Industrial Heating October 2011

Where Do I Go for Electric Heating Products? omega.com, of Course! Your single source for process measurement and con...

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Where Do I Go for Electric Heating Products?

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Ipsen delivers innovation. Visit our ASM Heat Treat 2011 booth #2123/2133 and check out our latest game-changing innovations.

STOP BY AND TRY YOUR KEY FOR A CHANCE TO WIN!

See Us at Booth #2123

SPEED UNIFORMITY EFFICIENCY

TECHNOLOGY

LP CARBURIZING FURNACES

CONTINUOUS FURNACES

Single and Multi-Chamber Designs Q Q Gas-Fired and Electrically Heated Units Q Q High Pressure Gas and Oil Quench Units Q Q Patented Cyclohexane Injection System Q Q Wide Range Of Companion Equipment Q

Single and Multi-Row Designs Q Q Gas-Fired and Electrically Heated Units Q Q Wide Range of Process Applications Q Q Various Levels of Automation Q Q Belt, Pusher, Roller Hearth, and Rotary Styles Q Wide Range Of Companion Equipment Q

For over 95 years, Surface Combustion has focused on applying our technical and practical experience to the pursuit of moving heat treating and furnace technology forward.

Surface Combustion will continue to work with our customers in providing them the best in rugged and reliable equipment and industry leading start-up/service capabilities, as well as process assistance, to meet all of their needs.

Q

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Enhancing Past Technologies Expanding Existing Technologies Establishing New Technologies

NITRIDING FURNACES

FURNACE AUTOMATION

Gas Nitrider Designs Q Q Ion (Plasma) Nitrider Designs Q Q Gas-Fired and Electrically Heated Units Q Q Vertical and Horizontal ConÚgurations Q Q Completely Automated Q Q Companion Gas Generators/Incinerators Q

Various Levels of Automation Available Q Q Available for Batch or Continuous Furnaces Q Q Complete Networking/Trending Available Q Q Standardized or Custom Packages Available Q

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Surface® Combustion See Us at Booth #1605

SURFACE COMBUSTION, INC. • 1700 INDIAN WOOD CIRCLE • P.O. BOX 428 • MAUMEE, OH 43537 PH: (419) 891-7150, (800) 537-8980 • FAX: (419) 891-7151 EMAIL: [email protected] • WEBSITE: www.surfacecombustion.com

See Us at Booth #1816

October 2011 • Vol. LXXIX • No. 10

CONTENTS

On the Cover:

A R T I C L E S

HybridCarb is shown next to a small furnace in operation.

53

Heat Treating

Greener Thermal Processing Leads to a Greener Bottom Line Aymeric Goldsteinas and Jim Grann – Ipsen, Inc.; Cherry Valley, Ill.

Most thermal-processing companies turn green at the thought of going green. Sustainability, grid parity, subsidies, LEED certification … What does it all mean when it comes to the bottom line? Induction Heat Treating

59

Computer Modeling Helps Identify Induction Heating Misassumptions and Unknowns Dr. Valery Rudnev – Inductoheat Inc.; Madison Heights, Mich.

Whenever someone is discussing induction heating, reference is often made to the skin-effect phenomenon, which is a fundamental property of induction heating. Skin effect represents a nonuniform distribution of an alternating current within the workpiece cross section.

67

Process Control & Instrumentation

Are Your Industrial Controllers Fluent in (M)any Languages?

F E A T U R E

Invensys Eurotherm; Ashburn, Va.

Over 30 process-automation network protocols exist in use today. Why is this important, and how do you decide which ones are best for your heat-treatment application? Read this discussion by industry experts to learn more.

73

Industrial Gases/Combustion

The Basics of Pulse Firing Dan Curry – Eclipse, Inc.; Rockford, Ill.

Pulse firing is a combustion heating-control method developed in Europe in the early 1970s. The number of pulse-fired burner applications in North America has been growing steadily from the 1990s. This article discusses the basics of pulse firing as it applies primarily to heat-treating furnaces.

77

Ceramics & Refractories/Insulation

Ceramics for Industrial Heating David Watkins – KEIR Manufacturing; Brevard, N.C.

Alumina ceramics and steatites have primarily been used in the furnace industry for electrical insulators with advantageous structural properties at elevated temperatures. As a result, the markets for applications of alumina continue to expand as engineers gain further positive experience with these materials. IndustrialHeating.com - October 2011 9

18 COLUMNS 18 Editorial Is Social Media Relevant to Technical People? Is social media relevant to the thermal-processing industry? Publisher Doug Glenn thinks that it is, and details some applications that may be of interest to you, including Industrial Heating’s Twitter Widget in support of the upcoming ASM Heat Treat Show.

