the most brittle surface layer. • If nitrided parts exhibit a shiny-gray surface after their removal from the furnace, the results should be viewed with suspicion. Invariably, the case will be shallow and below hardness. The parts should have a matte-gray appearance, although a slight discoloration does not indicate faulty nitriding. The opening of the furnace at too high a temperature or the presence of air leakage on cooling will account for the slight discoloration. Prior Heat Treatment In certain alloys, such as the 4100 and 4300 series, hardness of the nitrided case

Diffusion-related processes

Heat treatment

Surface engineering Surface modifications

Chemical modification (thermochemical treatments)

No chemical modification

Adding a substrate layer

Plating

Coating

Hard-facing

Surface heating

Mechanical treatment

Electrolytic

PVD

Overlays

Induction

Shot peen

Nitriding

Carburizing

Electroless

CVD

Thermal spray

Flame

Burnish

Nitrocarburizing

Carbonitriding

Ferritic

Austenitic

Laser

Fig. 3. Diffusion-related processes[2]

Typical processing sequence 40μu

Fig. 4. Typical nitrided case showing a surface compound (white) layer and subsurface diffusion zone[2]

50 April 2011 - IndustrialHeating.com

Forging

Normalizing

Annealing

Rough machining

Fig. 5. Typical nitriding manufacturing sequence[2]

Hardening & tempering

Finish machining

Nitride

Fig. 7. Typical plasma-nitrided load

is modified appreciably by core hardness (Fig. 10). Observe that a decrease in core hardness results in a decrease in case hardness. In order to obtain maximum case hardness, these steels are usually provided with maximum core hardness by tempering at the minimum allowable tempering temperature. All hardenable steels must be hardened and tempered before being nitrided. The minimum tempering temperature is usually at least 50°F higher than the maximum temperature to be used in nitriding. Typical tempers range from 1150-1350˚F (620-730˚C). Surface Preparation Nitriding is to be considered a white (clean) glove treatment, that is, all residuals including oils and grit must be cleaned off the surface of the parts prior to nitriding. Even skin oils from handling parts without clean gloves can be problematic. If parts are not absolutely clean, spotty case depths will result. One acceptable way to clean parts is by vapor degreasing and abrasive (aluminumoxide grit) cleaning just prior to nitriding. Another method involves a light phosphate coating. The steps involved are: • Degrease • Cold-water rinse • Oxalic-acid bath dip • Cold-water rinse

• Warm-water rinse • Phosphate solution dip If a decarburized surface is not removed before nitriding, the case will spall very readily. Nitriding Results The following results can be expected from the gas nitriding process: Surface Appearance Parts gas nitrided in ammonia should have a dull, matte-gray color (Fig. 11). Structure of the Nitrided Case In the nitriding process, the nitrogen that diffuses into the steel reacts with the nitride-forming elements present in solid solution. The hardening results from the reaction. The depth of case depends on how far beneath the steel surface nitrogen is able to diffuse during the nitriding period. The principle involved is that as the alloy elements are removed from solid solution, nitrogen (which is constantly being supplied from the surface) diffuses farther into the alloy and, thus, produces an increasingly deep case. The case depth for any given treatment time and temperature depends upon the amounts of alloy elements with which nitrogen must react before it can diffuse farther.

Fig. 8. Typical salt-bath-nitrided load

Nitrogen Concentration The nitrided medium needs to contain only sufficient active nitrogen to maintain the white layer (Fig. 12). Any increase beyond this point serves to increase the depth of white layer and does not affect the thickness of the inner (diffusion) layer. Corrosion Resistance The white layer has excellent corrosion resistance. In certain applications, it does not need to be eliminated. Dimensional Changes During nitriding, parts increase slightly in size because of the increase in volume that occurs in the case. This change causes a stretching of the core, which results in tensile stresses in the core that are balanced by compressive stresses in the case after the parts are cooled to room temper900 800 700 600 500 400 300 200

HV

Fig. 6. Typical gas-nitrided load

Temperature, ˚C 500 600 650

0

0.1 0.2 0.3 0.4 0.5 Depth below surface, mm

0.6

Fig. 9. Typical influence of tempering temperature on hardness and depth of nitrided case[4] (nitrided for 60 hours at 950°F/510°C) IndustrialHeating.com - April 2011 51

FEATURE | Heat Treating

Rockwell 15-N hardness

95

25 hours 20 - 30% dissociation

90

50 hours 20 - 30% dissociation

35 hours 20 - 30% dissociation

85 80 75 70

For this row of charts, steel was purchased as AMS 6382

0

4 3 2 1

4 3 2 1

5 10 15 20 25 Distance below surface, 0.001 in.

30 0

Core, Rc 1 21 to 23 2 26 to 28 3 33 to 35 4 36 to 37

5 10 15 20 25 Distance below surface, 0.001 in.

30 0

4 3 2 1

5 10 15 20 25 Distance below surface, 0.001 in.

30

Fig. 10. Case depth as a function of hardness gradient for 4140 steel[12]

ature (e.g., notch-sensitivity reduction – a localized surface effect). Tensile Stresses Tensile stress originates at imperfections cancelled by compressive stresses. Growth and Distortion Dimensional change in nitrided parts are governed largely by composition, tempering temperatures, time/temperature of nitriding, relative thickness of case/core, shape of the part and areas marked off to prevent nitriding. The amount of growth is usually constant for identical parts nitrided in different batches by a fixed processing cycle. After the amount of growth for a particular part has been determined experimentally, allowance for it can be made during final machining (prior to nitriding). Sharp corners or edges should be avoided on parts to be nitrided, because the projections formed at sharp corners are high in nitrogen content and susceptible to chipping. Sharp edges nitride through the section and are without support from

a soft ductile core. Parts nitrided by the two-stage process and not ground after nitriding have excellent dimensional stability. IH 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: heattreatdoctor@ industrialheating.com; web: www.heat-treatdoctor.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.

References 1. Herring, D. H., “What Happens to Steel During Heat Treatment? Part One: Phase Transformations,” Industrial Heating, April 2007. 2. Tarfa, Tahar Nabil, Controlled Gas Nitriding for Powertrain Components, Global Powertrain Conference, 2004, Nitrex Metals (www.nitrex.com) 3. Diggs, Thomas G., Rosenberg, Samuel J., and Geil, Glenn W., Heat Treatment and Properties of Iron and Steel, National Bureau of Standards, Monograph 88, 1966. 4. Principles of Nitriding and Nitrocarburizing, Atmosphere Heat Treating, Basic Seminar,

Ipsen International, 1998. 5. Winter, Karl-Michael, Nitriding Sensors & Controls, Nitrex Metals Nitriding Symposium, 2006 and private correspondence. 6. Lotze, Thomas, Gas Nitriding, Application Bulletin A4601, Super Systems, Inc. 7. Mr. James Oakes, Super Systems, Inc. (www.supersystems.com), private correspondence. 8. ASM Handbook, Volume 4, Heat Treating, 1991. 9. Pye, David, Practical Nitriding and Ferritic Nitrocarburizing, ASM International, 2003. 10. Source Book on Nitriding, ASM International, 1977. 11. Braziunas, V. Prokka, L, and Herring, D. H, “Automated Measuring System for Gas Nitriding/Nitrocarburizing,” Industrial Heating, January 2005. 12. Metals Handbook, Volume 2: Heat Treating, Cleaning and Finishing, ASM International, 1964, pg. 153. 13. Herring, D. H., “Cleaning of Parts and Fixtures,” Industrial Heating (www.industrial heating.com), Online Exclusive, Part 13, 2010.

Use this Mobile Tag to read this month's gas-nitriding online exclusive.

White layer

Diffusion layer

40μm Fig. 11.

Surface appearance of nitrided valve springs[5]

52 April 2011 - IndustrialHeating.com

Fig. 12.

Nitrided case[5]

From July 1981

Phone: 215-646-6600 www.selas.com

From March 1977

Phone: 800-343-0228 www.honeywell.com/hfs

FEATURE | Industrial Gases/Combustion

The Ellingham Diagram: How to Use it in Heat-Treat-Process Atmosphere Troubleshooting Michael J. Stempo – Air Liquide International U.S. LP; Houston, Texas The Ellingham diagram is not always thought of as a heat-treater’s tool. This article demonstrates its usefulness.

H

a arold Johann Thomas Ellingham (1897-1975) was a Brith ish physical chemist and is best b known for the diagrams named after him that plot the change in standard free energy with respect to temperature for reactions like the formation of oxides, sulfides and chlorine of various elements, such as: 2x

⁄y M + O2 ‹ 2 ⁄y MxOy

The oxide plot tends to be the most common and will be highlighted here as its applicability to heat-treating processes is the most relevant. This phenomenon was known before Ellingham’s time, but Ellingham demonstrated it more clearly and made it more accessible to industry as a tool. His diagram and its variants help to select the best reducing agent for various ores in the extractive-metal process. Ellingham discovered that by normalizing the thermodynamic functions to a given reaction with one mole of oxygen he was able to compare the temperature stability of many different oxides on the same diagram. In particular, and this reaction is critical to metal reduction systems that use carbon dioxide, he could show graphically that carbon becomes a stronger reducing agent as the temperature increases. The reduction of metal oxides with carbon (or carbon monoxide) to form the free, reduced metals is of immense industrial importance (blast furnace reduction of iron ores), and Ellingham diagrams show the lowest temperature at which the reaction will occur for each metal.

Let’s restate and go stepwise through the Ellingham diagram to set up and make clearer how metal heat treaters can use it. We can adapt the diagram from its original use as a higher-temperature extractivemetallurgy tool to one where we can predict the effects of protective atmospheres and common atmosphere impurities and their impact on heat-treated product. See Fig. 1 for the classic Ellingham diagram that would typically be used for heat-treating atmosphere processes. Background An Ellingham diagram is a plot of 6G (change in Gibbs free energy) versus temperature, which, for our purposes, would be a temperature in a continuous furnace by zone or in a batch furnace by time in the cycle. The Ellingham diagram shown is for metals reacting to form oxides. Since any explanation of how to calculate and plot an Ellingham diagram is more about the mechanics of the derivation process and less about how to use the tool, which is the intent of this article, the concept is covered very briefly here. Enthalpy (6H) and entropy (6S) are essentially constant with temperature. Unless a phase change occurs, the free energy (6G) versus temperature plot can be drawn as a series of straight lines, where 6S is the slope and 6H is the y-intercept. 6G = 6H – T 6S The slopes of those plotted lines change when any of the materials involved melt (M) or vaporize/boil (B). In a heat-treat

system this is (for the most part) irrelevant, except in the brazing and sintering processes where those phase changes (melting) can indeed occur. The free energy of formation is negative for most metal oxides, which means the reaction can proceed without further influence. Therefore, the diagram is drawn with 6G=0 at the top of the diagram, and the values of 6G shown are all negative numbers. Temperatures where either the metal or oxide melt (M) or vaporize (B) are marked on the diagram. Note that the majority of the plots for metals slope upward because both the metal and the oxide exist as condensed solid or liquid phases. The oxygen partial pressure is taken as 1 atmosphere, and all of the reactions are normalized then plotted to represent consumption of one mole of O2. Interestingly, there are two plots that do not look like all of the others. C + O2 => CO2 Carbon, a solid, reacts with one mole of oxygen and produces one mole of carbon dioxide (CO2), which results in little change of entropy – an almost horizontal plot. The other has a distinct negative slope: 2C + O2 => 2CO In this reaction, a solid once more reacts with one mole of gas but produces two moles of gas – carbon monoxide (CO). This causes a substantial increase in entropy, and the plot has a distinct IndustrialHeating.com - April 2011 55

FEATURE | Industrial Gases/Combustion

Ellingham Diagram for Metals Processing When plotting whether a given metal system will oxidize, reduce or remain as an oxide or pure metal, the Ellingham diagram does not indicate the quantitative rate of the reaction, only the probability of it occurring based on a given set of conditions. One can make the assumption that the reaction will qualitatively occur more rapidly as temperature increases or as the conditions for reducing or oxidation deviate farther from neutral-atmosphere conditions. We can use the diagram to determine the relative ease by which a metal can be oxidized or an oxide can be reduced. Metals plotted high up on the diagram are easier to reduce (noble metals) than those plotted lower on the diagram, which naturally tend to exist in very stable oxide forms. For example, Ag, or silver, is very hard to oxidize, while Ca, or calcium, does 56 April 2011 - IndustrialHeating.com

not naturally exist in its elemental form, indicating a very stable oxide form. The metal/metal oxide plots also interrelate to each other. A metal plotted below another metal can reduce the oxide of the one plotted higher up the diagram. Hence titanium, not the oxide, can reduce the oxide of chromium, which is plotted higher on the diagram. We can also use the diagram to determine the following at a given temperature: • The ratio of hydrogen to water/dewpoint (PH2/H2O) that can reduce a metal oxide to metal or prevent a metal from oxidizing • The ratio of CO to CO2 (PCO/CO2) that can reduce a metal oxide to metal or prevent a metal from oxidizing • The partial pressure of oxygen that will be in equilibrium with a metal oxide

Determining the Equilibrium Partial Pressure of Oxygen For a PO2 higher than the equilibrium value at a given temperature, the metal will be oxidized. Conversely, for an oxygen partial pressure that is lower than the equilibrium value at a given temperature, that metal will be reduced. Use the scale or nomograph to determine the equilibrium PO2 by the following method. Using a straightedge and knowing the temperature or series of temperatures you wish to use (and the metal/ metal-oxide system), put the one side of the straightedge on the upper left-hand corner of the diagram that is labeled “O” (near the Ag to silver-oxide plot). Next, position the straightedge from that anchor point to the temperature point where the metal in question intersects that temperature value. Now, continue across

PH 2 /PH2O O

o

10-8 10-7

PCO/PCO2

10-14 10-12 10-1010-910-8 10-7 10-6

-100 -200 -300

10-6

Cu 2O O =2 4Cu + 2 2C + O2 = 2CO

-400

10-5

10-5 10-4

-500

C -600

r + O2 4/3C

-700

-900

-1100

nO = 2M

M 10-14 M

M

l + O2 4/3A

Al 2O 3 = 2/3

gO = 2M + O 2 2CaO g M 2 = + O2 2Ca 0 200 PO2,(atm)

400 10-100

B

B

M

800

10

10-1 1 10

102 103

102

1000 10-60

1200 10-50

104

105

10-20

107

106

10-22

108

107

10-30 1400

109 1010

PCO/PCO2

1011

10-34

1010 1011

1013 1300 ˚C

109

1013

1014

PH2/PH2O

108

1012

1600 10-38

104

106

10-28

10-42

103

10-18

10-24

M M Melting point of metal B Boiling Point of metal M Melting point of oxide

10-80

1

105

M

600

10-2

10-1

10-16

10-26

Temp. ˚C

-1200

O Kelvin

M

SiO 2 O = Si + 2 TiO 2 = O Ti + 2

-800

-1000

+ O2 2Mn

Cr 2O 3 = 2/3

10-3 10-2

10-12

3/2Fe + O2 = 1/3Fe3O4

H

10-4

10-3 1 10-1 10-2 M 10-3 O4 -4 2Fe 3 10 M = M O2 + e iO oO 6F 10-5 M = 2N = 2C + O2 2H 2O + O2 = 2Ni o O O C + 2 2 2 2H 2 = 2C M + O2 10-8 2Co M C + O2 = CO2 10-10 M

4Ag + O2 = 2Ag2O

6G˚ = RTInpO 2,k j

negative slope. The severe negative slope of this carbon reaction results in an increasingly more powerful reducing agent as temperature increases. For example, at 1500˚C (2732˚F), the carbon reaction crosses under that for silicon dioxide (SiO2), resulting in the potential ability to reduce the highly stable compound of SiO2 to silicon under oxygen-starved conditions. Note on the diagram there is a scale on the right and along the bottom of the graph illustrating PO2 (atm). PO2 is plotted showing partial-pressure values from 1 to 10-100. It will be shown how to use this scale in the next section, along with the scales immediately to the right of this one showing the relationship of PH2/H2O and PCO/CO2 to the various metals and their oxides as a function of temperature. These partial-pressure values and their associated ratios can be plotted on the Ellingham diagram and can be obtained by sampling the process atmosphere at various temperatures, or at specific times (temperatures) in a cycle, using familiar and readily available atmosphere analytical tools (oxygen, hydrogen, dewpoint/moisture, CO and CO2).

1012

the straightedge plot to the value on the PO2 scale. This is the equilibrium partial pressure of oxygen. For this diagram, it is expressed in atmospheres. Once again, any oxygen partial pressure that is lower than the one derived will cause metallic reduction. Any partial pressure above will cause oxidation. For a real-life example, find the equilibrium partial pressure of oxygen for chromium at a temperature of 1300˚C (2372˚F). Put the straightedge on the “O” dot in the upper left hand corner of the diagram. Find the chromium plot and where it intersects the temperature of 1300˚C. While anchoring the one end of the straightedge on the “O” dot, move the other end of the straightedge so that it runs through that intersection point and continue down the straightedge to the PO2 scale. Read off the value, which should be 10-16 expressed in atmospheres. This is an extremely small amount of oxygen than can be present in

this high-temperature system before the deleterious effects of oxygen will adversely oxidize the metallic chromium. The effect of chromium oxidation by even the smallest amounts of oxygen can be countered by using a strong atmosphere reducing agent such as hydrogen. Let’s go next to determining the equilibrium ratio (PH2/H2O) or the hydrogen-to-water (dewpoint) ratio. Determining the Equilibrium PH2/H2O Ratio For a PH2/H2O, or hydrogen-to-water ratio, that is higher than the equilibrium value – relatively more hydrogen to water – at a given temperature, the metal will be reduced. For a PH2/H2O that is lower than the equilibrium value (relatively less hydrogen to water) at a given temperature, the metal will be oxidized. Using essentially the same straightedge method that we used above to plot the

equilibrium partial pressure of oxygen, we now plot from the “H” dot on the left side of the diagram through our desired metal and desired temperature and now read from the PH2/H2O plot on the right side of the diagram. A real-life example would be to find the equilibrium hydrogen-to-water ratio for chromium at a temperature of 1300˚C. Locate the straightedge left side on the “H” dot, pass through the chromium equation where it intersects at 1300˚C and read off the equilibrium hydrogen-to-water ratio value on the PH2/H2O scale. The value should be between 102 and 103. This represents a value of between 100 and 1,000 to 1 ratio of hydrogen needed to water or dewpoint level. For this exercise, we can estimate the hydrogen-to-water ratio to be 400 to 1. This is a high level of hydrogen that is necessary to counter the oxidizing effects of water or dewpoint on chromium,

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IndustrialHeating.com - April 2011 57

FEATURE | Industrial Gases/Combustion

hence the reason why most stainless steel (chromium present as an alloy) hightemperature processing is usually done in very high levels of hydrogen – often 100%. At the processing temperature of 1300˚F, in the presence of hydrogen, oxygen species will convert to water and become a part of whatever background moisture or dewpoint that might be in the process-atmosphere system. Enough hydrogen must be present in the atmosphere system to counter oxidation of chromium. With too low of a hydrogen ratio to a given moisture level, chromium oxidation will occur. With no hydrogen in such an atmosphere system (vacuumfurnace processes excluded), it is literally impossible to exclude enough oxygen from the system to prevent chromium oxidation. Determining the Equilibrium PCO/CO2 Ratio The PCO/CO2, or CO/CO2 ratio, is used with more frequency in extractive-metallurgy systems for all metals to determine whether this reaction will reduce or oxidize a given metal system at a given temperature. In heat-treated metals, the ratio is usually used for carbon-bearing iron alloys to determine whether the metal will decarburize or carburize. It is the backbone of carburizing and hardening and all of its derivative processes. The topic of carburization and its derivative processes is reserved for articles far beyond the space allotted and the scope of this article on the Ellingham diagram. There is far more to consider than merely plotting the equilibrium value for the CO/CO2 ratio. In these systems, we are often interested in depth of the carbon in the iron, activities, diffusion rates, time at temperature, degree of surface oxidation and its removal, carbon concentration profiles, avoiding intergranular oxidation (IGO), etc. to name but a few variables. However, we can get a rough idea of what the equilibrium ratio should be so that conditions can be set to promote deliberate decarburization in the case of electrical steels. In the case of 58 April 2011 - IndustrialHeating.com

carburization of steel, we can at least see what equilibrium ratio we must roughly exceed to cause the carburization process to occur. Summary Harold Ellingham’s work made clearer and more accessible, in an easy-tounderstand graphical format, the wellknown concepts of standard free energy with respect to temperature for reactions like the formation of oxides, sulfides and chlorides. In the case of his metal and metal-oxide diagram, by normalizing the thermodynamic functions to reaction with one mole of oxygen, Ellingham was able to compare the temperature stability of many different oxides on the same diagram. The result was his relatively easy-to-use Ellingham Diagram to determine reduction and oxidation conditions without resorting to painstaking efforts to interrelate all metal systems’ free-energy-based calculations from scratch. The addition of the original nomograph tool that plots, in a continuous scale, the values of PO2 for ease of calculation by the user is the work of F. D. Richardson and Jeffes. Since CO/CO2 and H2/H2O ratios are often used in conjunction with determining equilibrium partial pressure of oxygen, L.S. Darken and R.W. Gurry added their calculations as nomograph scales for these additional ratios. These diagrams have subsequently been referred to as Ellingham, Ellingham-Richardson, Darken and Gurry, or modified Ellingham diagrams. IH For more information: Contact Michael J. Stempo, P.E., business development/applications engineering, Air Liquid Industrial U.S. LP, 2700 Post Oak Blvd., Suite 1800, Houston, TX 77056; tel: 610-997-0936; fax: 713-803-7344; e-mail: [email protected]; web: www.us.airliquide.com

Use this Mobile Tag to go to a printable copy of the Ellingham Diagram. You can also use www. industrialheating.com/diagram

From Aug. 1977

Phone: 717-272-3051 www.hauckburner.com

This Vintage Cover shows a single high-velocity burner from Hauck Manufacturing Co. firing natural gas (above) and oil (below) at approximate stoichiometric fuel/air ratio. Contact Hauck Mfg. Co. at: P.O. Box 90, Lebanon, PA 17042 Phone: 717-272-3051 E-mail: [email protected] www.hauckburner.com

FEATURE | Materials Characterization & Testing

Practical Applications of Computational Thermodynamics and Kinetics to Heat Treatment

Microstructure courtesy of George F. Vander Voort (www.georgevandervoort.com)

Paul Mason – Thermo-Calc Software Inc.; McMurray, Pa. In his 100 th Heat Treat Doctor column, Dan Herring stated that heat treating can best be defined as “the controlled application of time, temperature and atmosphere to produce a predictable change in the internal structure (i.e. the microstructure) of a material.” He went on to add that “metallurgists are responsible to predict the microstructural changes that will occur in a component.”

