Industrial Heating November 2011

November 2011

Landing Strong p.37 Nadcap for HIP p.43 Cleaner Steelmaking p.47 Nitrided Microstructures p.51 Web Search Power Pages p.4 Materials Characterization & Testing Buyers Guide p.70

Do-It-Right DDo IIt Riight h Advisory p.56 A

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What you’ve been waiting for.

Introducing HybridCarb — a better choice from Ipsen ®

The new HybridCarb® from Ipsen is an ultra-efficient gassing system designed to replace endothermic generators and other gassing systems. Its core strength is precision gas control. Instead of burning excess gas off, the process gas is reconditioned and reused, increasing efficiency up to 90%. HybridCarb allows for the reduction of more than 40 tons of CO2 per year – the equivalent of planting 220 trees. Other benefits of HybridCarb include: • • • • • •

Quick and easy hookup Increased carburizing efficiency Improved hardness uniformity Significantly less expensive to operate than endogenerators Consumes significantly less gas Environmentally friendly and cost efficient

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Industrial Heating’s Web Search Power Pages ALLOYS & SPECIALTY METALS Steeltech Ltd. Steeltech has created a new line of energy-efficient, lightweight, sturdy baskets: the Cast-Lite Basket Series, which has resulted in more than a 25% increase in throughput. These baskets resist distortion, leading to a longer service life with minimal re-shaping required. Contact: 616-243-7920 www.steeltechltd.com Thermalloys Thermalloys is a manufacturer of tubes in high-performance FeCrAl alloys with higher oxidation resistance than any other commercial iron or nickel-based alloy. Applications include protection tubes and muffle tubes. Contact: 462-481-2577 www.thermalloys.com

BURNERS & COMBUSTION EQUIPMENT Eclipse, Inc. New self-recuperative burners from Eclipse have raised the bar for efficiency. The TJSR v5 burner delivers fuel-saving recuperation in a direct-fired, high-velocity burner. Contact: 815-877-3031 www.eclipsenet.com Maxon - A Honeywell Company Maxon – A Honeywell Company manufactures a full line of industrial combustion equipment, including hazardous duty shut-off valves, ultra-low NOx burners and flow control products. Contact: 765-284-3304 www.maxoncorp.com WS Thermal Process Technology: High-Efficiency Burners We offer the most efficient direct-fired and radiant tube burners and are a world leader in ceramic radiant-tube technology with over 15 years of experience. Contact: Lee Rabe, 440-365-8029 www.flox.com

CASTINGS/FABRICATIONS Castalloy Corp. Castalloy is a leading producer of high-alloy heat-resistant castings and manufacturer of a wide variety of cast products to meet a broad range of applications throughout the thermal-processing industry. Contact: 262-547-0070 www.castalloycorp.com Wirco, Inc. Wirco is the premier supplier of engineered heat-resistant castings/fabrications for the thermal-processing industry. Wirco proudly supplies high-quality baskets, cast trays, cast/fabricated radiant tubes, mesh products, rolls, fans, cast/fabricated racking fixtures, rails and chain guides. Contact: 800-348-2880; [email protected] www.wirco.com

4 November 2011 - IndustrialHeating.com

CONTROLS, INSTRUMENTATION & TESTING EQUIPMENT Applied Test Systems Applied Test Systems is a leading manufacturer of process heating and materials testing equipment designed for creep and tensile testing, burst testing, sealant testing, asphalt testing and a variety of process heating applications. Our products are supported by our A2LA-accredited service and calibration department. Contact: [email protected]; 724-283-1212 www.atspa.com Clemex Technologies: Hardness Testing Clemex CMT.HD is a field-proven hardness testing solution that offers unparalleled image quality and capabilities. Contact: 450-651-6573 www.clemex.com Quality Solutions: Hardness Testers Quality Solutions is now offering new technology in hardness testing from “ERNST,” one of the world’s leading manufacturers of hardness testing equipment. Contact: 855-263-1892 www.qs-hardnesstester.com Struers Inc. Struers offers an entire range of equipment and consumables for materialographic specimen preparation. To complement our materialographic products, Struers also sells an extensive line of hardness testers and microscopes. Contact: Bill Thompson, 888-787-8377 www.struers.com Yokogawa The UTAdvanced is Yokogawa’s newest controller that combines PID control and ladder logic. The universal flexibility and ample communication protocols makes the UTAdvanced the most efficient and easy-to-use hybrid controller. Contact: 800-258-2552 www.yokogawa.com/us

FURNACES & OVENS G-M Enterprises: Heat-Treating Furnaces G-M manufactures a wide range of furnaces, including vacuum, box, bell, batch and continuous. Contact: Suresh Jhawar, 951-340-4646 www.gmenterprises.com Ipsen Inc.: Heat-Treating Equipment Ipsen manufactures, retrofits and services vacuum and atmosphere thermal-processing equipment for TurboTreater, TITAN, MetalMaster,VFS HEQ/HIQ/VDS, aluminum brazers, vacuum carburizing, vacuum oil quench, Ivadizer and atmosphere products. Contact: Mark Heninger, 815-332-2512 www.ipsenusa.com SECO/WARWICK.: Heat-Treating Equipment SECO/WARWICK provides industrial metal heat-treatment furnaces used in a variety of processes for material finishing and component manufacturing applications. Contact: Dominick DiRienzo, 814-332-8437 www.secowarwick.com

Industrial Heating’s Web Search Power Pages FURNACES & OVENS cont.

REFRACTORIES & INSULATION

Surface Combustion, Inc.: Heat-Treating Furnaces Industrial heat-treating equipment including furnaces, auxiliary equipment, atmosphere generators and process controls. Contact: Daniel E. Goodman, 419-891-7150 or 800-537-8980 www.surfacecombustion.com

SGL Carbon LLC SGL is a full-service material supplier specializing in hightemperature applications and customer support. Contact: Lee Young, 610-670-4070 www.sglcarbon.com

HEATING ELEMENTS

Unifrax I LLC High-temperature insulation products including Fiberfrax ceramic fiber, Insulfrax and Isofrax soluble fiber, and Foamfrax thermal insulation. Contact: Virginia Cantara, 716-278-3832 www.unifrax.com

Custom Electric Manufacturing Co. Custom Electric designs and builds original equipment and replacement heating elements for heat treating, die casting and related industrial thermal-processing applications. Contact: Bob Edwards, 248-305-7700 www.custom-electric.com

THERMOCOUPLES

I Squared R Element Co. Starbar and Moly-D elements are made in the United States with a focus on providing the highest-quality heating elements and service to the global market. Contact: 716-542-5511 www.isquaredrelement.com

Furnace Parts LLC Furnace Parts is an industry leader in the manufacture of specialty thermocouples and temperature sensors. Our expertise includes a full line of assemblies. Contact: John Popovich, 800-321-0796 www.furnacepartsllc.com

Omega Engineering: Heaters OMEGA provides customers with a complete line of automation, data acquisition, electric heating and custom-engineered products. All products and literature are available through online shopping at our website. Contact: 203-359-1660 www.omega.com

NANMAC Corp.: High-Performance Thermocouples and RTDs Since 1956, Nanmac has been a dynamic leader in the specialized field of thermocouple and RTD manufacturing, for both industrial and research applications. Contact: Doug Joy, 508-872-4811 www.nanmac.com

VACUUM PUMPS/VALVES HOT ZONES Plansee USA LLC: Vacuum-Furnace Hot Zones PLANSEE USA is the industry leader in developing, designing and manufacturing high-temperature furnace products (hot zones, furnace racks, sintering boats, mill products and much more). Contact: 508-553-3800 www.plansee-usa.com

INDUCTION HEATING EQUIPMENT

Agilent Technologies A single source vacuum products supplier with more than 60 years of leadership in vacuum technology and an established reputation for delivering innovative vacuum solutions and dependable customer/technical care. Contact: 800-882-7426 www.agilent.com/chem/vacuum

CEIA USA CEIA manufactures induction heating generators, controllers and pyrometers that enable closed-loop feedback for precision heating. Designed for seamless integration into automation, CEIA’s generators can handle endless applications. Contact: 330-405-3190 www.ceia-usa.com

Metallurgical High Vacuum Corp. MHV offers new “Survivor™” pumps and remanufactures most high-vacuum pumps and blowers regardless of the original manufacturer: Stokes, Kinney, Tuthill MD, Leybold, Edwards, Dresser Roots, Aerzen, Varian, Welch, Rietschle, and Busch or Beach-Russ. Contact: Geoff Humberstone, 877-787-9880 www.methivac.com

Inductotherm Group: Thermal-Processing Equipment Inductotherm Group is a fully global group of manufacturing companies providing products such as: induction melting, induction heating and heat treating, induction welding, and vacuum induction melting and refining systems. Contact: Lauren Trimble, 609-267-9000 www.inductothermgroup.com

VAT Vacuum Valves VAT manufactures high-quality vacuum valves for a variety of applications ranging from rough to extreme UHV. Products include gate, angle, fast-closing, throttle, pressure control, all-metal and customized valves. Contact: 800-935-1446 www.vatvalve.com

Industrial Heating Online 24/7 at www.industrialheating.com

IndustrialHeating.com - November 2011 5

It's what's under

S U R FA C E INTEGRITY

R

that counts.

TECHNOLOGY

INNOVATION

“It’s what’s under the surface that counts...” This saying is used all too often in life in various circumstances. While it is important in the short run to have a good outward appearance to encourage the first conversation, first test drive or first visit, it is more important in the long term to have substance. Surface Combustion is proud to have both. In addition to the countless hours that Surface personnel participates in industry associations, organizations and events, serving on boards and committees, writing articles, attending trade shows and contributing to the growth and development of the heat treating industry,

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”.

Surface® Combustion

1700 Indian Wood Circle • P.O. Box 428 • Maumee, OH 43537 Ph: (800) 537-8980 • (419) 891-7150 Fax: (419) 891-7151 Email: [email protected] Website: www.surfacecombustion.com

November 2011 • Vol. LXXIX • No. 11

CONTENTS

On the Cover:

A R T I C L E S

A landing-gear outer nose cylinder ready for heat treatment in a vertical vacuum furnace is shown.

37

Landing-Gear Heat Treatment Paul Vanderpol – Goodrich; Oakville, Ontario, CANADA Carmine Filice – VAC AERO International Inc.; Oakville, Ontario, CANADA Dan Herring – The HERRING GROUP, Inc.; Elmhurst, Ill.

Aircraft landing gear are designed for extreme stress conditions. In normal circumstances, landing gear must dissipate the (kinetic) energy of vertical velocity on landing as well as provide ease and stability for ground maneuvering. Under extreme duty, landing gear must not collapse despite extraordinary forces exerted on them that push their design limits to the maximum. Heat Treating

43

New Checklist for Nadcap Audits Joanna Leigh – PRI; London, UNITED KINGDOM

The aerospace industry never stands still when it comes to finding ways it can improve on its systems and operations. The Nadcap accreditation program is no different.

47

F E A T U R E

Vacuum/Surface Treating

Melting/Forming/Joining

Clean-Steel Practices in the Melt Shop Chuck Fryman – Ellwood Quality Steels; New Castle, Pa.

Like many terms in the field of metallurgy, clean steel can mean different things to different people. Some think of clean steel as steel that is low in residual element content (such as phosphorus, antimony, tin, etc.). Clean steel could also refer to the surface quality of an ingot, slab or sheet.

51

Materials Characterization & Testing

Microstructure of Nitrided Steels George F. Vander Voort – Struers Inc.; Wadsworth, Ill.

Nitriding is one of the most interesting and useful surface-hardening techniques. It is unique in that during the nitriding process, the specimen is not heated into the austenite phase, and it does not rely upon the formation of martensite to achieve high hardness and useful properties. It is heat treated prior to nitriding, forming tempered martensite to obtain the desired core properties unlike all other surface heattreatment processes. IndustrialHeating.com - November 2011 7

14 COLUMNS 14 Editorial Aerospace Happenings With aerospace thermal processing being our annual focus in November, it seemed appropriate to look at what’s happening in the aerospace world. This segment of our market is doing well and is projected to continue to thrive for years to come.

16 Federal Triangle A Look to the Future A snapshot of how the U.S. is viewed by credible evaluators is not exactly encouraging. Barry Ashby believes that the solution to our country’s economic recovery and to the resurgence of manufacturing authority on the world stage requires a cultural realignment.

16

18 The Heat Treat Doctor™ Low-Temperature Vacuum Heat-Treatment Processes Low-temperature vacuum heat treatment is one of The Doctor’s favorites, offering unique advantages over other types of lowtemperature processing because component parts are placed in a controlled environment designed to minimize surface interactions.

22

22 Now You Know Gunmaking: Lock, Stock and Barrel In this second installment, we move from the barrel to look at the thermal processing of other components of the early rifle. Whether we’re talking about the rifles made in the 19th century or the authentic reproductions of today’s craftsmen, many of the pieces and parts involve thermal processing in their manufacture.

SPECIAL SECTIONS 24 IHEA Profile – Safety First at Annual Seminar

DEPARTMENTS 26 Industry News

78 Aftermarket

34 IH Economic Indicators

80 Classified Marketplace

74 Literature Showcase

86 Advertiser Index

76 Products

INDUSTRIAL HEATING (ISSN 0019-8374) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: INDUSTRIAL HEATING, P.O. Box 2147, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to INDUSTRIAL HEATING, P.O. Box 2147, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

8 November 2011 - IndustrialHeating.com

56 Do-It-Right Advisory Industrial Heating’s 6th annual Do-It-Right Advisory covers a range of heat-treat-related topics from the following contributors: Agilent Technologies, Dry Coolers, Furnace Parts, Metallurgical High Vacuum, Nanmac, Unifrax and United Process Controls. 70 Materials Characterization & Testing Buyers Guide

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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Everyday Metallurgy Heat Treatment is a Lifesaver Without heat treatment, many of the products we use daily would need to be designed differently or would not function as effectively. One ne of these is the automotive seat-belt clasp. s sp. sp

Facebook http://www.facebook.com/IndustrialHeating

White Paper Operating a Vacuum Furnace Under Humid Conditions

LinkedIn http://www.linkedin.com/groups?gid=3706207

Humidity, especially paired with high temperatures in the summer months, poses a significant challenge to the vacuum heat-treating process. Solar Atmospheres and Solar Manufacturing jointly released a new technical paper that offers insight and practical solutions on how to operate a vacuum furnace under humid conditions.

Twitter http://twitter.com/#!/IndHeat

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The 26th part of our Vacuum Heat-Treatment Series focuses on examples of certain standard and special processes run every day in vacuum equipment. The types of materials, products, and processes vary depending on the needs of the industry being serviced, but all take advantage of vacuum’s unique ability with respect to quality and repeatability of cycles and results.

Heat Treating Equipment for Efficiently Processing workloads from 500 to 90,000 lb.

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10 November 2011 - IndustrialHeating.com

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Online Exclusive Vacuum Applications (Part Four: More Standard & Custom Processes)

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Manor Oak One, Suite 450, 1910 Cochran Rd. • Pittsburgh, PA 15220 Phone: 412-531-3370 • Fax: 412-531-3375 Website: www.industrialheating.com Doug Glenn Publisher • 412-306-4351 [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

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AUDIENCE DEVELOPMENT Christina Gietzen Audience Dev. Specialist Alison Illes Multimedia Specialist Catherine M. Ronan Corp. Audience Audit Mgr. For subscription information or service, please contact Customer Service at: Ph: 847-763-9534 or Fx: 847-763-9538 or E-mail: [email protected] LIST RENTAL Postal contact: Kevin Collopy, Sr. Account Manager, Ph: 845-731-2684; Toll Free: 800-2232194 x684; [email protected] E-mail contact: Michael Costantino, Sr. Account Manager; Ph: 845-731-2748; Toll Free: 800-2232194 x748; [email protected] SINGLE COPY SALES Ann Kalb Ph: 248-244-6499, Fx: 248-244-2925, [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: 847-620-2525 • [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: John R. Schrei Corporate Strategy: Rita M. Foumia Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft IT: Scott Krywko Clear Seas Research: Beth A. Surowiec BNP Media Helps People Succeed in Business with Superior Information

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

Aerospace Happenings

W

i aerospace thermal processing being our anith nual focus in November, it seemed appropriate n to look at what’s happening in the aerospace t world. As a summary, a general comment would w be that this segment of our market is doing well and is projected to continue to thrive for years to come. Commercial airlines are in the cycle that planes need to be replaced, and they want to do this with newer, more efficient models. To confirm the future of the industry, in September, a Boeing Co. executive said that they continue to have a “very positive outlook on the commercial aerospace market” despite growing economic challenges. Much of the growth is being driven by low-cost carriers in emerging markets like China and India. Boeing indicated that fully 20% of their commercial plane demand is for models to replace older “gas-guzzlers.” In the third quarter of this year, Delta Air Lines confirmed its plan to purchase 100 Boeing 737 jets as part of a fleet upgrade. Delivery is scheduled for 2013 to 2018. Also, American Airlines placed an order for 460 aircraft – the largest order in history. It will be divided between Airbus (260) and Boeing (200). In Boeing news, the 787 Dreamliner was certified by U.S. and European Union regulators in late August. This means that the 787 complies with regulations and is safe to fly passengers. Through July, Boeing had d 827 Dreamliners on order from dozens of carriers and leasing sing companies worldwide. The first delivery was taken aken in late September by All Nippon Airways in Japan. In October, Boeing and Allegheny Technologies echnologies extended their long-term titanium ium supply agreement through the end of 2018. In Airbus news, Alcoa was recently awarded a multiyear supply agreement ent for aluminum sheet and plate products using Alcoa’s current and advanced-generation ration aluminum alloys. In June, Alcoa launched new proprietary alloys and advanced dvanced structural technologies designed gned to lower the weight, cost and maintenance of new aircraft as compared to the composite alternative. Airbus also signed a strategic collaboration with VSMPO-AVISMA, a major Airbus supplier since the 1990s, for the manufacture and supply of value-added titanium products. This would not be limited to the supply of raw material and forging but would potentially be extended to rough machining or 14 November 2011 - IndustrialHeating.com

pre-machining of titanium parts for a more vertically integrated supply chain. United Technologies Corp. (UTC) rocked the aerospace world with its late-September announcement that it had purchased Goodrich Corp. for $16.5 billion. The acquisition resulted in a reorganization of UTC into the aerospace unit, which includes Goodrich along with Pratt & Whitney jet engines and Hamilton Sundstrand, and the UTC Climate, Controls and Security Systems. UTC believes that the aerospace division positions itself better for the demand surge resulting from Boeing and Airbus’ record production levels. UTC is keeping Sikorsky Helicopters separate because it is an aircraft maker, not a supplier like the other divisions. The Pratt & Whitney division of UTC is transforming the aircraft industry with its new engine, which is quickly becoming the power plant of choice. Its PurePower geared turbofan engine is the result of more than a decade of research and an investment of at least $1 billion. The key attraction of the new engine is its 15% fuel savings, which is due to its unique operation as well as the weight reduction that accompanies its use. Because of the gearing, the fan can turn more slowly. As a result, it is larger, needs fewer blades, and moves more air. Also, its blades are wider. The slower speed results in quieter operation. The gearing allows the turbine to turn at a higher speed, which means it can be considerably shorter and lighter, resulting in engine weight reduction. Smaller aircraft manufacturing is an area of anticipated slower growth per a recent analysis by Forecast International. They predict that stronger growth won’t begin until after 2012. Business jet jets and light sport aircraft are not included in the forecast. Turboprop production is expected tto be flat for the next two years, with increa increases beginning in 2014. With the advent of the Dreamliner and othe other composite-intensive aircraft, a relatively new field of composite rerelati pair will soon become important. Composite repair is very different than working with aluminum and other materials. With 827 composite aircraft curre currently on order, we predict that composite-repair composite-repai technicians will be in demand in the coming mont months and years. SAE International is considering the management of the certification process for composite repair technicians. The FAA has documents outlining the necessary components of this training and certification. Hopefully, the industry will soon have a certification process to guarantee that FAA guidelines are met by new technicians entering the industry. IH

HIGH-TEMPERATURE TECHNOLOGY

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

A Look to the Future

A

s snapshot of how the U.S. is viewed by some credible evaluators includes items reported by The Economist. e The World Economic Forum downgraded the U.S. T from second to fourth place in global competitivef ness comparedd to other industrial nations to begin 2011. It also ranked America 40th among nations for the quality of its institutions, 54th in public trust of its politicians, 68th in regard to government efficiency and 87th for its macroeconomic environment. America’s own Brookings Institution, a liberal-leaning think tank, surveyed American business leaders and found that 33% think “instability of the policy framework” set by government is a major obstacle for business. For comparison sake, that figure was 14% in France and 5% in Chile. Recent decades’ data show trends about America’s goods-producing sectors that are not healthy and which the governing class refuses to recognize as cause-and-effect based. This is mostly due, in my view, to approaches that stress class-warfare, anti-business regulation and big deficit-spending policies enacted by Congress during the few years of the current Administration. The percent of employed labor in goods producing, per the U.S. Bureau of Labor Statistics, has steadily declined (measured in June of each year) from 36.1% in 1965 to 22.4% in 1988, 19% in 2000, 14.3% in 2009 and 12.9% in 2011. Since June 2000, 7,694 million (M) U.S. jobs have been eliminated with only 3,840 M in durable-goods production – only 49.91% of the total. From June 2000 through June 2011, goods-production employment is the only sector that has declined in the U.S. economy while increases occurred in all others, including: leisure and hospitality, utilities, health services, transportation, wholesale trade and government, which showed the largest numeric growth of all sectors. These are distressing facts, but why and what to do about it are more relevant questions regarding this worsening condition. A 2005 study by Citigroup analysts is cogently correct in citing the “plutonomy” issue – the U.S. rich, the rest and the verses that politicians articulate so often when

16 November 2011 - IndustrialHeating.com

trying to polarize class warfare. But there is much more than economic stratification as a societal driver. Equity markets and housing values have been volatile since 2007, so the current recession has pressed harder on the middle and lower classes of society. One in 12 non-manufacturing jobs has vanished; one in six blue-collar jobs in production, craft, repair and machine operations vanished in the past three years. There has been rising pay at the top and falling wages among lesseducated workers. The stable 17 to 19 M people employed in industry from 1960 to 2000 shrank to make the U.S. the number-two manufacturer and third agricultural nation on the planet in 2010. A look at demographics tells us why: 22-29% of all U.S. jobs will, or has the potential to, move overseas in the next two decades as both trade balances and technology will substitute foreign for U.S. workers. The biggest blow will be to those with inadequate job training and education. This is not an argument for more college graduates, which make up only 30% of the U.S. population, but for greatly enhanced education at every level. Family dysfunction is a primary indicator of this job problem. Among less-educated women, 44% of births occur outside of marriage and 54% occur among high-school dropouts. However, only 6% of college-educated women available for work had no job or children with no job. America cannot prosper with an unprepared labor pool of feral children with no means to learn the roads to success. Our national job problems are directly related to the existence of flash mobs of undisciplined young people stealing and destroying urban shopping malls. It is an urgent national need that family guidance, installing value systems in children and instilling personal responsibility become a national priority in order to correct the nation’s economic issues. Indeed, recovery from this recession is in large part a matter of changing the life path of the workforce and not endorsing and continuing the failed education systems that cannot ensure or foster the American dream. I contend that the solution to our economic recovery and to the resurgence of manufacturing authority on the world stage mostly requires a cultural realignment. America will do very well, thank you very much, if it is allowed to return to the principles that built the greatest civilization that has yet passed across the face of this Earth. IH

framing success

Honeywell proudly honors Loy Instrument, Inc. as Channel Partner of the Year. Honeywell proudly honors Loy Instruments, Inc. as Channel Partner of the Year. Loy Instrument, recognized for bringing value to their customers through their outstanding expertise and support since 1937, offers solutions in the process control and industrial combustion industry. Put their expertise to work for you.