20 Federal Triangle Revoke Export-Import Bank Charter It is time for our industrial leaders to speak to their elected ofﬁcials in the House of Representatives and Senate and urge them to disband Ex-Im Bank, revoke its charter and return export ﬁnancial services provided by private banks and insurance companies to its proper role. ole.

20

22 The Heat Treat Doctor™ Stress Corrosion Cracking Components fail for a variety of reasons, which includes a corrosion phenomena characterized by the fact that stress (and/ or deformation) is present to provide a trigger that leads to sudden n crack formation, propagation and failure.

28 Environmental & Safety Issues Fire Water (Part 2) This two-part column provides readers with some of the fundamentals about ﬁre sprinklers and related ﬁre-protection systems should they decide to re-evaluate their existing ﬁreprotection solutions.

28

30 Web Resources Thermal-Processing Tools & Tips on the Web

32 MTI Proﬁle – Certiﬁed Metal Craft 34 IHEA Proﬁle – IHEA Making Things Happen Internationally

DEPARTMENTS 36 Industry News

113 Products

50 Industry Events

116 Aftermarket

51 IH Economic Indicators

119 Classiﬁed Marketplace

110 Literature Showcase

126 Advertiser Index

SPECIAL SECTIONS 81 HTS Insider News from the ASM Heat Treating Society 87 ASM Heat Treating Society Conference & Exposition Exhibitor Booth Descriptions

10 October 2011 - IndustrialHeating.com

about the has the show us hta See p. g #HT S20 16 for detai

The ASM Heat Treating Society is pleased to introduce its new Board, which started its term effective tive Sept. 1. Board members are: Mr. Thomas E. Clements, President Engineering Mgr. – Metals & Thermal Processes Caterpillar Inc.; Peoria, Ill.

Mr. Christopher M. Klaren, en, member Manager Heat Treat Operations tions Deere & Company; Waterloo, oo, Iowa

Mr. Roger Alan Jones, Vice President Corporate President Solar Atmospheres Inc.; Souderton, Pa.

Ms. Meri Lazar, member Consultant; Philadelphia, Pa. a.

Mr. Terrence D. Brown, Past President Director – Commercial Bluewater Thermal Services; Greenville, S.C. Mr Robert Hill Board Liaison

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].

Tweet

New ASM HTS Board Starts Term

AS M Hea 26th Confe t Treating rence S and E ociety xposi Oct. 31 Duke tion Energy -Nov. 2

Mr. Ralph P. Poor, member er Director of Standard Products cts Surface Combustion Inc.; Maumee, Ohio Mr. Michael J. Schneider, r, FASM, member General Manager - Prod. Materials & Metallurgy

CincinConventio nati, O n Cent er hi

Industrial Heating is the ofﬁcial publication of ASM’s Heat Treating Society and ofﬁcial media partner of ASM’s HT Expo & Conference. Heat Treat Insider.indd 81

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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 AUDIENCE DEVELOPMENT Christina Gietzen Audience Development Coordinator Alison Illes Multimedia Specialist Catherine M. Ronan Corporate Audience Audit Mgr. For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected] LIST RENTAL Postal contact: Kevin Collopy at 800-223-2194 x684 [email protected] Email contact: Michael Costantino at 800-2232194 x748 [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

See Us at Booth #1727

12 October 2011 - IndustrialHeating.com

SOMETHING NEW IS ON THE HORIZON FROM SOLAR WE ARE ADVANCING THE CURVE IN HIGH PRESSURE GAS QUENCHING TECHNOLOGY. To learn more, visit us at booth #2305 at the 26TH ASM Heat Treating Society Conference and Exposition in Cincinnati, October 31–November 2, 2011.

The Brightest Solutions Through Ingenuity www.solarmfg.com PROUDLY MADE IN THE USA

See Us at Booth #2305

Twitter Widget for ASM Heat Treat Show

FORGExpo: A FREE International Virtual Event for the Forging Industry Sept. 28 • 9:00 a.m.-4:00 p.m. ET www.FORGExpo.com FORGExpo is the opportunity for you to connect with suppliers, network with peers, and learn from experts from all over the world – right from your computer. Whether you specialize in mass production or short runs, or whether you run a closed-die, open-die or ring-rolling operation, there will be something of interest for you at the industry’s very ﬁrst virtual event!

Everyday Metallurgy The Famous Ride of a Foundryman/Metallurgist Did you know that Paul Revere was an early metallurgist? Revere’s early education was sufﬁcient to enable him to later read the difﬁcult metallurgical books of his day. His early training was by his father, who was a Boston silversmith. A perfectionist throughout his life, he went on to become one of America’s greatest artists in silver.