CALPHAD – A Basis for Computational Thermodynamics and Kinetics Computational thermodynamics, specifically the CALPHAD (Computer cALculation of PHAse Diagrams) approach,[1] allows for the prediction of the thermodynamic properties of multicomponent, multiphase systems based on mathematical models that describe the Gibbs energy as a function of temperature, pressure and composition for each individual phase in a system. Parameters in the numerical models capture the composition and temperature dependence in binary and ternary systems and are optimized in order to best correspond to the experimental data available. Two benefits of this approach are that it ties together both thermodynamic properties and phase equilibria in a selfconsistent framework, and it allows for the extrapolation to multicomponent systems based on data obtained from binary and ternary systems. The advantage of this is that data are not fitted to specific alloys of a nominal composition but are calculated for a specific user-defined input chemistry. For more than 25 years, the CALPHAD method has been successfully applied by industry to assist in alloy design and process optimization for different alloy types including steels and ferrous-based

alloys, Ni-Superalloys, Al, Ti, Mg, etc. The CALPHAD approach has also been extended to modeling other properties, such as atomic mobilities, which enable diffusion coefficients as a function of temperature and local compositions to be derived and allow the time dependence of phase transformations and microstructural evolution to be predicted. Thermo-Calc – Thermodynamic Modeling and Phase Equilibria Thermo-Calc[2] is a software package for performing thermodynamic calculations for multicomponent systems and is used in conjunction with thermodynamic databases produced using the CALPHAD method. Databases are available for gas-phase calculations, steels, Ti, Al, Ni-superalloys and other materials. Thermo-Calc enables users to predict phases formed for equilibrium and metastable equilibrium conditions based on the composition of the system, temperature and pressure. Thermo-Calc is a very general tool, and it is not possible to cover the full range of applications here. However, some examples specifically of interest to the heat-treat community are described in the following subsections.

from the September 2010 issue of Industrial Heating by Winter and Torok[3] highlighted some different potentials that heat treaters need to control for a nitriding/nitrocarburizing treatment (Table 1). Each of these partial pressures, potentials and activities can be directly calculated from ThermoCalc using a database such as the SGTE Substance database.[4] Table 1. Potentials by process[3] Activity to potential

Partial pressure

Process

aN=K1*KN

KN=pNH3/p1.5H2

Nitriding

aC=K2*KCB

KCB=p2CO/pCO2

aC=K3*KCW

KCW=pH2*pCO/pH2O

aC=K4*KC-O2

KC-O2=pCO/p0.5O2

aC=K5*KC-CH4

KC-CH4=pCH4 /p2H2

aO=K6*KO

KO=pH2O/pH2

Nitrocarburizing

Oxi-nitriding/ postoxidizing

1.0 0.9 0.8

T-273.15, (BCC_A2) T-273.15, (FCC_A1#2) T-273.15, (M23C6) T-273.15, (M6C) T-273.15, (FCC_A1#1) T-273.15, (Liquid)

0.7 0.6 NPM

T

h article describes how comphis utational thermodynamics and u kinetics can assist the metallurk gist in making such predictions. g

0.5 0.4 0.3 0.2 0.1

Gas-Phase Equilibria – Furnace Atmosphere Thermo-Calc can be used to predict the activities, potentials and speciation of gasphase systems as a function of composition, temperature and pressure. An article

0 600

800

1000 1200 Temperature, ˚C

1400

Fig. 1. Influence of temperature on phases formed for an M42 tool steel (NPM is the numeral of moles of a phase normalized to one mole.) IndustrialHeating.com - April 2011 61

FEATURE | Materials Characterization & Testing

the influence of this on their properties is another aspect that can be investigated. It can be difficult and time consuming to characterize an alloy completely, especially in terms of the tail effects attributed to the variation of alloy composition. Computationally, one can investigate this in a time-efficient and cost-effective manner. For example, the temperature where sigma phase first appears for SAF 2507 is calculated as 1030°C (1886˚F) for the nominal chemistry, but with a possible range of ±60°C due to the variation in chemistry within its specified range. Multicomponent phase diagrams (isothermal and isoplethal sections) can also be constructed for alloys, beyond binary and ternary systems. Figure 2 shows an isoplethal section for an M42 tool steel. Furthermore, so called Lehrer diagrams, which show what type of compound layer to expect for the respective nitriding potentials controlled in the furnace, can also be calculated not just for pure iron but for multicomponent alloys as well. The Center for Heat Treating Excellence (CHTE) at Worcester Polytechnic Institute has calculated the diagram in Figure 3 for AISI 4140 steel[5] using Thermo-Calc. The examples given so far have all been related to steels, but heat treatment for other alloys, such as Al, Ni and Ti, can also be modeled using such tools. For example, Gupta et al[6] compared calculations made

Alloy Chemistry – Phase Equilibria Predictive calculations can also be made to see how the phases, the amounts of each phase and their composition vary with temperature or chemistry for a given alloy. For example, Figure 1 illustrates the phases that can form as temperature is varied for an M42 tool steel. Such calculations can be useful not only for alloy design but also for predicting whether deleterious phases could form prior to a heat treatment. This is based on the actual measured chemistry of a heat rather than discovering the phase during metallographic examination after the heat treatment has been performed. The formation of certain phases can be extremely sensitive to alloy chemistry, even those that are within the specified range of composition. Therefore, these types of calculations (when combined with the metallurgist’s experience) can be useful in deciding whether to take mitigating actions prior to the heat treatment. Such calculations can be especially useful when heat treating alloys of unfamiliar specifications in order to understand the alloys much better. Also, these step calculations can predict phase-transformation temperatures based on the actual (not nominal) chemistry (e.g., Aecm, Ae1, Ae3) and, thus, provide information on the solution temperatures of the precipitates. Compositional variation of alloys and 1500

DICTRA – Diffusion-Controlled Simulations DICTRA[2] is a software package for accurate simulations of diffusion in multicomponent alloys. It is a general 1-D code and can treat diffusion-controlled phase transformations (moving boundary problems), diffusion in one-phase systems and reactions in dispersed systems. The code cannot, however, treat diffusionless transformations such as martensitic transformations. DICTRA uses thermodynamic data obtained from Thermo-Calc and atomic mobilities derived using a CALPHAD approach based on the critical evaluation of experimental diffusion data for binary and ternary systems. Two examples using DICTRA are given here – carburizing and homogenization – and other illustrations are available in the literature of nitriding, nitrocarburizing, post-weld heat treatment, etc. Carburizing Since DICTRA considers fully coupled calculations between the thermodynamics of the system and the kinetics, it is possible to investigate the influence of the alloying chemistry on the diffusion coefficients (e.g., carbon) in the alloy.

10-1

Liquid

BCC_A2

1400

using Thermo-Calc with experimental observations for automotive alloy AA6111, which is a commercial sheet alloy.

hcp+fcc1 1300

BCC_A2 + M6C

1100

BCC_A2+ FCC_A1 + M6C

100 FCC_A1 + MC + M6C

hcp: ¡ Fe4N: av bbc: _ fcc1: (Fe0.63Cr0.36)1(N,Va)1 fcc2: (Cr0.57Fe0.25Mo0.16)1(N)1

Fe4N+hcp+fcc1

KN

Temperature, ˚C

1200

hcp

1000

Fe4N+hcp+fcc1+fcc2 FCC_A1+MC + M6C + M7C3

900 800

bcc+hcp+fcc2+Fe3C

BCC_A2 + Laves + M6C

700

BCC_A2 + MC + M23C6 + M6C

bcc+fcc2+Fe3C

600 0

0-1

0.5

1.0 Carbon, mass %

Fig. 2. Calculated isoplethal section for M42 tool steel

62 April 2011 - IndustrialHeating.com

1.5

0-2

450

500

550

600 650 Temperature, ˚C

Fig. 3. Calculated Leher diagram for AISI 4140 steel[5]

700

750

Ask the Expert 0.9

0.40

0.8

0.35

0.6

f = 9.1 • 10-9 [m/s] acgas = 0.67

Fraction of carbide

Carbon, wt. %

0.7

0.5 0.4 0.3

4 hr 1 hr

after 2.5h M7C3

0.25 0.20 0.15 0.10

cem M23C6

0.05

0.2

30 min 0.1 0.0 0.4 0.8 1.2 1.6 Distance from surface, mm

0.30

2.0

Fig. 4. AISI 1018 steel carburized at 899°C

However, DICTRA can also be used to predict the diffusion of carbon into an alloy directly. Boundary conditions can be defined as either the activity of the diffusing species at the surface, which can be predicted by Thermo-Calc, or the flux, which takes into consideration the mass transport of the diffusing species at the surface. Figure 4 illustrates a calculation of the carburization of AISI 1018 at 899°C (1650˚F). For highly alloyed steels, gas carburizing results in the formation of chromium-rich carbides that cause precipitation hardening in the surface. The precipitation of these carbides results in a decrease of chromium in the matrix phase, however, which has a detrimental effect on the corrosion resistance of the alloy. A compromise, therefore, needs to be made in order to maintain good corrosion resistance in the carburized layer. Traditional methods to balance these objectives have been by experiment only, but computational tools that enable a number of parameters involved in the carburizing process to be assessed (such as alloying elements, temperature, carbon flux, etc.) offer alternatives to this approach. Turpin et al[7] have used Thermo-Calc and DICTRA to optimize an alloy chemistry and heat treatment for martensitic steel. Figure 5 illustrates the simulated growth and dissolution of such carbides as a function of time and distance for an alloy with the composition Fe-13Cr-5Co-3Ni2Mo-0.07C. Homogenization Many Ni-based superalloy castings and ingots are given homogenization treatments

Tom Philips Senior Applications Engineer

0.0 0.0

0.2 0.4 0.6 0.8 Distance from surface, mm

1.0

Fig. 5. Predicting the amount and types of carbides that will form in Fe-13Cr-5Co-3Ni2Mo-0.07C

prior to further processing or hot working in order to evenly distribute the alloying elements throughout the microstructure. Jablonski and Cowen[8] used the Scheil model of Thermo-Calc to predict the ascast segregation present within Nimonic 105 and then used DICTRA to refine the homogenization treatment of this alloy. Confirming their conclusions with experimental studies, they were able to propose an alternative two-step heat-treatment schedule that resulted in better solute redistribution and reduced heat-treatment times, potentially leading to significant time and cost savings. Samaras and Haidemenopoulos [9] made a similar study of the microsegregation and homogenization of 6061 extrudable Al alloy. Conclusions The use of computational thermodynamics and kinetic simulations are well established in the areas of alloy design and process optimization. Predictive calculations can complement the experience and understanding of the metallurgist or R&D engineer, provide a deeper understanding of the chemical behavior of both known and new alloys, and can lead to time and cost reductions through a better understanding of the science behind the alloys and processes. IH For more information: Contact Paul Mason, Thermo-Calc Software Inc., 4160 Washington Road, Suite 230, McMurray, PA 15317; tel: 724731-0074; fax: 724-731-0078; e-mail: paul@ thermocalc.com; web: www.thermocalc.com

References available online

Q

What are the recommended procedures to safely introduce a flammable atmosphere into a continuous belt furnace?

A

For sintering and brazing atmospheres in a continuous belt type furnace with open ends, you must follow NFPA 86 Standard for Ovens and Furnaces. Typically, atmospheres containing greater than 4% hydrogen in nitrogen are considered flammable. In fact, any mixed atmosphere—even if it contains less than 4% hydrogen—is considered “indeterminate” and must be treated as if it were flammable. NFPA 86 recommends you satisfy the following conditions before introducing any flammable or indeterminate atmosphere is into the furnace: • At least one zone of the furnace must be hotter than 1400ºF. • The furnace must be purged with an inert gas until the atmosphere analysis indicates it’s below 50% of its LEL (lower explosive limit). General recommendation is to use five volume changes of inert gas flow. • There must be visible indication of purge flow. Plus, purge piping should have normally open solenoid valves. • The atmosphere system should be designed with interlocks so the flammable gases are shut off using normally closed solenoid valves in the event of power failure, a temperature drop below 1400ºF, or insufficient flow of the main atmosphere component. For a copy of our paper about the impact of temperature on flammability limits and furnace safety, visit www.airproducts.com/limits2 or call us at 800-654-4567 (mention code 851).

tell me more www.airproducts.com/metals © Air Products and Chemicals, Inc., 2011 (33426) J53

IndustrialHeating.com - April 2011 63

Industrial Heating is the Official North American Media Co-Sponsor of THERMPROCESS 2011

THERMPROCESS 2011 – 10th International Trade Fair and Symposium for Thermo Process Technology When: June 28-July 2; 9 a.m. to 6 p.m. daily Where: Düsseldorf Fairgrounds, Düsseldorf, Germany

T

h world’s largest thermal-processing show only comes he aaround once every four years. In 2007, 289 exhibitors aand more than 7,000 visitors took part in THERMPROC CESS. The event hopes to see an increase in both of h numbers b this year. THERMPROCESS exhibits will feature: those • Industrial furnaces, industrial heat-treatment plants and thermal processes • Equipment for special use • Components, equipment and other supplies • Occupational safety and ergonomics • Consulting, design, service and engineering • Trade associations and magazines • Training and education THERMPROCESS won’t be the only show in town. The Düsseldorf Fairgrounds will also host concurrently held fairs GIFA 2011 (12th International Foundry Trade Fair), METEC 2011 (8th International Metallurgical Technology Trade Fair) and NEWCAST 2011 (3rd International Trade Fair for Precision Castings). The

HELPFUL THERM PROCESS TIPS 64 April 2011 - IndustrialHeating.com

trade-fair quartet will present the entire value chain and offer international buyers, end users and industry leaders an important meeting platform. The shows will be accompanied by top-quality support programs featuring numerous seminars, international congresses and lecture series. In response to global climate change, trade-fair organizer Messe Düsseldorf has launched a campaign, “ecoMetals – Efficient Process Solutions,” for its quartet of shows. THERMPROCESS, GIFA, METEC and NEWCAST will highlight the trend toward higher environmental awareness, and exhibitors will present new developments in energy and resource efficiency. A special “ecoMetals” logo on their booths will identify participating exhibitors. Entrance passes are available in advance of the show online at www.thermprocess-online.com at reduced rates. A new feature for 2011 is the eTicket, which can be printed at home or be bought online during the trade fair to allow for last-minute planning. The eTicket also allows free use of all public transportation within the Rhine-Ruhr regional network (VRR) of Düsseldorf during THERMPROCESS 2011 to and from the show. One entrance pass, which can also be purchased on-site, allows admission to all trade fairs. For more information on the show(s), contact Messe Düsseldorf North America at 312-781-5180 or www.mdna.com. For hotel and/or travel information, contact TTI Travel at 866-6743476 or www.travel tradeint.com.

1

PUBLIC TRANSPORTATION is recommended to get to the fairgrounds. From downtown Düsseldorf, Tram No. U78 goes to the North Entrance, Tram No. U79 to the East Entrance and Bus No. 722 serves the East and South Entrances. From the airport, Bus No. 896 connects to all fairgrounds entrances.

2

TAXI FARES are made up of a basic flat rate plus a charge per kilometer; fares are generally higher than in the U.S. For tips, round up to the next full Euro amount (maximum 10%). Taxis must be boarded at taxi stands.

IHEA’s Resource Center at THERMPROCESS IHEA, in cooperation with Industrial Heating, is hosting a 48-square-meter Resource Center for the benefit of IHEA members and other thermal-processing companies that choose to participate at THERMPROCESS 2011. There are over a dozen IHEA member companies exhibiting at either THERMPROCESS or concurrent events METEC, GIFA and NEWCAST. Companies participating in the Resource Center will receive the following benefits, dependent upon their level of participation: • Access to food and beverages/refreshments throughout the week • Access to translation services • Access to private meeting rooms located in the Resource Center • Access to a presentation screen and scheduled presentation times that will be promoted by the Resource Center • Display of company literature and company logo within the Resource Center • Assistance with show vendors, shipping, housing and any other advice needed for conducting business internationally The Resource Center’s objective is to help small and mid-size companies have a more profitable and pleasurable exhibiting experience. The Resource Center will assist participating companies spend more time selling and less time worrying about logistics.

The following advertisers in this issue are exhibiting at THERMPROCESS 2011: Company

Booth #

Ad on page #

AFC-Holcroft

09 E03

28-29

Ajax Tocco Magnethermmic

10 G23

11

Bloom Engineering

09 C57

67 (vintage)

Dry Coolers

09 D17

48

Hauck Mfg. Co. (Elster)

09 D22

40

Inductoheat

10 B24

Back Cover

Inductotherm Group

10 B24

42

Industrial Heating

09 C12

93

IHEA

09 C12

26

MERSEN

09 C38

15

Selas Heat Technology Co.

09 D11

53

SGL Carbon Group

10 A38

35

Surface Combustion

09 F46

6

Unifrax

09 C28

17

3

RENTAL CARS are available from Autohansa, Avia, Europcar, Hertz, Sixt-Budget and other companies. Offices are located at the Düsseldorf airport, the main train station and several downtown locations. On the main streets in Düsseldorf, “Messe Düsseldorf” signs show the way to the fairgrounds, and parking signs will lead to one of the fairgrounds’ 12 parking lots.