To learn more about Loy Instrument, please visit www.loy-instrument.com/index.htm To learn more about Honeywell field solutions, please call 1-877-466-3993 or visit www.honeywell.com/ps/hfs © 2011 Honeywell International, Inc. All rights reserved.

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

Low-Temperature Vacuum Heat-Treatment Processes

L

ow-temperature vacuum heat treatment is one of The Doctor’s favorites, offering unique advantages T over other types of low-temperature processing since component parts (Fig. 1) are placed in a controlled environment designed to minimize surface interactions. Let’s learn more. Applications for this technology vary widely but generally fall into the following categories: • Aging • Annealing • Oxidizing/Bluing • Stress relief • Tempering

name a few. Most processes run in the temperature range of 175-730°C (3501350°F). Special applications extend these ranges down to as low as 120°C (250°F) and up to as high as 925°C (1700°F), but this is unusual. Temperature uniformity (Table 1) in dedicated vacuum furnaces is considered excellent throughout the standard temperature ranges listed. It is also worth noting that clean and/or bright work is most often associated with vacuum processing. Since “clean” and “bright” are very subjective terms and difficult to define in a universal way, we tend instead to say that the part surface is not metallurgically damaged. If a change occurs, it is generally a positive one. In all cases, the surface condition of the parts being processed are said to be improved.

Typical materials include: • Alloy and high-carbon steels (including maraging grades) • Beryllium copper and beryllium nickel • Brass • Copper • Inconel • Specialty alloys (Elgiloy®, NiSpan C, Nitralloy) • Stainless steels, including precipitation-hardening grades • Titanium alloys • Tool steels

Vacuum Designs Vacuum furnaces for low-temperature processing can be batch or continuous, stand-alone, integrated into continuous vacuum furnace systems or a separate “module” incorporated into a cellular system. For example, the basic operation for a batch vacuum furnace is as follows. Mechanical vacuum pumps, optionally equipped with blowers, produce vacuum levels down to 1.3 x 10-3 mbar (0.001 torr) with 6.7 x 10-3 mbar (0.005 torr) common. This is normally achieved within 10-30 minutes of the start of cycle, depending on the size of the pumping systems and the nature of any contaminants present on the workload. The unit is then backfilled in the range of 66.7 x 101 mbar (500 torr) negative pressure to 0.10 bar (1.5 psig) positive pressure with an inert gas such as nitrogen, argon or a mixture of nitrogen/hydrogen (3% maximum) and heating begins. Double pumpdown cycles are often found to

Low-temperature vacuum heat treatment is used by both captive and commercial heat treaters and spans such diverse markets as aerospace, automotive, electronics, optics, housewares, industrial products, tool & die, military/defense and farm implement to Table 1. Field data on low-temperature vacuumfurnace uniformity [1] Control temperature, °C (°F)

Deviation from control, °C (°F)

Total spread, °C (°F)

176.7 (350)

+1.2, - 0.2 (+2.0, - 0.5)

1.4 (2.5)

204.4 (400)

+1.1, - 0.0 (+2.0, - 0.0)

1.1 (2.0)

246.1 (475)

+1.9, - 0.3 (+3.5, - 0.5)

2.2 (4.0)

315.6 (600)

+1.1, - 2.0 (+2.0, - 3.5)

3.1 (5.5)

371.1 (700)

+2.8, - 0.5 (+5.0, - 1.0)

3.3 (6.0)

565.6 (1050)

+3.9, - 1.1 (+5.0, - 2.0)

5.0 (7.0)

676.7 (1250)

+2.2, - 0.6 (+4.0, - 1.0)

2.8 (5.0)

Notes: a. Class 1 per ASM 2750D (Pyrometry)

18 November 2011 - IndustrialHeating.com

Fig. 1. Annealing of nickel-based alloy jet-fighter afterburner assemblies

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

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

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

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

rial H

•

•

TH

surfaces, benefit from this type of treatment. 2. Heating and cooling is uniform and fast with minimum energy consumption. 3. High productivity requirements are best achieved by vacuum processing. The ability to heat slightly more rapidly and, especially, to cool much more rapidly in a positive pressure reduces cycle time. Gas-fired equipment is especially beneficial in this regard. 4. Minimum atmosphere consumption. Once partial pressure or backfill gas is introduced, only small amounts of make-up gas are needed. Even in cases where repeated gas flushing is required, far less atmosphere is needed. 5. Process control is absolute, includFig. 2. Annealing of beryllium-copper wire ing the ability to upload recipes (Photograph courtesy of Surface Combustion, Inc.) and download process and equipment variables in real time. Planned preventative-maintenance practices and a complete history are simple and Summing Up straightforward. IH Low-temperature vacuum processing of workloads is becoming References increasingly more common due to a need for improved surface 1. Herring, D. H., Low Temperature Vacuum Heat Treating, ASM Heat quality, better process repeatability, control of process and equipTreating Conference, 1997. ment variability, and the ability to predict quality results. Designs capable of meeting these needs are available and perform well. Some of the key considerations for choosing low-temperature vacuum processing can be summarized as: Use this Mobile Tag to read an earlier Heat Treat Doctor column on the 1. Vacuum heat treating is mandatory for parts that must be low-temperature annealing process. processed without surface damage (e.g., oxidation). Parts at all stages of the manufacturing process, not just finished be advantageous to speed the overall cycle time. After reaching setpoint and soaking at temperature, the cooling cycle is initiated. The materials of construction in the heating chamber are such that the furnace can be opened and unloaded at any required temperature. In most cases, however, surface condition is important and the workload must be cooled to at least 150°C (300°F) and more commonly to below 65°C (150°F), as measured by a thermocouple positioned in the workload itself. These units can be either gas fired (Fig. 2) or electrically heated. Fiber insulation is typical, often in the form of a “hard pack” or rigidized so as to withstand the high velocities produced by the convection fan. These design features translate into rapid heat-up and cool-down rates (Figs. 3 & 4).

1.1

1.1 Furnace temperature

0.8

0.9 Temperature, thousands

Temperature, thousands

0.9

Work temperature

0.7 0.6 0.5 0.4 0.3 0.2

500 pound load with T/C in a 1-inch diameter part

0.1 0

500 pound load with T/C in a 1-inch diameter part

1

1

0

20

40

60 80 Time, min.

Fig. 3. Typical heating-rate performance data[1]

20 November 2011 - IndustrialHeating.com

100

120

140

0.8 0.7 0.6

Work temperature

0.5 0.4 0.3 0.2

Furnace temperature

0.1 0

0

10

20

30 40 Time, min.

Fig. 4. Typical cooling-rate performance data[1]

50

60

70

Now You Know Thermal Processing & Metals in Everyday Life

Gunmaking: Lock, Stock and Barrel

I

n this second installment, we move from the barrel to look at the thermal processing of other components of the early rifle. Whether we’re talking about the rifles made in the 19th century or the authentic reproductions of today’s craftsmen, many of the pieces and parts involve thermal processing in their manufacture. Most of us think of the flintlock when we ponder rifles of this era. In fact, the flintlock was first invented in Paris in 1615. It was the choice ignition system until the middle of the 19th century. Because steel was not readily available in the 18th century, all of the ferrous parts of a gun were made of iron. Iron is not hardenable, so all of the parts of the lock – except the springs – were case hardened to protect them from wear. Case hardening was performed by burying parts in charred bone meal and powdered charcoal contained in a crucible. The crucible was placed in the forge, heated up and allowed to cook. At the end of three to four hours, the bone meal and parts were dumped into a bucket of water, resulting in a hardened surface. Today, internal lock parts are made from O1 tool steel, and the frizzen – the striker for the flint – is made from 1095 carbon steel. The frizzen creates the spark when the flint hits it by scraping a little bit of metal off each time. Obviously, the early case-hardened frizzens would need to be redone in time to provide a good, hard striking surface. In the 1830s, the percussion-lock system made its appearance. As the frontier was moving west, these guns gained in popularity in the western regions. The percussion lock would be the type found on many of the “mountain-man” rifles. As a result, reproductions tend to take on a local flavor. Most of today’s eastern gun reproducers tend to favor flintlocks, and many in the western U.S. favor the percussion locks. To make a reproduction gun, much of the old-time craftsmanship is still utilized. The purists reproduce the early techniques, which would include forging the trigger and lock and sand casting “furniture” such as the butt plate and trigger guard. Trigger springs are handmade from a truck leaf spring followed by a hardening and tempering process. These parts are heat treated using a forge or an oxy-acetylene torch to heat the piece to a red or red-orange color. Depending on the type of steel used, quenching is done in either oil or water. The quality of the hardening process is verified by the file test, which consists of running a hardened file over the part. If the part is marked by the file, it is rehardened. If not, the part is considered to be fully hardened. Tempering is performed by heating to a pale blue color, carefully heating above straw color to avoid overtempering.

22 November 2011 - IndustrialHeating.com

At Colonial Williamsburg gun shops, parts are tempered by soaking in molten saltpeter (~600°F). Cast brass would be rolled out to make the patchbox in the stock, which would hold tools such as a ball puller or a corkscrew-like device used for cleaning. True craftsmen will typically buy authentic brass 3/16-inch plate and roll it to about 1/16 inch (see photo below). The brass will need to be annealed during this process, which is done by heating to cherry red and quenching in warm water. This material might also be used for the side plate. Other decorative designs can be added based on the characteristics of the rifle being reproduced and/or the creativity of the craftsman making the reproduction. Early gunsmiths would add decorative flair by flattening a silver coin and making silver stars or moons to decorate the stock. Did you know that some of our present-day terms came from the use and manufacture of guns? The title of our column refers to everything involved in the gun and is used to represent inclusivity. “Flash in the pan” is a term to designate something that is fleeting and very temporary. It comes from flintlock firing where the spark wasn’t enough to fire, creating only a small flash in the pan. One that was new to me (as a gun term) was the saying “stop dragging your butt.” Tired soldiers on a long march were told this when they became too tired to carry their rifles and began dragging the bottom end (the butt) on the ground. Now you know how the rest of the rifle was, and still is, made by those craftsmen interested in re-creating some of our early gunsmithing history. IH

Rolling mill

When you turn to Castalloy’s line of quality castings and fabrications for the thermal processing industry, you will experience increased productivity that will impact your company’s bottom line. Our products are expertly designed to offer energy savings, minimize fixture weights, maximize service life and improve furnace throughput. Castalloy products provide the flexibility to handle multiple part numbers on common fixtures, reducing upfront alloy costs. Our fixtures can also be designed to help automate your part handling to reduce labor costs.

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Whether you choose our standard products or work with our engineers to customize fixtures for your application, Castalloy can take the heat. As a leader in the industry, Castalloy continues to offer quality products, at competitive prices and better value.

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

Safety First at Annual Seminar

E

x xplosions and fires in industrial heating systems can result in injury, loss of life, loss of property and loss r of o production. Understanding the required use of the American National Standards governing the compliA ant design and operation of furnaces and ovens is essential for everyone involved with this type of equipment. The Safety Standards & Codes Seminar for Industrial Furnaces and Ovens provides a complete review of NFPA 86: Ovens and Furnaces. This seminar is designed for individuals involved in the design, manufacture or operation of industrial furnaces and ovens. Over the course of two days, the seminar is intended to provide understanding of the NFPA 86 Safety Standards as they apply to industrial furnaces, ovens and heating systems used for processing materials and products. With the recently released 2011 version of NFPA 86, there is new information included in this seminar that is a must for those concerned about industrial heating safety. New information includes: • Introduction to NFPA 87-2011 – Recommended Practice for Fluid Heaters • Gas Line Evacuation (Purging) and Charging According to a past attendee, “It’s a great seminar. I feel that anybody that works with furnaces (operator, maintenance and engineer) should take this class.” Investing in employee education ultimately raises the standards and quality of the products being produced. Educating employees also decreases risks associated with operating the equipment and systems used in many production plants in the industry. IHEA’s

It’s standing room only at IHEA’s Safety Standards and Codes Seminar.

Safety Standards & Codes Seminar offers the education and training needed to keep employees current and knowledgeable, which leads to overall cost savings. Seminar speakers have firsthand working knowledge in the development of the NFPA 86 Standards, by either serving on the NFPA Technical Committee on Ovens and Furnaces or by being involved with IHEA in the review of standard changes. IHEA Fall Business Conference Recap The Fall Business Conference was held Sept. 28-29 at the historical Omni William Penn hotel in Pittsburgh, Pa. Opening night aboard the Gateway Clipper vessel “The Princess” brought IHEA members together for a dinner cruise and networking along the three rivers of Pittsburgh before getting to business in committee meetings and general sessions. This year’s presentations provoked lively discussion and insight regarding a range of judicious topics. Highlights included the everpopular update on what’s happening in Washington and how it affects the industry and a presentation by IHEA utility members on building business relationships. In addition to the regular IHEA committee meetings, the IRED committee and TC244 committee held sessions during the week. As usual, there was a wealth of information for all members to discuss. Attendee evaluations proved this to be another successful meeting. Not an IHEA member?

IHEA members enjoy the kickoff event at September’s Fall Business Conference on the Gateway Clipper in Pittsburgh, Pa.

24 November 2011 - IndustrialHeating.com

Attend any IHEA educational offering and find out why you need to be a member. The money you invest in training and educating yourself and your employees will be returned to you and your company in the quality of your products and services! Visit www.ihea.org for more information.

Industry News

Listen to the News! Visit www.industrialheating.com/podcasts for Industrial Heating’s twice-monthly news podcasts.

Equipment News Vacuum Furnace SECO/WARWICK Corp. is in production of a three-chamber vacuum furnace for Therm-Tech of Waukesha, Inc. The furnace is a CaseMaster Evolution® T12 dedicated for low-pressure carburizing and oil quenching. The furnace comprises preheating and processing chambers and an oil tank, which allow for significant increases in productivity. The furnace will provide lowpressure carburizing through the use of FineCarb® technology and low-pressure carburizing with pre-nitriding with PreNitLPC® technology. SECO/ WARWICK expects to ship the furnace during the fourth quarter of 2011. www.secowarwick.com

Induction Hardening Systems EFD Induction landed three major induction hardening orders from China’s coal-mining industry. The orders involve hardening and tempering lines for 5- to 60-mm-diameter chain. The systems are being constructed at EFD Induction facilities in Norway and China and are due for delivery in the first half of 2012. The first order involves an induction hardening and tempering solution for the China Coal Zhangjiakou Coal Mining Machinery Company (CZCM). CZCM plans to install the EFD Induction hardening line, which will feature four induction heating units, in a new chain manufacturing plant. The second order involves a complete hardening and tempering line for the Xian Heavy Equipment ChengHe Coal Machinery

26 November 2011 - IndustrialHeating.com

Company. The line, which is designed for 24- to 36-mm-diameter chain, will include four induction heating units. The third order – from the Changchun Northeast Conveyor Equipment Manufacture Company – is for a hardening and tempering line for 36- to 60-mm-diameter mining chain. The line has six induction power sources and an hourly output capacity of up to 2,000 kg. www.efd-induction.com

Nitriding System Nitrex Metal shipped a compact nitriding system to the European subsidiary of U.S. tube-bending tools manufacturer OMNI-X. The model NXK-409 furnace – with a workload capacity of 660 pounds – will be used to nitride tube-bending tooling such as bend dies, clamp dies and pressure dies. The complete NXK system also includes integrated automation and NITREG® control technology, which will ultimately result in improved tool durability and bending quality. The system was installed at the Brno, Czech Republic facility. www.nitrex.com

Industry News

ATTENTION Are Your Furnace’s Alloy Tubes suffering from any of the following symptoms?  Carburation (Embrittlement)  Creep/Distortion  Oxidation  Thermal Shock  Melt-Through  Weld Failure

Immunize Your Furnace with INEX Composite Radiant Tubes. Improve Performance and Increase Tube Life address 9229 Olean Road, Holland, NY 14080 email ).%8 ).%8INCNETsweb www.inexinc.net phone 716.537.2270

Heat Exchangers Wall Colmonoy’s Aerobraze Engineered Technologies of Oklahoma City, Okla., announced that the U.S. Air Force (USAF) has awarded it a multi-year, multimillion dollar contract for the re-core y of heat exchangers to support the F-15 global fleet. The highly maneuverable F-15, F 15 designed to fl flyy combat missions, missions, is considered the premier air-superiority fighter jet..

W ll C Wall Colmonoy l d developed l d hi high-temperature ht t ffurnace b brazing i th thatt is used extensively in the heat-exchanger manufacturing process. The company’s brazing expertise has resulted in significant cost savings for the USAF. Deliveries are scheduled to begin in the fall of 2011. www.wallcolmonoy.com

Heat-Treatment Line SOLO Swiss installed an automatic heat-treatment line for German company Heckler & Koch. The line is equipped with a nitriding and nitrocarburizing furnace; two austenitizing, carburizing and carbonitriding bell furnaces with a working temperature up to 1050°C; a quenching oil tank; a tempering furnace under N2

More than a great name. Process-Proven Equipment in Gas or Electric. Lindberg has a long-standing reputation as a single-source supplier for the heat treating industry, from initial design, to construction, services and genuine factory parts. For quality, value, reliability and technical support,t, the choice is simple. Call the Lindberg Heat Treating Team today.