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

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P d Product off the h Month M h Raytek Raytek announced an enhanced version of its ThermoView™ Pi20 process imager with DataTemp® Pi (DTPi) software. This rugged, yet easy-to-operate thermal imaging solution includes two additional cameras, a new enclosure and C++ software development kit (SDK), allowing for use in a wide range of industrial environments. Designed for automated monitoring and control of continuous or stationary targets, the ThermoView Pi20 ﬁxed-mounted process imager provides an automated view of your process, allowing plant operators to shorten process start-up times and lower production line changeover costs. The camera is paired with the intuitive DTPi software, which minimizes h mi minim nimize izess or or elim eeliminates limina inates tes the long learning g curve curve associated with many process imaging systems.

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424 Buckbee Street Rockford, IL 61104 Tel: 815.963.0005 / Fax: 815.963.5673 www.beavermatic.com / E-mail: [email protected] See Us at Booth #2001

16 October 2011 - IndustrialHeating.com

Visit us at www.beavermatic.com

Take advantage of Industrial Heating’s Twitterr widget – brought to you by Invensys Eurotherm – for or th the e upcoming upcomin upco ming g ASM ASM Heat Treat Conference and Exhibition. Here’s how it works: Tweet about the show using the hashtag #hts2011, and your tweet will show up on IH’s homepage. In addition, during the show, TVs and computers will be strategically placed around the show ﬂoor. Your tweets – using hashtag #hts2011 – will appear on those screens (in addition to IH’s homepage), scrolling throughout the event.

See Us at Booth #1811

Editorial Doug Glenn, Publisher | 412-306-4351 | [email protected]

Is Social Media Relevant to Technical People?

S

ocial media is the craze these days. The question is, “Is it relevant to the thermal-processing industry?” For those of you shaking your head “no” right now or thinking the equivalent, keep on truckin’ because chances are very good that your disinterest in social media will not hurt you in the short-term or intermediate-term future. But there are some interesting applications of social media that may surprise you. For example, did you know that if you search “heat treat” on YouTube, 525 results appear? A large percentage of these are industrial in nature. However, you will have to skip over a good number of “Zeno Heat Treat – Acne Miracle” videos to get to the truly industrial applications. Eurotherm has a pretty active YouTube channel that you can access by going to www.youtube.com/ heattreatandbeyond. Other notable YouTubers are Inductoheat (www.youtube.com/inductoheatinc), Inductotherm Corp., (www.youtube.com/inductothermcorp), Ipsen (www.youtube. com/ipsenheattreatnews), Rex Heat Treat (www.youtube. com/rexheattreat), Solar Atmospheres (www.youtube.com/ solaratmospheres) and a whole boatload of one-offs dealing with how to heat treat knife blades and/or gun barrels. Industrial Heating also has a YouTube channel (www.industrialheating.com/ihmagazine) with over 45 videos available for viewing – some technical, but the vast majority are business and/or promotional related. I gave a talk one year ago dealing with social media to a furnace manufacturer. At that time, there were essentially zero companies using YouTube in the thermal-processing industry. Today, it is catching on. By my estimation, YouTube holds the greatest potential to be useful to thermal-processing professionals. Industrial Heating will continue to work on organizing and clearly presenting video content provided by the industry. Stay tuned. Another useful social-media tool 18 October 2011 - IndustrialHeating.com

with reasonable applicability for the thermal-processing industry is LinkedIn (www.linkedin.com). If you have not already, you should create an account and then join the “Industrial Heating” group on LinkedIn. It is a great place to connect and meet industry people you might not otherwise know. LinkedIn is more business-focused than Facebook, but it can serve the same networking purpose – keeping people in touch with each other and helping them do their jobs better. If you have a LinkedIn account, you can join Industrial Heating’s LinkedIn group by going to www. industrialheating.com/connect. Other social media includes Facebook, Google+ (a new kid on the block) and Twitter. Let me encourage you to take advantage of Twitter this month. Here’s how. During the ASM Heat Treating Society’s Heat Treat Conference and Exposition, Eurotherm, in cooperation with Industrial Heating, will be sponsoring “Twitter Screens.” There will be large-panel TV screens posted around the exhibit hall where Twitter users can post their comments to be read by all passers-by. In addition, if you can’t make it to the event, you can follow the Twitter feeds on Industrial Heating’s website … even if you aren’t a Twitter user. At the bottom of Industrial Heating’s home page (www.industrialheating.com), you’ll see a graphic like the one shown here. This “Twitter Widget” will scroll the Tweets, and you can keep up with what is happening at the show – what’s good, what’s not so good and what is fantastic. Social media is not for everybody. But for those of you that are so inclined (and the numbers are growing), please feel free to participate in the ﬁrst-ever Twitter event. If you want your comments to be posted to the aforementioned Twitter widget and Twitter Screens during the show, be sure to use the following hashtag – #hts2011 (you must include the #). For example: #hts2011 This heat treat event is the best in years. It doesn’t matter if the hashtag is ﬁrst, last or in the middle, as long as there is a space before and after. It will be picked up and appear on the widget. This is an excellent opportunity to experiment with social media. IH