4

THE KATI COMPUTERIZED CATALOG display system makes it easy to find the location of every exhibitor and product category. KATI terminals are located in every hall.

5 6 7

THE EXHIBIT HALLS are linked by protected walkways, moving sidewalks and shuttle buses. LOCATED IN THE MIDDLE OF THE FAIRGROUNDS is a food store, hardware store and telecommunication store as well as a post office, bank and travel agency. IMPORTANT GERMAN SIGNS at the fairgrounds and their English translation: Messe = Fairgrounds; Eingang = Entrance; Ausgang = Exit; Notausgang = Emergency exit; WC = Restroom IndustrialHeating.com - April 2011 65

HALL OF INNOVATORS Industrial Heating celebrates its 80th Anniversary with a dedication to the following innovators, who have made significant contributions to the thermal-processing industry. They leave a legacy through their experience, enthusiasm and unwavering commitment. Wally Bamford P. Eng, FASM Submitted by Can-Eng Furnaces Wally Bamford founded Can-Eng Furnaces in 1964. Through his leadership, he brought successful and innovative thermal processing equipment to the many industries Can-Eng serves, including Fluidized Bed Furnaces, High-efficiency Continuous Porcelain Enameling Furnace Systems, Continuous Mesh Belt Furnace Systems and Basketless Aluminum Heat Treating Systems. Wally Bamford was a Board Member and the first International President of the Metal Treating Institute and a founding Board Member of the ASM Heat Treating Society.

Harold Ipsen 1916-1965 Submitted by Ipsen Inc. In 1948, the Ipsen’s owned a pottery business. When their kiln furnace failed, Harold Ipsen decided to build his own, incorporating his experiences as a heat treater. From this start, Harold founded Ipsen Industries to provide atmosphere and vacuum equipment with features and performance that have defined our industry. Harold Ipsen held more than 30 patents, and the tradition of innovation he started more than 60 years ago continues today.

William R. Keough Submitted by AFC-Holcroft William R. Keough started Atmosphere Furnace Company (now AFCHolcroft) in 1962 along with CAPCO, a commercial heat-treating shop specializing in the austempering process. The two businesses expanded and evolved, becoming AFC-Holcroft, Austemper Inc., Atmosphere Heat Treat and the Applied Process Group. Keough obtained numerous patents during his long professional career. He was honored as an “Industry Legend” by the Metal Treating Institute and received the Shoemaker Award from ASM’s Detroit Chapter.

66 April 2011 - IndustrialHeating.com 66 April 2011 - IndustrialHeating.com

Jack Beavers 1931-1983 Submitted by BeaverMatic, Inc. Innovator and entrepreneur, Jack Beavers is most recognized for his design of the exterior transfer system that is easily accessible for maintenance and provides precision transferring of loads with a pull-push RAM mechanism. Utilizing his knowledge and experience as a maintenance man, Beavers was given the opportunity to design and build the transfer system he envisioned. This exterior transfer system consists of rams, hooks and tails, which have been closely associated with Beavers and his successful BeaverMatic internal-quench furnace design.

William R. Jones Submitted by the Solar Group of Companies William R. Jones has over 45 years of experience in the fields of vacuum furnace design and vacuum processing. He has written many technical publications on vacuum technology and holds 15 patents on various aspects of furnace designs. He served as president of Abar Corp. in the early 1970s, and in 1978 he founded Vacuum Furnace Systems (VFS). In 1982, he founded Solar Atmospheres, which has grown to be the largest privately owned commercial heat-treating group in the U.S. In 2002, he added Solar Manufacturing to the group to provide advanced vacuum furnace designs and equipment for the heat-treating industry.

Stan Matys 1929-2011 Submitted by I Squared R Element Co. Stan Matys, an MIT graduate with a degree in engineering, was a genius, an innovator, an entrepreneur and the co-founder of I Squared R Element Co. Matys invented the SiC hot surface igniter and the SiC spiral element process that is used to produce the best heating element in the world. He developed the process in 1961, and it is still used today in manufacturing industries in the U.S., China, Japan and Scotland.

Charles (Chuck) Taylor McClelland 1924-2005 Submitted by Industrial Heating Chuck McClelland was past owner, editor and publisher of Industrial Heating. After serving in World War II, he earned a journalism degree from Penn State University. McClelland worked for Loftus Engineering and Research Cottrell prior to taking over as editor and publisher of Industrial Heating in 1972. He focused on establishing relationships with heat treaters and equipment manufacturers and strived to provide readers with the most up-to-date information. Perhaps his greatest accomplishment was making the magazine a truly international publication by traveling extensively to trade shows around the world and translating Industrial Heating into Chinese. Known for his thought-provoking and humorous editorials, McClelland’s last issue was September 1988.

John C. “Charlie” McMullen Submitted by Unifrax I LLC Charlie McMullen was a research scientist for The Carborundum Company Fibers Division, which later became Unifrax. In 1942, he invented a revolutionary ceramic fiber that was trademarked under the Fiberfrax® name. Today, McMullen’s spirit of innovation continues at Unifrax, where Fiberfrax ceramic-fiber products are manufactured in over 50 product forms that provide a wide variety of high-temperature solutions for industries throughout the global market.

Henry M. Rowan Submitted by Inductotherm Group Henry M. Rowan is founder and chairman of Inductotherm Group, the world’s largest designer and manufacturer of systems for the thermal-processing industry, including induction melting, heattreating, vacuum melting and welding equipment. Rowan built Inductotherm’s first melting furnace in his backyard in 1953. From that modest beginning, Inductotherm, and now Rowan Technologies, has become a global industrial corporation with companies and customers around the world.

May 1962 For more than 75 years, Bloom Engineering Co. has worked to provide innovative solutions to customers’ energy problems. The processes may have changed, but the company’s focus remained the same. Today, with headquarters in Pittsburgh, Pa. – and offices in Shanghai, China; Dusseldorf, Germany; Sao Paulo, Brazil; Pune, India; and Moscow, Russia – Bloom Engineering’s traditional engineered problemsolving approach now reaches globally. Contact your local Bloom Engineering representative to find out how the company can solve your energy and environmental issues. www.bloomeng.com Established: 1934

IndustrialHeating.com - April 2011 67 IndustrialHeating.com - April 2011 67

1936

ANNIVERSARY LOGOS In celebrating our 80th Anniversary, Industrial Heating would also like to commemorate the long history of the following companies. This sampling of historic and current logos shows the longevity of the thermal-processing industry. Each logo, arranged by year established, includes a website for more information. 1882

1937

1916 BUILT BY

2010

www.whkay.com

www.fireye.com 1947

1962

instruments international

www.taylor-winfield.com

www.afc-holcroft.com

www.landinstruments.net

1896

1936

1948

www.belmontmetals.com 1999 1896

1986

www.selas.com 1902

2011 2010

www.honeywell.com www.varianinc.com 1908 1948

www.eclipsenet.com

www.buehler.com 1936

1915 1985

www.surfacecombustion.com

68 April 2011 - IndustrialHeating.com 68 April 2011 - IndustrialHeating.com

www.leco.com

www.ipsenusa.com

MADE IN THE U.S.A. SINCE 1965 BUILD IT WITH NEWPORT® NEWPORT began manufacturing electronic instrumentation in 1965 and quickly earned a reputation for designing and building the world’s most accurate industrial instrumentation. The award-winning NEWPORT i®Series Controllers, Panel Meters, and Signal Conditioners connect directly to an Ethernet network and can send and receive data in standard TCP/IP packets over the LAN and the Internet. The new NEWPORT wiSeries wireless transmitters let you record data and view readings and charts over an Ethernet network or the Internet without any special software—just your Web Browser. QUALITY The NEWPORT® line of signal conditioners, transmitters, controllers and meters offers state-ofthe-art technology, uncompromising accuracy, and quality backed by the best warranty in the business. NEWPORT® devices cover the broadest selection of signal inputs including: process/DC voltage & current, strain, temperature from thermocouples, RTD’s, and non-contact infrared detectors, frequency, pulse, AC voltage & current, analytical measurements including pH, and much more. CUSTOM ENGINEERING NEWPORT custom engineers hardware, software and firmware for OEM applications. From simple modifications of existing products to custom designed instruments and systems.

NEWPORT instruments are designed and manufactured in the U.S.A.

newportUS.com® 2229 South Yale Street • Santa Ana, CA 92704-4401 e-mail: [email protected] ©COPYRIGHT 2011 NEWPORT ELECTRONICS, INC. ALL RIGHTS RESERVED.

1954

1973 197 9 3

2002

www.wisoven.com

www.solarmfg.com

1976

2004

1960

www.AQIEng.com

1962

2005 www.inductiontooling.com 1998

1976

www.steeltechltd.com www.nova-gas.com www.centorr.com 1980

History of the Industrial Heating logo 1931

11956 195 6

www.exergen.com

1983 2001

www.alliedhightech.com www.inductotherm.com

1934

1985

1958

www.drycoolers.com www.cec-intl.com

1977

1986

1971 1971

1993 www.techinduction.com

www.beavermatic.com

70 April 2011 - IndustrialHeating.com

1996

2000

www.unifrax.com

www.industrialheating.com

From August 1982

Phone: 248-624-8191 www.afc-holcroft.com

From Feb. 1985

Phone: 856-829-2000 www.tmvacuum.com

Company Listings AFTERMARKET DIRECTORY 3T True Temperature Technologies - Buehler, A Div. of Illinois Toolworks Inc.

Alphabetized Company Listings

W

e elcome to Industrial Heating's 2011 Aftermarket D Directory - a comprehensive look at post-sale parts a services. This thorough resource is split into and two easy-to-use sections. The first directory, Company Listings (pages 73-76), contains an alphabetized list of companies. Here you will find a number of businesses that specialize in aftermarket assistance. The second directory, Capabilities Listings (pages 7881), details the capabilities of the previously listed companies. The purpose of this Aftermarket Directory is simple - Industrial Heating wants you to be able to find who and/or what you need to get your equipment up and running properly ... and in a timely manner. Take advantage of this two-part directory now. This directory is also available at www.industrialheating.com/ aftermarket.

Abell Combustion Inc. Kimberton, PA (610) 827-9137 www.abellcombustion.com

-Agilent Technologies (formerly Varian Inc.), Vacuum Products Lexington, MA www.agilent.com/chem/vacuum (800) 882-7426 Fax: (781) 860-5437 Steve Palmer SEE OUR AD ON PAGE 21

Ace Industrial Mfg. Temecula, CA; (951) 302-2212 www.aceindustrialmanufacturing.com Penn Lenson, Pres.

Air & Energy Systems Inc. Matthews, NC; (704) 814-9221 www.airandenergyinc.com Bill Dudley, Pres.

Advanced Cerametrics Inc. Lambertville, NJ; (800) 261-1208 www.advancedcerametrics.com

Ajax Electric Co. Huntingdon Valley, PA; (800) 516-9916 www.ajaxelectric.com; John Barry, Pres.

Advanced Heat Treat Corp., Plant 1 Waterloo, IA; (319) 232-0745 www.ahtweb.com

Ajax TOCCO International Birmingham ENGLAND, U.K. 44 (0)121 3228000 www.ajaxtocco.co.uk

3T True Temperature Technologies Misgav ISRAEL; 972-4-9990025 www.accuratesensors.com

Advanced Heat Treat Corp. Monroe, MI; (734) 243-0063 www.ahtweb.com Advanced Heat Treat Corp. Waterloo, IA (319) 232-5221 www.ahtweb.com Mikel Woods, Sales/Mktg. Dir. Aero SPC Inc. Greer, SC; (216) 401-6200 www.aerospc.com Carolyn Deans, Nadcap Advisor AFC-HOLCROFT Wixom, MI www.afc-holcroft.com (248) 624-8191 Fax: (248) 668-9604 SEE OUR AD ON PAGES 28-29

-Ajax TOCCO Magnethermic Warren, OH www.ajaxtocco.com (330) 372-8511 Fax: (330) 372-8608 Tom Elson, Natl. Sales Mgr. SEE OUR AD ON PAGE 11 Ajax TOCCO Magnethermic Nanhui Indl. Zone, Shanghai CHINA www.ajaxtocco.com 86 21 68009546 Fax: 86 21 68009542 SEE OUR AD ON PAGE 11 Ajax TOCCO Magnethermic North Canton, OH www.ajaxtocco.com (330) 818-8080 Fax: (330) 818-8085 Dave Dicola, V.P., Aftermarket SEE OUR AD ON PAGE 11

Ajax TOCCO Magnethermic Koto-Ku, Tokyo JAPAN www.ajaxtocco.com 81 3 3647 7661 Fax: 81 3 3647 7662 Dave Dicola, V.P. Aftermarket SEE OUR AD ON PAGE 11 Ajax TOCCO Magnethermic Canada Ltd. Ajax, ON CANADA www.ajaxtocco.com (905) 683-4980 Fax: (905) 683-6550 Dave Dicola, V.P., Aftermarket SEE OUR AD ON PAGE 11 Ajax TOCCO Magnethermic Corp. Wickliffe, OH; (440) 833-0386 www.ajaxtocco.com Dave Dicola, V.P. Aftermarket Ajax TOCCO Magnethermic Corp. Madison Heights, MI www.ajaxtocco.com (248) 399-8601; (800) 547-1527 Fax: (248) 399-8603 SEE OUR AD ON PAGE 11 Ajax TOCCO Magnethermic Corp. Longview, TX; www.ajaxtocco.com (903) 297-2526 Fax: (903) 297-1547 Dave Dicola, V.P., Aftermarket SEE OUR AD ON PAGE 11 Ajax TOCCO Magnethermic Corp. Queretaro, El Marques, QRO CP 76246 MEXICO www.ajaxtocco.com 011-52-442-221-5415 Fax: 011-52-442-221-5090 Dave Dicola, V.P. Aftermarket SEE OUR AD ON PAGE 11 Ajax TOCCO Magnethermic Corp. Boaz, AL www.ajaxtocco.com (256) 593-7770; (800) 547-1527 Fax: (256) 593-4735 SEE OUR AD ON PAGE 11 Alcon Industries Inc. Cleveland, OH; (216) 961-1100 www.alconalloys.com Kurt Shubert, Sales Engr.

Alloy Engineering Berea, OH; (440) 243-6800 www.alloyengineering.com Patt Cretu-Ball, Sales/Mktg. Mgr. Alpha 1 Induction Service Center Columbus, OH www.alpha1induction.com (800) 991-2599; Fax: (614) 253-8981 Gil Traverse SEE OUR AD ON PAGE 58 American Isostatic Presses Inc. Columbus, OH; (800) 375-7108 www.aiphip.com; Michael Neer, Gen. Mgr. Applied Ceramics Inc. Doraville, GA; (678) 735-4925 www.appliedceramics.com Sean McDevitt, Sales Engr. ARCADIS US Inc. Indianapolis, IN; (317) 632-0520 www.arcadis-us.com Ashly Insco, CHMM/Principal ASCO Valve Inc. Florham Park, NJ; (800) 972-2726 www.ascovalve.com Atmosphere Recovery Inc. Eden Prairie (Minneapolis), MN; (952) 941-6500 www.atmrcv.com Axim Mica Inc. New Hyde Park, NY; (516) 233-2237 www.aximmica.com BeaverMatic Inc. Rockford, IL www.beavermatic.com (815) 963-0005; Fax: (815) 963-5673 Kary Peterson, Pres. SEE OUR AD ON PAGE 10 Blackhawk Combustioneering Ltd. Hamilton, ON CANADA (905) 547-5757 www.blackhawkcombustion.com Blasdel Enterprises Inc. Greensburg, IN; (812) 663-3213 www.blasdel.net; Bill Blasdel Blastcrete Equipment Co. Aniston, AL; (256) 235-2700 www.blastcrete.com

ALD-HOLCROFT Wixom, MI; (248) 668-4130 www.ald-holcroft.com Jody Page, Aftermarket Sales

Bloom Engineering Co. Inc. Pittsburgh, PA; (412) 653-3500 x3278 www.bloomeng.com John Dormire, V.P. Sales

Alhern-Martin Industrial Furnace Co. Troy, MI; (248) 689-6363 www.alhern-martin.com James B. Van Etten, V.P.

Buehler, A Div. of Illinois Toolworks Inc. Lake Bluff, IL; (847) 295-6500 www.buehler.com David Rollings, V.P. Sales

Parts z Service z Rebuilds z Retrofits z Burners Elements z Combustion Controls z Control Panels Thermal Profiling z Waste Heat Recovery Energy Recovery Systems z Electric to Gas Conversions t: 905-356-1327

f: 905-356-1817

e: [email protected]

www.can-eng.com

-Find more information on these companies at www.industrialheating.com/aftermarket

IndustrialHeating.com - April 2011 73

Company Listings AFTERMARKET DIRECTORY Can-Eng Furnaces - Induction Tooling Inc. Electronic Development Labs Inc. Danville, VA; (800) 342.5335 www.edl-inc.com Jean Moore, Sales Mgr.

Great Lakes Industrial Solutions Inc. Brunswick Hills, OH; (330) 635-0272 www.greatlakesindustrialsolutions.com Jason L. Gillis, Pres.

Elnik Systems, PVA MIMtech LLC Cedar Grove, NJ; (973) 239-6066 www.elnik.com Claus J. Joens, Pres.

Grieve Corporation Round Lake, IL; (847) 546-8225 www.grievecorp.com Frank Calabrese, V.P. Sales

Enterprise Equipment Co. Detroit, MI; (313) 366-6600 www.eecoinc.com Tim Manor, V.P.

Harper International Lancaster, NY; (716) 684-7400 www.harperintl.com Tom O'Connor, After Market Mgr.

Epcon Industrial Systems LP The Woodlands, TX; (936) 273-3300 www.epconlp.com Nedzad Hadzajlic, Engr.

Harrop Industries Inc. Columbus, OH; (614) 231-3621 www.harropusa.com Daniel O'Brien

Delta Cooling Towers Rockaway, NJ; (973) 586-2201 www.deltacooling.com

ETS Schaefer Corp. Macedonia, OH; (800) 863-5400 www.etsschaefer.com Dennis Guilmette, Sales/Mktg. Mgr.

Demtrol Systems Div. Hartland, WI; (262) 367-7548 Rande Ziman, Sales Eng.

Exergen Corp. Watertown, MA; (617) 923-9900 www.exergen.com

Hauck Mfg. Co. Lebanon, PA www.hauckburner.com (717) 272-3051 Fax: (717) 273-9882 Michael Shay SEE OUR AD ON PAGE 40

Despatch Industries Minneapolis, MN; (952) 469-5424 www.despatch.com Paula McGranahan, Sales Assoc.

Fiber Materials Inc. Biddeford, ME; (207) 282-5911 www.fibermaterialsinc.com Matt Bernier, Sr. Sales Engr.

CEIA USA Twinsburg, OH www.ceia-usa.com (330) 405-3190 Fax: (330) 405-3196 SEE OUR AD ON INSIDE BACK COVER

Dry Coolers Inc. Oxford, MI www.drycoolers.com (800) 525-8173; (248) 969-3400 Fax: (248) 969-3401 Brian Russell, Pres. SEE OUR AD ON PAGE 48

Fireye Inc. Derry, NH; (603) 432-4100 www.fireye.com John Devine, V.P. Sales/Mktg.

-Centorr Vacuum Industries Inc. Nashua, NH; (603) 595-7233 www.centorr.com Steve Hewitt, V.P. Oper.

-Duralite Inc. Riverton, CT; (860) 379-3113 www.duralite.com

Fluxtrol Inc. Auburn Hills, MI; (248) 393-2000 www.fluxtrol.com

Ceramic Solutions Inc. Conroe, TX; (936) 588-2646 www.ceramicsolutionsconroe.com

Duraloy Technologies Inc. Scottdale, PA; (724) 887-5100 www.duraloy.com Donna Manz, Cust. Serv. Mgr.