P.O. Box 131 | 3827 Riverside Road | Riverside, MI 49084 | USA | Phone: (269) 849-2700 | Fax: (269) 849-3021 | [email protected] www.lindbergmph.com/IH

28 November 2011 - IndustrialHeating.com

atmosphere; a washing machine with two tanks; storage with 16 loading/unloading ramps; and a 5-axis robot. The useful loading dimensions are approximately 500 mm (19.7 inches) in diameter, 700 mm (27.5 inches) in height and a maximum load weight of about 300 kg (661 pounds). The line is designed for the heat treatment of gun and pistol parts. The installation provides a loadmanagement system with remote supervision from Switzerland and an integrated and flexible production system with a wide range of treatments. Heckler & Koch develops infantry weapon systems. www.soloswiss.com

Vacuum Angle and Inline Valves for all vacuum ranges and applications

Bell-Type Annealing Plant LOI Thermprocess, a company of the LOI Italimpianti Group, received a contract from Russian steel company NLMK for the supply of a new HPH® bell-type annealing plant. Under the contract, LOI is to supply 23 annealing bases, 12 gas-fired heating hoods and 10 cooling hoods, including all the necessary ancillary facilities for the company’s Lipetsk plant. The HPH bell-type annealing furnaces will be used to anneal cold-rolled coils of low-carbon and low-alloy thin sheet up to a width of 1,850 mm (72. 8 inches) and a maximum thickness of 2.6 mm (0.1 inches). Each base will have a maximum stack height of 5,600 mm (220.5 inches) and a maximum stack weight of 150 tons. The capacity of the entire plant is to be 480,000 tons per year. LOI Thermprocess is also supplying the complete control system for the plant. www.loi-italimpianti.com

Ultra Low NOx Emissions of 20 ppm or Less

Better valves for less money

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TriOx Triple-Air Staged Ultra Low NOx Burner • Direct spark or pilot ignition • Ambient or pre-heated air • Low excess air operation (5%) for maximum fuel efficiency • Proven benefit of scale and dross reduction in steel and aluminum applications • Low CO emissions on cold start

Hauck’s TriOx burner is ideally suited for aluminum furnaces, steel reheat furnaces, thermal fluid heaters, and other high temperature heat processes requiring ultra low NOx emissions. Capacities range from 4.2 to more than 27 MM Btu/hr (1380 to 8960 kW) with five sizes and four models to choose from. Hauck Manufacturing Company, PO Box 90, Lebanon, PA 17042 Phone: 717-272-3051 Fax: 717-273-9882

®

www.hauckburner.com

IndustrialHeating.com - November 2011 29

Industry News

Controls United Process Controls (UPC) upgraded the system controls of two Surface Combustion batch IQ furnaces used by precisiongear manufacturer United Gear & Assembly. The modernized HMI platform based on Protherm 600 controllers from UPC offers a new level of speed, accuracy and flexibility in creating and modifying carburizing recipes. Menu screens and programming are more user-friendly when it comes to finding data and making changes, and new recipe entries are easier to create, thus reducing setup time. Furnace I/Os and all process data coming back to the Protherm 600 are trended automatically, which helps pinpoint problems quickly and efficiently, saving operator hours and downtime. The enhanced controls also provide the United Gear & Assembly plant with the option to integrate UPC instrumentation with SCADA at a future expansion. Furthermore, with quenching functions embedded into the Protherm 600, the system achieves effective utilization of the quench cycle and eliminates standby power consumption, conserving energy and reducing utility costs. Hudson, Wis.-based United Gear & Assembly is an ISO/TS 16949-registered contract manufacturer of precision gears and shafts and is a strategic/core supplier to several global OEMs. www.group-upc.com

THE

SCIENCE

> Manufacturing vacuum furnaces and ovens in our New Jersey facility since 1965 > Unsurpassed temperature uniformity, precision control and data logging > Easier AMS2750D and NADCAP conformance > Offering a range of sizes and options to fit your budget

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30 November 2011 - IndustrialHeating.com IH11084TM.indd 1

OF VACUUM

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Cinnaminson, NJ USA 10/20/08 1:24:04 PM

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Industry News

Business News DOWA to Acquire Shares in Hightemp Furnaces DOWA Thermotech Co. Ltd. entered into an agreement with Hightemp Furnaces Ltd. (HTF) to acquire shares in HTF, which is the largest heat-treatment and industrial furnace manufacturer in India. The share acquisition date is scheduled for the end of September, with DOWA Thermotech acquiring up to 80% of shares outstanding in HTF at that time. HTF, which operates five plants in India, has maintained a relationship with the DOWA Group for over 20 years, including the licensing of technology in 1985 and capital participation in 1991. The heat-treatment market is expected to grow significantly in India in association with the expansion of automobile production. After acquiring the controlling interest, the DOWA Group will establish a firm position in the expanding Indian market by adding DOWA Thermotech’s manufacturing technologies and its network of Japanese customers to HTF’s business base. The group will also seek to meet demand from DOWA Thermotech’s Japanese customers for advancement and business expansion in India by enhancing the lineup of batch furnaces and introducing new manufacturing technologies, such as continuous furnaces, from Japan, in addition to the existing licensing of technologies.

Carpenter to Expand Powder Facility in Sweden

Radiant Heater Tubes Cast or Fabricated

All Stainless & High Nickel Alloys All Styles Including Straight Tubes, S, O, W, U, and Specialty Tubes with or without Flanges, Insulation, Bellows and Collars

Carpenter Technology announced a major expansion of its Carpenter Powder Products facility in Sweden (CPP AB). According to CPP AB, the investment will include construction of a new building and installation of a melting and gas atomization unit with related powder-handling equipment. The new facility will more than double current capacity levels. At an approximate cost of $30 million, the expansion project is scheduled for completion in early 2013. The facility will also feature proprietary technological advancements to provide for improved powder-metal quality and mechanical-property capabilities. Located in Torshälla, CPP AB is a joint-venture operation with Sandvik Materials Technology and is one of three powder-metal manufacturing sites associated with Carpenter Powder Products (CPP), a subsidiary of Carpenter Technology Corporation.

Alcoa to Invest in Iowa Plant

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Alcoa announced it will expand its Davenport, Iowa, rolledproducts plant to meet rising demand from the automotive market. The expansion will take the aerospace materials facility, which is widely known for its 220-inch-wide mill, and create additional production dedicated to the automotive market. The growth project, which will entail an investment of approximately $300 million, will create an additional 150 full-time jobs in Davenport once completed. In addition, an incremental 150 jobs will be created during construction. The expansion is expected to be completed by the end of 2013.

Solar Atmospheres Awarded Heat-Treating Contract A major prime contractor in the nuclear field awarded Solar Atmospheres of Western PA a multimillion-dollar purchase order for the vacuum thermal processing of nickel-based nuclear steam-generator tubing. Solar was selected for its unique ability to process the 48-foot-long parts. According to Solar, the customer faced a critical and out-of-the-ordinary challenge of vacuum stress relieving massive parts. The company’s distinctive furnace capability was a perfect match for the project.

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Industry News

Economic Indicators

Selas Acquires Ray Burner Product Line Selas Heat Technology Co. LLC announced the acquisition of the Ray Burner product line from its owner. Ray Burner has provided a wide range of dual-fuel package burners for the industrial combustion markets primarily in North America since 1872. Ray Burner burners can be applied to a wide variety of equipment, including heat-treating furnaces and kilns. They can also meet low-NOx requirements without steam injection or flue-gas recirculation. Selas expects to leverage its global multi-channel sales and marketing network to improve distribution of these products. Selas will transition the production of the line to one of its facilities in the coming months.

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34 November 2011 - IndustrialHeating.com

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FEATURE | Vacuum/ Surface Treating

Landing-Gear Heat Treatment

Fig. 1. Landing incident at LAX International Airport – jammed nose wheel Airbus A320-232[1]

Paul Vanderpol – Goodrich; Oakville, Ontario, CANADA Carmine Filice – VAC AERO International Inc.; Oakville, Ontario, CANADA Dan Herring – The HERRING GROUP, Inc.; Elmhurst, Ill. Aircraft landing gear are designed for extreme stress conditions. Just ask the Jet Blue passengers and crew of Flight 292 (Fig. 1) whose lives depended on the integrity of a properly designed and heat-treated nose-wheel landing beam. In normal circumstances, landing gear must dissipate the (kinetic) energy of vertical velocity on landing as well as provide ease and stability for ground maneuvering. Under extreme duty, landing gear must not collapse despite extraordinary forces exerted on them that push their design limits to the maximum.

T

h main components of a landhe ing-gear structure are wheels i and brakes, axles, bogie beams a (a.k.a. truck beams), shock ab( sorbers (a.k.a. shock struts), and drag and side braces. Primary design considerations on landing gear include maximum sink speed, spin up, spring back, lateral drift (on landing), towing, jacking, turning, braked roll, taxi, rebound, pivoting (main landing gear only), crashworthiness and fatigue. Secondary loads include retraction/extension, aerodynamic loads, lock/ unlock loads and emergency extension. In addition, nose landing-gear specific forces include dynamic breaking, nose-gear yaw and steering. Alloys used in these applications must have high strengths, normally between 260-300 ksi (1,792-2,068 MPa). Vacuum Oil Quenching To achieve their design and performance goals, landing-gear specifications and cycles have been developed to extract the optimum heat-treat response (and mechanical properties) from these alloys. Vacuum heat treatment followed by oil quenching and double tempering produces a microstructure with high strength and excellent toughness, ideal for applica-

tions involving heavy loading and fatigue. During hardening, internal stresses created from the thermal shock of direct oil quenching almost always cause some degree of distortion in these components. A final machining allowance is often left on critical dimensional features to compensate for distortion. Due to the difficulty of machining these alloys in the hardened condition, however, machining allowances must be minimized. In the current environment of cost and lead-time pressures, reducing distortion during thermal processing has become a primary objective for heat treaters of landing-gear components. Vacuum oil quenching offers the economic and environmental benefits for processing these critical-performance components. This is especially true for the bogie beam (Fig. 2). Since vacuum furnaces are inherently leak tight, control of surface chemistry is assured, and problems with decarburization and high-temperature oxidation are avoided. Vacuum processing also allows producers of aircraft landing gear to finish machine critical surfaces on these components prior to heat treating. This, in turn, reduces final machining costs when the part is in the hardened condition. Further, quench-related distor-

tion is minimized through load transfer to the quench tank via high-speed elevator. Heat treaters equipped with vertical vacuum oil-quench capability are well suited for processing landing-gear components. Since section thicknesses are large, fast to medium-fast oil quenchants are typical so as to achieve the throughhardened microstructure requirements. Large variations in hardness (surface to core) cannot be permitted.

Fig. 2. Landing-gear outer nose cylinder for vacuum heat treatment (Boeing 747-8 Aircraft). Net weight 295 kg (650 pounds)

IndustrialHeating.com - November 2011 37

FEATURE | Vacuum/ Surface Treating

Fig. 3. Vacuum furnace designed for the heat treatment of aircraft landing-gear and other critical-performance components – Style 40 (Model VAV-72114-MPOGQ)

Racking and fixture design are also critical to ensure the parts heat uniformly, do not experience thermal distortion (which can be considerable) and enter the oil in a vertical orientation for uniform heat transfer along the length of the parts. How it Works Style 40 Furnace The Style 40 furnace (Fig. 3), commissioned in 1989 and still in operation today, can handle workloads up to 1,600 kg (3,500 pounds) and 1.8 m (72 inch diameter) x 2.9 m (114 inch) tall. Landing-gear components are loaded vertically onto a support fixture. The furnace heating chamber is mounted on a movable gantry. During loading, the gantry moves aside and the load is placed onto the quench elevator. Prior to this, the quench oil is transferred to a reservoir tank so as to avoid contact with the load prior to entry into the vacuum chamber. The elevator lowers the load into the empty quench tank, and the heating chamber moves into position over the quench tank, then lowers and seals to the quench-tank flange. A vacuum seal door and hearth doors within the heating chamber open, and the elevator raises the load into the heating chamber. As the elevator withdraws into the quench tank, the hearth doors close to support the load and the seal door closes to isolate the heating chamber. After the 38 November 2011 - IndustrialHeating.com

Fig. 4. Vacuum furnace designed for the heat treatment of aircraft landing-gear and other critical-performance components – Style 80 (Model VAV-7276-MPOGQ)

loading sequence is complete, the quench oil is pumped back into the quench tank from the reservoir tank. After pumpdown, ramping and stabilizing at the hardening temperature, the chamber is backfilled with nitrogen gas to equalize the pressure between the chamber and the oil quench tank. The furnace doors then open, and the elevator raises to support the load and then descends quickly (within 10 seconds) into the 40,000-liter (10,500-gallon) quench tank to complete the process. Style 80 Furnace The Style 80 furnace (Fig. 4), commissioned in 2009, is capable of running workloads up to 1,600 kg (3,500 pounds) and 1.8 m (72 inch) diameter by 1.9 m (76 inch) high. Parts are loaded vertically onto a support fixture. The furnace bell is raised into the up position, exposing the hearth table. The seal door separating the quench tank from the hot zone is closed.

After the load is placed on the hearth table, the loader is retracted out of the furnace and the bell is lowered. The furnace is pumped down and processing commences. During processing, the furnace chamber is evacuated to a pressure of approximately 10-2 mbar (7.5 x 10-3 torr). The oil quench tank is also evacuated to a pressure of approximately 400 mbar (300 torr). When chamber evacuation reaches a preset pressure, heating of the load starts until the recommended austenitizing temperature (Table 1) is achieved. Heating ramp rates are selected to minimize thermal gradients within the load without creating excessive cycle times. Control of the ramp rate during heating is an important factor in relieving stresses that may have been created during machining of the components being heat treated. During heating, the load is also held at an intermediate temperature around 620°C (1150°F) for a short period of time to further improve temperature

Table 1. Typical heat treatments for aerospace landing-gear materials [1] Tempering temperature[a] 1st 2nd

Preheat temperature °F (°C)

Austenitizing temperature

Oil temperature

Deep freeze temperature

300M (4340M)

500 (930)

870 (1600)

80 (175)

-

300 (575)

300 (575)

HP9-4-30

500 (930)

840 (1550)

80 (175)

- 75 (-100)

500 (930)

500 (930)

AF1410

500 (930)

840 (1550)

80 (175)

- 75 (-100)

500 (925)

500 (925)

AeroMet 100

500 (930)

885 (1625)

80 (175)

- 75 (-100)

480 (900)

480 (900)

Alloy

Notes: [a]Tempering temperature depends on desired final properties (except for 300M/4340M)

Fig. 5. (left) 3-D rendering of Style 100 furnace (Model VAV-72138-MPOGQ) and quench tank Fig. 6. (center) Finite element analysis – BLG bogie beam (Airbus A380) Fig. 7. (right) Static and dynamic testing of individual landing gear

uniformity. Maintaining temperature uniformity throughout the cycle is essential to prevent the buildup of thermal stresses and to ensure that all sections of the load undergo the microstructural transformations needed to achieve the desired mechanical properties. After the load is soaked for a sufficient period of time at the austenitizing temperature, the oil quenching process can begin. The first step in this process is the backfilling of the furnace chamber (with nitrogen gas) to 400 mbar (300 torr) or just below atmospheric pressure to equalize to the pressure in the oil quench tank between the furnace and the oil quench. Next, the vacuum seal door is opened and the quench elevator is raised to a point where it again supports the weight of the load. The load bars are then retracted, and the elevator and load rapidly descend (within 10 seconds) into the quench tank. After the load is lowered into the quench tank, power to the heating elements is shut off and the seal door is closed. The quench blower is then activated to cool the heating chamber to ambient temperature. The quench tank contains 35,000 liters (9,300 gallons) of quench oil. Electric heaters and coolers regulate oil temperature. Careful monitoring of quench-oil conditions is an important factor in part distortion control. At the end of cycle, the furnace is backfilled with nitrogen to atmospheric pressure and the bell is raised to the up position. The seal door opens up, and the

elevator raises the load out of the oil (at slow speed) to the up position. The load bars extend, and the elevator lowers the hearth table and load onto the load bars. The elevator then lowers to standby position just below the seal door. The seal door closes, and the loader moves in to unload the parts from hearth table. Style 100 Furnace VAC AERO International’s furnace manufacturing division is presently building a larger oil quench vacuum furnace (Fig. 5) capable of running 1,800 kg (4,000 pounds) workload dimensions of 1.8 m (72 inch) diameter by 3.5 m (138 inch). This unit is expected to be qualified and production-ready by the third quarter of 2012. Product Analysis & Testing By their very nature, landing-gear components are complex machined parts with numerous section changes and transitions. As such, landing-gear manufacturers do extensive design and structural analysis to ensure proper product performance. Structural analysis determines such factors as limit loads (so no detrimental permanent deformation occurs) and ultimate loads (so no rupture, collapse or other failure modes occur) where ultimate loads are typically 1.5 times limit loads. Component finite element analysis (FEA) methods (Fig. 6) using solid models support fatigue analysis and identify stress concentrations (so-called “hot spots”). These techniques are now also employed

for ultimate performance analysis (e.g., linear elastic FEA with traditional margin-of-safety calculations, non-linear elasto-plastic analysis (so-called “Riks” collapse analysis) and advanced analysis techniques (e.g., pin/socket joint contact and non-linear “collapse” analysis) as well as assembled system analysis. Margin-of-safety calculations are used with load or stress calculations. In most situations, a component or section of a component experiences more than one type of load or stress simultaneously, so individual load (or stress) ratios and a utilization factor is calculated (Eq. 1). R=

Applied load Allowable load

or R =

Applied stress Allowable stress

(1)

Where R = Load (or Stress) ratio A subscript is normally used to indicate the type of load ratio (Table 2). A lowercase f is used for applied stress, and an upper-case F is used for allowable stress. Table 2. Stress formulas Stress ratio

Type of stress

RT = fT / FTU

Tension

RHT = fHT / FTU

Hoop tension

RC = fC / FCY or RC = fC / FCOL

Compression

RHC = fHC / FCY

Hoop compression

RB = fB / FBU

Bending

RS = fS/ FSU

Shear

RST = FST/ FSU

Torsion

IndustrialHeating.com - November 2011 39

FEATURE | Vacuum/ Surface Treating

Now it's easier than ever to stay connected to the best source of news and technology in the industry!

Structural analysis is performed on such components as sockets, lugs, pins, columns and bearings. These sections are under combined loads including: • Axial loads in tension = f T or FTU • Column axial loads in compression = fC or FCOL • Local crippling loads in compression = FCC • Shear loads = fS or FSU • Bending modulus of rupture = f B or FBU • Torsional modulus of rupture = FST • Hoop stress = FTU (pcrit) A utilization factor (i.e. “factor of utilization in combined loading”) is then calculated, as is the margin of safety (Eq. 2).

www.industrialheating.com/connect

M.S. = 1/U - 1.0

(2)

where U = utilization factor; M.S. = margin of safety Testing (Fig. 7) confirms the results of FEA and combined loading calculations.

Conclusions Experience in the heat treatment of landing-gear components and using the right supplier partner is critical, as is having the right type of equipment, controls and cycle repeatability to ensure that the rigid standards of the aircraft industry are met or exceeded. IH References 1. www.AirlineSafety.com 2. Mackenzie, Scott, “Heat Treatment of Landing Gear,” Heat Treating Progress, Volume 8, Issue 3, May/June 2008. 3. Pritchard, Jeff, “Advanced Techniques for Distortion Control During Oil Quenching,” 17th ASM Heat Treating Society Conference Proceedings, ASM International. For more information: Contact Carmine Filice, director Thermal Processing division, VAC AERO International Inc., 1371 Speers Rd., Oakville, ON L6L 2X5 CANADA; tel: 905-827-4171 ext 235; fax: 905-827-7489; e-mail: [email protected]; web: www. vacaero.com

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FEATURE | Heat Treating

New Checklist for Nadcap Audits Joanna Leigh – PRI; London, UNITED KINGDOM The aerospace industry never stands still when it comes to finding ways it can improve on its systems and operations. The Nadcap accreditation program is no different.