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

Revoke Export-Import Bank Charter

T

h is still time to change bad policy and practices to here make it right. H.R. 2072 is now probably law passed to m reauthorize Export-Import (Ex-Im) Bank through fedr eral ﬁ scal year 2014 – a charter that would have othere wise expired Sept. 30, 2011. Common sense says to expect a stinky if the title on a bank charter is “Securing American Jobs Through Exports Act.” An Ex-Im report to Congress from several industry associations, including the U.S. Chamber of Commerce, all laud Bank activities and claim that trade ﬁnancing supported $34.4 billion in exports and 227,000 U.S. jobs at over 3,300 companies last year. Poppycock is a nice word to summarize this claim. What follows here is a discussion of why that is so, together with what should be done to set the record (and U.S. policy) straight. Ex-Im was created by Executive Order #6581 in February 1934 by President Franklin D. Roosevelt to “assist ﬁnancing U.S. trade with the Soviet Union,” which was then entering the world scene as successor to czarist Russia. The U.S. Constitution did not then and does not now authorize use of taxpayer funds to aid politically favored groups. However, the ExIm mission is still driven today by political rather than economic logic. Obama Administration goals under a National Export Initiative (NEI) speciﬁcally seek to double U.S. exports while increasing Ex-Im administrative expense allowances by 25%. Ex-Im assists only 1.9% of exports today, but it imposes artiﬁcial constraints in ﬁnancing conditions. For example: • It sets a goal of not less than 10% credit and insurance costs for “renewable energy” end uses (only 2.2% last year were “environmentally beneﬁcial” and just 0.23% have met the renewable energy target over the past eight years). • It requires any transaction over $10 million to deliver goods on a U.S. ﬂagged ship (with the limited number of U.S. ﬂag carriers, transportation costs are high enough to nullify any potential beneﬁts of Ex-Im ﬁnancing). • It requires that ﬁnanced export contain not less than 25% U.S. content in products as a means to ensure U.S. employment (a burden for industry to ensure while remaining cost competitive with a global supply chain). • It supersedes private bank ﬁnancing and makes taxpayers liable for defaults. (Ex-Im claims to ﬁnance only transactions too risky for private banking and lends only to credit-worthy borrowers. Being too risky and a safe bet cannot be simultaneous.)

20 October 2011 - IndustrialHeating.com

Another result of Ex-Im existence is that 10 ﬁrms got 92.8% of all loans and guarantees last year, and just three companies got 72.3% of all support (in order, Boeing, KBR Inc. and General Electric). The Bank even stacks the deck against U.S. industry by subsidizing foreign competition. For example, the fourth most favored loan and guarantee recipient is PEMEX, the state-owned Mexican oil company. Small businesses accounted for only 20% of all Bank authorizations, a much smaller share than the 32% small business contributed to national exports in 2010. Small and midsized U.S. industry is disproportionately under-served by Ex-Im Bank. The bottom line is that export subsidies via Ex-Im ﬁnancing: does not aid U.S. employment; favors speciﬁc large businesses and industrial sectors; violates the U.S. law of the land; and costs the taxpayer more than any purported beneﬁts. Further, Ex-Im refuses to provide information on speciﬁc allegations of its corrections to market failures and does not share any information with private banks that aid export trade. It is obvious that management of the Ex-Im Bank does not accept views drawn by many observers and critics that the Bank puts resources to less efﬁcient use than private-sector analogs and creates distortions in the national economy. Bank management does not, moreover, accept the conclusion made by many organizations that have studied its activities (Pew Charitable Trusts, Government Accountability Ofﬁce and Congressional Research Service) that it has a net negative impact on national beneﬁts and purpose. It is long past time to restrict and disband this institution that was and remains a creature of the Progressive wing of the political spectrum that encourages pervasive and invasive government. It must also be recognized that Washington-located associations and lobbying groups do not speak for affected American business. It is time for our industrial leaders to speak to their elected ofﬁcials in the House of Representatives and Senate and urge them to disband Ex-Im Bank, revoke its charter and return export ﬁnancial services provided by private banks and insurance companies to its proper role. IH