-Can-Eng Furnaces International Ltd. Niagara Falls, NY www.can-eng.com (905) 356-1327 Fax: (905) 356-1817 Kim Lamarino, Sr. Sales Rep., Parts & Service Cashvac Inc. Woodstock, IL; (815) 337-7400 www.cashvac.com; Bob Fergus Casso-Solar Technologies LLC Pomona, NY; (845) 354-2010 www.cassosolartechnologies.com Ivan Pearl, Sales Coord. Castalloy Waukesha, WI; (262) 547-0070 www.castalloycorp.com Mike Roozrokh, Dir. Sales CEA Instruments Inc. Westwood, NJ; (201) 967-5660 www.ceainstr.com Steven Adelman, V.P. Sales/Mktg. CEC Combustion Services Group, Combustion Safety Inc. Cleveland, OH; (216) 749-2992 www.combustionsafety.com Jason Safarz, Sr. Account Engr.

CFF Kilns & Furnaces, Keith Co. Pico Rivera, CA; (562) 948-3636 www.cffkilns.com Charles A. Hones, Buzzer Gas Equipment Amityville, NY; (631) 842-8886 www.charlesahones.com CLEPCO / Intelligent Heater LLC Homestead, FL; (800) 241-0412 www.intelligentheater.com Joyce Rogers, Gen. Mgr. CM Furnaces Inc. Bloomfield, NJ; (973) 338-6500 www.cmfurnaces.com -Conrad Kacsik Instrument Systems Inc. Solon, OH; (440) 836-0103 www.kacsik.com; Jacob Kacsik Consolidated Engineering Company Kennesaw, GA; (800) 486-6836 www.cec-intl.com Scott Fagan, Aftermarket Sales Mgr. Control Concepts Inc. Chanhassen, MN; (952) 474-6200 www.ccipower.com Convectronics Inc. Haverhill, MA; (978) 374-7714 www.convectronics.com Steve Becker, Gen. Mgr.

Custom Electric Manufacturing Co. Wixom, MI www.custom-electric.com (248) 305-7700 Fax: (248) 305-7705 SEE OUR AD ON PAGE 23 Dalton Electric Heating Co. Inc. Ipswich, MA; (978) 356-9844 www.daltonelectric.com DATAPAQ Inc. Wilmington, MA; (978) 988-9000 www.datapaq.com William Adaschik, Natl. Sales Mgr. Deformation Control Technology Inc. Cleveland, OH; (440) 234-8477 www.deformationcontrol.com Lynn Ferguson, Pres.

Durex Industries Cary, IL; (847) 639-5600 www.durexindustries.com Terry Smith, Natl. Sales Mgr. Dynamic Systems Inc. Redmond, WA; (800) 342-3999 www.abarcode.com -Ebner Furnaces Inc. Wadsworth, OH; (330) 335-1600 www.ebner.cc Herbert Gabriel, V.P. Sales Eclipse Inc. Rockford, IL; (815) 877-3031 www.eclipsenet.com; PJ OKeefe, Mktg. ECM-USA Inc. Kenosha, WI; (262) 605-4810 www.ecm-usa.com Dennis Beauchesne, Gen. Mgr. Edwards Vacuum Inc. Tewksbury, MA; (800) 848-9800 www.edwardsvacuum.com Eldec Induction USA Inc. Auburn Hills, MI; (248) 364-4750 www.eldec.de ELECTROHEAT Hartford, WI; (800) 925-8565 www.eheatllc.com; John Krebs, M/M

74 April 2011 - IndustrialHeating.com

Fives North American Combustion Inc. Cleveland, OH; (216) 271-6000 www.fivesgroup.com

-H.C. Starck Inc., Fabrication Products Euclid, OH www.hcstarck.com (216) 692-3990 Fax: (216) 692-0029 SEE OUR AD ON PAGE 89 Hi-Tech Furnace Systems Inc. Shelby Township, MI; (586) 566-0600 www.hi-techfurnace.com Hi-Temp Fabrication Buffalo, NY; (716) 852-5655 www.hi-tempfab.com

Fuel Applications Ltd. Hamilton, ON CANADA; (905) 525-9700 www.fuelapplications.ca

Hoffer Flow Controls Inc. Elizabeth City, NC; (252) 331-1997 www.hofferflow.com Janna Critcher, Mktg. Mgr.

Furnace Control Corp., a member of United Process Controls West Chester, OH; (513) 772-1000 www.group-upc.com

Hydro-Thermal Corp. Waukesha, WI; (262) 548-8900 www.hydro-thermal.com

Furnace Parts LLC Cleveland, OH www.furnacepartsllc.com (800) 321-0796; (216) 676-5005 Fax: (216) 676-5557 John Popovich, V.P. Sales/Mktg. SEE OUR AD ON PAGE 57 Furnaces, Ovens & Baths Clarkston, MI; (248) 625-7400 www.fobinc.com Bob Bosquez Gasbarre Products Inc., Sinterite Products St. Marys, PA; (814) 834-2200 www.gasbarre.com -GeoCorp Inc. Huron, OH; (419) 433-1101 www.geocorpinc.com James LaFollette, Sales Mgr. G-M Enterprises Corona, CA www.gmenterprises.com (951) 340-4646 Fax: (951) 340-9090 SEE OUR AD ON PAGE 19

Hyper Alloys Inc. Roseville, MI; (586) 772-0571 www.hyperalloys.com Pamela Neumann-Liedke, Pres. I Squared R Element Co. Inc. Akron, NY; (716) 542-5511 www.isquaredrelement.com Gary Schwartz, Sales Mgr. IGS Inc., Sealant Technology Div. Meadows Lands, PA (724) 222-5800 www.igscorp.com John Hulme, V.P. Sales Imtek Environmental Corporation, Odor & Pollution Control Div. Alpharetta, GA; (770) 667-8621 www.noodor.com Induction Professionals Youngstown, OH; (330) 779-3456 www.inductionprofessionals.com Tom Kearney, Gen. Mgr. Induction Tooling Inc. North Royalton, OH; (440) 237-0711 www.inductiontooling.com David Lynch, Engrg. V.P.

Bold listing indicates an advertiser in this issue

Company Listings AFTERMARKET DIRECTORY Inductoheat Inc. - Process-Electronic GmbH Inductoheat Inc., An Inductotherm Group Co. Madison Heights, MI www.inductoheat.com (248) 585-9393; (800) 624-6297 Fax: (248) 589-1062 Steve Fillip, Aftermarket Sales Dir. SEE OUR AD ON BACK COVER Industrial Furnace Interiors Inc. (IFI Inc.) Sterling Heights, MI; (586) 726-2388 www.ifi-inc.com Clyde Bennett, Gen. Mgr. Industrial Gas Engineering Westmont, IL; (630) 968-4440 www.igefans.com Dean Keal, V.P. Industrial Thermal Systems Inc. Cincinnati, OH; (800) 752-3697 www.industrialthermal.com Robb Jackson, Pres. Industronics Service Co. South Windsor, CT; (860) 289-1551 www.industronics.com Dean Hills, Member Mgr. -INEX Inc. Holland, NY www.inexinc.net (716) 537-2270 Fax: (716) 537-3218 SEE OUR AD ON PAGE 40 INFICON East Syracuse, NY; (315) 434-1100 www.inficon.com

-J. L. Becker Company Plymouth, MI www.jlbecker.com (734) 656-2000 Fax: (734) 656-2009 Dave Peterson, Sales Mgr. SEE OUR AD ON PAGE 31 JO-MAR Industries Troy, MI; (248) 588-9625 [email protected] Richard J. Roth, Pres. Keith Company Pico Rivera, CA; (562) 948-3636 www.keithcompany.com -Kleenair Products Co. Inc. Clackamas, OR; (503) 653-6925 www.kleenairusa.com Kolene Corp. Detroit, MI; (313) 273-9220 www.kolene.com Dennis McCardle, V.P.-Sales

Mid-Mountain Materials Inc. Mercer Island, WA; (800) 382-2208 www.mid-mountain.com

LECO Corporation St. Joseph, MI www.leco.com (269) 985-5496; (800) 292-6141 Fax: (269) 982-8977 SEE OUR AD ON PAGE 12

Milwaukee Technologies Inc. Milwaukee, WI; (414) 453-8111 www.brinellmachines.com Frank E. Pleili, Pres.

Linn High Therm GmbH 92275 Eschenfelden/ GERMANY; (49) 9665 9140-0 www.linn.de; Horst Linn, Pres.

Ipsen Inc., Aftermarket Support (AMS) Cherry Valley, IL www.ipsenusa.com/after market_support.shtml (815) 332-2553 Fax: (815) 332-2659 SEE OUR AD ON PAGES 25 & 34

-L & L Special Furnace Co. Inc. Aston, PA; (610) 459-9216 www.hotfurnace.com Tom Schultz, Sales Mgr. Lone Star Induction Inc. Corsicana, TX; (866) 403-5744 www.LoneStarInduction.com

Ircon Inc. Santa Cruz, CA; (831) 458-3900 www.ircon.com

Lucifer Furnaces Inc. Warrington, PA; (215) 343-0411 www.luciferfurnaces.com Larry Jones, Mgr.

Irwin Car & Equipment Irwin, PA; (724) 864-8900 www.irwincar.com David Fitzpatrick

LVR Inc. Northhampton, PA; (610) 262-1535 www.lvrinc.com Paul Ernest, V.P. Sales/Mktg.

Jackson Transformer Company Tampa, FL www.jacksontransformer.com (813) 879-5811 Fax: (813) 870-6405 William E. Terlop, Pres. SEE OUR AD ON PAGE 38

Mangold Engineering Inc. Pomona, CA; (909) 622-1091 www.mangoldengineering.com

JC Cole & Associates Inc. Epping, NH; (603) 679-2440 www.heattreatmat.com Joanne C. Cole, Pres.

Marathon Monitors (Beijing) Co. Ltd., a member of United Process Controls Beijing CHILE; +86 (10) 82770618 www.mmichina.cn

Mannings USA Dover, NJ; (800) 447-4473 www.manningsusa.com Dan Ciarlariello, Sales Mgr.

Omega-Vanzetti Inc., Div. Omega Engineering Stamford, CT; www.vanzetti.com (203) 359-1660 Fax: (203) 359-7700

Metallurgical High Vacuum Corp. Fennville, MI www.methivac.com (269) 543-4291 (877) 787-9880 Fax: (269) 543-4750 Dave Petersen, Sales Mgr. SEE OUR AD ON PAGE 30

Lanly Company Cleveland, OH; (216) 731-1115 www.lanly.com

Inter-Power Corporation Almont, MI; (810) 798-9201 www.interpwr.com

OMEGA Engineering Inc. Stamford, CT; (203) 359-1660 www.omega.com SEE OUR AD ON INSIDE FRONT COVER

MEGTEC Systems DePere, WI; (920) 336-5715 www.megtec.com Tom Golden, Engrg. Serv. Mgr.

Koolant Koolers by Dimplex Thermal Solutions Kalamazoo, MI; (800) YOU-KOOL www.dimplexthermal.com

Lindberg/MPH, SPX Corp. Riverside, MI; (269) 849-2700 www.lindbergmph.com Joel Shingledecker, Sales Mgr.

Omega Castings Inc. Battle Creek, MI; (269) 968-8105 Robert S. Cutshall, Pres.

Maxon, A Honeywell Company Muncie, IN; (765) 284-3304 www.maxoncorp.com Larry Hyland, Inside Sales Mgr.

Metro Services Inc., Combustion & Controls Engrg. Chattanooga, TN; (800) 736-6145 www.metroservicesinc.com Scott Norton, V.P.

Inland Vacuum Industries Inc. Churchville, NY; (585) 293-3330 www.inlandvacuum.com Peter Yu, Pres.

Invensys Eurotherm Ashburn, VA; (703) 724-7300 www.eurotherm.com

Marathon Monitors Inc., a member of United Process Controls West Chester, OH; (513) 772-1000 www.group-upc.com

Omegadyne Inc. Sunbury, OH; (800) 872-3963 www.omegadyne.com Pacific Transducer Corp., dba PTC Instruments Los Angeles, CA; (310) 478-1134 www.ptc1.com; Linda A. Wolfe, Gen. Mgr. Pall Corp. Port Washington, NY; (516) 484-5400 www.pall.com Palmer Wahl Temperature Products Asheville, NC; (828) 658-3131 www.palmerwahl.com Richard Santangelo, Cust. Serv. Paragon Industries L.P. Mesquite, TX; (972) 288-7557 www.paragonweb.com Arnold Howard, Dir. Bus. Dev. -Park Thermal International (1996) Corp. Georgetown, ON CANADA; (905) 877-5254 www.parkthermal.com Jay Mistry, CEO

Mitutoyo America Corporation Aurora, IL; (630) 820-9666 www.mitutoyo.com Nabertherm Inc. New Castle, DE; (302) 322-3665 www.nabertherm.com

Phoenix Induction Corp. South Lyon, MI; (248) 486-8760

-National Element Inc. Brighton, MI www.nationalelement.com (248) 486-1810; (800) 600-5511 Fax: (248) 486-1649 Steve Best, Gen. Mgr. SEE OUR AD ON PAGE 33

Pillar Induction, formerly ABP Induction LLC Brookfield, WI; (800) 896-7954 www.pillar.com Jody Smith, Dir. Aftermarket Sales/Serv.

New Castle Refractories Co. Inc., Resco Products Inc. Greensboro, NC; (336) 299-8516 x16 www.rescoproducts.com Kevin Frederes, Reg. Mgr.

Plansee USA LLC Franklin, MA; (508) 553-3800 www.plansee-usa.com Mike Ferullo, Bus. Segment Mgr.

Pittsburgh Industrial Furnace Co. Pittsburgh, PA; (412) 431-7272 John A. Schifano, Pres.

Precision Plus Vacuum Parts Niagara Falls, NY; (800) 526-2707 www.precisionplus.com

Nitrex Metal GmbH Fribourg SWITZERLAND; 41-26-49332-54 www.nitrex.com Andrzej Czelusniak, Sales Mgr. Nitrex Metal Inc. Montreal, QC CANADA; (877) 335-7191 www.nitrex.com Paul Oleszkiewicz, V.P. -Oerlikon Leybold Vacuum USA Inc. Export, PA; (724) 327-5700 www.oerlikon.com/leyboldvacuum Mario Vitale, Regl. Market Mgr. Olson Industries Burgettstown, PA; (724) 947-3300 www.olsonind.com Bryan Kraus, Pres.

-Find more information on these companies at www.industrialheating.com/aftermarket

Preco Inc. Somerset, WI; (715) 247-3285 www.precoinc.com Pregl Services Inc. Rock City, IL; (815) 986-5467 www.pregl.com Process-Electronic France, a member of United Process Controls Besancon FRANCE; 33 (03) 8148-3737 www.process-electronic.com Emmanuel Jeanguyot Process-Electronic GmbH, a member of United Process Controls Heiningen GERMANY; 49 7161 94888-0 www.process-electronic.com Michael Winter, Managing Dir. R&D

IndustrialHeating.com - April 2011 75

Company Listings AFTERMARKET DIRECTORY Process-Electronic Sp. z o.o. - Zion Industries Inc. Process-Electronic Sp. z o.o., a member of United Process Controls Sosnowiec POLAND; +48 (32) 2966600 www.process-electronic.com Mr. Jerzy Dybski Process Instruments Inc. Pittsburgh, PA; (412) 431-4600 www.procinst.com ProInduction Inc. Milton, WI; (866) 685-4800 www.proinduction.com Christos Angelakis, V.P. Pyrometer Instrument Co. Inc. Windsor, NJ; (609) 443-5522 www.pyrometer.com Qual-Fab Inc. Avon, OH; (440) 327-5000 www.qual-fab.net Brice E. Blackman, Pres. Radyne Corp., An Inductotherm Group Co. Milwaukee, WI; (800) 236-8360 www.radyne.com CJ Singh, Cust. Serv. Mgr. Raytek Corp., Automation Products Div. Santa Cruz, CA; (831) 458-3900 www.raytek.com Reade Advanced Materials Providence, RI; (401) 433-7000 www.reade.com Recco Furnaces, Keith Co. Pico Rivera, CA; (562) 948-3636 www.reccofurnaces.com RKC Instrument South Bend, IN; (574) 273-6099 www.rkcinst-usa.com Jolene Wolverton, Sales Admin. Robson Industries Inc. West Chester, PA; (888) 567-8308 www.robsonind.com Don Robson, Pres. Rolled Alloys Temperance, MI; (800) 521-0332 www.rolledalloys.com John Thackray, V.P. Saint-Gobain Ceramic Materials Worcester, MA; (508) 795-5577 www.refractories.saint-gobain.com Sandvik Heating Technology USA Amherst, NY; (716) 691-4010 www.kanthal.com SCHMETZ GmbH Menden GERMANY; 49 (0) 2373 686-154 www.schmetz.de Hubert Schulte, Export Mktg. Mgr. -SECO/WARWICK Corp. Meadville, PA (814) 332-8400 www.secowarwick.com Dan Alabran, Aftermarket Serv. Mgr.

SGL Technic, Polycarbon Div. St. Marys, PA www.sglcarbon.com (814) 781-2695 Fax: (814) 781-2697 Debbie Larnder SEE OUR AD ON PAGE 35 Shenango Advanced Ceramics LLC, Resco Products New Castle, PA; (724) 652-6668 www.rescoproducts.com Kevin Frederes, Reg. Mgr. Shimadzu Columbia, MD; (410) 381-1227 www.ssi.shimadzu.com Christopher Gaylor, V.P. Sales -Signature Vacuum Systems Inc. Meadville, PA; (814) 333-6891 www.signaturevacuum.com Greg Kimble, Sales Mgr. Skamol Americas Inc. Charlotte, NC; (704) 544-1015 www.skamol.com -Solar Manufacturing Souderton, PA www.solarmfg.com (267) 384-5040 Fax: (267) 384-5060 Dennis Hiddemen, Aftermarket Sales Mgr. SEE OUR AD ON PAGE 9 Spirec N.A. Inc. Paterson, NJ; (973) 569-9277 www.spirec.com Ed Kitlas, Pres.

TE Wire & Cable Saddle Brook, NJ (201) 845-9400; www.tewire.com Joanne Ward, Cust. Serv. Mgr. Teledyne Hastings Instruments Hampton, VA; (757) 723-6531 www.teledyne-hi.com Will Harrison, Sales Mgr./Sr. Appl. Tenova Core Coraopolis, PA; (412) 262-2240 www.tenovacore.com David Pekor, Mgr. Furnace Tech. Srvs. The Rembar Company LLC Dobbs Ferry, NY (914) 693-2620; www.rembar.com Hal Rostad, Sales Mgr. Thermafiber Inc. Wabash, IN; (888) 834-2371 www.thermafiber.com Thermal Ceramics Augusta, GA; (706) 796-4200 www.thermalceramics.com Thermal Products & Solutions Kent, OH; (330) 678-4328 www.hothermal.com Thermal Technology LLC Santa Rosa, CA (707) 571-1911 www.thermaltechnology.com Thermaltek Inc. Concord, NC; (704) 784-3001 www.thermaltek.com

Struers Inc. Cleveland, OH; (888) Struers www.struers.com

Thermcraft Inc. Winston Salem, NC (336) 784-4800 www.thermcraftinc.com Thomas M. Crafton, Pres.

Sun-Tec Corporation Novi, MI; (248) 669-3100 www.sunteccorp.com

Thermo Transfer Inc. Shelbyville, IN; (317) 398-3503 www.thermotransferinc.com

Super Systems Inc. Cincinnati, OH; (513) 772-0060 www.supersystems.com Bob Fincken, Natl. Sales Mgr.