I

n June 2011, the Nadcap Management Committee (NMC) balloted for the creation of a new Heat Treating audit checklist. AC7102/6 has been in the works for the past two years and was approved this year in June as a new checklist for Hot Isostatic Pressure (HIP). It is expected to be fully implemented by the end of 2011. The reason for developing this new checklist revolves around casting of metal parts for engines. Whenever a part is cast, the metal poured into the mold will cool, leaving small air pockets within it. In many cases this will not be problematic. Given the conditions of flight, such as the high velocity of these planes or the extreme temperatures they endure, however, a high level of scrutiny and standards of quality must be applied. These small air pockets can affect the structure of the part, which means that a part designed for 10,000 hours of usage may only endure around 8,000 hours. The HIP process is designed to remove these air pockets by putting the still-molten casting in an autoclave, where it is subjected to very high pressure and temperature to evacuate the air pockets from

the metal. These air pockets are squeezed out to create a more homogenous metal that will in turn give the casting a much stronger structure. Theoretically, this process can be performed on any metal castings. However, in the majority of cases it is done for nickel-based alloys built as engine parts, such as the blades in an engine. Only a relatively small section of the global aerospace supplier base provides parts in this manner. In fact, this almostniche heat-treating checklist will affect only approximately 1% of aerospace suppliers. So, why is PRI developing it? PRI is the not-for-profit trade association that administers the Nadcap program. As Nadcap is industry-managed, PRI is a very customer-focused organization. This new checklist was requested by the Nadcap subscribers with a goal of reducing the number of redundant audits. Often a supplier may have the same activity audited several times a year. This makes the overall cost excessively high without adding value. It creates cost in manpower, as suppliers must commit staff to the audit process, which means pulling them away from their day-to-day work. It also adds cost for the aerospace prime contractors

who must pay for their own auditors to perform the audit. As a result, the industry representatives on the Nadcap Heat Treating Task Group decided that they wanted this special-process activity to be covered by the Nadcap audit process, thus saving both the Nadcap-subscribing primes and the suppliers time and money as well as standardizing the level of quality required by the industry. Joe Pinto, PRI vice president and COO, explained, “Nadcap exists to support the aerospace industry to achieve excellence in special process and product quality. I am pleased to see the Nadcap Heat Treating Task Group members furthering their commitment to quality and efficiency by

Joe Pinto IndustrialHeating.com - November 2011 43

FEATURE | Heat Treating

adding to the scope of the Nadcap audit. Following careful study, we do not expect there to be a change in the levels of nonconformance when Nadcap takes over the audit process at the end of the year, but this will be continually monitored. It is not the goal of Nadcap, or the aerospace industry, to look for faults but to fairly assess capability and competency.” In practical terms, audits to this new checklist will be comprised of two job audits. They will be carried out over one thermal cycle. As HIP job audits are already included on the existing checklist, they will replace two job audits from the 10 core heat-treating checklist when HIP needs auditing. If a supplier only requires HIP auditing, then the number of jobs audits will be extended to three rather than

two. Due to the nature of HIP, however, it is likely to be a very rare occurrence that a supplier will require only this audit. Nonetheless, this rare occurrence has been considered by the NMC. In an effort to continually improve the Nadcap program, the Heat Treating Task Group has created a survey for suppliers to fill out after every Nadcap Heat Treating audit. This is a good opportunity for the suppliers to help shape the future of the program. Our most recent June results have shown that the Nadcap auditor spends up to three-quarters of their time in the production areas, with the rest mostly spent reviewing records and other paperwork. In addition, there is an encouraging level of consistency between the Nadcap auditors. Of the respondents,

87% were going through re-accreditation audits, and 76.6% of them advised that they saw greater consistency between the auditors compared to previous years. From PRI’s perspective, ensuring auditor consistency in terms of checklist interpretation is very important because it maintains the integrity of the audit. There will naturally be some variability, but the fact that the Nadcap Heat Treating Task Group has demonstrated improvement in this area is important. Earlier this year, the Nadcap Heat Treating Task Group also ran a “Voice of the Customer” survey. The survey results showed that when asked how well Nadcap Heat Treating Audits currently mitigate risk to end-user product non-conformance or customer requirements non-

PRI Launches 2011 Nadcap Supplier Survey

T

he 2011 Nadcap Supplier Survey opened for responses on June 20, 2011. All accredited suppliers are encouraged to complete the survey online to give their feedback on their experiences of Nadcap. The official launch coincided with the Nadcap Meeting, a forum for primes and suppliers that takes place three times a year in locations worldwide. Take the survey online at: https://www.surveymonkey. com/s/2011SupplierSurvey This biennial survey is an initiative of the Nadcap Supplier Support Committee (SSC), which exists to represent and be the voice of the supplier community. The committee is made up of active Nadcap-accredited suppliers who are there to help new suppliers through the process as well as assisting experienced suppliers in establishing, maintaining and improving their accredited processes.

44 November 2011 - IndustrialHeating.com

This is the fifth issuance of a global aerospace supplier survey by the SSC. Previous surveys have been conducted in 2003, 2005, 2007 and 2009. Valid trending data has already been identified, and this year’s survey will contribute to the overall picture. For example, in 2003, 25% of respondents indicated that in the areas related to Nadcap accreditation, they had seen an increase in quality. By 2009, that had risen to 83% of respondents. SSC Chairman Eric Jacklin is enthusiastic about the supplier survey. He said, “The supplier survey allows us to gain a better understanding of those people we are here to represent – aerospace suppliers worldwide. With this knowledge, we are able to concentrate our resources on areas of particular interest to the global supply chain. This is an excellent opportunity for suppliers to have their voice heard and contribute to the future development of the Nadcap program.”

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FEATURE | Melting/ Forming/Joining

Clean-Steel Practices in the Melt Shop Chuck Fryman – Ellwood Quality Steels; New Castle, Pa. Like many terms in the field of metallurgy, clean steel can mean different things to different people. Some think of clean steel as steel that is low in residual element content (such as phosphorus, antimony, tin, etc.). Clean steel could also refer to the surface quality of an ingot, slab or sheet.

T

h most popular definition of clean steel is in reference to he steel with low inclusion content. This article will review s some of the techniques that are used to produce steel with s low inclusion content and how these practices are used in l steelmaking.

What Is an Inclusion? Inclusions are non-metallic particles that are trapped in the solid steel matrix of a forging or rolled product. Exogenous inclusions are those that come from sources outside of the steel, such as refractory bricks or flux used in molds and casters. Exogenous inclusions are typically large (>1 mm in size) because they originate as “crumbs” of these outside sources that become entrapped in the steel while it is being processed in liquid form. Indigenous inclusions are those that are formed from chemical reactions inside the liquid steel as it is processing, such as when manganese combines with sulfur in the liquid steel to form small manganese-sulfide inclusions. Indigenous inclusions are typically on the micro scale (0.001-1.000 mm in size). When striving for clean steel, it is the indigenous inclusions that we are trying to control. Indigenous inclusions can further be separated into two main categories for steel: oxides and sulfides (Fig. 1). Oxides are generated for the most part by the addition of aluminum or silicon during secondary steelmaking. Sulfides are generated during solidification when sulfur combines with a sulfide former, most commonly manganese. Oxygen is Introduced in the EAF, Removed in the LF Electric steelmaking starts with primary steelmaking in the electric arc furnace (EAF). It is the job of the EAF to turn solid scrap into raw liquid steel. Oxygen is blown into the EAF throughout primary steelmaking to accelerate the melting process through the addition of chemical energy. The oxygen also combines with carbon and phosphorus to form oxides that are removed from the bath. Carbon leaves the bath in the form of CO and CO2 gas, while phosphorus leaves the bath in the form of P2O5 which be-

comes part of the slag floating on top of the liquid steel. After primary steelmaking in the EAF, the steel is tapped into a ladle and moved to the ladle furnace (LF) for secondary steelmaking. In secondary steelmaking (aka ladle refining), alloys are added, and the temperature of the liquid steel is adjusted by heating with carbon electrodes. One of the main goals in secondary steelmaking is to remove all of the oxygen that was introduced in the EAF. This is done mostly by the addition of (what else) a deoxidant. The most common deoxidants are aluminum and silicon. Both of these elements have a strong affinity for oxygen, so once they are introduced, they begin to combine with free oxygen dissolved in the steel to form aluminum oxides or silicon oxides. The removal of oxygen by adding an element with a strong affinity for oxygen is known as “killing.” This is why you might hear steel referred to as “aluminum killed” or “silicon killed.” After killing the steel, you are left with a multitude of either SiO2 or Al2O3 particles in the liquid steel. Now that we have generated all of these oxides, the idea is to remove them by moving them to the slag. This can be accomplished given enough time and stirring. By stirring the bath via magnetic induction stirring and/or inert gas bubbling through the Inclusions in steel Exogenous

Indigenous Oxides

Sulfides

Refractory brick Flux powder Refractory nozzles

Al2O3

MnS

SiO2

Fig. 1. Types of inclusions found in steel

Globular oxides

IndustrialHeating.com - November 2011 47

FEATURE | Melting/ Forming/Joining

processing time in the ladle furnace, most of the oxides should be removed from the liquid steel and trapped in the liquid slag on top of the steel.

Fig. 2. Clean-steel practices begin in the ladle furnace.

bottom of the ladle, the oxide particles are brought into contact with each other. When the oxides run into each other, they tend to agglomerate and make bigger oxides. As these alumina and silica particles agglomerate and form larger oxides, they have more buoyancy and have a greater tendency to float to the slag on top of the liquid-steel bath. To accomplish this removal of oxygen by deoxidant addition, you must have effective stirring to bring the oxides in contact with each other and sufficient time for the agglomeration and floating to take place. By the end of the

Sulfur Removal in the LF While oxygen is being removed with the help of aluminum and silicon, other processes are at work in the LF to remove sulfur. As mentioned earlier, sulfide inclusions are generated during solidification when sulfur combines with manganese to form MnS. The most effective way to reduce the number of MnS inclusions in the final product is to reduce the sulfur content of the steel. The reason we have sulfur in the steel in the first place is because it is an inherent element in iron ore itself and, therefore, is typically found in steel scrap as well. Sulfur is also added to the system as a tramp element contained in some ferro alloys such as ferro chrome. In order to remove sulfur, we need to produce a compound similar to the oxides generated when we killed the steel. For steelmaking purposes, this compound is CaS. Sulfur will combine with calcium through the following simple reaction:

less oxygen there is dissolved in the steel. So adding deoxidant will drive the above reaction to the right. In other words, deoxidizing aids in sulfur removal. Another way to drive this reaction to the right is to make sure there is plenty of CaO in the slag. A slag that is diluted with CaO has a higher capacity to absorb CaS. Again, increasing the reactants on the left side of the equation drives the reaction to the right and aids in sulfur removal. Achieving the Lowest Possible Inclusion Content So far we have discussed the mechanisms by which oxide and sulfide inclusions are removed from the liquid steel. It is impossible to achieve perfect steel cleanliness by these methods, however, and there will always be some inclusions that remain in the steel. The goal is to reduce the inclu-

CaS

Slag

AL2O3 Al + O

Ca + S

CaO + S A CaS + O

However, the more complete picture of what is actually happening in an aluminum-killed steel is given by this reaction:

Liquid steel

3(CaO) + 2Al +3S A 3(CaS) + Al2O3

The amount of oxygen in the steel is directly related to how much deoxidant (Al) is in the steel. The more deoxidant, the

Fig. 3. In the ladle furnace, sulfur and oxygen are removed from the steel and are pushed to the slag through various chemical reactions and kinetic processes.

Processing Aerospace Materials Although low-density metals such as titanium and aluminum alloys receive most of the attention in the aerospace industry, steel remains the material of choice for many airplane components. However, not just any steel will do when it comes to building planes. Steels that are used in aerospace applications such as landing gear and bulkheads need to have good fatigue properties to survive the cyclic loading that these components receive. In order to have good fatigue properties, the steel must be high strength and have a low inclusion content. Inclusions, or any other imperfections in the steel matrix, act as stress concentrators. These stress concentrators are then likely to act as fatigue-crack initiation sites. Once a fatigue crack is initiated,

48 November 2011 - IndustrialHeating.com

it does not require as much energy to propagate the crack. Given enough cycles of sufficient stress, a fatigue crack will grow and eventually lead to failure. To produce clean steels such as those required for aerospace applications, clean-steel practices like the ones outlined in this article must be employed. In addition to these clean-steel practices, many aerospace steels are also required to undergo secondary melting operations such as vacuum-arc remelting (VAR) or electro-slag remelting (ESR). These remelting processes take an air-melted ingot and remelt it under controlled conditions to refine the steel further, resulting in steel with even fewer inclusions.

sion content to as low of a level as possible. As mentioned previously, the most important processing variables for inclusion removal are time and adequate mixing. It takes time for the oxide particles to meet up with each other in the liquid steel and agglomerate, and the agglomeration of the oxide particles is necessary for the oxides to achieve adequate buoyancy to float up to the slag on top of the liquid bath. Adequate mixing also facilitates agglomeration of the oxide particles. The more the steel is stirred and mixed, the more likely the oxide particles are to come in contact with each other. Time and stirring also aid in sulfur removal. Proper stirring of the steel will increase the slag-steel interaction in the ladle. Increased surface-area interaction between the steel and the slag promotes the kinetics of the calcium-sulfur reaction. As mentioned earlier, it is also important to have a high CaO content in the slag to increase its capacity to absorb sulfur. Hence, the keys to sulfur removal are often shortened to the brief couplet “Lime and Time.” IH For more information: Chuck Fryman, metallurgist, Ellwood Quality Steels, 700 Moravia St., New Castle, PA 16101; tel: 724-6586527; fax: 724-658-6802; e-mail: [email protected]; web: www. ellwoodgroup.com

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FEATURE | Material Characterization & Testing

Microstructure of Nitrided Steels George F. Vander Voort – Struers Inc.; Wadsworth, Ill. Nitriding is one of the most interesting and useful surface-hardening techniques. It is unique in that during the nitriding process, the specimen is not heated into the austenite phase, and it does not rely upon the formation of martensite to achieve high hardness and useful properties. It is heat treated prior to nitriding, forming tempered martensite to obtain the desired core properties unlike all other surface heat-treatment processes.

T

h processing associated with he nitriding does have some adn vantages in avoiding problems v such as quench cracking and s distortion. It also has some side benefits in improved corrosion resistance and generation of beneficial residual compressive stresses, which improves fatigue resistance. Nitrided surfaces do exhibit high surface hardness, leading to improved wear resistance. Of course, like any process, there are disadvantages. One that has always plagued nitriding is the very long cycle time to achieve a decent case depth, about 20 times longer than for carburizing considering equal case depths. The other problem has been the generation of the compound layer, often erroneously called the “white-etching layer,” which is brittle and is generally deleterious if present. Etching does not color this layer white; it is white, just as it was as-polished, since

the etchant had no effect on the layer. Literature Review The literature on the microstructure of nitrided steels does, unfortunately, contain numerous errors and could be improved. Examples of the microstructures of nitrided steels in the literature are often subpar and even poor or false. Phase identification of the compound layer and the underlying diffusion zone need work. In the past, bulk X-ray diffraction on the OD surface has been the chief tool for phase identification. While a useful tool, it needs augmentation by microanalytical methods with very small spatial resolution for phase identification. Limited work has been done using well-established tools such as the transmission electron microscope. This is partly due to the difficulty in preparing thin foils from relatively small regions at the surface compared to the ease in preparing foils from bulk specimens. Also,

it is somewhat a reflection of the types of research studies being funded at universities in the U.S. The writer is currently exploring the use of electron backscattered diffraction (EBSD) with the scanning electron microscope (SEM) to see if this technique can provide an easier approach for analysis of the compound layer. In the literature, one can see nitrided examples of low-carbon steels; low-carbon, low-alloy steels; and HSLA (highstrength, low-alloy) steels (none of these contain significant amounts of alloying elements that form hard nitrides, such as Al, Cr, V or Mo). They exhibit an outer layer, called the “compound layer,” which is reported to be composed of iron nitrides: av (Fe4N) and ¡ (Fe2N1-x) phases. Little, if any, solid-solution strengthening occurs from the diffused nitrogen into the steel. Some needle-like intragranular iron nitrides, probably av, may be seen in ferrite grains below the compound layer,

400

Hardness, Knoop

350 300 250 200 150

Fig. 1. Microstructure of salt-bath nitrided, resulfurized 1215 carbon steel with a compound zone (black arrow), no diffusion zone and some nitride needles (white arrows) in the ferrite grains. Etched with a 10:1 mixture of 4% picral and 2% nital (1250X, oil immersion).

100 0

0.2

0.4

0.6

0.8

1

Depth, mm

Fig. 2. Knoop hardness profile (100 gf load) starting as close as possible to the compound layer to a depth of 1 mm. IndustrialHeating.com - November 2011 51

FEATURE | Material Characterization & Testing

0.002"

Fig. 4. Nitralloy 135 with a nitrided surface case free of any harmful compound layer. Etched with 2% nital followed by 10% sodium metabisulfite. Note the white grain-boundary films (white arrows) in the 500X micrograph.

0.002"

Fig. 5. The white grain-boundary films that are relatively parallel to the surface were darkened (white arrows) by etching with alkaline sodium picrate at ~90˚C for 60 seconds. This etch colors cementite, Fe3C, when used in this manner (original at 500X).

Hardness, Knoop

1200 1000 800 600 400 200 0 Depth, mm

Fig. 6. Knoop hardness profile plot (100 gf load) for Nitralloy 135, free of any compound zone, showing a very high hardness case. 0.010"

Fig. 3. Composite image made from several contiguous fields to show the case/core microstructure of the Nitralloy 135 specimen, etched with a 10:1 mix of 4% picral and 2% nital (originals at 200X).

but they have little influence on the case hardness. Consequently, nitriding has been mainly centered upon steels that contain elements that form very fine, very hard nitrides: Al, Cr, V and Mo. Elements such as Ti and Zr do form very hard nitrides in steels, but they are comparatively quite large (in the μm range) and do not create a case-hardness profile. The original experiments [1] on nitriding performed by Adolph Machlet at the American Gas Company in Elizabeth, N.J., (see U.S. Patent 1,092,925, dated 24 June 1913) focused on nitriding carbon 52 November 2011 - IndustrialHeating.com

steels. In 1906, Adolph Fry of the Krupp Steel Works in Essen, Germany, began a similar study of nitriding.[1] However, Fry realized early in his work that alloying elements were necessary to develop commercially useful nitrided steels. Fry’s U.S. patent (1,487,554) was granted on March 18, 1924. Fry learned that only steels containing additions of Cr, Mo, Al, V or W could achieve a high surface hardness when nitrided. His work at Krupp led to the development of the Nitralloy grades. Etchants

A perusal of publications regarding nitriding reveals a range of etchants that have been used. Nital, by far the most widely used etchant for steels, has been commonly used for nitrided steels. McQuaid and Ketcham used 4% nital to etch nitrided Cr-Al and Mo-Al steels and AISI/SAE 4615 in their study published

in 1928.[1] Robert Sergeson, a research metallurgist at the Central Alloy Steel Corporation in Canton, Ohio, and an early researcher of the nitriding process, introduced the use of a 10-to-1 solution of 4% picral plus 4% nital in 1929 (although many people have used 2% nital instead of 4%).[2] This is an excellent etchant. Lightfoot and Jack[3] studied nitriding with and without formation of the compound layer. They noted that during nitriding a carbon-rich layer is created ahead of the nitrided case. This carbon precipitates as cementite in grain boundaries that are roughly parallel to the surface. This carbon accumulation caused by the inward diffusion of nitrogen has been verified by others.[4-6] Jegou et al.[6] used the electron microprobe to measure the nitrogen and carbon profiles through the nitrided case. These authors showed the grain-boundary films darken in specimens

nitrided for 10 and 100 hours when they etched with ”boiling picral.” They probably used boiling alkaline sodium picrate. It is well known that alkaline sodium picrate used at 80-100°C will darken cementite (Fe3C) carbide. Albert Sauveur, dean of American metallurgists, attributed [7] the boiling alkaline sodium-picrate etch for identification of cementite to Kourbatoff in 1906. Despite studies proving that the white grain-boundary films in the diffusion zone are cementite, numerous authors have stated that they are nitride (Reference 8, for example). This seems to be a common natural error, assuming that the white grainboundary film is a nitride just like the compound layer. The only systematic study on the use of etchants to identify the phases in the compound zone and the white grainboundary films is by Mridha and Jack.[9] They evaluated 10 different etchants and showed that for nitrided pure iron, nital does not distinguish the phases in the compound zone. They concluded that the best reagents to distinguish av from ¡ are picral (etches boundaries in the nitride phases), Vilella’s reagent (attacks boundaries in ¡ and stains av), a sulfatechloride solution (stains only ¡) and Oberhoffer’s reagent (a short 2-5 second etch dissolves ¡). For alloy steels (chiefly 3% Cr steels), the boundary of the nitrided zone was best revealed using picral, Marble’s and Oberhoffer’s reagents. The latter two etchants best revealed the extent of the carbide-enriched region beneath the nitrided region. The sulfate-chloride reagent was sensitive to all constituents. The best etchant for revealing the white grain-boundary films of cementite was alkaline sodium picrate used at 85°C for 2 minutes. This etch also revealed the presence of cementite in the compound zone. Cementite was confirmed using X-ray diffraction. They recommended etching nitrided steels first with alkaline sodium picrate and then with Oberhoffer’s reagent for 3 seconds. Reference 10 by the same authors covers the characterization

of nitrided 3% Cr steels using etchants selected based upon this study.[9] Microstructures An example of a low-carbon, resulfurized steel – AISI/SAE 1215 – that was saltbath nitrided is shown in Figure 1. This specimen was etched with a 10-to-1 mix of 4% picral to 2% nital, an etchant that has often been used to reveal the structure of nitrided steels. Note that we see a welldeveloped compound layer. Because 1215 has no appreciable content of alloying elements that would form alloy nitrides (Al, Cr, V, Mo or W), there is no diffusion zone (as shown later for Nitralloy 135 and 41B50). Note the iron-nitride “needles” (arrows) intragranular within the ferrite grains beneath the compound layer. Figure 2 shows a plot of Knoop hardness (100 gf load) versus depth curve starting as close as possible to the compound layer. This layer is too thin to actually test, so the first indent is not able to evaluate the actual hardness of the compound layer. But one can see from the rest of the data that nitriding has had only a minor influence on the case hardness. Figure 3 shows the case/core microstructure of gas-nitrided Nitralloy 135, an alloy developed by Fry’s work reported above, which contains ~1.1% Al, ~1.6% Cr and ~0.2% Mo – good nitride formers. Note that this specimen does not exhibit a compound layer. With today’s digital technology, we can create a mosaic image from a series of images of contiguous fields, where we control the lighting and then “weld” the digital images together with appropriate software. This is marvelous technology compared to the older, very painful practice of trying to glue prints taken in a similar alignment, which can no longer be done. Figure 4 shows the white grain-boundary films in the diffusion zone that have often been erroneously identified as nitrides (in studies without any analytical work) because they are white. Figure 5 shows that these grain boundaries are darkened when etched with hot alkaline sodium picrate, proving that they are cement-

Electroless Ni plating 1 2 3

Fig. 7. Microstructure (as-polished) of a failed nitrided 41B50, lightly resulfurized (note MnS stringers – white arrows) chuck jaw for a lathe. The surface was plated with electroless Ni for edge support. The black arrows point to the complex compound layer (original at 500X).