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1.06.2011

Innovative Heat Treatment Vacuum Solutions

If you are looking for a new vacuum system for your heat treatment tasks, check out the innovative vacuum solutions provided by Oerlikon Leybold Vacuum! Our products excel with highest robustness and extreme compactness, combined with lowest power consumption and noise emission. Get the details at www.oerlikon.com/leyboldvacuum

Oerlikon Leybold Vacuum GmbH Bonner Strasse 498 D-50968 Köln T +49 (0)221 347-0 F +49 (0)221 347-1250 [email protected] www.oerlikon.com/leyboldvacuum

Oerlikon Leybold Vacuum USA, Inc. 5700 Mellon Road Export, PA USA T 1-800-764-5369 F 1-800-215-7782 [email protected] www.oerlikon.com/leyboldvacuum

See Us at Booth #2142

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

Stress Corrosion Cracking

C

omponents fail for a variety of reasons, which includes a corrosion phenomena characterized by the fact that stress (and/or deformation) is present to provide a trigger that leads to sudden crack formation, propagation and failure. Let’s learn more. Stress corrosion cracking (SCC) is the type of failure mechanism caused by a combination of environmental, material and stress conditions (Fig. 1). It is generally considered the most complex of the failure modes since it can attack soft or hard parts; ferrous or nonferrous materials; ferritic or austenitic structures; and materials in the unalloyed or alloyed state. Cracks may propagate in a transgranular or intergranular fashion or in a combination of the two. The stress, however, must be in the form of tensile stress above some minimum (i.e. threshold) value, usually below the yield stress of the material and in the presence of a corrosive environment that includes sulﬁdes, chlorides, caustics and hydrogen. Temperature is a signiﬁcant environmental factor affecting crack formation, and pitting is commonly associated with SCC phenomena. In addition, catastrophic failure can occur without signiﬁcant deformation or obvious (surface) deterioration of the component. The SCC phenomena can be affected by many factors in addition to stress level, including alloy composition, microstructure, concentration of corrosive species, surface ﬁnish, micro-environmental surface effects, temperature, electrochemical potential and the like. Further complications are initiation and propagation phases and the observation that in some cases cracks initiate at the base of corrosion pits. Mechanisms There is no identiﬁed single mechanism explaining SCC, but several theories have been proposed. • Active path propagation: Localized preferential corrosion (a.k.a. dissolution) at the crack tip, along a susceptible path, with the bulk of the material remaining in a more passive state. The rate of metal dissolution can be several orders of magnitude higher when an alloy is in its active state compared to its passive condition. • Hydrogen embrittlement: High hydrogen concentrates in highly stressed regions, such as at the crack tip or other stress concentrators, leading to localized embrittlement. • Brittle ﬁlm-induced cleavage: Cracks initiated in a brittle surface ﬁlm may propagate (over a microscopic distance) into underlying, more ductile material before being arrested by ductile

22 October 2011 - IndustrialHeating.com

blunting of the crack tip. If the brittle ﬁlm re-forms over the blunted crack tip (under the inﬂuence of corrosion processes), such a process can be repeated over and over again. Negating the Effects of SCC A combination of good design, correct selection of SCC-resistant materials, environment management, maintenance and inspection can effectively control this type of corrosion. Stresses to consider include: Operational conditions • Applied (tensile) stresses Thermally induced factors • Temperature gradients • Differential thermal forces (expansion and contraction) Buildup of corrosion products • Volumetric dependent Assembly issues • Poor ﬁt up (tolerance problems) • Tightening/torqueing • Press and shrink ﬁts • Fastener interference • Joining method Residual stresses (from the manufacturing processes) • Joining (welding, brazing, soldering) • Forging or casting • Surface treatment (plating, mechanical cleaning, etc.) • Heat treatment (quenching, phase changes) • Forming and shaping • Machining • Cutting and shearing One of the most important considerations to negate the effects of SCC is choosing the proper alloy. It is relatively simple to choose a component with adequate strength and good (general) corrosion resistance. However, knowing the particular type of SCC issues that may be at work in the application is an important step in achieving a resistant material. In certain environ-

Environment

Materials susceptible

Stress

Fig. 1. Factors contributing to stress corrosion cracking

“G-M Furnaces are simply outstanding: especially the hot zones, controls and powerful external quench system….. they are the best I have seen. Our G-M Furnaces are work-horses and require minimum maintenance. G-M has the best service and “after the sale” support we have experienced. We have fourteen (14) G-M Vacuum Furnaces and three (3) more High Temperature Box Furnaces. Fourteen (14) Vacuum Furnaces consist of eight (8) 6-Bars, three (3) 10-Bars and three (3) 2-Bars In addition to Furnaces we have also purchased eight G-M replacements Hot Zones for our other Vacuum Furnaces.” - Bob Muto, Plant Manager American Brazing a Division of Paulo Products Company