-Tuthill Corporation Springfield, MO (800) 825-6937 www.tuthill.com Angie Burlison, Mktg. Coord.

-Surface Combustion Inc. Maumee, OH www.surfacecombustion.com (419) 891-7150; (800) 537-8980 Fax: (419) 891-7151 Daniel E. Goodman, V.P. Sales SEE OUR AD ON PAGE 6 Swenson & Associates Co. Detroit, MI; (313) 882-5504 Swerea IVF S-431 53 Molndal SWEDEN 46-31-706 60 00 www.ivfsmartquench.com Taylor-Winfield Technologies Inc. Youngstown, OH; (330) 448-4464 www.taylor-winfield.com

United Process Controls West Chester, OH (513) 772-1000 www.group-upc.com United Vacuum Hamburg, NJ; (888) 742-7202 www.unitedvacuum.com Unitherm Furnace Corp. Wentzville, MO; (636) 327-5777 www.unithermfurnace.com Frank Lim, Pres. Upton Industries Inc. Roseville, MI; (586) 771-1200 www.uptonindustries.com Kenneth M. Minoletti, V.P.

-VAC AERO International Inc. Oakville, ON CANADA www.vacaero.com (905) 827-4171 Fax: (905) 827-0468 Bill Potts, Mgr. Sales/Cust. Serv. SEE OUR AD ON PAGE 37 Vacuum Engineering Services Co. Inc. East Windsor, CT; (860) 627-7015 www.vacuumengineering.com Vacuum Processes Inc. Everett, PA; (814) 652-6767 www.vacpro.com; John Swatkoski, Pres. Vitta Corporation Bethel, CT; (203) 790-8155 www.vitta.com; K. Skandera, Sales Waukee Engineering Company Inc., a member of United Process Controls Milwaukee, WI; (414) 462-8200 www.waukeemeters.com Dirk Pfeil, Gen. Mgr. -Wellman Furnaces Inc., a Precious Technology Group Co. Shelbyville, IN; (317) 398-4411 www.wellmanfurnaces.com Wilson Instruments Norwood, MA; (781) 828-2500 www.wilsoninstruments.com -Wirco Inc. Avilla, IN www.wirco.com (800) 348-2880; (260) 897-3768 Fax: (260) 897-2525 SEE OUR AD ON PAGE 13 -Wisconsin Oven Corp. East Troy, WI www.wisoven.com (262) 642-3938 Fax: (262) 363-4018 Mr. Steve Bertschinger, Service Sales Mgr. -Wonder Weld Induction Co. Orient, OH; (614) 875-1447 www.wonderweld.com WS Thermal Process Technology Inc. Elyria, OH; (440) 365-8029 www.flox.com Yokogawa Corporation of America Newnan, GA; (800) 258-2552 www.yokogawa.com/us John Jerman, Mgr. Zion Industries Inc. Valley City, OH; (330) 483-4650 www.zioninduction.com; Bobby Puls, Pres. If your company was not included in this directory, please contact Erin Mygal at (248) 786-1684, Fax: (248) 283-6617; e-mail: [email protected] to have your contact information put into our database.

Parts z Service z Rebuilds z Retrofits z Burners Elements z Combustion Controls z Control Panels Thermal Profiling z Waste Heat Recovery Energy Recovery Systems z Electric to Gas Conversions t: 905-356-1327

f: 905-356-1817

76 April 2011 - IndustrialHeating.com

e: [email protected]

www.can-eng.com

Bold listing indicates an advertiser in this issue

From March 1995

Phone: 951-340-4646 www.gmenterprises.com

This Vintage Cover features a G-M bottom load vacuum furnace as installed in the Welded Duct Center, a manufacturing business unit in the Fabrication Division of Boeing Commercial Airplane Group. Contact G-M Enterprises at: 525 Klug Circle, Corona, CA 92880-5452 Phone: 951-340-4646 Fax: 951-340-9090 Web: www.gmenterprises.com

Capabilities Listings AFTERMARKET DIRECTORY

Aftermarket Parts, Company Capabilities & Consulting Services

I

f you are looking for aftermarket parts, company resources aand/or consulting services, the following pages will be a tremendous aid in your search. Here you can locate both a specific company and what they have to offer. This section is broken down into the following main categories: General Capabilities; Refractory & Insulation; Compliance; Direct-Fired, Electric & Atmosphere Furnace Systems; Vacuum Furnace Systems; Induction Systems; Ancillary Equipment; and Energy Conservation. The main categories are broken down even further into several sub-categories. This directory is also available at www.industrialheating.com/ aftermarket.

GENERAL A – ALLOY FABRICATION B – CONSULTING C– CONTROLS TROUBLESHOOTING & UPGRADES E– EQUIPMENT RENTAL & LEASING F– GAS/ELECTRIC FURNACE CONVERSIONS G– REPLACEMENT, SERVICE H– INSTRUMENT CALIBRATION I – MATERIALS TESTING & METALLURGICAL EVALUATIONS J – POST-QUENCH SPRAY/DRINK WASHER-PROCESS UPGRADE K– PROCESS IMPROVEMENT & COST REDUCTION ANALYSIS L – TEMPERATURE CONTROL/ CALIBRATION M– TEMPERATURE UNIFORMITY SURVEY N– TRAINING & EDUCATION O – TROUBLESHOOTING & REPAIR 3T True Temperature Technologies–K,L Abell Combustion Inc.–F Advanced Heat Treat Corp.–B,I Advanced Heat Treat Corp.–B,I Advanced Heat Treat Corp., Plant 1–B,I Aero SPC Inc.–B,I,K,M,N AFC-HOLCROFT–A,C,F,J,N,O - Agilent Technologies (formerly Varian Inc.), Vacuum Products–H Air & Energy Systems Inc.–B,C,F,K,L,M,N Ajax Electric Co.–A,B,C,N Alcon Industries Inc.–A ALD-HOLCROFT–M,N,O Alhern-Martin Industrial Furnace Co.–A,B,C,F,G,H,K,L,M,N,O Alloy Engineering–A

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American Isostatic Presses Inc.–L,M ARCADIS US Inc.–B,N ASCO Valve Inc.–L Atmosphere Recovery Inc.–C,E,G,K BeaverMatic Inc.–F,O Blackhawk Combustioneering Ltd.– B,C,F,G,H,K,L,M,N,O Blastcrete Equipment Co.–E Bloom Engineering Co. Inc.–F,H,K Buehler, A Div. of Illinois Toolworks Inc.–I Can-Eng Furnaces International Ltd.–A,B,C,F,K,M,N,O Cashvac Inc.–B,E Casso-Solar Technologies LLC–F,K Castalloy–A CEA Instruments Inc.–G,H CEC Combustion Services Group, Combustion Safety Inc.–B,C,K,N,O Centorr Vacuum Industries Inc.– C,H,M,O CFF Kilns & Furnaces, Keith Co.–A,C,F,K,O Charles A. Hones, Buzzer Gas Equipment–O CLEPCO / Intelligent Heater LLC–C,L CM Furnaces Inc.–M,N,O Conrad Kacsik Instrument Systems Inc.–C,E,F,G,H,L,M,N,O Consolidated Engineering Company– A,C,F,G,H,K,L,M,O Control Concepts Inc.–C,F,O Convectronics Inc.–C,M Custom Electric Manufacturing Co.–K,O DATAPAQ Inc.–H,K,L,M Deformation Control Technology Inc.–B,I,K Despatch Industries–C,F,H,L,M,N,O Dry Coolers Inc.–B Duralite Inc.–A Duraloy Technologies Inc.–A,I

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Durex Industries–L Dynamic Systems Inc.–K Ebner Furnaces Inc.–A,F,M Eclipse Inc.–C,F,K,L,M,N,O ECM-USA Inc.–K Edwards Vacuum Inc.–H Eldec Induction USA Inc.–B,E ELECTROHEAT–B,N,O Electronic Development Labs Inc.– G,H,L,M,O Elnik Systems, PVA MIMtech LLC– I,K,L,M Epcon Industrial Systems LP–A,B,C,E,F,J,K,O Exergen Corp.–L Fiber Materials Inc.–B,I Fireye Inc.–C Fives North American Combustion Inc.–B,C,F,G,K,M,N,O Fluxtrol Inc.–B,K,N,O Fuel Applications Ltd.–B,C,F,G,L,M,O Furnace Control Corp., a member of United Process Controls– B,C,F,G,H,K,L,M,O Furnace Parts LLC–A,G,H,K,L,M,O Furnaces, Ovens & Baths–A,B,C,F,G,O Gasbarre Products Inc., Sinterite Products–A,C,F,G,H,L,M,O GeoCorp Inc.–G,L,M G-M Enterprises– A,B,C,H,K,L,M,N,O Great Lakes Industrial Solutions Inc.–A Grieve Corporation–C,F Harper International–A,C,E,O Harrop Industries Inc.–I,O Hauck Mfg. Co.–C,F,G,H,L,N,O Hi-Tech Furnace Systems Inc.– A,B,C,F,G,K,N,O Hoffer Flow Controls Inc.–C,G,K Hyper Alloys Inc.–A I Squared R Element Co. Inc.–F Imtek Environmental Corporation, Odor & Pollution Control Div.–L Inductoheat Inc., An Inductotherm Group Co.–I,O Industrial Furnace Interiors Inc. (IFI Inc.)–F Industrial Gas Engineering–O Industrial Thermal Systems Inc.– C,F,G,H,K,L,M,O Industronics Service Co.– C,F,G,H,K,L,M,N,O INEX Inc.–F Invensys Eurotherm–C,G,H,L,M,N,O Ipsen Inc., Aftermarket Support (AMS)–B,C,F,G,H,I,K,L,M,N,O Ircon Inc.–L,M Irwin Car & Equipment–A J. L. Becker Company– A,B,C,F,G,J,K,M,N,O Keith Company–A,C,F,K,O

- Kleenair Products Co. Inc.– B,C,F,G,H,K,L,M,N,O Lanly Company–C,F,K,L,M,N,O LECO Corporation–H,I Lindberg/MPH, SPX Corp.–A,C,F,M,O Lucifer Furnaces Inc.–K Mangold Engineering Inc.– A,B,C,E,F,G,H,I,J,K,L,M,N,O Mannings USA–C,E,F,G,H,L,O Marathon Monitors (Beijing) Co. Ltd., a member of United Process Controls–B,C,F,G,H,K,L,M,O Marathon Monitors Inc., a member of United Process Controls– B,C,F,G,H,K,L,M,O Maxon, A Honeywell Company–F MEGTEC Systems–K Metro Services Inc., Combustion & Controls Engrg.–B,C,F,G,H,L,N,O Milwaukee Technologies Inc.–I Mitutoyo America Corporation–H Nabertherm Inc.–L,M,O - National Element Inc.–A Nitrex Metal GmbH–B,C,F,I,K Nitrex Metal Inc.–B,C,F,I,K Olson Industries–A,C,F,L,M Omega Castings Inc.–B,I OMEGA Engineering Inc.–H,L,M Omega-Vanzetti Inc., Div. Omega Engineering–G,L Omegadyne Inc.–H Pacific Transducer Corp., dba PTC Instruments–G,H,I,L Palmer Wahl Temperature Products–H,L - Park Thermal International (1996) Corp.–A,B,C,E,F,G,K,L,O Pillar Induction, formerly ABP Induction LLC–C,I,N,O Pittsburgh Industrial Furnace Co.– B,C,F,G,H,K,L,M,N,O Precision Plus Vacuum Parts–O Preco Inc.–I,K Pregl Services Inc.–B,C,G,M,N,O Process-Electronic France, a member of United Process Controls– B,C,F,H,K,L,M,O Process-Electronic GmbH, a member of United Process Controls– B,C,F,G,H,K,L,M,O Process-Electronic Sp. z o.o., a member of United Process Controls– B,C,F,G,H,K,L,M,O Process Instruments Inc.– C,G,H,L,M,O ProInduction Inc.–B,N,O Pyrometer Instrument Co. Inc.–L Qual-Fab Inc.–A Raytek Corp., Automation Products Div.–H,L,M Reade Advanced Materials–A Recco Furnaces, Keith Co.–A,C,F,K,O

Parts z Service z Rebuilds z Retrofits z Burners Elements z Combustion Controls z Control Panels Thermal Profiling z Waste Heat Recovery Energy Recovery Systems z Electric to Gas Conversions t: 905-356-1327

f: 905-356-1817

78 April 2011 - IndustrialHeating.com

e: [email protected]

www.can-eng.com

Bold listing indicates an advertiser in this issue

Capabilities Listings AFTERMARKET DIRECTORY

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RKC Instrument–C,G,L Robson Industries Inc.–B,C,K,O Sandvik Heating Technology USA–F SECO/WARWICK Corp.–A,C,F,L,M,N,O Shimadzu–I Signature Vacuum Systems Inc.– B,C,G,N,O Solar Manufacturing–F Struers Inc.–I,K Sun-Tec Corporation–H,I,O Super Systems Inc.–C,G,L,M,N,O Surface Combustion Inc.– A,C,F,H,I,L,M,N,O Swenson & Associates Co.–A TE Wire & Cable–C,H,L,M Teledyne Hastings Instruments–G,H Tenova Core–C,G,H,K,L,M,N,O The Rembar Company LLC–A Thermal Products & Solutions– B,C,F,K,N,O Thermal Technology LLC–B,C,M,N,O Thermaltek Inc.–F Thermcraft Inc.–C,F,H,L,M,O Thermo Transfer Inc.–A,F United Process Controls– B,C,F,G,H,K,L,M,O Unitherm Furnace Corp.–C,F,H,L,M Upton Industries Inc.–A,F VAC AERO International Inc.–C,H,L,M,O Vacuum Engineering Services Co. Inc.–B,C,E,G,O Vacuum Processes Inc.– A,B,C,E,F,G,H,K,L,N,O Vitta Corporation–A Waukee Engineering Company Inc., a member of United Process Controls– B,C,F,G,H,K,L,M,O Wellman Furnaces Inc., a Precious Technology Group Co.– A,B,C,F,G,L,N,O Wilson Instruments–H,I,L Wirco Inc.–A Wisconsin Oven Corp.–A,F,M,O Wonder Weld Induction Co.–B,C,E,O WS Thermal Process Technology Inc.–K Yokogawa Corporation of America– C,G,H,K,L,N,O Zion Industries Inc.–N

REFRACTORY & INSULATION A– REFRACTORY INSTALLATION & DRY OUT B– REPLACEMENT & UPGRADE Ace Industrial Mfg.–B AFC-HOLCROFT–A,B Ajax Electric Co.–A,B Applied Ceramics Inc.–B Axim Mica Inc.–A,B Blastcrete Equipment Co.–B CFF Kilns & Furnaces, Keith Co.–A,B Charles A. Hones, Buzzer Gas Equipment–B Electronic Development Labs Inc.–B Elnik Systems, PVA MIMtech LLC–B ETS Schaefer Corp.–A,B Fives North American Combustion Inc.–A,B Fuel Applications Ltd.–A,B Furnaces, Ovens & Baths–A,B Gasbarre Products Inc., Sinterite Products–B Harper International–B Harrop Industries Inc.–B Hi-Tech Furnace Systems Inc.–A,B Hi-Temp Fabrication–A,B Industronics Service Co.–A,B Ipsen Inc., Aftermarket Support (AMS)–A,B - J. L. Becker Company–A,B Keith Company–A,B

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Lindberg/MPH, SPX Corp.–A,B Linn High Therm GmbH–A,B LVR Inc.–A,B Mangold Engineering Inc.–A,B Mannings USA–A Mid-Mountain Materials Inc. New Castle Refractories Co. Inc., Resco Products Inc.–B Park Thermal International (1996) Corp.–A,B Pittsburgh Industrial Furnace Co.–A,B Plansee USA LLC–B Recco Furnaces, Keith Co.–A,B Saint-Gobain Ceramic Materials–B SECO/WARWICK Corp.–A,B SGL Technic, Polycarbon Div.–A,B Shenango Advanced Ceramics LLC, Resco Products–B Skamol Americas Inc.–A,B Surface Combustion Inc.–A,B Tenova Core–B Thermafiber Inc.–B Thermal Ceramics–B Thermo Transfer Inc.–A Unitherm Furnace Corp.–A,B VAC AERO International Inc.–B Vacuum Processes Inc.–A,B Wellman Furnaces Inc., a Precious Technology Group Co.–A,B Wonder Weld Induction Co.–B

COMPLIANCE A–HAZARDOUS WASTE & EPA B–AIRCRAFT & INDUSTRY SPECIFICATION C–NFPA D–WORKER SAFETY/OSHA E–TECHNICAL STANDARDS & SAFETY AUTHORITY (TSSA) SUBMISSIONS & APPROVALS

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Abell Combustion Inc.–C Alhern-Martin Industrial Furnace Co.–C ARCADIS US Inc.–A,D Blackhawk Combustioneering Ltd.–E Bloom Engineering Co. Inc.–A CEA Instruments Inc.–A,D CEC Combustion Services Group, Combustion Safety Inc.–C,D Centorr Vacuum Industries Inc.–C,D Conrad Kacsik Instrument Systems Inc.–B,C DATAPAQ Inc.–B Demtrol Systems Div.–A Despatch Industries–A,B,C,D Eclipse Inc.–A,C Epcon Industrial Systems LP–A Fives North American Combustion Inc.–A,C Fuel Applications Ltd.–E Furnace Control Corp., a member of United Process Controls–C GeoCorp Inc.–B G-M Enterprises–B,C,D Grieve Corporation–C Imtek Environmental Corporation, Odor & Pollution Control Div.–A,C,D Industrial Thermal Systems Inc.–C Ipsen Inc., Aftermarket Support (AMS)–B,C,D Kleenair Products Co. Inc.–C Lanly Company–C Lindberg/MPH, SPX Corp.–B Marathon Monitors Inc., a member of United Process Controls–C MEGTEC Systems–A Nabertherm Inc.–B Olson Industries–C Park Thermal International (1996) Corp.–B Pittsburgh Industrial Furnace Co.–C

Plansee USA LLC–B - Surface Combustion Inc.–C Tenova Core–A Thermal Products & Solutions–C United Process Controls–C Unitherm Furnace Corp.–B,C - VAC AERO International Inc.–B Vacuum Processes Inc.–D Waukee Engineering Company Inc., a member of United Process Controls–C - Wellman Furnaces Inc., a Precious Technology Group Co.–C - Wonder Weld Induction Co.–A,D

DIRECT-FIRED, ELECTRIC & ATMOSPHERE FURNACE SYSTEMS A–ATMOSPHERE COMPOSITION ANALYSIS B–ATMOSPHERE GENERATOR SERVICES C–COMBUSTION SYSTEMS SERVICES D–EMISSION TESTING E–FIELD SERVICE F–HEAT TRANSFER ANALYSIS G–HEATING ELEMENT ANALYSIS H–INSTALLATION & START-UP I–PREVENTATIVE MAINTENANCE J–UPGRADES, OVERHAULS & MODIFICATIONS K–REPLACEMENT & SPARE PARTS L–HIGH TEMPERATURE ALLOY FANS

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-Find more information on these companies at www.industrialheating.com/aftermarket