Electroless Ni plating 1 2 3

Fig. 8. Failed 41B50 chuck jaw with a nitrided surface exhibiting a massive compound layer etched with 10:1 mix of 4% picral and 2% nital (original at 500X). 1 2

3

20 μm

Fig. 9. Failed 41B50 chuck jaw etched with 10% Na2S2O5. The black arrow points to the Ni plating . The green, red and blue arrows point to the complex compound layer, while the white arrows point to the white grain-boundary films approximately parallel to the surface. Note the cracks in the complex brittle compound layer that failed in service (original at 500X). IndustrialHeating.com - November 2011 53

FEATURE | Material Characterization & Testing

Mns Electroless nickel

Mns 0.002"

0.002"

Fig. 10. Views of the surface (left) and diffusion zone (right) of the nitrided 41B50 specimen after etching with alkaline sodium picrate (90˚C for 90 seconds) that colors cementite (red arrows – originals at 500X). 900 Hardness, Knoop

800 700 600 500 400 300 200 100 0

0.1

0.2

0.3

0.4 Depth, mm

0.5

0.6

0.7

0.8

Fig. 11. Knoop hardness (100 gf load) profile of the failed nitrided 41B50 chuck-jaw specimen revealing a low hardness in the complex compound layer.

ite. Figure 6 shows the Knoop hardness (100 gf load) profile for this specimen – markedly better than for the 1215 carbon steel shown in Figure 2. A more complex example of a nitrided alloy steel, resulfurized 41B50, is shown in Figure 7. This was a chuck jaw made for a lathe that broke as soon as it was put into service due to the brittle nature of the surface layer. The specimen was electroless nickel-plated to enhance edge retention. Figure 7 shows the surface in the aspolished condition. Note the MnS stringers in this lightly resulfurized alloy steel. Three zones can be seen in the complex compound layer. This type of complex compound zone has been reported in the literature, but it is not common. Zone 1 is believed to be epsilon phase formed by outward diffusion of Fe along pore channels and reaction with N at the surface. Zone 2 is believed to be porosity in the epsilon phase (according to the literature), which may be filled with oxide. Examination of this zone with dark54 November 2011 - IndustrialHeating.com

field illumination did not confirm that the black spots are holes, however, nor did the inital SEM examination at high magnification. So, more work is needed to positively identify this dark portion of the compound zone. Zone 3 is the classic mixture of epsilon and gamma-prime phase. In the microscope there is a slight dark/light contrast difference between the two phases, which can be faintly seen in the micrograph. Figure 8 shows the complex compound zone after etching with the 10:1 mixture of 4% picral to 2% nital. Note that detail is revealed in the compound zone (Zone 3). Figure 9 shows the compound zone and diffusion zone after etching with 10% sodium metabisulfite. There is what appears to be oxidation between the electroless nickel plating and zone 1, as also shown in Figures 7 and 8. Figure 10 shows two views of the complex compound layer and the diffusion zone of the failed nitrided part after etching with alkaline sodium picrate at 90°C for 90 seconds to color the

cementite. Note that the lower edge of the compound zone (area 3) contains cementite, as reported by previous researchers. The white grain-boundary films are darkened by the alkaline sodium-picrate etch while the coarser cementite in zone 3 of the compound layer is a mix of blue and blackish particles. Figure 11 shows the Knoop hardness (100 gf load) profile for the failed nitrided 41B50 chuck-jaw specimen. Note that the hardness in the outer dark surface (zone 2) of the compound zone is lower than the inner (zone 3) layer. Zone 1 is far too thin to determine its hardness accurately. 41B50 contains ~0.95% Cr and ~0.20% Mo, but neglible Al (a small amount may be present for grain refinement). Note that the maximum case hardness obtained in the nitrided 41B50 specimen is much lower (~620-690 HK) than obtained for the nitrided Nitralloy 135 specimen (~1000-1040 HK) with ~1.1% Al, 1.6% Cr and ~0.2% Mo (Fig. 11 compared to Fig. 6). Both cases, however, are markedly harder than that of the nitrided 1215 carbon steel (~300-340 HK) in Fig. 2. This shows just how critical it is to develop an alloy composition that will form very hard, very small nitrides. Conclusions Metallography, when properly performed, is an exceptionally important tool for studying the microstructure of nitrided steels, as well as other heat-treated metals and alloys. All etchants are not equal, and nital is not always the best etch for all steels, despite its wide usage. Different steel compositions do respond quite differently to nitriding, as illustrated by the comparison of a nitrided carbon steel with two alloy steels – one with a greater concentration of alloying elements that will form very fine, hard nitrides compared to the leaner alloy. The Knoop hardness profiles for these three steels were markedly different. Nitriding processes must be controlled to eliminate the brittle compound layer, which has been known to cause failures when present. The work shows that the compound layer can be rather variable in appearance. It is also common to see white

grain-boundary films only in the boundaries that are parallel or nearly parallel to the specimen surface. These films have frequently been claimed to be nitrides, but numerous studies have proven that they are cementite. The exact mechanism for the formation of these films has not been fully defined, although there are a few good preliminary studies. It appears that as nitrogen is diffused into the steel, carbon is pushed from the surface inward. Only limited electron microprobe (EMPA) work has been done to study the C and N case profiles, but these show that the C is depleted at the surface and pushed inward while the N content is highest at the surface and drops as the case hardness decreases. Application of good analytical techniques, such as EBSD and the EMPA, in future studies should enhance our understanding of the nitriding process. IH

References 1. H.W. McQuaid and W.J. Ketcham, “Some Practical Aspects of the Nitriding Process,” Trans. of ASST, Vol. 14, 1928 (Republished in the Source Book on Nitriding, American Society for Metals, Metals Park, Ohio, 1977, pp. 1-25). 2. R. Sergeson, “Investigations in Nitriding,” ASST Nitriding Symposium, 1929 (republished in the Source Book on Nitriding, American Society for Metals, Metals Park, Ohio, 1977, pp. 26-55). 3. B.J. Lightfoot and D.H. Jack, “Kinetics of Nitriding With and Without White-Layer Formation,” Heat Treatment ’73, The Metals Society, December 1973 (republished in the Source Book on Nitriding, American Society for Metals, Metals Park, Ohio, 1977, pp.248-254). 4. L. Barrallier et al., “Morphology of Intergranular Cementite Arrays in Nitrided Chromium-Alloyed Steels,” Materials Science and Engineering, Vol. A393, 2005, pp. 247-253. 5. V. Yu. Traskine et al., “Physicochemical Mechanics of Structural Transformations in Nitrided Steel,” Colloid Journal, Vol. 67, No. 1, 2005, pp. 97-102.

6. S. Jegou, L. Barrallier, R. Kubler and M.A.J. Somers, “Evolution of Residual Stress in the Diffusion Zone of a Model Fe-Cr-C Alloy During Nitriding,” HTM J. Heat Treatment Mat., Vol. 66, No. 3, 2011, pp. 1-8. 7. A. Sauveur, The Metallography and Heat Treatment of Iron and Steel, 4th ed., McGraw-Hill Book Co., NY, 1935, pgs. 482, 502 and 504. 8. R. Agnelli et al., “Failure Analysis in Tool Steels,” Failure Analysis of Heat Treated Steel Components, L.C.F Canale, R.A. Mesquita and G.E. Totten editors, ASM International, Materials Park, Ohio, 2008, pp. 311-350. 9. S. Mridha and D.H. Jack, “Etching Techniques for Nitrided Irons and Steels, Metallography, Vol. 15, No. 2, May 1982, pp. 163-175. 10. S. Mridha and D.H. Jack, “Characterization of Nitrided 3% Chromium Steel,” Metal Science, Vol. 16, August 1982, pp. 398-404. For more information: Contact George F. Vander Voort, Consultant – Struers Inc., 24766 Detroit Rd., Westlake, OH 44145; tel: 847-6237648; e-mail: georgevandervoort@yahoo. com; web: www.struers.com and www. georgevandervoort.com.

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IndustrialHeating.com - November 2011 55

Courtesy of Agilent Technologies

How to Detect Leaks in Vacuum Furnaces ll vacuum furnaces, whether they are hot zone, ion carburizing or low-pressure carburizing types, require the maintenance of a leak-free environment in order to control the transformation of materials to meet strict product-quality requirements. Unfortunately, every vacuum furnace will eventually develop leaks that can compromise the integrity of the material being processed. Leaks can also damage internal furnace components. This explains why a leak-tight system is so critical to achieving consistent and accurate treatment of any material within a furnace chamber. Different metals in the furnace expand at different rates when the furnace is in operation, sometimes opening up leaks that are not present at lower temperatures. Such leaks can develop in multiple process-gas entries, valves, feedthroughs and door seals. Large leaks in a vacuum furnace will be very obvious. The furnace will not pump down or the hot zone will show clear signs of oxidation. Small leaks, however, often go undetected because the pumping system can easily offset any leak impact. System operators may be misled by gauge readings that still show adequate vacuum levels. But even small leaks can result in major problems, especially in the most critical applications.

A

Comparing Pump-Down Cycle A relatively simple leak-detection method is to compare the pumpdown cycle with a previous cycle made when the system was in a good working order. If the vacuum level improves with each successive pumpdown, then outgassing should be suspected. Outgassing can also be detected in large vacuum furnaces when large pressure spikes occur or when pressure rises during the heating portion of a process cycle. Performing Vacuum-Decay Measurement Another simple leak detection method involves performing a vacuum-decay measurement. This test is accomplished by closing the valve between the vacuum pump and the chamber, which stops the evacuation process. After a short stabilization time, the pressure can be observed looking for a pressure rise or vacuum decay. The vacuum-decay rate is defined as the difference in the vacuum levels at the beginning and the end of the measurement divided by the elapsed time. It is normally expressed in microns/hour. For most vacuum applications, a vacuum-decay rate above 10 microns/ hour in the heating chamber is unacceptable. Both of these methods are affected by the overall cleanliness of the furnace. To properly perform a vacuum-decay test, the furnace must be clean, cold, empty and outgassed to obtain a true leak-up rate value. If it isn’t, a conditioning cycle should be run. This is a time-consuming process that normally involves heating the equipment to 50°F-100°F (30°C-55°C) higher than the furnace’s normal operating temperature for two to four hours. Then a vacuum is drawn and the furnace is cooled overnight. It’s important to note that a vacuum decay test determines the existence of a leak and quantifies its magnitude, but it does not identify its location. 56 November 2011 - IndustrialHeating.com

Leak checking a door assembly

Helium Leak Detection Helium leak detection is the most powerful method of validating the integrity of a vacuum furnace. Helium makes an ideal tracer gas because it is present in only small amounts in the ambient air, resulting in low background noise. In addition, helium is readily available on a worldwide basis and is not toxic, flammable or reactive. It offers major advantages over other leak-detection methods as it can pinpoint the location of leaks and is not affected by outgassing. In addition, helium leak detection is so fast that it can easily be performed as a routine operation at the start of each production run. Helium leak detection works as follows. Helium is applied to one side of a containing wall. Any helium that leaks through the wall is measured by a helium-tuned mass spectrometer. The high amount of helium released by a leak relative to low ambient levels means that only a medium-sensitivity instrument is required to detect a leak. For this reason, moderately priced equipment performs just as well in this application as high-performance detectors with sophisticated amplification systems that drive up both initial and maintenance costs. It’s important to note that most vacuum furnaces are not considered clean by vacuum standards, so it is important to select only helium leak detection equipment tailored to industrial applications as opposed to those designed for laboratory use. The leak detector must be able to withstand operation in an environment containing oil and water vapors and, to provide the reliability required for production operations, must be resistant to mechanical vibrations. Do-It-Right Advisory

Agilent Offers Everything Vacuum for Your Industrial Heating Process

tes, Inc. Composi Carbon f o sy e urt Photo co

Agilent NHS-35 Diffusion Pump

Agilent MR-15 Leak Detector with Remote

Agilent MS Series Rotary Vane Pump

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High Capacity Agilent RVPs and Roots Systems

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shaft seal technology Proven technology with many installations worldwide

www.agilent.com/chem/vacuum

Courtesy of Dry Coolers

How to Recapture Waste Heat from Combustion Save Energy, Save Money The widespread use of recuperative burners to preheat combustion air has boosted efficiency throughout most of the heatprocessing industry. The savings in gas consumption pays for the equipment and the “carbon footprint” is reduced. For most industrial users, however, opportunities still exist for recuperating and putting to use much of the waste heat currently being exhausted from their facilities. Tax incentives and various energy programs can help fund a project, and potential upcoming legislation may put pressure on industry to reduce greenhouse-gas emissions. Here are some practical approaches to this timely topic. Heat Your Wash or Rinse Tank Measure the flow and temperature of your exhaust streams. A source of heat that is adequate to fully supply or at least substantially augment an existing demand should be identified. The vented exhaust from combustion can be ducted to a heat recovery unit with a gas-to-liquid heat exchanger to preheat boiler feed water or another nearby process (Figure 1). Many heat-related processes are preceded or followed by a heated wash or rinse tank, which are also good candidates for recovered heat. Rinse tanks, boiler feed water and other applications may be heated directly in the heat recovery unit. Other fluids may have to be indirectly heated (using an intermediate heat exchanger) due to chemistry or lack of cleanliness. Process Control Methods One challenge is to match the demand for recuperated heat with the available supply of heat. One way to accomplish this is to pull only as much heat as needed from the exhaust stream by utilizing a simple modulating damper to bypass excess heat around the heat transfer coil, controlling the amount of heat reclaimed. An alternate method is the utilization of variablespeed exhaust blowers. A temperature probe in the tank can be used to signal the heat recovery unit to operate, and a temperature probe in the outlet of the heated fluid stream can be used to proportionately control the bypass damper or variable-speed blower. This will prevent any overheating of the heat transfer fluid. If there is not enough heat to fully satisfy the demand, consider preheating or assisting the current system. For large exhaust streams, consider a modular approach using several units for different users (Figure 2).

58 November 2011 - IndustrialHeating.com

Figure 1. Gas-to-liquid heat recovery unit

Figure 2. Modular application for washer and boiler preheat

Heat Recovery Tips • Match the materials of construction to the temperature of the exhaust stream • Consider variable-frequency drives for blowers as a means of temperature control • A backup heating system may be advisable • Allow for thermal expansion in equipment, ducts and piping • Look for close-proximity heat users to minimize installation costs • Insulate ductwork and fluid piping for maximum efficiency Do-It-Right Advisory

Courtesy of Furnace Parts

How to Make System Accuracy Testing Easy nyone who takes their thermal-processing systems seriously knows the importance of performing system accuracy tests (SATs). These tests are crucial in the effort to assure your equipment is running true to form. SATs can be quite problematic, however, due to issues such as location of the control thermocouple, the potential for leaks in vacuum furnaces and other situations that make performing the SAT difficult. While provisions in AMS 2750D allow the use of resident SAT thermocouple assemblies in these special situations, how confident can you be knowing that the resident SAT thermocouple is continually subjected to the same operating conditions as your control thermocouple? Due to the stresses created by thermal cycling, it is a fact that the calibration of a thermocouple may change during its use. The amount of change depends on such factors as temperature range, time and environmental conditions under which the item is used. Additionally, resident SAT thermocouples, as well as non-resident SAT thermocouples, need to be recalibrated as described in AMS 2750D (Table 1). If you happen to use a special dual-thermocouple assembly consisting of one side being the control thermocouple and the other as the resident SAT thermocouple, you could possibly incur some additional furnace downtime due to the need to change out resident SAT assemblies as compared with non-resident thermocouples. The prudent thing to do, whenever possible, is to perform the traditional SAT using a separate SAT Sensor as stated in AMS 2750D paragraph 3.4.4.2: “The tip (measuring junction) of the SAT sensor shall be as close as practical to the tip (measuring junction) of the controlling, monitoring or recording sensor, but the tip-to-tip distance shall not exceed 3 inches (76 mm). Subsequent SAT tests shall utilize SAT thermocouple(s) placed in the same locations/positions/depth as the initial test.” This method is commonly referred to as a “probe check.” In order to make this task go smoothly, it is important to assure your control thermocouple assemblies include the proper hardware to accommodate the SAT process. One type of thermocouple hardware specifically designed to accommodate non-resident SAT probes is the proprietary G7 Open Terminal Head As-

A

sembly (Fig. 1). This design has a built-in probe thermocouple port in the head, protected from environmental hazards by a sliding gate when not in use, that allows for the easy and repeatable insertion of an SAT sensor probe into the protection tube right alongside of the control thermocouple elements so they are tip-to-tip as prescribed in AMS 2750D. This prevents the need for the resident SAT, subject to the continual thermal exposure of the control thermocouple. Without this continual exposure, the non-resident probe has greater life. Once the SAT has been completed, the SAT sensor is removed and is no longer subjected to continuous exposure to elevated temperatures, thus helping to maintain its measurement integrity during calibration cycles. The bottom line is that furnace accuracy and “uptime” equates to greater revenue. Ensuring the accuracy of your control thermocouples using probe checks gives you the confidence that your furnaces are operating within tolerance. The calibrated probe provides the traceability to back up that confidence. With the advent of a thermocouple that allows for the repeatable and consistent means of performing SAT probe checks, you eliminate furnace downtime associated with the change-out of a resident SAT thermocouple. Taking into account the minimal added expense of the introduced design versus the cost of furnace downtime, considering its use is a wise choice.

Fig. 1. G7 Open Terminal Head Assembly

Table 1. Sensors and Sensor Calibration System accuracy test (3.1.6)

Base or types B, R, and S noble metal

System accuracy tests

60 November 2011 - IndustrialHeating.com

Before first use. Recalibration:(8) 6 months - Types B, R, & S 3 months - Types J & N not permitted - other base metal

Primary or secondary standard

Base metal ±2 °F (±1.1 °C) or ±0.4% Noble metal ±1.0 °F (±0.6 °C) or ± 0.10%, Type R, S ± 0.25%, Type B

Do-It-Right Advisory

IT’S TIME FOR SAVINGS

Offering Today’s Temperature Measurement Solutions Furnace Parts, LLC, offers the best in temperature measurement solutions. With quick turnaround and affordable prices, heat treaters trust our expertise in Industrial Thermocouples and Temperature Sensors. We offer a full range of products, including: High Temperature Thermocouples – Type S, R and B platinum/rhodium assemblies for high temperature, furnace control and vacuum applications Mineral Insulated Metal Sheathed (MgO) Thermocouples – compact, moisture-proof and pressure resistant; ideal for control or load thermocouples or for temperature uniformity surveys (TUS) and system accuracy tests (SAT). Type J, K and N assemblies Insulated Wire Thermocouples – custom assemblies for a wide variety of environments and applications; available in a wide variety of insulation types in both standard and special limit tolerances Platinum Reclamation Program: Reduce your total thermocouple costs with our platinum reclamation program. We can tailor one to your speci½c needs. Furnace Parts products are certi½ed to meet AMS 2750D, CQI-9, BAC-5621K, and NADCAP speci½cations. We are dedicated to providing our customers with the highest level of service, creative solutions and short product lead times. Call 800-321-0796 or visit furnacepartsllc.com for information.

Courtesy of Metallurgical High Vacuum

How to Lower Lifetime Pump Cost with Smart Maintenance ndustrial furnaces are costly and valuable assets. They need periodic maintenance to keep them running. This maintenance includes rebuilding or replacing components, controllers and even vacuum pumps. Here’s where it can get complicated, because furnaces can have a decadeslong life when maintained properly. Shut downs (especially unplanned ones), however, cost production time and repairs that get expensive. Experienced users look beyond low initial costs to determine the cost of ownership over the long run. So, what can a smart technical support department do about it? They can keep good system performance records like pump-down and processing times, ultimate pressure, cycle times, etc. These can help to understand what is happening with a system over time. Look for things like changes in parts, materials, preparation or maintenance. When vacuum fur-

I

nace cycles run long or the ultimate pressure can’t be attained, it can be caused by vacuum leaks, heat exchanger water leaks, contamination or malfunctioning pumps. If you have spares on hand, you can swap out the malfunctioning pump or blower with minimum downtime and get started on repairs or rebuilding. Pump Rebuilding Do you fix them in house or send them out? This depends on many issues, but it boils down quickly to time and money. Economics may dictate that rebuilding your Stokes, Kinney, Leybold or other brand pump makes the most sense. Purchasing decisions can look like just a matter of price. In real life, though, it gets more complicated. Proper analysis of your total cost is needed to evaluate the differences in rebuilds from different vendors, and it can show you how to get $60,450 more in profits.