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•

•

rial H

TH

Optical microscopy a) Failed component

(b) Grain-boundary attack (500X unetched)

Scanning electron microscopy (c) Intergranular attack

Fig. 2. Fastener failure – Stress corrosion cracking[2]

ments, it may be necessary to choose a material that will experience some general corrosion since general corrosion is visually evident, and, with proper preventative maintenance, general corrosion can be seen and components replaced as necessary. On the other hand, SCC is rarely visually apparent and often occurs without warning (Fig. 2). When it does, a catastrophic failure often follows. Other methods include removing the corrosive environment or changing the manufacturing process or design to reduce the tensile stresses. A combination of good design, careful selection of stress corrosion-resistant grades (e.g., stainless steel) and effective management, including maintenance and inspection, all can effectively control corrosion. Speciﬁc steps can be taken to prevent the onset of SCC and minimize its consequences when it does occur by: • Consideration of the potential for SCC during the design and fabrication of components • Selection of appropriate material grades • Maintaining a chemical balance of the environment • Ensuring that the potential for (organic or inorganic) contamination is minimized • Maintaining proper environmental conditions (e.g., air quality) • Regular inspections of components for signs of corrosion and SCC Importance of Material Selection In many applications, austenitic stainless steel fasteners (e.g., ASTM A193 grade B8) of 304 and 316 stainless steels provide good general corrosion resistance and are commonly requested. However, in marine environments where stainless steel would seem to be the logical choice, alloy-steel fasteners are preferred due to SCC concerns. Chlorides, ﬂuorides and other halogens are known catalysts for chloride SCC. In order to reduce their susceptibility to general corrosion, alloy-steel fasteners such as grade B7 are usually provided with some type of protective coating (e.g., zinc or cadmium plating). However, the designer must still be aware that 24 October 2011 - IndustrialHeating.com

this can lead to another form of corrosion due to environmental stress cracking in the form of liquid metal embrittlement (LME) or a related failure mode, solid metal induced embrittlement (SMIE). Therefore, appropriate cautions must be taken. In addition to SCC, other forms of embrittlement include: (a) environmentally induced cracking due to such factors as cold work (i.e. residual stress), welding, grinding, thermal treatment or service conditions; (b) hydrogen embrittlement from plating, welding, cathodic protection and as a by-product of general corrosion; (c) corrosion fatigue; and (d) liquid-metal embrittlement. In Conclusion Careful consideration of the factors discussed above as well as taking the time to understand how and where a component will be used in service can help minimize stress corrosion cracking in most applications. IH References: 1. Naumann, Friedrich Karl, Failure Analysis: Case Histories and Methodology, Dr. Riederer-Verlag GmbH, 183. 2. Mr. Alan Stone, Aston Metallurgical Services Company, Inc. (www. astonmet.com), private correspondence. 3. Reilly, Peter, “Swimming in the Dangerous Waters of Stress Corrosion,” Roof Consultant (www.roofconsultant.co.uk) 4. Spence, Thomas, “Selecting the Right Fastener,” Materials Newsletter, Flowserve (www.ﬂowserve.com). 5. Fastenal (www.fastenal.com) 6. www.corrosion-club.com 7. Corrosion Doctors (corrosion-doctors.org) 8. ASTM International (www.astm.org)

Use this Mobile Tag to go to Dan's Experts Speak blog for more SCC information.

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At Ipsen we believe that innovation drives excellence. Our dedicated research and development team – Team Innovation – is constantly pushing the boundary of possibilities and dreaming a future of thermal processing excellence. Here are just some of our firsts:

1960 First MetalMaster® Horizontal vacuum furnace

1951 IpsenLab established for heat treating and application engineering

1975 First fully automated atmosphere furnace line

1992 First Carb-o-prof® Carbon Profiling System 2001 First Global V

1973 First continuous vacuum aluminum brazing furnace

1984 First TurboTreater® high pressure gas quench vacuum furnace

1968 First vacuum oil quench furnace

1997 New MultiMaster semicontinuous vacuum furnace

2005 First SuperTurbo® 12 bar furnace

a legacy of firsts.