Abell Combustion Inc.–C,H,J Ace Industrial Mfg.–J,K Advanced Cerametrics Inc.–K AFC-HOLCROFT–B,C,E,H,I,J,K,L Air & Energy Systems Inc.–C,H,I,J,K Ajax Electric Co.–E,H,J,K Alcon Industries Inc.–J,K,L Alhern-Martin Industrial Furnace Co.–A,B,C,D,E,F,G,H,I,J,K Alloy Engineering–L Applied Ceramics Inc.–K ASCO Valve Inc.–E,K Atmosphere Recovery Inc.–A Axim Mica Inc.–I,K BeaverMatic Inc.–B,C,E,F,H,I,J,K,L Blackhawk Combustioneering Ltd.– A,B,C,D,E,H,I,J,K Blasdel Enterprises Inc.–K Bloom Engineering Co. Inc.–C,E,F,J,K Can-Eng Furnaces International Ltd.–B,C,E,H,I,J,K Casso-Solar Technologies LLC–J,K CEA Instruments Inc.–A CEC Combustion Services Group, Combustion Safety Inc.–A,C,E,F,H,J Centorr Vacuum Industries Inc.– E,G,H,I,J,K Ceramic Solutions Inc.–K CFF Kilns & Furnaces, Keith Co.– C,E,G,H,I,J,K,L Charles A. Hones, Buzzer Gas Eqpt.–J CM Furnaces Inc.–E,H,I,J,K Conrad Kacsik Instrument Systems Inc.–B,C,E,G,H,I,J,K Consolidated Engineering Company– C,E,G,H,I,J,K Control Concepts Inc.–J,K Convectronics Inc.–K Custom Electric Manufacturing Co.–C,F,G,I,J,K Dalton Electric Heating Co. Inc.–K Deformation Control Technology Inc.–F Demtrol Systems Div.–C Despatch Industries–C,E,G,H,I,J,K Duralite Inc.–G,K Duraloy Technologies Inc.–K Durex Industries–K

- Ebner Furnaces Inc.–E,H,I,J,K Eclipse Inc.–C,D,E,H,I,J,K Elnik Systems, PVA MIMtech LLC–J,K Enterprise Equipment Co.–K Epcon Industrial Systems LP–C,D,E,F,H,I,J,K ETS Schaefer Corp.–E,J Exergen Corp.–F,I Fireye Inc.–C,J,K Fives North American Combustion Inc.–C,E,F,H,I,J,K Fuel Applications Ltd.–C,E,H,I,J,K Furnace Control Corp., a member of United Process Controls– A,B,C,E,H,I,J,K Furnace Parts LLC–K Furnaces, Ovens & Baths–B,C,E,G,H,I,J,K Gasbarre Products Inc., Sinterite Products–B,E,F,H,I,J,K - GeoCorp Inc.–K G-M Enterprises–A,B,C,E,F,G,H,J,K,L Great Lakes Industrial Solutions Inc.–K Grieve Corporation–E,H,I,K Harper International–E,H,J,K Harrop Industries Inc.–C,J Hauck Mfg. Co.–A,C,D,E,F,H,I,J,K - H.C. Starck Inc., Fabrication Products–K Hi-Tech Furnace Systems Inc.– A,C,E,F,G,H,I,J,K Hi-Temp Fabrication–J Hydro-Thermal Corp.–K Hyper Alloys Inc.–K I Squared R Element Co. Inc.–G,K IGS Inc., Sealant Technology Div.–K Industrial Furnace Interiors Inc. (IFI Inc.)–G,I,J,K Industrial Gas Engineering–K,L Industrial Thermal Systems Inc.– B,C,D,E,H,I,J,K Industronics Service Co.–B,C,E,G,H,I,J,K - INEX Inc.–C,F,J,K Ipsen Inc., Aftermarket Support (AMS)–A,B,C,E,F,G,H,I,J,K Ircon Inc.–D,G,I Irwin Car & Equipment–I,K - J. L. Becker Company– A,B,C,E,F,G,H,I,J,K,L Keith Company–C,E,G,H,I,J,K,L - Kleenair Products Co. Inc.– B,C,D,E,F,G,H,I,J,K Lanly Company–C,E,H,I,J,K Lindberg/MPH, SPX Corp.– B,C,E,H,I,J,K,L Linn High Therm GmbH–J,K - L & L Special Furnace Co. Inc.–J Lucifer Furnaces Inc.–A,C,H,J,K Mangold Engineering Inc.– A,B,C,D,E,F,G,H,I,J,K,L Mannings USA–C,E,G,I,J,K Marathon Monitors (Beijing) Co. Ltd., a member of United Process Controls– A,B,C,E,H,I,J,K Marathon Monitors Inc., a member of United Process Controls– A,B,C,E,H,I,J,K Maxon, A Honeywell Company–C,K MEGTEC Systems–I,J,K Metro Services Inc., Combustion & Controls Engrg.–C,D,E,H,I,J,K Nabertherm Inc.–E,F,H,J,K - National Element Inc.–G,K Nitrex Metal GmbH–A,H,J Nitrex Metal Inc.–A,H,J Olson Industries–C,E,H,I,J,K Omega Castings Inc.–K OMEGA Engineering Inc.–K Pall Corp.–I Palmer Wahl Temperature Products–F,G,I Paragon Industries L.P.–J,K - Park Thermal International (1996) Corp.–C,E,G,H,I,J,K

IndustrialHeating.com IndustrialHeating.com- April - April20011 2011 79

Capabilities Listings AFTERMARKET DIRECTORY

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Pittsburgh Industrial Furnace Co.– C,E,F,H,J,K Plansee USA LLC–G,H,J,K Precision Plus Vacuum Parts–I,J,K Pregl Services Inc.–E,H,J Process-Electronic France, a member of United Process Controls– A,B,C,E,H,I,J,K Process-Electronic GmbH, a member of United Process Controls– A,B,C,E,H,I,J,K Process-Electronic Sp. z o.o., a member of United Process Controls– A,B,C,E,H,I,J,K Process Instruments Inc.–C,E,I,K Qual-Fab Inc.–J,L Raytek Corp., Automation Products Div.–D,G,I Recco Furnaces, Keith Co.– C,E,G,H,I,J,K,L Sandvik Heating Technology USA–G,J,K SECO/WARWICK Corp.– B,C,E,H,I,J,K Spirec N.A. Inc.–J,K Super Systems Inc.–B,C,K Surface Combustion Inc.– A,B,C,E,H,I,J,K Swenson & Associates Co.–K,L TE Wire & Cable–K Tenova Core–A,B,C,D,E,F,G,H,I,J,K The Rembar Company LLC–K Thermal Ceramics–F Thermal Products & Solutions– C,E,H,I,J,K Thermal Technology LLC–E,G,H,I,J,K Thermaltek Inc.–G,J,K Thermcraft Inc.–C,E,G,H,I,J,K Thermo Transfer Inc.–B,C,E,H,I United Process Controls– A,B,C,E,H,I,J,K Unitherm Furnace Corp.–B,C,E,H,I,J,K Upton Industries Inc.–E,H,J,K Vacuum Processes Inc.– A,D,E,F,G,H,I,J,K,L Waukee Engineering Company Inc., a member of United Process Controls– A,B,C,E,H,I,J,K Wellman Furnaces Inc., a Precious Technology Group Co.–E,F,G,H,J,K Wirco Inc.–K,L Wisconsin Oven Corp.–E,H,I,J,K WS Thermal Process Technology Inc.–C,D,E,F,H,I

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VACUUM FURNACE SYSTEMS A–FIELD SERVICE B–HOT ZONE REBUILD & REPLACEMENT C–INSTALLATION & START-UP D–LEAK DETECTION & REPAIR E–PREVENTATIVE MAINTENANCE F–PUMP REPAIR & MAINTENANCE G–UPGRADES, OVERHAULS & MODIFICATIONS H–REPLACEMENT & SPARE PARTS Advanced Cerametrics Inc.–H - Agilent Technologies (formerly Varian Inc.), Vacuum Products–D,F,G,H

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Alcon Industries Inc.–B,G,H ALD-HOLCROFT–A,B,C,D,E,F,G,H Applied Ceramics Inc.–B,H ASCO Valve Inc.–A,G Axim Mica Inc.–B,D,E,H Cashvac Inc.–A,D,E,F,G CEC Combustion Services Group, Combustion Safety Inc.–D Centorr Vacuum Industries Inc.– A,B,C,D,E,G,H Ceramic Solutions Inc.–H Conrad Kacsik Instrument Systems Inc.–A,C,E,G,H Consolidated Engineering Company–H Control Concepts Inc.–G,H Convectronics Inc.–H Custom Electric Manufacturing Co.–B,H Dalton Electric Heating Co. Inc.–H Durex Industries–H ECM-USA Inc.–A,C,E,G,H Edwards Vacuum Inc.–A,D,F,H Elnik Systems, PVA MIMtech LLC– A,B,E,H Enterprise Equipment Co.–H ETS Schaefer Corp.–G Exergen Corp.–E Fiber Materials Inc.–B,G Furnace Control Corp., a member of United Process Controls–C,G Furnace Parts LLC–H Furnaces, Ovens & Baths–A,B,C,E,G Gasbarre Products Inc., Sinterite Products–A,B,C,D,G,H GeoCorp Inc.–H G-M Enterprises–A,B,C,D,E,F,G,H Great Lakes Industrial Solutions Inc.–H H.C. Starck Inc., Fabrication Products–B,G,H Hi-Tech Furnace Systems Inc.–F,H Hi-Temp Fabrication–G Hyper Alloys Inc.–H IGS Inc., Sealant Technology Div.–H Industrial Furnace Interiors Inc. (IFI Inc.)–H Industrial Gas Engineering–H INFICON–D Inland Vacuum Industries Inc.–E,F Ipsen Inc., Aftermarket Support (AMS)–A,B,C,D,E,F,G,H Ircon Inc.–E JC Cole & Associates Inc.–B,H Lindberg/MPH, SPX Corp.–A,E,G,H Mangold Engineering Inc.– A,B,C,D,E,F,G,H Marathon Monitors (Beijing) Co. Ltd., a member of United Process Controls–C,G Marathon Monitors Inc., a member of United Process Controls–C,G Metallurgical High Vacuum Corp.– A,D,F,H Nabertherm Inc.–C,H National Element Inc.–H Oerlikon Leybold Vacuum USA Inc.–D,F,H OMEGA Engineering Inc.–E Palmer Wahl Temperature Products–E Park Thermal International (1996) Corp.–G,H Plansee USA LLC–B,C,E,G,H

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Precision Plus Vacuum Parts– A,B,D,E,F,G,H Pregl Services Inc.–A,B,C,D,E,F,G,H Process-Electronic France, a member of United Process Controls–C,G Process-Electronic GmbH, a member of United Process Controls–C,G Process-Electronic Sp. z o.o., a member of United Process Controls–C,G Process Instruments Inc.–A Qual-Fab Inc.–G,H Raytek Corp., Automation Products Div.–E SCHMETZ GmbH–A,B,D,E,H SECO/WARWICK Corp.– A,B,C,D,E,F,G,H SGL Technic, Polycarbon Div.– A,B,G,H Signature Vacuum Systems Inc.– A,B,C,D,E,F,G,H Solar Manufacturing–A,B,C,D,E,G,H Spirec N.A. Inc.–G,H Super Systems Inc.–D Surface Combustion Inc.– A,B,C,D,E,G,H Swenson & Associates Co.–H TE Wire & Cable–H Teledyne Hastings Instruments–H The Rembar Company LLC–B,G,H Thermal Technology LLC– A,B,C,D,E,F,G,H Tuthill Corporation–A,E,F,H United Process Controls–C,G United Vacuum–F VAC AERO International Inc.– A,B,C,D,E,F,G,H Vacuum Engineering Services Co. Inc.–A,B,C,D,E,F,G,H Vacuum Processes Inc.– A,B,C,D,E,F,G,H Waukee Engineering Company Inc., a member of United Process Controls–C,G Wellman Furnaces Inc., a Precious Technology Group Co.–A,B,C,G,H

INDUCTION SYSTEMS A–COIL DESIGN & EFFICIENCY IMPROVEMENTS B–COIL REPAIR & REPLACEMENT C–FIELD SERVICE D–INSTALLATION & START-UP E–LOAD MATCHING SERVICES F–POWER SUPPLY SERVICE & UPGRADES G–PREVENTATIVE MAINTENANCE H–UPGRADES, OVERHAULS & MODIFICATIONS I–REPLACEMENT & SPARE PARTS J–REPAIR & REPLACEMENT Ajax TOCCO International– A,B,C,D,E,F,G,H,I,J - Ajax TOCCO Magnethermic– A,B,C,D,E,F,G,H,I,J Ajax TOCCO Magnethermic– A,B,C,D,E,F,G,H,I,J Ajax TOCCO Magnethermic– A,B,C,D,E,F,G,H,I,J Ajax TOCCO Magnethermic–

A,B,C,D,E,F,G,H,I,J Ajax TOCCO Magnethermic Canada Ltd.–A,B,C,D,E,F,G,H,I,J Ajax TOCCO Magnethermic Corp.– A,B,C,D,E,F,G,H,I,J Ajax TOCCO Magnethermic Corp.– A,B,C,D,E,F,G,H,I,J Ajax TOCCO Magnethermic Corp.– A,B,C,D,E,F,G,H,I,J Ajax TOCCO Magnethermic Corp.– A,B,C,D,E,F,G,H,I,J Ajax TOCCO Magnethermic Corp.– A,B,C,D,E,F,G,H,I,J Alcon Industries Inc.–H,I Alpha 1 Induction Service Center– A,B,C,D,E,F,G,H,I,J Axim Mica Inc.–B,G,I,J CEIA USA–A,F,I - Centorr Vacuum Industries Inc.–C,D Ceramic Solutions Inc.–I Consolidated Engineering Company–I Control Concepts Inc.–F Convectronics Inc.–I Durex Industries–A,B,I Eldec Induction USA Inc.– A,B,C,D,E,F,G,H,I,J ELECTROHEAT–A,B,C,D,E,F,H,I,J ETS Schaefer Corp.–H Exergen Corp.–G Fiber Materials Inc.–H Fluxtrol Inc.–A,B,G,H Furnaces, Ovens & Baths–C,D,F,G,H Gasbarre Products Inc., Sinterite Products–H,I,J Great Lakes Industrial Solutions Inc.–I Hi-Temp Fabrication–I IGS Inc., Sealant Technology Div.–I Induction Professionals–A,B,G,H,I,J Induction Tooling Inc.–A,B,C,D,G,I Inductoheat Inc., An Inductotherm Group Co.–A,B,C,D,E,F,G,H,I,J Inter-Power Corporation–A,B,F,G,H,I,J Ircon Inc.–G Jackson Transformer Company–J JC Cole & Associates Inc.–I JO-MAR Industries–A,B,H,J Mannings USA–A,B,C,D,F,G,H,I,J Olson Industries–H,I Palmer Wahl Temperature Products–G - Park Thermal International (1996) Corp.–H Phoenix Induction Corp.– B,C,D,E,F,G,H,I,J Pillar Induction, formerly ABP Induction LLC–A,B,C,D,E,F,G,H,I,J Precision Plus Vacuum Parts–G,I ProInduction Inc.–A,B,C,D,E,F,G,H,I,J Radyne Corp., An Inductotherm Group Co.–A,B,C,D,E,F,G,H,I,J Raytek Corp., Automation Products Div.–G Spirec N.A. Inc.–H,I Taylor-Winfield Technologies Inc.– A,B,F,H,I Vacuum Processes Inc.– A,B,C,D,E,F,G,H,I,J - Wonder Weld Induction Co.– A,B,C,D,E,F,G,H,I,J Zion Industries Inc.–A,B

Parts z Service z Rebuilds z Retrofits z Burners Elements z Combustion Controls z Control Panels Thermal Profiling z Waste Heat Recovery Energy Recovery Systems z Electric to Gas Conversions t: 905-356-1327

f: 905-356-1817

80 April 2011 - IndustrialHeating.com

e: [email protected]

www.can-eng.com

Bold listing indicates an advertiser in this issue

Capabilities Listings AFTERMARKET DIRECTORY

ANCILLARY EQUIPMENT A–COOLING EQUIPMENT REPAIR & REPLACEMENT B–SOFTWARE C–TUBE & PIPE COILING MACHINES

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Alhern-Martin Industrial Furnace Co.–A Alpha 1 Induction Service Center–A Conrad Kacsik Instrument Systems Inc.–B Deformation Control Technology Inc.–B Delta Cooling Towers–A Despatch Industries–A Dry Coolers Inc.–A Dynamic Systems Inc.–B Eldec Induction USA Inc.–A Furnace Control Corp., a member of United Process Controls–B Furnaces, Ovens & Baths–A Gasbarre Products Inc., Sinterite Products–A Hi-Tech Furnace Systems Inc.–A Induction Professionals–A Industrial Thermal Systems Inc.–A Inter-Power Corporation–A Ipsen Inc., Aftermarket Support (AMS)–A J. L. Becker Company–A Koolant Koolers by Dimplex Thermal Solutions–A Lanly Company–A Mangold Engineering Inc.–A Marathon Monitors (Beijing) Co. Ltd., a member of United Process Controls–B Marathon Monitors Inc., a member of United Process Controls–B Nabertherm Inc.–B Nitrex Metal GmbH–A Nitrex Metal Inc.–A Olson Industries–B Park Thermal International (1996) Corp.–A Pillar Induction, formerly ABP Induction LLC–A Pittsburgh Industrial Furnace Co.–A Pregl Services Inc.–A,B Process-Electronic France, a member of United Process Controls–B Process-Electronic GmbH, a member of United Process Controls–B Process-Electronic Sp. z o.o., a member of United Process Controls–B Radyne Corp., An Inductotherm Group Co.–A Robson Industries Inc.–A Signature Vacuum Systems Inc.–A Spirec N.A. Inc.–A Super Systems Inc.–B Swerea IVF–A,B Tenova Core–A Thermal Products & Solutions–B United Process Controls–B Vacuum Processes Inc.–A Waukee Engineering Company Inc., a member of United Process Controls–B Wonder Weld Induction Co.–A

CFF Kilns & Furnaces, Keith Co.–A,B Dry Coolers Inc.–B Eclipse Inc.–A Fives North American Combustion Inc.–A Fuel Applications Ltd.–B G-M Enterprises–A,B Industrial Thermal Systems Inc.–A - INEX Inc.–B Ipsen Inc., Aftermarket Support (AMS)–A Ircon Inc.–A Keith Company–A,B - Kleenair Products Co. Inc.–B Lanly Company–A,B

MEGTEC Systems–A,B,C Metro Services Inc., Combustion & Controls Engrg.–A Olson Industries–B Palmer Wahl Temperature Products–A Raytek Corp., Automation Products Div.–A Recco Furnaces, Keith Co.–A,B Robson Industries Inc.–B Tenova Core–A Thermal Ceramics–B Thermal Products & Solutions–A,B Vacuum Processes Inc.–B,C WS Thermal Process Technology Inc.–A,B

The contents of this directory are intended for the use of individuals and/or companies looking to purchase equipment, services and/ or supplies. Use of this directory for sales solicitations of any type, including phone, fax, e-mail or regular mail, is prohibited unless expressly approved by the publisher.

2 May ✦ Howe Memorial Lecture David K. Matlock Armco Foundation Fogarty Professor, Department of Metallurgical and Materials Engineering, Colorado School of Mines, Golden, Colo., USA ✦ International Alliance Lecture ✦ Technical Sessions ✦ Industry Exposition 3 May ✦ President’s Award Breakfast Frederick “Fritz” Henderson Senior Vice President, Sunoco Inc.

✦ Technical Sessions ✦ Industry Exposition

ENERGY CONSERVATION A–ENERGY AUDIT B–HEAT RECOVERY C–SOLVENT RECOVERY Air & Energy Systems Inc.–B Alhern-Martin Industrial Furnace Co.–A Atmosphere Recovery Inc.–A Blackhawk Combustioneering Ltd.–A - Can-Eng Furnaces International Ltd.–A CEC Combustion Services Group, Combustion Safety Inc.–A,B

--Find Findmore moreinformation informationononthese thesecompanies companiesatatwww.industrialheating.com/aftermarket www.industrialheating.com/aftermarket

4 May ✦ Town Hall Forum ✦ Technical Sessions ✦ Industry Exposition 5 May ✦ Plant Tours

IndustrialHeating.com IndustrialHeating.com -- April April 20011 2011 81 81

Are you a leader in the industry? Build your business and your career for today, and for tomorrow. You can’t afford to miss the 26th ASM Heat Treating Society Conference and Exposition – Heat Treat 2011. The ASM Heat Treating Society and the American Gear Manufacturers Association once again partner to create an exciting mix of education, technology, networking and exposition opportunities.