Tables 1 & 2 show the true value of a Stokes 412 pump rebuild over a five-year period. This information was provided by a client. Cost of ownership becomes clearer as you look at annual costs. These figures are for illustration only, as the labor rates and hourly costs vary, but you can see how an estimate can help solve the problem if you look beyond the initial cost. The difference in initial costs ($9,300 vs. $22,325) is reflected in the monthly cost differences ($1,380/month vs. $372/month) once you look at the long-term results. The total life cost ($82,775 versus $22,325) becomes $60,450 saved over the five-year life of the pump. So, from 17 months on the savings are pure profits to the company. There are a lot of detailed reasons why a better remanufactured pump will last longer, and Metallurgical High Vacuum would be happy to provide you with those details. All you have to do is contact us.

Table 1 Item

Vendor X

Cost for 5 years of service

Notes

Initial rebuild cost for 9 months of service

$7,500

$52,500

Process contaminants wear pump quickly

Maintenance cost to swap pump

$500

$3,500

Labor – in-house time (7X)

Shipping expense

$325-up

$2,275-up

Freight (7X)

Furnace downtime (1 day per rebuild)

$2,500

$17,500

Production lost – # of days @ $105/hour

Rejected parts –depends on items/load

$1000-up

$7,000-up

Customer relations damaged

Total

$9,300

$82,775 $1,380/month

Table 2 Item

Vendor M

Cost for 5 years of service

Notes

Initial rebuild cost for 60 months of service

$18,000

$18,000

On-board filters remove contaminants

Maintenance cost to swap pump

$500

$500

Labor – in-house/time

Shipping expense

$325-up

$325-up

Freight

Furnace downtime

$2,500

$2,500

Production lost – 1 day @ $105/hour

Rejected parts –depends on items/load

$1,000-up

$1,000-up

Customer relations damaged

Total

$22,325

$22,325 $372/month

62 November 2011 - IndustrialHeating.com

Do-It-Right Advisory

Courtesy of Nanmac Corporation

How to Maximize Thermocouple Life working at temperatures over 1000°C (1832°F), he life of a thermocouple depends on several factors – even the oils from the user’s hands or any dirt will the better one knows the environmental conditions under have a significant effect on the sheath and reduce which the sensor will be used, the better they can design the the protection time offered the internal elements. thermocouple. Consider that thermocouples generally are Finally, a process of evacuating all air from made with a protection tube. The purpose of the tube is quite simply inside the sheath and back-filling with inert gas to protect the thermocouple. Therefore, if you can prolong the life of will extend the life of all thermocouples used to the protection tube, you prolong the life of the thermocouple. measure high temperatures. This process does add Environmental conditions include whether it is oxidizing, expense to a purchased sensor and considerable time neutral or reducing. Also included are the peak-use temperature, to self-made thermocouples. With this in mind, one number and duration of cycles, time at peak, etc. Even if should consider the “downtime” factor when requesting the thermocouple sheath remains intact and the sensor this design. Let’s say that this design costs even five seems to be working, thermocouples (particularly platinum) times as much as a standard design (highly unlikely) but will decalibrate as they are exposed to more and higher reduces or eliminates downtime in the process. It may be temperature cycles. worth the added expense. For temperatures up to 1000°C (1832°F), one can use In oxidizing temperatures between 1000°C-2350°C stainless steel or Inconel sheaths. Standard sheath sizes are (1832°F-4262°F), the protective sheaths generally are from 1/16 inch up to 1 inch NPT (1.315 inch). The thicker ceramics such as Al2O3, MgO, Zirconia or Quartz, and the wall of the protection tube, the longer the thermocouple will last under most conditions. the elements are typically either Platinum or Tungsten Internal construction will consist of either a hardthermocouples such as types S, R, B (platinum/rhodium) or fired ceramic insulator or compacted ceramic powder C, D and G (tungsten/rhenium). and at least a pair of thermocouple wires. One should In reducing or inert atmospheres, one can use refractoryuse the largest diameter wires possible for longer metal sheaths such as tantalum or molybdenum. In carbonizing life. In addition, single-pass swaging (the process of atmospheres, it is advisable to coat the high-temperature compacting the ceramic powder within the sheath) (greater than 1650°C) section of the tantalum or molybdenum is preferred over multiple-pass swaging. Multiplesheath with a thick layer of tungsten. By applying this tungsten pass swaging distorts the shape of the round coating, one could expect 10x the life of an uncoated device. wire and weakens it, thus limiting its life under cyclical conditions. Of the three different hot junction designs – ungrounded, grounded and exposed junctions – an ungrounded junction will almost always provide the longest life. This style can Keys to Maximizing withstand cycling better and provides Thermocouple Life protection from the environment.

T

Particular attention should be paid to how the welded junction is formed within the sheath. If the junction is formed such that it can expand and contract with thermal cycles, the thermocouple element’s wires will be much less likely to break. All internal components must be kept very clean and dry. Any contamination, including how the sensor is handled at installation, will have negative affects on the sensor. If the user will be 64 November 2011 - IndustrialHeating.com

• Prolong the life of the protection tube • Use a thick-walled protection tube • Use the largest diameter wires possible • Use an ungrounded junction design • Use the proper thermocouple type for the temperature to be measured

Do-It-Right Advisory

Courtesy of Unifrax

How to Determine Material Selection with Energy Efficiency

W

ith energy prices steadily increasing, now is the time for owners and operators of high-temperature furnaces to reexamine their options with regard to energy efficiency. Aside from the obvious area of burner combustion efficiency, one other key place to look is the wall thermal efficiency in the furnace. Upgrading to a higherperforming insulation can provide energy savings…but how do you know you’ll get your money’s worth? Examine Your Options In a recent experiment, three different types of insulation were evaluated for their energy-saving potential in a typical high-temperature furnace (2300°F): • 12 inches of dense refractory material • 12 inches of typical dense refractory material plus 2 inches of a patented foam/fiber insulation on the furnace hot face • 12 inches of patented ceramic fiber modules To perform the heat-loss evaluation, engineers used 3E Plus®, a computer program that is available free of charge from the North American Insulation Manufacturer’s Association. The model

assumed that the furnace was located in a factory with an 80°F ambient temperature and no wind speed, that natural gas costs were $8 per million Btu (typical in August 2006) and that the furnace operates 6,500 hours per year (about three quarters of the time) with 75% combustion efficiency. The results are summarized in Table 1. Clearly, the continued use of standard dense refractory materials will result in a large rate of heat loss from the furnace walls, and this energy use will cost the owner/operator about $72 per square foot each year. By veneering this dense refractory material with 2 inches of foam/ fiber insulation, the owner/operator can reduce that heat loss by more than half, resulting in an annual energy cost of $34 per square foot. Replacing the standard dense refractory material with the ceramic fiber modules provides the greatest efficiency improvement – 73%. Energy Savings The estimated energy savings shown in the model are dramatic and can be achieved in a real manufacturing plant. Furthermore, as shown in Table 1, the owner/operator can reduce the furnace skin temperature by almost 200°F, thereby significantly improving worker safety. To determine the best course of action in your facility, balance the cost to retrofit the furnace interior with a veneer of foam/fiber insulation against the cost to remove the conventional dense refractory material and replace it with ceramic fiber modules. Either option will dramatically reduce energy use. The latter, however, will save the greatest amount of energy and can therefore make the greatest improvement. Unifrax has developed a furnace-audit initiative in which a representative can conduct an audit of the furnace of an end-use customer. The data collected in this audit is used by our experienced engineers to provide a valuable analysis of the furnace-lining performance and make recommendations for increased furnace efficiency by utilizing a furnace upgrade or refractory replacement with a Fiberfrax® lining system. A computer-modeling program presents the results in terms of Btu’s saved, as well as the actual dollar savings that can be realized. In today’s world of high energy costs, it pays to carefully consider your furnace insulation options.

Table 1: Insulation Model Exterior Surface Temperature (°F)

Heat Loss/Area (Btu/hr – ft2)

Annual Cost of Natural Gas/Area ($/ft2 – year)

Improvement over Option 1

12 in. of Dense Refractory Material

411

1046

$72.14

-

12 in. of Dense Refractory Material + 2 in. of Foam/Fiber Insulation*

279

494

$34.72

52%

12 in. of Ceramic Fiber Modules**

212

284

$19.58

73%

*Fiberfrax® Foamfrax® Grade II insulation, and **Fiberfrax® Anchor-Loc® 2600 modules, supplied by Unifrax, Niagara Falls, N.Y.

66 November 2011 - IndustrialHeating.com

Do-It-Right Advisory

Anytime, Anywhere

®

Anchor-Loc 3 insulating fiber

modules keep your project on schedule with consistent, reliable performance anywhere in the world. ®

Anchor-Loc 3 insulating fiber modules are specifically designed and manufactured for the global market, providing a winning combination of performance, reliability and consistency you can count on anywhere in the world. This new generation ® Insulating Fiber Modules of Anchor-Loc modules is designed to meet a wide range of application requirements in a variety of heat processing vessels. They provide continuous S-folded blanket construction for improved thermal performance in high temperature applications and are available in various fiber chemistries, temperature grades and densities to meet the most demanding requirements. Anchor-Loc 3 modules offer:

Consistent design & quality assurance Anchor-Loc 3 module design features construction from a continuous fold of spun blanket, stainless steel alloy hardware and center mount attachment. The design allows for consistent furnace layout, ease of installation and dependable service life. All components meet or exceed established industry standards assuring the same high quality worldwide.

Fast, cost-effective delivery The Unifrax sales team provides design recommendations, engineering layout and product sourcing options, ensuring a costeffective furnace lining solution wherever you’re located in the global market.

Universal specifications

For more information and a list of our worldwide manufacturing locations, visit the Unifrax website, call 716-278-3800 or email [email protected].

Anchor-Loc 3 modules are produced in each of our global manufacturing centers using the same raw material specifications, dimensional tolerances and assembly procedures, providing product uniformity and consistency worldwide.

www.unifrax.com

Courtesy of Marathon Monitors Inc., a member of United Process Controls

How to Find the Best Oxygen-Sensor Technology for Your Process

W

ith a relatively large number of oxygen-sensor suppliers, it can be difficult to get past the sales pitch and find out exactly what sensor technology (not brand) will best match your process, procedures and budget. What’s best for neutral hardening is often poorly suited to high %C carburizing unless it is complemented with other capabilities or procedures. Conversely, the technologies that provide the best accuracy for high carbon levels tend to be more fragile and short-lived. Fundamentally, nearly all oxygen probes (commonly known as “carbon probes”) used in heat treating are relatively simple electrochemical cells – two electrodes with solid electrolyte between them that conducts oxygen ions. When it comes to finding the ideal probe, it’s these electrodes and the specific electrolyte used in the probe that determine accuracy and thermal ruggedness. Longevity is also affected by the electrodes and the electrolyte as well as the sheath material and construction of the sensor. The vast majority of oxygen probes are designed with either nickel-based or platinum-based electrodes. Nickel electrodes usually come in the form of the probe’s sheath (typically RA330, RA253 or alloy 600), whereas platinum electrodes are usually sandwiched between the electrolyte and the sheath. Both nickel and platinum will “crack” methane and other hydrocarbons and, as a result, produce excess carbon. This means that the more nickel or platinum one has in the electrode, the less accurate the reading of the probe will be. Conversely, less nickel or platinum tends to shorten probe life. Fortunately, inaccurate readings can be corrected usi using “process factors” (a.k.a. CO factors) foundd in most instrumentation: Cut Cu a part, run shim or dew point to find the real %C and correct the instrument reading to match h the probe. Some think this method is a bit of a cheat, but the reality is that no probe will ever bee able to account for all the he variables that affect the reall %C. For example, part alloy l y type, surface condition, load ad surface area and exact atmosphere composition all have a significant impact on the carbon n diffusion rate and are undetectable abble by any oxygen probe. When it comes to electrolytes, there ere are two primary types on the mararket today: SIRO2 and slipcast. SIRO2 O2

68 November 2011 - IndustrialHeating.com g.com com

technology uses a small slug of zirconium dioxide ceramically welded to an aluminum-oxide tube. It is coated with platinum for its electrodes. This technology tends to need higher corrections in very high carbon atmospheres but is highly resistant to thermal and mechanical shock. Slipcast technology uses a long, test-tube-shaped piece of zirconium dioxide. These can use either nickel or platinum electrodes. When fitted with lower-nickel (such as RA253MA) electrodes, slipcast provides the most accurate uncorrected reading at high carbon levels but still cannot account for methane or load surface-area variations. They also tend to be more prone to thermal shock when used in zones with rapidly changing temperatures (pit lids). Recently, some probes are using a newer design that is a hybrid – it uses a small, replaceable tip with an alumina tube to provide ruggedness, but the tip itself responds more like a slipcast probe. What’s more, this new technology uses a modular sheath design so that the electrode (sheath) can be optimized for the process. For low carbon levels an alloy 600 sheath could be used to maximize life, while at high carbon levels a more exotic alloy such as Kanthal APM could be used to minimize cracking and maximize accuracy. When it comes to selecting the right technology for an oxygen probe, there are many options. Most probes can be used in any situation as long as care is taken to avoid thermal shock and correct for gas cracking. With careful consideration and consultation with experts, it is possible to find a technology that maximizes ser service life while minimizing expense and maintaining acceptable accuracy. United Process Controls’ table accur experts are available ble globally to help find the right technology your application. for yo ion.

Do-It-Right Advisory

Materials Characterization & Testing

Chemical/Surface AnalysisChemical/Surface Equipment-Spot Analysis Tests Kits, Metal/Alloy Tests Kits, Metal/Alloy Equipment-Spot

Welcome to the 10th Annual Materials Characterization & Testing Buyers Guide Chemical/Surface AnalysisChemical/Surface Equipment-Spectrometers, Mass Analysis Equipment-Spectrometers, Mass

Chemical/Surface AnalysisChemical/Surface Equipment-Spectrometers, Emission Analysis Equipment-Spectrometers, Emission

If you are looking to purchase materials characterization and/or testing equipment for your production processes, it is well worth Compression Testers (SeeCompression Universal Testing Machines) Testers (See Universal Testing Machines)

Borescopes, Other Visual Borescopes, Inspection Equipment/Systems Other Visual Inspection Equipment/Systems

your time to view this easy-to-read directory. Just Ànd the piece of equipment you’re looking for, then look for the corresponding

Hardness Testers/Accessories Hardness Testers/Accessories

Gas Analyzers

Film Thickness Meters Film Thickness Meters

Gas Analyzers

Fatigue Testers Fatigue Testers

Furnaces/Environmental Chambers (Laboratory) Chambers (Laboratory) Furnaces/Environmental

Fastener Testers Fastener Testers

Fracture Toughness Testing Equipment Fracture Toughness Testing Equipment

Extensometers Extensometers

Electromagnetic Testers Electromagnetic Testers

Dilatometers

Suppliers

Eddy Current Testers/Accessories Eddy Current Testers/Accessories

materialstesting, click “Suppliers” and conduct your search.

Creep Testers

2. Go online to www.industrialheating.com/

Dilatometers

are an advertiser in this issue. Go to the Advertiser Index on page 86 to Ànd that company’s contact information.

Creep Testers

1. If the supplier is in bold-face type, they

Corrosion Testing Equipment Corrosion Testing Equipment

Two Easy Ways to Contact a Supplier:

Bend Testers (See Universal Testing Machines) Bend Testers (See Universal Testing Machines)

CONTACTING A SUPPLIER

Adhesion/Bond-Strength Testers Adhesion/Bond-Strength Testers

have to do is follow the simple instructions in the “Contacting A Supplier” box below.

Flexural Testers (See Universal Testing Machines) Flexural Testers (See Universal Testing Machines)

companies that offer it. Equipment and companies are both listed alphabetically. To Ànd a supplier’s contact information, all you

•

Advanced Technology Corp. AFFRI Inc.

•

•

AMWEI Thermistor Co. Ltd.

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American Stress Technologies Inc. Applied Test Systems - see our ad on page 49

•

•

•

•

•

•

• •

Buehler

•

CEA Instruments Inc.

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Clemex Technologies Inc. - see our ad on page 77

•

Dynamic Systems Inc. EDAX Inc.

• •

Electronic Development Labs Inc. Engineering Systems Inc.

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•

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Excel Technologies Inc.

• • • •

Extec Corp. GeoCorp Inc.

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Gilmore Diamond Tools Inc.

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IBG NDT Systems Inc.

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INFICON

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Jentek Sensors Inc.

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Kahn Instruments Inc.

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LECO Corporation - see our ad on page 34

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Magnetic Analysis Corp.

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70 November 2011 - IndustrialHeating.com

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Heating and do not necessarily represent the entire materials characterization & testing industry. To be included as a supplier in this Buyers Guide, please contact

Doug Glenn at 412-306-4351 or by e-mail at doug@ industrialheating.com.

• Impact Testers

• Load Cells

Load Cells

Suppliers listed in this Buyers Guide responded to a special mailing by Industrial

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Strain Gages

Strain Gages

www.industrialheating.com/materialstesting

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Thickness Gages Torsion Testers

Thickness Gages Torsion Testers

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Viscometers

Viscometers

Universal (Tension/Compression) Machines/Accessories UniversalTesting (Tension/Compression) Testing Machines/Accessories

Ultrasonic Testers/Accessories Ultrasonic Testers/Accessories

Thermal Analyzers

Thermal Analyzers

Tensile Testers (See Universal Testing Machines) Tensile Testers (See Universal Testing Machines)

Temperature Measuring Devices (Pyrometers, Thermcouples, Ir Thermometers, Etc.) Thermcouples, IR Thermometers, etc.) Temperature Measuring Devices (Pyrometers,

Stiffness Testers

Stiffness Testers

Sorters (Metals And Alloys) Sorters (Metals and Alloys)

Software (MechanicalTesting) Testing, Nondestructive Testing) Software (Mechanical Testing, Nondestructive

Residual Stress Analyzers/Testers Residual Stress Analyzers/Testers

Recorders/Controllers, Temperature Recorders/Controllers, Temperature

Radiographic Testing Equipment/Accessories Radiographic Testing Equipment/Accessories

Porosimeters

Penetrant Testing Equipment/Accessories Penetrant Testing Equipment/Accessories

Analyzers Particle/Powder AnalyzersParticle/Powder (Size Surface Area, Etc.) (Size Surface Area, etc.)

Modulus Testers, DynamicModulus Testers, Dynamic

Microscopes-Stereo

Microscopes-Light, Metallurgical Microscopes-Light, Metallurgical

Microscopes-Electron, Transmission Microscopes-Electron, Transmission

Microscopes-Electron, Scanning Microscopes-Electron, Scanning

Microscope Accessories Microscope Accessories

Metallographs

Metallographic Specimen Metallographic Preparation Equipment/Supplies Specimen Preparation Equipment/Supplies

Magnetic Particle Testing Magnetic Equipment/Accessories Particle Testing Equipment/Accessories

Leak Testers

Leak Testers

Infrared Thermography Equipment Infrared Thermography Equipment

Impact Testers

Image Analysis Systems (For Quantitative Metallography) Image Analysis Systems (For Quantitative Metallography)

Buyers Guide AVAILABLE ONLINE This directory can be found online at:

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IndustrialHeating.com - November 2011 71

Materials Characterization & Testing SEARCH ONLINE You can conduct your product/supplier search online at:

Hardness Testers/Accessories

Gas Analyzers

Furnaces/Environmental Chambers (Laboratory)

Fracture Toughness Testing Equipment

Flexural Testers (See Universal Testing Machines)

Film Thickness Meters

Fatigue Testers

Fastener Testers

Extensometers

Electromagnetic Testers

Eddy Current Testers/Accessories

Dilatometers

Creep Testers

Corrosion Testing Equipment

Suppliers

Compression Testers (See Universal Testing Machines)

materialstesting, click “Suppliers” and conduct your search.

Chemical/Surface Analysis Equipment-Spot Tests Kits, Metal/Alloy

2. Go online to www.industrialheating.com/

Chemical/Surface Analysis Equipment-Spectrometers, Mass

are an advertiser in this issue. Go to the Advertiser Index on page 86 to Ànd that company’s contact information.

Chemical/Surface Analysis Equipment-Spectrometers, Emission

1. If the supplier is in bold-face type, they

Adhesion/Bond-Strength Testers

Two Easy Ways to Contact a Supplier:

Borescopes, Other Visual Inspection Equipment/Systems

CONTACTING A SUPPLIER

Bend Testers (See Universal Testing Machines)

www.industrialheating.com/materialstesting

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Newage Testing Instruments Inc. Newport Electronics Inc. Nova Analytical Systems Inc. OXY-GON Industries Inc.