2007 Second Generation TurboTreater®

2008 First TITAN® H2 Furnace

2006 First Tiny Turbo®

2010 First Vertical TITAN®

2011 First HybridCarb® Precision Gassing System

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Environmental & Safety Issues Richard J. Martin | Martin Thermal Engineering, Inc. | 310-937-1424 | [email protected]

Fire Water (Part 2)

L

a month’s column began a review of ﬁre-protection ast strategies and systems for industry. This month, we s conclude that review. c

NFPA Guidance NFPA publishes more than a dozen standards addressing automatic ﬁre-protection systems, including NFPA 10 (portable ﬁre extinguishers), NFPA 12 (carbon dioxide), NFPA 13 (sprinklers), NFPA 17/17A (dry-chem and wet-chem), NFPA 15 (water spray), NFPA 750 (water mist) and NFPA 25 (water-based system maintenance). Water-Based Systems The water-based technologies each have advantages and disadvantages that users should be aware of. Water-based systems should never be employed to control ﬁres where water-reactive chemicals are located. Steam is the least-utilized option in this grouping, having only non-mandatory design guidance (see NFPA 86). Steam can be useful to extinguish ﬁres inside enclosures by displacing oxygen. It may have fewer negative side-effects than liquid water. However, steam has two major drawbacks that limit its usefulness. Escape of steam into occupied spaces creates a scald hazard. And unlike liquid water, steam’s ability to cool hot materials (e.g., burning embers or burning liquids) is limited. Water-mist is a relatively new technology. The ﬁrst systems were installed in passenger ferries in the 1940s, and the ﬁrst NFPA standard was published in 1994 as Halon systems were being phased out. Because the agent application rate is considerably lower than sprinklers, water-mist systems are particularly useful where the water supply is limited. Since the water is delivered in liquid form, however, the quenching effect is preserved. Further, the small size and large number of the droplets can block radiant heating of adjacent combustibles. Negatives for mist include the requirement for compressed air as an atomizing medium and the limited “reach” for each nozzle. Fixed water-spray systems provide droplets that are intermediate in size to those of sprinklers and mist systems but do not require an atomizing medium. Water-spray nozzles are often employed to extinguish combustible liquid ﬁres through a combination of wider coverage than mist and smaller droplets than sprinklers. Because the volume of water released is high, means for drainage is required. Examples of water-spray appli28 October 2011 - IndustrialHeating.com

cations include conveyors that move combustible materials, ﬁxtures with densely packed combustibles such as cable-trays and the exterior of enclosures requiring heat-exposure protection. Sprinkler systems are by far the most commonly implemented ﬁre-protection technology. The ﬁrst edition of NFPA 13 was published in 1896, and the current version incorporates a great deal of engineering know-how on detection, actuation, piping, water supplies and nozzle coverage. Sprinkler systems are distinguished by the detection/actuation method and whether the pipe is wet or dry out to the nozzles. A “deluge” system employs open heads installed in a dry pipe with an upstream actuation valve. An automatic sprinkler system contains closed heads with a plug/stopper that ruptures at a prescribed temperature to permit ﬂow. Automatic sprinklers may be employed with a wet-pipe or dry-pipe distribution network, depending on the temperature of the protected space (i.e. ambient spaces, ovens or freezers). Non-Water-Based Systems Carbon dioxide and dry- or wet-chemical extinguishment systems round out the primary technologies for ﬁre protection of commercial and industrial hazards. Dry- and wet-chemical systems are designed to discharge an agent (often sodium or potassium bicarbonate in particle or slurry form) onto surfaces to smother ﬂames and cool heated materials. The agent is distributed using an expellant gas through a ﬁxed network of pipes. As the agent contacts burning materials, the particles or droplets suppress the ﬁre by both heat removal and chemical interruption of combustion chain reactions. Dry- and wet-chemical systems are often employed where lubricants, fuels, hydraulic ﬂuids or cooking oils are at risk of being overheated and ignited. In CO2 systems, the agent is stored as a highpressure liquid that expands to a gas upon passage through nozzles, thereby providing a rapid cooling effect and displacement of oxygen. Due to the maturity of this technology, available design guidance is extensive. Precautions must be taken to prevent asphyxiation when utilizing CO2 in “occupiable” but “normally unoccupied” spaces such as transformer rooms, utility tunnels and liquid storage areas. The discharge of CO2 systems produces ice particles that can lead to the accumulation of static charge followed by sparking discharge. Conclusion Design, installation and maintenance of any ﬁre-protection system should be carried out by qualiﬁed personnel. Local ﬁre authorities frequently require and participate in annual inspections to ensure system readiness. IH

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Web Resources

Thermal-Processing Tools & Tips on the Web

onth Friend of the M

Social Media Social media, particularly LinkedIn, is populated with interesting discussion and useful Q&As. Here’s an edited sample of some of these. Number of Sensors for TUS Q: I just received a write up for not having test thermocouples within 3 inches of each process or load thermocouple when performing a TUS. This is apparently for comparison purposes. I already have nine thermocouples being used. Do I really need to add additional test thermocouples? I don’t recall seeing this in AMS 2750D. Interested in the answer? Link to it here: http://www.heattreatforum.com/vbulletin/showthread.php?t=600 Automotive Castings Q: What are the critical levels of sulphur, phos, manganese and chrome in grade-25 automotive-component castings?