Is your company a leader in the heat treating industry?

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

The prime location, a great partnership in co-location, and the fact that the manufacturing sector is getting stronger and capital purchases are on the rise make Heat Treat a winner for you in 2011.

Join innovators, influencers and decision makers in the heat treating industry from around the world to discuss main technical areas of interest and gather for two new features – the special Bill Jones Honorary Symposium in celebration of his many years of equipment and process development and successful implementation in vacuum heat treatment, and the Emerging Technologies Symposium featuring theory and practical applications and technology trends/stateof-the-industry.

Custom exhibit, sponsorship and advertising packages are available.

Be sure to plan to attend and support this global event.

Prime exhibit space is selling quickly so now’s the time to reserve your space and lock in your booth

Visit www.asminternational.org/heattreat for the latest conference and exposition information.

We’re your partner for connecting you to highlyqualified attendees and delivering you access to buyers and decision makers in the heat treat industry.

location. Contact Kelly Thomas, National Account Manager at [email protected] or 440.338.1733. Sponsored by:

Media Sponsor:

Literature/Website Showcase Refractories & Insulating Materials | Ceramic Fixtures & Components | Materials Characterization & Testing Equip. High-Temperature Insulation Mersen As an expert in composite/graphite refractory materials and high-temperature insulation, Mersen combines unique expertise in the field of heat-treatment ovens. Our range of products includes a variety of rigid and flexible insulation materials that can be coated or impregnated. www.mersen.com

Charging Systems SGL Group – The Carbon Company Charging systems made from SIGRABOND® carbon fiber-reinforced carbon provide a number of advantages over systems made of high-temperature steel or molybdenumchromium or nickel-chromium alloys. Low thermal expansion and high creep resistance of our SIGRABOND charging systems guarantee that the workpieces do not undergo distortion. www.sglgroup.com

Insulation Unifrax I LLC New Foamfrax™ Insulation offers exceptional energy savings, installation speed and lining performance for upgrades of existing fiber linings, lining over refractory, and furnace lining patches or refits. It can be gunned IH09074ATS.indd directly onto metal, refractory or fiber surfaces and installed at rates in excess of 1,000 board feet/hour. Call: 716-278-3800; or visit us at www.unifrax.com.

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Industrial Heating

Technical Ceramics Ceramic Solutions Inc. Ceramic Solutions Inc. distributes a wide range of materials and products for the hightemperature ceramic and metal-processing industries. Products available from stock include: rollers, support tubes, spacers, furnace tubes and more. Materials available include: alumina, mullite and silicon carbide. www.ceramicsolutionsconroe.com

Materials Testing Equipment Applied Test Systems This brochure gives an overview of ATS’ extensive line of affordable yet uncompromising materials testing equipment. ATS is large enough to offer an extensive line of standard products. However, it is and always will be flexible enough to custom-tailor any systems for a specific application. Contact: 724-283-1212 www.atspa.com

CUSTOM Reprints 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 Profiles, Literature Features, and much more. Customize your reprints with your company’s ad, special message or even the cover of Industrial Heating. 200 March

9

dia p.3 ng in In ardeni Gear H Steel ss le Stain ng p.45 Nitridi Heat entury 21st-C p.51 Treating t -Elemen Heating 5 Q&A p.5 ers chamb ers le vacuum s to Chamb d multip e system Vacuum supplie -furnac y.The rson has vacuum industr BEPete plier of ufacturing h, a sup cations to TevTec ed-materials man ted to specifi as the anc rso n e fabrica ete wer the adv BEP ers se s and chamb wh ich cho , facilitie vacuum TevTech, its experience by d provide e of r becaus supplie . control quality on.com epeters www.b Drive son, Inc. Murphy BEPeter strial Park, 40 Avon Indu 02322-1121 6675 800.446. Avon, MA 7900 • Sales: 436. Tel: 508. 436.7999 omer Support Fax: 508. Cust .com Sales & peterson General l sales@be dica .com mation: Perio Infor trialHeating 2009 28 March

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9

First IQ Batch Furnace Certified to Carburize Wind-Turbine Gears James Caton and Mike LaPlante – Flame Metals Processing Corp., Rogers, Minn Working together, a Minnesota commercial heat treater, a Michigan manufacturer of atmosphere heat-treating furnaces and an Ohio furnace-controls company have developed the first integral-quench batch furnace in the U.S. approved for carburizing critical gears for wind-turbine applications. The Minnesota company is now certified to carburize gears to this rapidly growing energy market.

ews ews New tr y N stry st u ustr ndu IInd

F

llame Metals Processing Corp., R Rogers, Minn., is a 23-year-old ccompany that heat treats ferrrous and nonferrous components in atmosphere and vacuum furnaces at two locations in the Twin Cities area. Today, the company also is a certified supplier of carburized gears for wind-turbine applications. In 2006, Flame Metals was approached by Columbia Gear, Avon, Minn., a gearmanufacturing company servicing a number of original equipment manufacturers. One of its customers was a large international manufacturer of wind turbines looking for a commercial heat treater capable of meeting its performance standards. Flame Metals saw this as an opportunity to become involved in a new market. To demonstrate its capabilities, a process-development and certification program was undertaken. Industry

up to 40 years and are pushing for warranties of five years or longer on critical components. These requirements have made heat treating an increasingly important step in the manufacturing process. The gears Flame Metals was asked to carburize range in size from 24-36 inches in diameter, weigh from 600-3,000 pounds and require long heat-treat cycles. The gears are made of high chromium, high-

molybdenum steels like 4320, 4820, 9310 and 18CrNiMo7-6. Furnace Selection The first challenge facing Flame Metals was to determine the type of furnace it would use for the gear-carburizing program. Conventional thinking dictated a pit furnace. They are tight, simple to operate and can handle large loads. The

erican North Am Official Co-Sponsor Media rred

Prefe And Most Application Requirements ting.com strialhea gears, shafts and splines Wind-turbine • www.indu must meet tough performance standards ication PublHeati ng

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because equipment is 250 feet or more off the ground and usually located in remote areas to accommodate rotating blades that can have a 300-foot span. Because wind turbines are difficult and expensive to service, companies and individuals investing in this technology expect a service life of

AFC-Holcroft worked with Super Systems, Inc. to modify its BatchMaster furnace management system to meet the wind-turbine gear-carburizing requirements of Flame Metals. Reprinted from Industrial Heating January 2009

HT-First IQ Batch.indd 40

1/30/09 1:10:21 PM

Contact Becky McClelland at 412-306-4355 for details IndustrialHeating.com - April 2011 83

Literature/Website Showcase Materials Characterization & Testing Equip. | Miscellaneous Metallographic Equipment Buehler The new Delta® Manual Abrasive Cutter provides industrial strength with simple and reliable operation. Features a large blade capacity, heavy-duty motor, steel cabinetry floor stand, fiberglass hood and easy to use controls. The manual cutting lever gives the cutting action “feel” and allows for feed rate adjustment. www.buehler.com

Hardness Testing & Image Analysis Clemex Technologies Inc. Clemex CMT.HD is a field-proven hardness testing solution that offers unparalleled image quality and capabilities, and it is fully ASTME E-384 and DIN/ISO 6507 compliant. Clemex CMT.HD now offers more by adding a free copy of Image Analysis software Clemex Vision Lite. www.clemex.com

Automated Hardness Testing

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

LECO Corp. The AMH43 includes an optional Advanced Analysis Module with complete sample profile, available Color Hardness/Contour Map, and pattern support for welding studies. Designed for a number of applications, the AMH43 measures impressions of various surface conditions and supports both microindentation and macro/Vickers hardness testing. www.leco.com

Hardness Testing Equipment Proceq USA New Hardness Testing Equipment. Proceq USA is pleased to announce the new Impact Device S for use with the EQUOtip 2 portable hardness tester.-The new Impact Device S shows 10 times better wear than the Impact Device D at less than twice the price. Call us at 412-264-8440. www.proceq-usa.com

Plant Mangement Software Program

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 84 April 2011 - IndustrialHeating.com

Cornerstone Systems Inc. With over 350 installations, Visual Shop is the top-selling plant management software program for the commercial heat-treating industry. It includes quotations, orders, certifications, expediting, scheduling, tracking, shipping, invoicing, A/R, sales analysis, webbased customer portal and much more. Visit our website or call us (800-275-4274) to arrange a demo. www.csivisualshop.com

ASM Heat Treating Society Membership Heat Treating as a Community In 1986, psychologists McMillan and Chavis defined the sense of community as “a feeling that members have of belonging, a feeling that members matter to one another and to the group, and a shared faith that members’ needs will be met through their commitment to be together.” They further went on to identify four key elements in that definition, with “membership” being amongst them. Membership in the various communities we belong to in our lives is critical to how we define ourselves. It provides a sense of belonging and identification marked by the personal investments we make into those communities. When we first meet others, we provide glances of who we are – often by identifying the communities to which we belong, including those surrounding our careers. On that profile, we would be prone to seeing “heat treaters.” A major part of being a member of a community is establishing relationships with the others in the group. Over time, we strengthen those connections as we get to know more about each other, to the point that co-workers even develop close friendships. A key function of the ASM Heat Treating Society is to serve as a conduit for keeping in touch with each other. As part of the effort to do that, the ASM Heat Treating Society, in preparation for this year’s ASM HTS Conference & Exposition in Cincinnati, is launching a campaign to reconnect with each other. During the next six months, we want to re-establish those relationships – working and personal – that we had with each other as heat treaters. Unfortunately, with recent economic pressures, we all became somewhat consumed in the day-to-day grind and forgot about the people side of things. In each future installment of HTS Insider, we will discuss the people side of things in “Where Are They Now?” for members of our community, the ASM Heat Treating Society. To contribute information, simply send us your quick notes via e-mail to MemberServiceCenter@ asminternational.org. We look forward to your input!

HTS EVENT 26th ASM Heat Treating Society Conference and Exposition Oct. 31 – Nov. 2, 2011 Duke Energy Convention Center Cincinnati, Ohio USA Conference Co-chairs B. Lynn Ferguson, Deformation Control Technology Inc. Roger A. Jones, Solar Atmospheres Dale Weires, Boeing Philadelphia The ASM Heat Treating Society and American Gear Manufactures Association (AGMA) are co-locating at HT 2011. The 2011 Heat Treat Society Conference and Exposition is shaping up to be a don’t-miss event! A total of 93 papers will be presented over the 2-1/2 day conference, and the exposition floor is on its way to a complete sellout. In an effort to excite and engage students at all levels, a mini-Materials Camp® will be held on the show floor on Tuesday and Wednesday (Nov. 1 and 2). More than 400 high-school students have registered to attend and take part in the demonstrations. For college and graduate students, the Heat Treat Society will be conducting a poster contest as well as awarding travel grants to those schools who apply for it. The event will also feature a Special Symposium in honor of William R. Jones, president and CEO of Solar Atmospheres Inc., whose contributions to the heat-treating industry are enormous. Mark your calendars and continued on page 86

ASM HTS Forms Reference Publications Committee The Heat Treating Society has formed a Reference Publications Committee chaired by George Totten, FASM, president of G.E. Totten & Associates LLC. The mission of the committee is to direct the ongoing review, updating and expansion of reference material related to heat treating and allied technologies for the ASM Handbook series and e-book technical publications. We are looking for candidates to serve on the committee. Recommendations or expressions of interest should be sent to [email protected]. Please include “Reference Publications Committee” in the subject line.

IndustrialHeating.com - April 2011 85

continued from page 85

plan to attend HT 2011 in Cincinnati, Ohio. Look for early registration and housing specials, and take advantage of group discounts. Visit www.asminternational.org/heattreat for more information. Prime exhibit space, advertising and sponsorship packages are available. To reserve yours today, contact Kelly Thomas, national account manager, at 440-338-1733 or kelly. [email protected].

Heat Treat 2011’s Virtual Trade Show MyHeatTreatExpo.com is your quickest way to Heat Treat 2011! Don’t miss an opportunity to join the growing list of exhibitors and visitors. Attendees can browse the expo and search the show by product, booth number or company name. Exhibitors get early visibility to prospective customers, and they can showcase their products and services, reach customers and prospects worldwide, and increase exposure by driving traffic to their website. For more information, contact Kelly Thomas, national account manager, at 440338-1733 or [email protected].

Robert Gaster to Receive CHTE Distinguished Service Award Robert Gaster, a senior staff engineer for materials engineering at the Deere & Company Moline Technology Innovation Center, will receive the Distinguished Service Award from the Center for Heat Treating Excellence (CHTE), part of the Metal Processing Institute (MPI) at Worcester Polytechnic Institute (WPI). The award, which will be presented during the annual CHTE spring meeting May 24-25, recognizes individuals who, in the judgment of the CHTE board, have made significant, commendable and long-standing contributions to the promotion of CHTE. Among CHTE’s most ardent supporters, Gaster has served in several capacities during his tenure with the center. He was chair of the board and the project-selection committee and served on CHTE’s strategic-planning committee. Gaster joined John Deere after receiving a B.S. in metallurgy from Iowa State University. At Deere & Company, he is responsible for 86 April 2011 - IndustrialHeating.com

enterprise heat-treating technology and innovation and consultation, and he has additional responsibilities in wearresistant coatings and metallurgical consulting for Deere & Company manufacturing units. He has been a member of ASM for 37 years and is a founding member of the Heat Treating Society. He served in many leadership positions, including HTS board director (2000-2003) and HTS president (2003-2005). He also has served on various HTS committees, including the Awards and Nominations, Finance, Technology & Programming, and Research & Development Committees as well as the ASM Volunteerism Committee.

ASM Education and Training Upcoming Heat Treating Courses: May 9-11, 2011 Heat Treatment, Microstructure, and Performance of Carbon and Alloy Steels Instructor: George Krauss, FASM; Homewood Suites, Beachwood, Ohio This course reviews the microstructural constituents in carbon and alloy steels and microstructural variations resulting from alloying and the manufacturing process. Heat treatment, phase transformations and resulting microstructures are described and related to mechanical properties and performance. Special attention is given to the effects of processing, alloying and heat treatment on fracture behavior and potential embrittlement phenomena. June 20-22, 2011 Heat Treating for the Non-Heat Treater Instructor: D. Scott MacKenzie, FASM; Homewood Suites, Beachwood, Ohio This course is for the NON-heat treater (part designers, material specifiers, purchasing agents and technicians) who needs a basic education in heat treating and needs to learn how to “speak the language.” The focus is on the “value added” by heat treating. The effects that heat-treating process parameters have on final product properties and the links between microstructure and mechanical properties are discussed. Course dates subject to change. For more information about these and other ASM education options, contact the Member Service Center at 800-336-5152, ext. 0; John Peppler at 440-338-5151; or MemberServiceCenter@ asminternational.org. On the Web, visit www.asminter national.org > Education & Training.

New Education Course Offerings! ASM Harvard Business-Skills Courses Now you can take ASM’s new online courses, developed by Harvard Business Publishing, addressing daily management responsibilities ranging from running a meeting to developing a strategy and everything in between. Choose from more than 42 key management topics taught by world-renowned experts, practitioners and business leaders. Courses include real-world scenarios and self tests and offer downloadable forms and worksheets (ideal for continuous use and flexible application). A self-directed format allows managers to hone new skills and receive instant feedback in a safe online environment. Receive Certificates of Achievement upon completion. Begin improving your management expertise today with ASM Harvard Business Skills courses. Take a look and register online. Visit http://www.asminternational.org/portal/site/www/education/ harvard.

Don’t Forget to Check Out ASM International on Facebook Facebook is an alternative way for members and customers to interact. We encourage wall postings, discussions, member experiences, reviews of our products and services, photos from events, “happy member” photos, best-practices, etc. Find out what’s going on at ASM (you’ll need a FB account), and stay in touch with your society and your colleagues on Facebook.

!

oday ter t s s i g re count and s Plan Group di ilable. a v a are

AeroMat – What you need to know about the future of the aerospace industry • Distinguished Plenary Presentations include: New and better materials and • Hypersonic Flight: The Final Frontier significant advancements in process of Aeronautics technologies are discovered each year. Kevin Bowcutt – The Boeing Company AeroMat provides the information you • Volcanic Ash – Aircraft Engine Encounters need. No where else can you get this high-level Michael George Dunn – The Ohio State University aerospace materials knowledge.

Sponsored by:

Co-located with:

Media Sponsor:

• Co-location with SAMPE • Technical Program featuring the latest advances in the aerospace community delivered by industry • Special Thermal Spray for Aerospace Session • Industry-Driven Education Short Courses • Expanded Exposition – Exhibit, sponsorship and advertising opportunities are still available • Unlimited Networking Opportunities • Significant Group Discounts Available

• MMPDS Handbook – What? Why? And How? – An FAA Perspective Robert Eastin – FAA Richard Rice – Battelle • Investments in our Future: Exploring Space through Innovation and Technology Michael J. Gazarik – NASA • A Vision on the Development of More Efficient Aircraft Structures Waldir Gomes Gonçalves – Embraer • Materials and Processes Technology – Stability in an Uncertain Space Industry Jerrol (Jay) Littles – Pratt & Whitney Rocketdyne

Keep current with our ever-changing industry at AeroMat. Register today at www.asminternational.org/aeromat. Nowhere else can you get this high-level aerospace materials knowledge.

IndustrialHeating.com - April 2011 87

Products

Insulation Wool Morgan Technical Ceramics Superwool® Plus is 17% more energy efficient than traditional refractory ceramic fiber (RCF) and any other Alkaline Earth Silicate (AES) insulations. Superwool Plus is ideal for furnace linings in the iron, steel and aluminum industries as well as all applications requiring high-temperature processing. This enables users to increase manufacturing process efficiencies and make significant cost savings associated with energy usage. The material provides excellent insulation in high-temperature environments up to 2192°F (1200°C).

Superwool Plus has up to 20% lower thermal conductivity than competitive insulations and enhanced energy-saving properties with much improved handleability. It also delivers high performance with less mass and blanket thickness than alternative products. The insulation fiber blanket has high tensile strength with good handling ability. It is currently available in blanket, modules, Pyro-Bloc® modules, paper and bulk (chopped and unchopped). www.thermalceramics.com

Digital Force Gauge

From March 1927

Phone: 248-624-8191 www.afc-holcroft.com

88 April 2011 - IndustrialHeating.com

Mark-10 The all new Series 3 digital force gauges are designed for tension and compression force testing in quality control, manufacturing and R&D areas. A range of capacities from 0.12 to 500 pounds (0.5 N to 2500 N) is available to address numerous applications in virtually every industry, including medical device, automotive, aerospace and others. Accuracy is better than +/-0.3% of full scale. The force gauges feature a sampling rate of 2,000 Hz; large, backlit graphic display; and simple, intuitive menu structure for quick access to the gauges’ features and configurable parameters. Data output is possible via USB for further analysis on a PC. Integrated setpoints with indicators are ideal for pass-fail testing. The gauges are overload protected to 150% of capacity, and an analog load bar is shown on the display to help the user identify when an overload condition is imminent. www.mark-10.com

Products

Hardness Test Blocks

Selective Soldering Fixture

Wilson Hardness These Brinell hardness test blocks are supplied with the industry’s most comprehensive certificate of calibration, traceable to National Institute of Standards and Technology (NIST). Designed with a test surface measuring 6 x 4.5 inches, the number of indents per block has been increased from 35 to 80 on average, providing 128% more tests on a single test block. The larger size and increased life will result in fewer orders, resulting in lower administrative costs for consumers. An engraved indent placement pattern ensures appropriate indent spacing is maintained, eliminating erroneous readings. These test blocks are both ASTM E10 and ISO 6506 compliant. www.wilsoninstruments.com

Datapaq The PA2200A selective soldering fixture simplifies selective soldering process monitoring, which helps to optimize the manufacture of electronic assemblies used in a wide range of automotive and aerospace products. Selective soldering is employed in applications where a small number of conventional components need to be soldered to a very high standard on an electronic assembly containing mostly surface-mounted components. With the PA2200A, manufacturers can quickly and easily measure process stability during selective soldering. This includes monitoring both pre-heat and solder pot performance with a single fixture. They can also compare the performance of a number of selective soldering machines and easily replicate temperature profiles in separate manufacturing locations worldwide. www.datapaq.com

Documenting Process Calibrator E Instruments The DPC 2000 will meet your calibration needs with the highest accuracy in its class of up to 0.015% of reading. The DPC 2000 measures and simulates: DC voltage, DC current, 13 types of thermocouples (J, K, T, E, R, S, B, C, XK, BP, L, U and N), 13 types of RTDs, frequency, loop supply and pressure. In addition, it stores up to 21 data points per instrument and up to 50 instruments in non-volatile memory. The data can be uploaded to a PC for analysis with Microsoft Excel or a full database program. www.e-inst.com

Materials | Development | Solutions

Heat Treating Solutions Furnace Repair and Operations Are you heat treating large aerospace parts in vacuum furnaces? Do you have high production parts to be brazed through controlled atmosphere furnaces? Are you annealing medical and aerospace products to critical specifications? H.C. Starck, a leading supplier of molybdenum, tungsten, tantalum, and alloys such as la-doped molybdenum and TZM, has the product solution for you. H.C. Starck’s value-added products are used for heat treating, sintering, annealing, brazing, and all high temperature furnace applications in the medical, aerospace, defense and automotive industries. > Furnace Parts > Heat Shields > Sintering Boats

> Heating Element Materials > Molybdenum & Tungsten Mill Products

Learn how H.C. Starck can become your strategic partner for high tech materials by calling +1 617.584.9322 or email [email protected]. Visit us on the web at www.hcstarck.com.