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Omega Engineering - see our ad on inside front cover

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Phase II Machine & Tool Inc.

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Proceq USA Inc. Proto Manufacturing Inc.

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Quality Solutions - see our ad on page 45 Shimadzu Scientific Instruments Struers Inc. - see our ad on page 36

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Sun-Tec Corporation TBW Industries Inc. Technology for Energy Corporation (TEC) Thermo Scientific Tinius Olsen Inc.

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Ulbrich Stainless Steels and Special Metals Inc. United Testing Systems Inc. Unitron Ltd. Vulcan Electric Co.

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Wilson Instruments

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Yokogawa Corporation of America - see our ad on back cover

Innovation in Automation 72 November 2011 - IndustrialHeating.com

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Sorters (Metals And Alloys)

Software (Mechanical Testing, Nondestructive Testing)

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Viscometers

Universal (Tension/Compression) Testing Machines/Accessories

Ultrasonic Testers/Accessories

Torsion Testers

Thickness Gages

Thermal Analyzers

Tensile Testers (See Universal Testing Machines)

Temperature Measuring Devices (Pyrometers, Thermcouples, Ir Thermometers, Etc.)

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Strain Gages

• Residual Stress Analyzers/Testers

Recorders/Controllers, Temperature

Radiographic Testing Equipment/Accessories

Porosimeters

Penetrant Testing Equipment/Accessories

Particle/Powder Analyzers (Size Surface Area, Etc.)

Modulus Testers, Dynamic

Microscopes-Stereo

Microscopes-Light, Metallurgical

Microscopes-Electron, Transmission

Microscopes-Electron, Scanning

Microscope Accessories

Metallographs

Metallographic Specimen Preparation Equipment/Supplies

Magnetic Particle Testing Equipment/Accessories

Load Cells

Leak Testers

Infrared Thermography Equipment

Impact Testers

Image Analysis Systems (For Quantitative Metallography)

Buyers Guide If you have any questions about the directory, contact Industrial Heating Publisher Doug Glenn at 412-306-4351 or via e-mail: [email protected]. If you are a supplier and are not listed in this Buyers Guide, please contact us immediately. We may be able to list your company in the online directory.

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www.wilson-hardness.com

IndustrialHeating.com - November 2011 73

Literature/Website Showcase Vacuum Furnaces & Components | Heating Elements Vacuum Furnace Selection Guide

Thermal-Processing Systems

G-M Enterprises An (8) eight-page, full-color handout for prospective furnace buyers. The handout is a checklist of considerations when purchasing a new vacuum furnace. Please call for our "Guide to the Selection of Vacuum Furnaces." Phone: 951-340-4646. www.gmenterprises.com

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

TITAN Vacuum Furnace Ipsen Ipsen dreamed of engineering a vacuum furnace that was cost effective to produce, deliver and operate. The result: TITAN® offers a wide range of sizes, versatility of processes, speed and uniformity while maintaining costeffective pricing, delivery and operation. www.ipsenusa.com

Nonferrous and Heat-Treat Furnaces

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

Furnaces

LindbergMPH LindbergMPH, one of the world’s largest manufacturers of nonferrous and heat-treat furnaces, has a long-standing reputation as a single-source supplier, including design, construction, services and genuine factory parts. For quality, value and reliable service, call 800-873-4468. www.lindbergmph.com

Can-Eng Furnaces Since 1964, Can-Eng has been designing and manufacturing industrial heat-treating equipment for commercial and captive heat treaters, stamping and fastener companies, automotive component producers, the iron and steel industries, and aluminum foundries. Take a closer look at the systems we have to offer. For more information, call 905-356-1327 or visit us at www.can-eng.com.

Heat Treating Data Book

Heating Elements

SECO/WARWICK Corp. SECO/WARWICK has published the 9th edition of its famous Heat Treating Data Book complete with updated tables and a new format. Customers may receive one copy free, two or more copies for $2.00 each. Visit www. secowarwick.com and click on "Heat Treating Data Book."

Custom Electric Mfg. Co. For more than 30 years, Custom Electric has offered affordable, high-quality elements for all styles of furnaces and ovens. Our elements are used worldwide by leading manufacturers because they lower costs by reducing downtime. Call 248-305-7700 or visit www.custom-electric.com.

Vacuum Furnaces

Heating Elements

Solar Manufacturing Solar Manufacturing has over 100 combined years of experience in vacuum furnace design. Featured are improved graphite insulation materials, curved graphite heating elements, tapered gas nozzles, high-velocity gas quench systems, SolarVac 3000 interactive control systems, ConserVac energy management system and Magnetic Specialties Smart Power Supplies. www.solarmfg.com

I Squared R Element Co. Starbar and Moly-D elements are made in the United States with a focus on providing the highest-quality heating elements and service to the global market. I Squared R Element has been providing high-quality service for 40 years. www.isquaredrelement.com

74 November 2011 - IndustrialHeating.com

Literature/Website Showcase Materials Characterization & Testing Equipment 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

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 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

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

Hardness Testers Quality Solutions Quality Solutions is now offering new technology in hardness testing from “ERNST,” one of the world’s leading manufacturers of hardness testing equipment since 1954. The new “Depth of Penetration” testers checks case depth from 0.002” to over 0.100” in three minutes with a non-destructive test. No more sectioning, mounting or tedious checking. www.qs-hardnesstester.com

Duramin-A300 Struers Duramin-A300 – Struers introduces a hardness tester based on innovative closedloop technology, eliminating dead weights. Featuring: test load range 0.981N to 306.6N, completely automatic test cycles, automatic exchange of indenter and lens, automatic lens focusing, high-resolution CCD cameras, automatic image evaluation. www.struers.com

Over 40 years of service and reliability I Squared R Element Co., Inc. Akron, NY Phone: (716)542-5511 Fax: (716)542-2100

Email: [email protected] www.isquaredrelement.com IndustrialHeating.com - November 2011 75

Products

Product of the Month Internal Quench Furnace Systems

Ipsen delivers more air time. When you buy a TITAN® vacuum furnace for brazing engine components, you’re buying peace of mind. That’s because TITAN® features: • Operation anywhere in the world within 10 weeks • Design for streamlining NADCAP certification • Uptime supported by global parts, service and training network • One global standard • Easy transition between languages, voltages and units of measure Visit www.IpsenUSA.com/titan to learn more.

SPEED UNIFORMITY EFFICIENCY 76 November 2011 - IndustrialHeating.com

BeaverMatic® BeaverMatic’s internal quench furnace systems are the workhorse of every heat-treat shop. Long known as Beavers, IQFs are available in a variety of sizes and configurations. Smaller-capacity furnaces include BeaverMatic’s unique Beaver Ram pull-push transfer system, and larger furnaces include push-push load transfer systems. Since process versatility is a key to the success of every heat-treating shop, the IQF can be configured for carburizing, hardening and carbonitriding. Standard sizes ranging from 24 inches wide x 36 inches long x 26 inches high with 750-pound capacity to 36 inches long x 72 inches long x 36 inches high with 6,000-pound ound capacity are available. In addition, BeaverMaticc now has designs available for manufactura anufacturing equipment with high igh work chambers to customer’s exact e size requirements as an alternative ernative to pit furnaces. This equipment i ipment can have work chamberss as large as 48 inches wide x 72 inches long x 96 inchess high and weight capacity up to 15,000 pounds. www.beavermatic.com

Bearing Material Metallized Carbon Corp. Metcar Grade M-11 is a plain, unimpregnated, carbon-graphite material that has good self-lubricating qualities and good wear resistance when running dry at temperatures up to 650°F. It is an economical grade that is suitable for bearings that must run continuously at relatively light load and low speed. Metcar Grade M-11 is extensively used for bearings in equipment such as hightemperature air dampers and high-temperature conveyors. Metcar Grade M-11 is available in all Metallized Carbon standard sleeve bearing, standard flange bearing and standard thrust bearing sizes. It is also available in all of the standard, self-aligning pillow block and self-aligning flange block assemblies offered by Metallized Carbon. Bearings in the grade can also be manufactured to meet your size specifications. www.metcar.com

Quenchants Houghton International Aqua-Quench 145 and Aqua-Quench 245 provide greater stability against microbial intrusions and extend the life of induction hardening systems by up to 100%. Spray nozzles and filters run clean, and quenched parts have uniform surface quality because Aqua-Quench 145 and Aqua-Quench 245 are water-based, minimizing sticky deposits. Aqua-Quench 145 and Aqua-Quench 245 users can select the quenching speed of the solutions to suit the steel hardenability and component requirements by varying concentrations of the quenchants. This allows uniform quenching, which eliminates steam pockets and the formation of soft spots on quenched parts. www.houghtonintl.com

Thermal Imager Omega Engineering The OSXL160 thermal imager is the most versatile and competitively priced unit on the market. It has an extraordinary temperature range of -20 to 1200°C (-4 to 2192°F). Special features include: voice annotation, analysis software, FLASH memory storage, USB connection to PC, and a colored thermal image with sounds and alarms. Applications for the OSXL160 include high-temperature processes, heat leakage detection, automotive use and many more. The OSXL has power, range and versatility atility all in a lightweight, rugged, handheld d body.

tion time and maintenance costs by combining multiple inputs uts into a single transmitter. Temperature data is sent via a secure wireless link to an ISA100.11a 00.11a gateway receiver, making that data available to a wide range of plant instruments and data-acquisition and control systems. The field-replaceable internal battery pack that powers the YTMX580 provides rovides years of continuous operation under normal conditions. www.yokogawa.com/us

CLEMEX

intelligent microscopy

MicroHardness Testing & Image Analysis Built in

www.omega.com

Heat Exchanger xchanger Munters The Thermo-T™ tubular heat exchanger recovers energy from processes with temperatures up to 2000°F with up to 80% effectiveness. Built to handle high temperatures and corrosive environments, Thermo-T can be constructed with a variety of materials to best suit your application. Welded construction prevents cross-contamination, and integral thermal-expansion joints allow the heat-exchanging tubes to expand in hightemperature applications without causing excessive stress to the unit. Numerous configurations and airflows from 3,000 SCFM to 30,000 SCFM ensure Thermo-T’s adaptability. Thermo-T is also available with options to facilitate cleaning, including access doors and an integral water-wash system. www.munters.us

Temperature Transmitter Yokogawa Corp. of America The YTMX580 wireless multi-input temperature transmitter is battery powered and features an industry-leading eight analog input channels, each configurable for thermocouple, RTD, DCV and 4-20mA measurement. The YTMX580 is a cost-effective way to measure multiple temperature points in distant plant locations where there is no signal cabling or power available for traditional wired instrumentation. With eight input channels, the YTMX580 increases operating efficiency and reduces installa-

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

IndustrialHeating.com - November 2011 77

The Aftermarket Parts, Services & Consulting Resources

THE AFTERMARKET

$

125 pparts arts

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

PARTS • SERVICE • CONSULTING

$149 per month for a single two-color card $199 per month for a single four-color card

YOUR GLOBAL SOURCE FOR QUALITY HEAT TREAT FURNACE PARTS & SERVICE

Call: 248-624-8191 Fax: 248-668-9604

Contact Becky McClelland Ph: 412-306-4355 Fax: 248-502-1076 Call TODAY!

Induction Heating

Melting

Forging

Spare Parts Used and rebuilt power supplies Coil design, repair and development for Induction Heating, Melting and Forging Equipment

We Guarantee Our Work!

[email protected]

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OEM PARTS + SERVICE + REBUILDS + UPGRADES 1525 Old Alum Creek Drive Columbus, OH 43209-2712 Ph: (614) 253-8900 Fax: (614) 253-8981

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

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

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

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

CUSTOM HIGH-TEMPERATURE VACUUM FURNACES

Brazing Furnaces Annealing Furnaces Atmosphere Generators Batch Furnaces Integral Quench Furnaces Continuous Pusher Furnaces Car Bottom Furnaces Tip Up Furnaces Computer Management Systems Installations - Rebuilds Used Equipment - Spare Parts BILL VAN ETTEN - Sales (734) 656-2000 Ext. 125 Fax: (734) 656-2009 • Cell: (313) 680-1982 Email: [email protected]

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

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

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

Electric Heating Elements For a broad range of applications Find out more at… www.Duralite.com 78 November 2011 – IndustrialHeating.com

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

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

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

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

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

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

Aftermarket Services for Induction Equipment

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

s s s s s s s s

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

Induction O.E.M. for

Used Heat Treating Furnaces and Ovens

Pillar Induction

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

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

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

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

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

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

£‡nää‡xxn‡ÇÇÎÎ

ÜÜÜ°«ˆ>À°Vœ“ÊÊUÊÊÃiÀۈViJ«ˆ>À°Vœ“

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

Tubes Retorts Corrugated Boxes and Baskets Serpentine Trays Muffles Stainless Fixtures

• • • • • • •

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

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

Visit Industrialheating.com/ helpwanted to find out how the

Industrial Heating

Classified Marketplace can help you target qualified job candidates!

REPLACEMENT ALLOY ROLLS AND RADIANT TUBES

www.thermotransferinc.com

www.qual-fab.net

VACUUM FURNACE REBUILDS • • • •

Hot Zones Pumps Leak Detection Service

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

WONDER WELD INDUCTION Energy Efficient Preheaters You Can Spend 15 Hours Preheating or you can spend 15 Minutes 50 lbs. to 1500 lbs. Weld Preheating, Dies, Core Boxes, Patterns

GUARANTEED WORK FOR 33 YEARS Tel: 614-875-1447 Fax: 614-870-0236

WWW.WONDERWELD.COM

IndustrialHeating.com – November 2011 79

Classified Marketplace

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

Rates Per Column Inch

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

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

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

BUSINESS OPPORTUNITY

“Nadcap and You… Achieving Excellence Together.” Build your business with the support of a Global Industry Leader. Performance Review Institute is seeking experienced Aerospace auditors to work as independent contractors for the Nadcap Heat Treating program. As an independent contract auditor for the Nadcap program, you will perform heat treating audits, complete audit reports, and have the opportunity to train associate auditors. Typical auditor qualifications often include: • Bachelor’s Degree in a technical field or 10 years heat treating and/or brazing experience • 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 • Ability to communicate in multiple languages • Strong interpersonal skills The following are specific criteria for Heat Treating: • Bachelor Degree in a technical field OR High School Diploma and 10 years heat treating and/or brazing experience, 5 years of which are “hands-on” experience (preferably in the aerospace industry) with some of the following heat treating processes: aluminum, titanium, heat resisting alloys, brazing, carburizing and nitriding. • Understanding of AMS2750 or Pyrometry specification As an independent contract auditor, you will enjoy: • A Flexible Schedule • Competitive Daily Rate • Reimbursable Travel & Living Expenses • Skills Workshop • Ability to work from the location of your choice See why Nadcap has been attracting & retaining some of the best partners 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 organization.

80 November 2011 – IndustrialHeating.com

LHS Air Heater

Built-in thermocouple with digital temperature readout

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

REPRINT PLAQUES are Now Available Contact Becky McClelland at 412-306-4355 [email protected] FOR SALE New Design

SPARK IGNITER Used for the automatic ignition of recuperative burner systems.

le

Always Online at: www.industrialheating.com

The Next Generation

ths A vailab

This established commercial heat treater is located in the Midatlantic U.S. This is a proÀtable heat treat shop offering a variety of different processes. For further details please contact Becky McClelland by email: [email protected] or call 412-306-4355. A non disclosure agreement will be required.

PROCESS HEAT

Leng

Commercial Heat Treat Shop for Sale

FOR SALE

*Diff erent

BUSINESS OPPORTUNITIES

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

Classified Marketplace

http://twitter.com/IndHeat www.industrialheating.com/FB-UsedEquip

FOR SALE

FOR SALE

FOR SALE Surface Combustion 3 Chamber Furnace

FOR SALE

48 x 36 x 24" Nitrogen and Oil Quench New Moly Hearth 412-781-3553 [email protected] FOR SALE

AFC Mesh Belt Austemper Furnace System 750 Lbs/Hr, 1700ÝF, 30"W x 6"H x 120" long includes loader, furnace, salt tank, wash, exit conveyor & control panel.

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

Canefco Direct Gas Fired Draw Furnace

EQUIPMENT FOR SALE

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.

Gas-Fired Carbottom Furnace

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

6’ W x 6’ H x 12’ L Maximum Temp: 2000˚F Fiber Lined 50,000# Payload Complete with Instruments

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

EQUIPMENT FOR SALE

FOR SALE

Mowry Enterprises, Inc.

For more information, please call 1-877-834-4328 (HEAT) ONLINE AT: WWW.INDUSTRIALHEATING.COM

FOR SALE

Vacuum Furnace For Sale Abar Ipsen Bottom Load Vacuum Furnace 48” Diameter x 60”H 2400°F Diffusion Pump Updated Controls

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.

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

“Featured Equipment”

VFS HL 36: 2500 F, 24” x24” x38” graphite hot zone, High vacuum, PLC/ touch screen controls, Pressure Quench

• 24" Wide belt washer

VFS HL 50: 36” x 30” x 48”, graphite hot zone, high vaucum, 1200 CFM external quench, 2650 F

• W/A Spinner hanger

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

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

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

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

• 24" Dia. Rotary drum washer • Induction equipment • (2) available: Jensen doubledoor, walk-in batch oven. 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] IndustrialHeating.com – November 2011 81

Classified Marketplace

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

FOR SALE

FOR SALE

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

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

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

FOR SALE

36"w x 22' long x 16" high, 120 kW, 1250ÝF, complete w/controls

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

Lightnin Mixers (7) Available 5 HP, 1725 RPM, Complete w/ propellers and agitators. Shaft length 46" L, Small Propellers 8"W - Large Propellers 19"W For more information, please call your sales representative at 1-877-834-4328 (HEAT).

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

FOR SALE

For $25.00 We Will Post and Link Your Ad Online Visit industrial heating online at www.industrialheating.com FOR SALE Diffusion Bonding

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82 November 2011 – IndustrialHeating.com

Densification

http://twitter.com/IndHeat www.industrialheating.com/FB-UsedEquip

FOR SALE

FOR SALE

FOR SALE Rad Con Bell Annealing Furnace 132" Diameter x 66"H, 60 Ton Load Capacity, 1600˚F, Gas Fired, N2 Atmosphere, 3 Bases, 3 Retorts, 1 Furnace

Furnaces, Ovens and Baths 4790 White Lake Road Clarkston, MI. 48346 248.343.1421 - Cell E-Mail: [email protected] Website: www.fobinc.com

FOR SALE Ipsen Horizontal Front Loading Cold Wall Vacuum Furnace • • • • • • • •

FOR SALE

Surface Pit Carburizer • ID: 48" Diam. x 72" Deep • Dual Fuel: Electric or Gas • Model "ERT" – Electric Radiant Tube • Bottom Alloy Recirculating Fan • Atmosphere Capable • Control Panel + Digital Controls Cleveland, OH Ph: 440-519-3800 Email: [email protected]

Visit Industrialheating.com/ helpwanted to find out how the

Classified Marketplace

• • • • • • • •

With A Car Bottom For Loading/Unloading. Model # VFCB-48X96X48(24)R, Serial # 54960 48" w x 48" h x 96" l Load Size: 3000 lbs, Vacuum: 10-4 Barr 450 KVA, 480 Volts, 60 Cycles, 3 Phase, 4000,000 BTUH, 2400 Deg F Thermocouples - Nickel-Molybdenum-Nickel Two Cooling Fans, 10 HP Each C/W Mechanical Pump - Model 412H, 300 CFM, 10 HP, Diffusion Pump - 18", 20,000 CFM Oil Capacity - 10 Pints, Heaters - 10KW, 480 Volts Booster Pump - Roots Model 1722, 1250 CFM Diffusion Pump - Varian HS20 Holding Pump - Leybold Trivac D25B Roughing Pumps - Two (2) Stokes 412 Unit has Return Water System C/w Free Standing Control, Console Complete With Strip Chart Recorder/Controller, Excess Temperature Controller, Soak Times, Vacutronik (Indicates Vacuum Pressure) Warning Signals, Bell Alarm & Horn Alarm. Park Thermal International (1996) Corp. 62 Todd Road, Georgetown, Ontario L7G 4R7 Toll Free: 877-834-4328 • Fax: 905-877-6205 [email protected] • Web: www.parkthermal.com

FOR SALE

Industrial Heating

Classified Marketplace can help you target qualified jjob candidates! q

IndustrialHeating.com – November 2011 83

Classified Marketplace

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

IC M A R E . BLE C T PA M T E S T GH CA ALAN FOR SALE

Since 1936

HI

––––– ATMOSPHERE GENERATORS ––––– 750CFH Endothermic Ipsen (Air) Gas 1000CFH Ammonia Dissoc. Drever Elec 1000CFH Ammonia Dissoc. Hayes (1994) Elec 1000CFH Exothermic Gas Atmos. Gas 1500CFH Endothermic Ipsen Elec 3000CFH Endothermic Lindberg (3) Gas 3600CFH Endothermic Surface Gas 5600CFH Endothermic Surface (5) Gas 6000CFH Gas Atmos. Nitrogen Generator Gas 10.000CFH Exothermic Seco/Warwick (2) Gas