IndustrialHeating.com - April 2011 89

Products

Inductor Technology

Busch USA

GH Induction Atmospheres Microfusion technology allows identical inductors to be produced from the same 3-D manufacturing mold. The inductor (the business end of induction heating machines used for metal hardening, brazing and other metal-heating processes) consists of specially shaped conductive material through which alternating electrical current is passed. Traditional inductor manufacturing is a one-off process; copper tubing is shaped by hand to conform to engineering specifications. This makes it exceptionally difficult to manufacture absolutely identical inductors with the same performance characteristics. With Microfusion technology, multiple inductors can be produced from the same pre-qualified mold. This increases repeatability and consistency when multiple induction systems are running the same process, and significantly reduces maintenance and calibration time when inductors need to be changed. www.inductionatmospheres.com

Rotary Claw Vacuum Systems Mink series rotary claw vacuum systems with variable-speed controls provide true on-demand performance for a wide range of industrial processes and applications. These high-efficiency systems automatically regulate the speed of the individual pump modules to match the system load, greatly reducing both energy and maintenance costs. These systems also feature 100% oil-less compression and minimal maintenance. www.buschusa.com

Electrically Heated Oven Precision Quincy Corp. The 49C-650D is an electrically heated oven that is available in NFPA 86 Class A or Class B configuration. The oven is a popular choice among heat processors for most curing/drying/pre̺heating needs because of its ability to successfully process a wide range of materials. The 49C-650D’s compact design features two independent oven chambers (stacked one above the other), each with separate controls, and shares a single dampered exhaust system. A robust piece of equipment, it weighs in at 1,180 pounds with two internal working spaces of 32 inches wide x 18 inches deep x 18 high and exterior dimensions of 43 inches wide x 29 inches deep x 45 inches high. The oven is capable of reaching and maintaining a maximum temperature of 650°F. An optional matching heavy-duty stand provides a stable base that adds an extra 24 inches to the overall height of the oven – a useful feature that makes for easier product loading and removal. This oven is factory wired, tested and balanced prior to shipping to ensure quick, trouble-free startup. www.precisionquincy.com

From Sept. 1936

Phone: 419-891-7150 www.surfacecombustion.com

90 April 2011 - IndustrialHeating.com

S No pon w sor Av sh ail ip ab s le

2011 Heat Treat China Show and 3rd China Heat Treat Forum

May 25-27, 2011 • Beijing International Convention tion Center

Presented by:

Call today for more information! Doug Glenn Publisher, Industrial Heating (412) 306-4351 [email protected] www.industrialheating.com

Heat Treat China 2011 will bring together industry professionals from China, USA and Brazil in the largest production and processing market for heat treatment. As a sponsor, you will have the opportunity to network with attendees and demonstrate and discuss cutting-edge technologies and stateof-the-art equipment. Nearly 3,000 professionals are expected to attend, and all sponsors will receive the full registration list.

Who Will Attend: • • • • • • • • • • •

Heat Treat Companies Auto and Motorcycle Parts Manufacturers Aviation and Space Manufacturers Forging Companies Gear Manufacturers Bearing Manufacturers Mechanical Manufacturers Iron and Steel Companies Non-ferrous Companies Heat Treat Equipment Manufacturers Other Manufacturers

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! 92 April 2011 - IndustrialHeating.com

Industrial Heating TRAINING 2011 Invest 60 Minutes and LEARN Induction Success or Failure: Optimum Frequency for Your Process

60 mins./webinar including Q&A. Sign Up TODAY Online At: webinars.industrialheating.com By the way, did we mention ....  No software to install  Industry expert speakers  Live Q&A sessions  We send an e-mail reminder  Previous webinars archived  All three webinars are FREE!

2:00 p.m./May 19 Selection of the correct operating frequency for an induction-heating application can spell the difference between a successful process and the inability to perform. This Webinar will explore the theory behind frequency selection and the methods for obtaining the optimum frequency for the application. Typical applications will be covered as well as those special areas where multiple frequencies and high frequencies can be job specific.

Temperature Sensing/Control: The Right Tools Save You Money 2:00 p.m./August 18 Topics to be covered include: principles of temperature measurement; types of sensors and suitable applications; response, accuracy and quality control; nonuniformities, errors and numerical models; indicators, switches, transmitters and telemetry; and sensors for safety, environmental control and process control.

Secrets of Hardness & Mechanical Testing 2:00 p.m./November 11 This webinar will focus on hardness testing (e.g., Brinell, Rockwell, Rockwell Superficial, Microhardness) and include examples of common testing problems encountered. The presenter will also discuss various other types of mechanical-testing methods, including fatigue, tensile strength, impact, shear and torsion testing. Other types of industry tests such as stress rupture, stress durability, pull-out/push-out, vibration, engagement, wear, microstructure, chemical analysis and corrosion will also be covered.

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East Windsor, CT, manufacturing company is looking for a field service tech for repair of vacuum heat treating equipment. Ideal candidate would have experience troubleshooting vacuum furnace electrical circuits. Email resume to [email protected]. www.vacuumengineering.com

[email protected] attn: mht manager now Modern Industries, Inc. www.modernind.com

HELP WANTED

“Nadcap and You… Achieving Excellence Together.” Build Your Career with a Global Industry Leader. Performance Review Institute is seeking Aerospace experienced consultant auditors for the Nadcap Heat Treating program. As a Nadcap auditor, you will perform heat treating audits, complete audit reports, and have the opportunity to train associate auditors. The ideal candidate will possess the following general background: • Bachelor’s Degree in a technical field • Understanding of General & Aerospace quality systems (ISO, AS/EN/JISQ9100) • Familiarity with General Consensus specifications and Aerospace Standards • Computer skills in word processing, spreadsheets, email and internet • Desire to travel • Multi-lingual a plus • Strong interpersonal skills The following are specific criteria for Heat Treating: • Five (5) years “hands-on” experience (preferably in the aerospace industry) with the following processes: Aluminum Heat Treating, Titanium Heat Treating, Heat Resisting Treating, Heat Resisting Alloys, Brazing Alloys • Understanding of AMS2750 or Pyrometry specification As an innovative industry leader, we are proud to offer our auditors: • Flexible Schedules • Competitive Daily Rate • Paid Travel & Living Expenses • Paid Annual Training • No Need to Relocate

Always Online at: www.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.

See why Nadcap has been attracting & retaining some of the best professionals in the industry! Apply on-line today, via our application website, www.eAuditStaff.com. Determine your area of auditor expertise in one or more of these specific disciplines: Chemical Processing, Coatings, Composites, Conventional Machining, Elastomer Seals, Electronics, Fluid Distribution Systems, Heat Treating, Materials Testing, Non-Metallic Materials Testing and Manufacturing, Nondestructive Testing, Nonconventional Machining, Sealants, Surface Enhancement and Welding. For more information on PRI and the Nadcap program, visit our website, www.pri-network.org. Nadcap is administered by the Performance Review Institute, an equal opportunity employer, who values the diversity of our work force and the knowledge of our people.

96 April 2011 – IndustrialHeating.com

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

Classified Marketplace FOR SALE

FOR SALE

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CASHVAC INC. • • • • •

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

IndustrialHeating.com – April 2011 97

Classified Marketplace

Since 1936

––––– ATMOSPHERE GENERATORS ––––– 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 10.000CFH Exothermic Seco/Warwick (2) Gas –––––––––– BOX FURNACES –––––––––– Huppert Elec 2000˚F 8" × 12" × 6" Lucifer Up/Down Elec 2000/1250˚F 9" × 14" × 9" 9" × 18" × 9" Lucifer Up/Down Elec 2000/1250˚F 12" × 24" × 8" Lucifer Up/Down (Muffle) Elec 2100˚F 12" × 24" × 8" Hayes (Atm) Elec 1800˚F Elec 2000˚F 13" × 24" × 12" Electra Up/Down Fce. Works (Muffle) Gas 2000˚F 12" × 24" × 8" 14" × 24" × 12" Lindberg H2 Retort Elec 2150˚F Elec 2350˚F 17"×14.5"×12" L&L (New) 22"×36"×17" Lindberg-Retort Elec 2100˚F Lindberg Elec 2000˚F 24"×36"×18" 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 Gas 1850˚F 288" × 60" × 36" Sauder "Tip-Up" –––––––––– 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 ––––––––– 24" × 36" × 24" ALD - 6 Bar (1997) Elec 2450˚F Elec 2450˚F 24" × 36" × 24" ALD - 6 Bar –––– 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 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 Elec 2400˚F 16" × 24' × 4" Abbott (Atmos.) Muffle 24" × 17' × 28" Jensen – Dual Belt Gas 500˚F Gas 500˚F 24" × 19' × 30" Jensen 24" × 30' × 30" Jensen Gas 500˚F Elec 500˚F 24" × 40' × 18" Despatch 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

–––––––––– 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 Wilson Hardness Testers (RC) SBS Air/Oil Coolers ––––––– OVENS/BOX TEMPERING –––––– Gas 1250˚F 12" × 18" × 12" Surface 12" × 18" × 12" Lucifer Elec 1250˚F 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 Elec 1250˚F 15" × 24" × 18" Lindberg 18" × 36" × 18" Surface Gas 1200˚F 18" × 48" × 18" Lucifer Elec 1400˚F 20" × 18" × 20" Blue-M Elec 400˚F 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 20" × 18" × 20" Despatch Elec 500˚F 20" × 24" × 20" Despatch Elec 1350˚F 24" × 24" × 24" Grieve Elec 850˚F 24" × 26" × 24" Grieve Gas 500˚F 24" × 24" × 36" New England Elec 800˚F 24" × 24" × 48" Blue-M (2) Elec 600˚F Elec 500˚F 24" × 36" × 24" Demtee (N2) 24" × 36" × 24" Surface Gas 1400˚F 24" × 36" × 24" Paulo Gas 1250˚F 25" × 20" × 20" Blue-M Elec 650˚F 25" × 20" × 20" Blue-M Elec 1300˚F Elec 850˚F 26" × 26" × 38" Grieve (2) 30" × 48" × 54" Lindberg Gas 1250˚F 36" × 24" × 24" Young & Bertke Elec 400˚F 36" × 24" × 48" Blue-M Elec 600˚F 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 36" × 60" × 36" CEC (2) Elec 650˚F 36" × 36" × 120" Steelman Elec 450˚F 38" × 20" × 26" Grieve Elec 850˚F 38" × 26" × 38" Grieve Elec 1250˚F Elec 600˚F 48" × 24" × 48" Blue-M 48" × 30" × 42" Despatch Gas 850˚F 48" × 30" × 48" P-Quincy Elec 500˚F 48" × 48" × 72" Lydon Bros. Elec 450˚F 48" × 48" × 72" Gruenberg Elec 500˚F 48" × 48" × 84" Gruenberg Elec 450˚F Elec 500˚F 48" × 72" × 72" Mich. Oven 50" × 50" × 50" Grieve Gas 850˚F 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" × 96" × 72" Despatch (2) Gas 750˚F Gas 500˚F 72" × 72" × 72" Mich. Oven 72" × 120" × 72" Grieve Gas 450˚F 72" × 144" × 42" Bowman (Car) Gas 1000˚F 84" × 96" × 72" Despatch (2) Gas 750˚F 96" × 120" × 96" Poll. Cont. Burn-off Gas 850˚F

Industrial Heating

REPRINTS 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 for details Always Online at: www.industrialheating.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 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

98 April 2011 – IndustrialHeating.com

Classified Marketplace FOR SALE

FOR SALE New Design

SPARK IGNITER

FOR SALE

Used for the automatic ignition of recuperative burner systems.

AFC Mesh Belt Austemper Furnace System *Diff erent Leng ths A vailab le

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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. NEW DESIGN • Improved Performance • Longer Life • Larger Gap • Floating Spark • Direct Replacement Call for model/ pricing information

*We offer both designs

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

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

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

Fax Your Ad To: Becky McClelland at 248-502-1076 Or Mail To: Industrial Heating Manor Oak One, 1910 Cochran Road, Suite 450, Pittsburgh, PA 15220 Or Call (412) 306-4355 • Email: [email protected]

FOR SALE Diffusion Bonding

Densification

SVLXQLIRUPO\GLVWULEXWHGSODWHQSUHVVXUH &)0RO\KHDWHUVVKLHOGV SODWHQV [7RUU+LJK9DFXXP'LIIXVLRQ3XPSV )PLQ)DVW&RROLQ$UJRQIURP)WR) SRXQGORDGFDSDFLW\ %DWFKRU6HPLFRQWLQXRXV 8VHGIRUKLJKYROXPHSURGXFWLRQRIGLIIXVLRQERQGHG7LWDQLXP :HFDQFXVWRPL]HWKLVV\VWHPWRPHHW\RXULPPHGLDWH QHHGV /RFDWHGLQVRXWKHUQ1HZ(QJODQG IndustrialHeating.com – April 2011 99

Classified Marketplace FOR SALE

FOR SALE

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

Industrial Heating REPRINTS An excellent marketing opportunity!

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

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

for sale

Standard Fuel Engineering Mesh Belt Conveyor-Type Tempering Furnace 1050˚F maximum temperature Single zone Direct Gas Burner Garden City Recirculating Fan 48” wide x 45’-0” overall length Barber Colman Temperature Controls

TWO AVAILABLE!

For more information contact our sales team at: [email protected] or 734.656.2000 ext. 2

100 April 2011 – IndustrialHeating.com

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

FOR SALE

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

FOR SALE

H

Bonds Most Materials

Park Thermal Electric Re-Circulating Furnace

Resists Chemicals, Electricity,

120 KW, 52" W x 50" H x 9' long, 1400ÝF. Complete with Digital Controls. Mint Condition.

Molten Metals and Abrasion

2300 F

AFC Mesh Belt Tempering Furnace

O

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

FREE MATERIALS HANDBOOK

COTRONICS CORP.

Lindberg Electric Rotary A-1 Condition

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

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

Bring Your Heat Treating In-House Contact Becky McClelland at 412-306-4355 for details

• • • • •

Energy Efficient Temperatures to 3000˚F Electric or Gas Atmospheres Easy to Operate

WWW.LUCIFERFURNACES.COM • Phone: (800) 378-0095 • Fax: 215-343-7388 IndustrialHeating.com – April 2011 101

Advertiser Website Index Page 87 28-29,71,88 21 63 81 11 58 39 83 82,87 92 10 31 67 73 Inside Back Cover 38 36 84 23 48 57 19,77 89 40,60 54 32 Back Cover 42 40 25, 34 38,47 12 15 30,59 4,5 33 69 32 27 Inside Front Cover 30 53 35 9 6, 90 47 41 3,72 17 37 13

Company AeroMat 2011 AFC-Holcroft Agilent Technologies, Vacuum Products Div. Air Products and Chemicals, Inc. AIST Ajax TOCCO Magnethermic Corp. Alpha 1 Induction Ameritherm Applied Test Systems Inc. ASM International AVS BeaverMatic, Inc. Becker, Co. J. L. Bloom Engineering Can-Eng Furnaces Ltd. CEIA USA Ltd. Ceramic Solutions Inc. CLEMEX Cornerstone Systems Inc. Custom Electric Manufacturing Co. Dry Coolers Inc. Furnace Parts G-M Enterprises H.C. Starck Inc. Hauck Manufacturing Honeywell Process Solutions IFI Inc. Inductoheat®, Inc. Inductotherm Group INEX Incorporated Ipsen, Inc. Jackson Transformer Co. LECO Corp. Mersen Metallurgical High Vacuum Corp. Nanmac Corp. National Element Inc. Newport Electronics, Inc. North American Cronite, Inc. Nutec Bickley Omega Engineering, Inc. Proceq USA Inc. Selas Heat Technology Co. LLC SGL Carbon, LLC Solar Manufacturing Surface Combustion Inc. Thermo-Calc Software Thermprocess Show T-M Vacuum Products, Inc. Unifrax LLC Vac Aero International Inc. WIRCO, Inc.

102 April 2011 - IndustrialHeating.com

Phone 800-336-5152 248-624-8191 800-882-7428 800-654-4567 724-814-3000 800-547-1527 800-991-2599 585-889-9000 800-299-6408 800-336-5152 212-248-0200 815-963-0005 734-656-2000 412-653-3500 905-356-1327 888-532-CEIA 936-588-2646 450-651-6573 800-275-4274 248-305-7700 800-525-8173 800-321-0796 951-340-4646 617-584-9322 717-272-3051 602-293-1288 586-726-2388 800-624-6297 609-267-9000 716-537-2270 800-727-7625 813-879-5811 800-292-6141 01 46 91 54 00 269-543-4291 508-872-4811 800-600-5511 800-NEWPORT 800-243-4123 52-81-8151-0800 203-359-1660 800-839-7016 215-646-6600 800-727-4474 215-258-3350 800-537-8980 724-731-0074 332-781-5180 856-829-2000 716-278-3800 905-827-4171 800-348-2880

Website www.asminternational.org/aeromat www.afc-holcroft.com www.agilent.com/go/varian www.airproducts.com/metals www.aistech.org www.ajaxtocco.com www.alpha1induction.com www.ameritherm.com www.atspa.com www.asminternational.org www.avs.org www.beavermatic.com www.jlbecker.com www.bloomeng.com www.can-eng.com www.ceia-usa.com www.ceramicsolutionsconroe.com www.clemex.com www.ask4csi.com www.custom-electric.com www.drycoolers.com www.furnacepartsllc.com www.gmenterprises.com www.hcstarck.com www.hauckburner.com www.honeywell.com/ps/hfs www.ifi-inc.com www.inductoheat.com www.inductothermgroup.com www.INEXinc.net www.ipsenusa.com/sintering www.jacksontransformer.com www.leco.com www.mersen.com www.methivac.com www.nanmac.com www.nationalelement.com www.newportUS.com www.afegroup.com www.nutecbickley.com www.omega.com www.proceq-usa.com www.selas.com www.sglcarbon.com www.solarmfg.com www.surfacecombustion.com www.thermocalc.com www.mdna.com www.tmvacuum.com www.unifrax.com www.vacaero.com www.wirco.com

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