–––––––––– 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" × 120" × 12" Ransohoff Belt Washer/Dryer Gas Wilson Hardness Testers (RC) SBS Air/Oil Coolers 132" Diam. x 66" High Rad Con (Bell) Gas 1600˚F 30" x 48" Surface Charge Cars (3)

–––––––––– BOX FURNACES –––––––––– 9" × 14" × 9" Lucifer Up/Down Elec 2000/1250˚F 9" × 18" × 9" Lucifer Up/Down Elec 2000/1250˚F 12" × 24" × 8" Lucifer Up/Down (Muffle) Elec 2100˚F 12" × 24" × 8" Hayes (Atm) Elec 1800˚F 13" × 24" × 12" Electra Up/Down Elec 2000˚F 14" × 24" × 12" Lindberg H2 Retort Elec 2150˚F 36" dia. x 48 dp. Lindberg Elec 1400˚F 14.5"×12" L&L (New) Elec 2350˚F 17"×14.5"×12" L&L (New) Elec 2350˚F 24"×36"×18" Lindberg Elec 2000˚F 24"×36"×24" Lindberg Elec 2100˚F 39" x 144" x 56" Nabertherm Kiln Elec 2450˚F 72"×72"×48" R&G Elec 2000˚F

––––––– OVENS/BOX TEMPERING –––––– 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 15" × 24" × 18" Lindberg Elec 1250˚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" × 18" × 20" Despatch Elec 500˚F 20" × 24" × 20" Despatch Elec 1350˚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 24" × 36" × 24" Lindberg Elec 1250˚F 24" × 36" × 24" Demtee (N2) Elec 500˚F 24" × 36" × 24" Paulo Gas 1250˚F 25" × 20" × 20" Blue-M Elec 650˚F 26" × 26" × 38" Grieve (2) Elec 850˚F 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" P-Quincy Elec 350˚F 36" × 36" × 36" Grieve (2) Elec 650˚F 36" × 36" × 36" Trent Elec 1200˚F 36" × 48" × 60" Blue-M Elec 600˚F 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 1000˚F 38" × 26" × 38" Grieve Elec 1250˚F 38" × 28" × 28" Trent (Top load) Elec 900˚F 48" × 24" × 48" Blue-M Elec 600˚F 48" × 30" × 42" Despatch Gas 850˚F 48" × 48" × 48" Lydon Bros. Elec 1200˚F 48" × 48" × 60" Gasmac Burn-off (2) Gas 850˚F 48" × 48" × 60" P-Quincy Elec 800˚F 48" × 48" × 72" Lydon Bros. Elec 450˚F 48" × 48" × 84" Gruenberg Elec 450˚F 48" × 72" × 72" Mich. Oven Elec 500˚F 50" × 50" × 50" Grieve Gas 850˚F 54" × 68" × 64" Despatch Elec 500˚F 60" × 64" × 72" Poll. Cont. Burn-off Gas 850˚F 60" × 54" × 60" Lydon Bros. Elec 1200˚F 66" × 96" × 72" Gruenberg Elec 500˚F 72" × 96" × 72" Despatch (2) Gas 750˚F 72" × 72" × 72" Mich. Oven Gas 500˚F 72" × 120" × 72" Grieve Gas 450˚F 84" × 96" × 72" Despatch (2) Gas 750˚F 84" × 168" × 84" Cincinnati (2) Gas 500˚F 120" × 120" × 96" Steelman (New) Elec 500˚F

–––––––––– PIT FURNACES –––––––––– 14" Dia × 60"D Procedyne Fluid Bed Elec 1850˚F 22" Dia × 26"D L&N Elec 1400˚F 22" Dia × 26" L&N Nitrider Elec 1200˚F 36" Dia x 48" Lindberg Elec 1400˚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 48" Dia × 72"D Surface (Atmos.) Elec/Gas 1850˚F 60" Dia × 144"D Lindberg Elec 1400˚F ––––––––– VACUUM FURNACES ––––––––– 18" × 27" × 14" VFS (HL-26) Elec 2650˚F 24" × 36" × 18" Ipsen VFC-424 Elec 2400˚F 48" × 60" Ipsen Bottom Load Elec 2400˚F –––– INTEGRAL QUENCH FURNACES –––– 8" × 18" × 8" Ipsen Gas 1850˚F 15" × 24" × 10" L&N Tricarb Elec 1850˚F 24" × 36" × 24" Lindberg (Top Cool) Elec 2000˚F 30" × 48" × 30" Surface Elec 1750˚F 30" × 48" × 30" Surface Gas 1850˚F ––––––– BELT FURNACES/OVENS ––––––– 4" × 4' × 2" Wat-Johnson (Atmos.) Elec 1800˚F 24" × 5' × 6" Darvon (New) Elec 400˚F 12" × 15' × 4" Sgt. & Wilbur (1994) Muffle Gas 2100˚F 16" × 24' × 4" Abbott (Atmos.) Muffle Elec 2400˚F 24" × 17' × 28" Jensen – Dual Belt Gas 500˚F 24" × 19' × 30" Jensen Gas 500˚F 24" × 30' × 30" Jensen Gas 500˚F 24" × 40' × 18" Despatch Elec 500˚F 24" × 40' × 18" Despatch Gas 650F 28" × 18' × 12" Hayes Elec 800F 32" × 21' × 18" Sunbeam Elec 1450˚F 36" × 108" × 34" Process Heating Elec 300˚F 42"× 24'× 30" Jensen Gas 500˚F 60"×45'×12" W-House Roller Hearth Gas 1700˚F

84 November 2011 – IndustrialHeating.com

SIVE ADHE

E & SMoist Creamy Putty Just Apply and Let Dry Bonds Most Materials

Resists Chemicals, Electricity, Molten Metals and Abrasion

2300 F O

FREE MATERIALS HANDBOOK

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

FOR SALE

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]

FOR SALE

VACUUM PUMPS SALES AND SERVICE

CASHVAC INC. • • • • •

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

• FREE ESTIMATES AND DELIVERY

Factory Trained Stokes Pumps/Blowers

TOLL FREE: 1-800-397-1600 Specializing in Stokes Vacuum Pumps

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

http://twitter.com/IndHeat www.industrialheating.com/FB-UsedEquip

Advertise Online With Industrial Heating Build your brand and stay in front of prospective customers by building on traditional print advertising with one of IH’s many online options. www.industrialheating.com

Classified Marketplace FOR SALE

FOR SALE All Surface Combustion Equipment: • Gas Fired Super Allcase Integral Quench Furnace 30” x 48” x 30”, 1750˚F, with Top Cool, SBS chiller and controls. • Electric Super Allcase Integral Quench Furnace 30” x 48” x 30”, 1750˚F, 140 KW with Top Cool, SBS cooler and controls. • Electric Super Allcase Integral Quench Furnace 30” x 48” x 30”, 1750˚F, 180 KW with SBS cooler and controls. • Electric Tempering Furnace 30” x 48” x 30”, 1400˚F, 81 KW with controls. • Gas Dunk Washer 30” x 48” x 30”, 180˚F with controls. For more information, please call your sales representative at 1-877-834-4328 (HEAT).

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

FOR SALE

FOR SALE

Contact Susan Heinauer at 412-306-4352 [email protected]

• 44”W x 12”H x 20’L Heat, Belt Furnace, Gas Fired, 1250°F • 2500 CFH AFC/Holcroft Endo Gas Generator, Air Cooled • 24” Diameter Rotary Drum Washer, W/R/D, Gas, Stainless • 24”W x 6”H Belt Washer, W/R/D, Electric, Stainless • Air to Oil Heat Exchangers – 4 Total • 28" Diameter x 72" Deep, Lindberg, 2000-F, Carburizer, Electric. • Stokes 1722 Package Systems – Rebuilt – 1 Available (412-11 w/615 Blowers) • Varian Leak Detectors – 1 Available • 24” Diameter x 48” Deep, L & N Pit Nitrider, 1750˚F • 40”W x 18”H x 36’L, Holcroft Roller Hearth, Gas, 1300˚F • Box Furnaces – All Sizes (30) In Stock • Conveyor Ovens – All sizes (20) In Stock • 72"W x 6"H x 24' , Holcroft, Atmosphere, 1600˚F, Mesh Belt • 102” x 72” x 16”H, Holcroft Slot Forge, 2200˚F, Gas, UNUSED • Induction Heating, 7.5 kW to 750 kW, 1 kHz to 450 kHz, 21 In Stock • 36” x 48” x 30”H, Surface Combustion Batch Tempers, 1400˚F, Gas • 59”W x 67”H x 50”L, Despatch, 1000°F, Atmosphere w/Forced Cooling, 2 Available • 8 Cubic Feet Jet Wheel Blast Multi Tumble Shot Blast Machines w/Loader, 2 Available • Dual Rotary Drum Washer, 2 Stage w/Blow Off, 23” Diameter x 15’L, Stainless Drums • 132" Diameter x 66"H Bell Furnace, 1600°F, Gas, Atmosphere • 36"W x 30"H x 48"L Temper, Surface Combustion, 1250°F, Electric • 36"W x 36"H x 72"L Temper, Wisconsin, 1250°F, Electric • Holcroft Direct Fired 2 Row Pusher, 21" x 42" Trays, 1750° • 38" Dia. x 84" Deep, Lindberg Pit Furnace, 1250-F, Elec., Atmos/Cool. • 48"W x 7"H x 21'L, 1750-F, Electric, Cast Link Belt Furnaces - 3 Available

Contact: Jeffrey D. Hynes 248.343.1421 or [email protected]

FURNACES OVENS & BATHS For a complete inventory listing with photos visit www.fobinc.com IndustrialHeating.com – November 2011 85

Advertiser Website Index Page

COMPANY NAME

PHONE

WEBSITE ADDRESS

57 49 50 10 25 45 23 11 77 27 59 61 19 55 29 41 17 75 32 46 28 3,76 12 55 34 28 63 65 49 31 Inside Front Cover Inside Back Cover 32 45 9 30 42 15 75 33 35 13 36 6 40 30 67 69 29 26 21 73,74 Back Cover

Agilent Technologies, Vacuum Products Div. Applied Test Systems Inc. ASM International BeaverMatic, Inc. Can-Eng Furnaces International Ltd. Capitol Vacuum Castalloy Inc. CEIA USA Ltd. CLEMEX Technologies Inc. Custom Electric Manufacturing Co. Dry Coolers Inc. Furnace Parts LLC G-M Enterprises Graphite Metallizing Corp. Hauck Manufacturing Heatbath Corp./Park Metallurgical Honeywell I Squared R Element Co. Inc. Induction Tooling Inc. Inductotherm Group INEX Incorporated Ipsen Inc. Kurt J. Lesker Co. L & L Special Furnace Co., Inc. LECO Corp. Lindberg/MPH Metallurgical High Vacuum Corp. Nanmac Corp. North American Cronite, Inc. Nutec Bickley Omega Engineering, Inc. Plansee USA LLC Qual-Fab, Inc. Quality Solutions Raytek Corp. Rous Hi-Temp Product Co., Ltd. SECO/WARWICK Corp. SGL Carbon, LLC Shaanxi Sinwa International Trading Co., Ltd. Solar Manufacturing Southern California Gas Co. Steeltech Ltd. Struers, Inc. Surface Combustion Inc. Thermalloys T-M Vacuum Products, Inc. Unifrax, LLC United Process Controls VAT, Inc. Wellman Furnaces Inc. Wisconsin Oven Corp. Wilson Instruments Yokogawa Corp. of America

800-882-7428 800-299-6408 800-336-5152 815-963-0005 905-356-1327 800-237-3933 262-547-0070 888-532-CEIA 450-651-6573 248-305-7700 800-525-8173 800-321-0796 951-340-4646 914-968-8400 717-272-3051 413-452-2000 877-466-3993 716-542-5511 440-237-0711 609-267-9000 716-537-2270 800-727-7625 800-245-1656 610-459-9216 800-292-6141 269-849-2700 269-543-4291 508-872-4811 800-243-4123 215-638-4500 203-359-1660 800-782-6659 440-327-5000 812-704-5491 800-227-8074 0086-533-3580575 814-332-8400 800-727-4474 86-29-85325399 215-258-3350 800-847-5497 616-243-7920 888-787-8377 800-537-8980 46-248-12577 856-829-2000 716-278-3800 800-547-1055 781-935-1446 317-398-4411 262-642-3938 800-695-4273 800-258-2552

www.agilent.com/chem/vacuum www.atspa.com www.asminternational.org www.beavermatic.com www.can-eng.com www.capvac.com www.castalloycorp.com www.ceia-usa.com www.clemex.com www.custom-electric.com www.drycoolers.com www.furnacepartsllc.com www.gmenterprises.com www.graphalloy.com/IH www.hauckburner.com www.heatbath.com www.honeywell.com/ps/hfs www.isquaredrelement.com www.inductiontooling.com www.inductothermgroup.com www.INEXinc.net www.ipsenusa.com/sintering www.lesker.com www.hotfurnace.com www.leco.com www.lindbergmph.com www.methivac.com www.nanmac.com www.afegroup.com www.nutecbickley.com www.omega.com www.plansee-usa.com www.qual-fab.net www.qs-hardnesstester.com www.raytek.com www.rous-hitemp.com www.secowarwick.com www.sglcarbon.com www.refrachina.com www.solarmfg.com www.socalgas.com www.steeltechltd.com www.struers.com www.surfacecombustion.com www.thermalloys.com www.tmvacuum.com www.unifrax.com www.group-upc.com www.vatvalve.com www.wellmanfurnaces.com www.wisoven.com www.wilson-hardness.com www.yokogawa.com/us

15b3

No. Copies of Single Issue Published Nearest to Filing Average No. CopiesAverage Each Issue Average No.No. Copies Copies Ea Ea Date 12 12 During Preceding 12 Months Extend Extend andand Nature Nature of Circulation of Circulation During During Preceding Preceding M M 20469 19498 Total Total Number Number of Copies of Copies (net(net press press run)run) irect Outside County Paid/Requested Mail Subscriptions stated Form 3541. (Include direct Outside County Paid/Requested Mail Subscriptions stated on on PSPS Form 3541. (Include direct written request from recipient, telemarketing Internet requests from recipient, paid written request from recipient, telemarketing andand Internet requests from recipient, paid f copies, subscriptions including nominal subscriptions, employer requests, advertiser's proof copies, subscriptions including nominal raterate subscriptions, employer requests, advertiser's proof copies, 15702 15827 exchange copies.) andand exchange copies.) written In-County Paid/Requested Mail Subscriptions stated Form 3541. (Include direct written In-County Paid/Requested Mail Subscriptions stated on on PSPS Form 3541. (Include direct written tions request from recipient, telemarketing Internet requests from recipient, paid subscriptions request from recipient, telemarketing andand Internet requests from recipient, paid subscriptions exchange including nominal subscriptions, employer requests, advertiser's proof copies, exchange including nominal raterate subscriptions, employer requests, advertiser's proof copies, andand exchange 0 0 copies.) copies.) Sales through Dealers Carriers, Street Vendors, Counter Sales, Other Paid Sales through Dealers andand Carriers, Street Vendors, Counter Sales, andand Other Paid or or 494 352 Requested Distribution Outside USPS Requested Distribution Outside USPS

15b4 15c

ss Mail) Requested Copies Distributed Other Mail Classes Through USPS (e.g. First-Class Mail) Requested Copies Distributed by by Other Mail Classes Through thethe USPS (e.g. First-Class Mail) Total Paid and/or Requested Circulation Total Paid and/or Requested Circulation

15d1

,(include Outside County Nonrequested Copies stated Form 3541 Sample copies, Outside County Nonrequested Copies stated on on PSPS Form 3541 (include Sample copies, including Requests Over 3 years Requests induced a Premium, Bulk Sales Requests including Requests Over 3 years old,old, Requests induced by by a Premium, Bulk Sales andand Requests including rces) Association Requests, Names obtained from Business Directories, Lists, other sources) Association Requests, Names obtained from Business Directories, Lists, andand other sources)

15 15a

ment Statement of Ownership, of Ownership, Management, Management, and Circulation and Circulation (Requester (Requester Publications Publications Only) Only) Publication ation Detail Detail 1 Publication Publication Name Name INDUSTRIAL HEATING 1 Publication Number Publication Number 488-250 2 ISSN ISSN 0019-8374 3 Filing Date Filing Date 09/23/2011 4 Issue Frequency Issue Frequency MONTHLY 5 Number of Issues Published Annually Number of Issues Published Annually 12 6 Subscription AnnualAnnual Subscription Price Price 115.00 7 Complete Address of Known Office of Publication Complete MailingMailing Address of Known Office of Publication 2401 W BIG BEAVER RD STE 700 7 TROY, OAKLAND, MI 48084-3333 7 CATHERINE RONAN ContactContact PersonPerson 7 Telephone (248) 244-8259 Telephone 8 Complete Address of Headquarter or General Business Office Publisher W of BIG BEAVER RD STE 700 Complete MailingMailing Address of Headquarter or General Business Office2401 of Publisher General Business Office of Publisher 8 TROY, MI 48084-3333 9 Publisher and complete address) DOUG GLENN Publisher (Name(Name and complete mailingmailing address) 9 "MANOR OAK ONE, STE. 450" 9 190 COCHRAN RD 9 PITTSBURGH, PA 15220-1203 9 Editor (Name and complete address) REED MILLER Editor (Name and complete mailingmailing address) 9 "MANOR OAK ONE, STE. 450" 9 190 COCHRAN RD 9 PITTSBURGH, PA 15220-1203 9 Managing Editor (Name and complete address) Managing Editor (Name and complete mailingmailing address)

15b1

15b2

15d2

15d3 Owner 10 Line Line 10 10 10 10

Full Name BNP MEDIA TAGGART E HENDERSON HARPER T HENDERSON MITCHELL L HENDERSON

Complete Mailing Address 2401 W BIG BEAVER RD STE 700, TROY, MI 48084-3333 2401 W BIG BEAVER RD STE 700, TROY, MI 48084-3333 2401 W BIG BEAVER RD STE 700, TROY, MI 48084-3333 2401 W BIG BEAVER RD STE 700, TROY, MI 48084-3333

Bondholders, Mortgagees, Other Security Holders nKnown Bondholders, Mortgagees, Other Security Holders 11 Line Line

Full Name

Complete Mailing Address

13 14

INDUSTRIAL HEATING 09/01/2011

Publication Publication Title Title Issuefor Date for Circulation Data Below Issue Date Circulation Data Below

1 2 3 4

86 November 2011 - IndustrialHeating.com

15d4 15e 15f 15g 15h 15i

uests In-County Nonrequested Copies stated Form 3541 (include Sample copies, Requests In-County Nonrequested Copies stated on on PSPS Form 3541 (include Sample copies, Requests Over 3 years Requests induced a Premium, Bulk Sales Requests including Over 3 years old,old, Requests induced by by a Premium, Bulk Sales andand Requests including rces) Association Requests, Names obtained from Business Directories, Lists, other sources) Association Requests, Names obtained from Business Directories, Lists, andand other sources) st-Class Nonrequested Copies Distributed Through USPS Other Classes of Mail (e.g. First-Class Nonrequested Copies Distributed Through thethe USPS by by Other Classes of Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% Limit mailed at Standard Mail or Package Mail, Nonrequestor Copies mailed in excess of 10% Limit mailed atckage Standard Mail or Package Services Rates) Services Rates) s, Nonrequested Copies Distributed Outside Mail (include Pickup Stands, Trade Shows, Nonrequested Copies Distributed Outside thethe Mail (include Pickup Stands, Trade Shows, Showrooms Other Sources) Showrooms andand Other Sources) Total Nonrequested Distribution Total Nonrequested Distribution Total Distribution Total Distribution Copies Distributed Copies notnot Distributed Total Total Percent Paid and/or Requested Circulation Percent Paid and/or Requested Circulation

16

Publication of Statement of Ownership Publication of Statement of Ownership

17 17 17

Signature Signature andand Title Title of Editor, of Editor, Publisher, Publisher, Business Business Manager, Manager, or Owner or Owner Title Title Date Date

Version

PSPS Form Form 3526, 3526, September September 2007 2007

0 16196

0 16179

3243

2330

0

0

13

0

398 3654 19850 619 20469 81.59

594 2924 19103 395 19498 84.69

Publication of this statement will of bethis printed in the NOVEMBER, 2011 iss Publication of this statem Publication statem 2011 issue of this publication RONA2C (CatherineRONA2C Ronan) RONA2C (Catherine (Catherine RoRo 09/23/2011 03:32:5409/23/2011 PM 09/23/2011 03:32:54 03:32:54 PMPM

When it’s your products job to provide heat to the customer...

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800-258-2552

AD111103

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