Brian Kandell

A: Phosphorous at 0.33 will have phosphide eutectic on the cell boundries and will either leak in pr. testing or crack in application. If the % of steel in the cupola is raised by 5%, both will come down. Use low phosphorous pig. We have added up to 20% steel in cupola. For this particular automotive grade, use less scrap and try to balance them.

rian is the technical sales manager & energy and environmental business unit head for Micropyretics Heaters International, Inc. (MHI, Inc.) located in Cincinnati, Ohio. He is responsible for organizing and developing technical heating solutions.

Use this Mobile Tag for more answers on LinkedIn: 17-4 Stainless Heat Treatment Q: Does anyone have data re hardness/tensile change of 17-7PH stainless, CH 900 condition, when held at 900°F for greater than 1 hour? I need data for 8-24 hour temperature exposure if possible. A: You’re over-aging the material, so the tensile and hardness will go down. The material wasn’t designed to do this. You most likely will have to try different times and make your own chart of hardness versus tensile. The discussion can also be found on LinkedIn. Blogs The Importance of Post-Weld Heat Treatment http://www.brighthub.com/engineering/mechanical/articles/110118.aspx This blog is a brief but thorough discussion of PWHT. The Experts Speak http://www.industrialheating.com/Articles/The_Experts_Speak Our experts provide insight on a wide range of thermal processes. Patents Bearing patent http://www.patentstorm.us/patents/7857518/description.html A composite steel bearing is discussed. 30 October 2011 - IndustrialHeating.com

B

College: 1. Wright State University 2. University of Cincinnati Degree: 1. B.S. in Biomedical Engineering 2. M.S. Materials Science and Engineering Marital Status: Married with two kids – 2 years old and 6 months old Activities: Brian enjoys coin collecting (numismatics), golﬁng, cooking, grilling and camping. On a fall weekend, you might ﬁnd him grilling with family and friends or playing a round of golf. Favorite Car: When asked about his favorite vehicle, Brian said a red Ford F-150 with manual transmission was his ﬁrst (and favorite) vehicle. IH Reader: Brian has been an Industrial Heating reader for about ﬁve years. Find us on www.industrialheating.com/facebook

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

Certified Metal Craft Specializing in Brazing and Heat Treating

C

e ed Metal Craft is a third-generation, veteranertiﬁ owned, Nadcap-accredited brazing and heat-treating o facility located, in El Cajon, Calif. f The company started from modest beginnings. In June 1969, the Wiederkehr family purchased a 6,000-square-foot facility, formerly Star Heat Treat and Fishing Supplies, in La Mesa, Calif. At ﬁrst, Certiﬁed Metal Craft provided a variety of brazing and heat-treat services for the San Diego market with just a few salt pots, tempering/aging ovens and a high-temperature glo-bar furnace equipped with retorts for atmosphere work using argon, nitrogen and hydrogen. Back then the company’s big account was Buck Knives, but it also provided services for Convair, General Electric, Rohr Industries and Teledyne Ryan to name a few. In the mid-1980s, Certiﬁed Metal Craft purchased its ﬁrst vacuum furnace. Soon after, its customer base began to grow. By 1990, the company purchased its second vacuum and quickly outgrew the La Mesa facility. Due to an expanding customer base and an increase in services offered, Certiﬁed Metal Craft needed a larger facility. In late 1994, the company found – and purchased – a 28,000-square-foot building in El Cajon that ﬁt its needs. Then things got interesting for Certiﬁed Metal Craft. The company purchased a third vacuum furnace in 1995 and added ofﬁce space to accommodate its expanding workforce. Since the mid-1990s, Certiﬁed Metal Craft has added ﬁve vacuum furnaces, two endothermic furnaces and nine other pieces of support equipment. In addition, the company installed a G-M aluminum drop-bottom furnace and two companion age ovens, cryogenic processor, induction unit and production blast equipment. Certiﬁed Metal Craft has also purchased conductivity equipment for aluminum work and numerous inspection units. Today, the company performs a wide variety of services (brazing, normalizing, annealing, stress relieving, hardening, aging, tempering, sintering, case hardening, carburizing, carbonitriding) for the aerospace, auto, military and medical industries.

32 October 2011 - IndustrialHeating.com

Now in its 43rd year in business, Certiﬁed Metal Craft continues to support its customer’s needs. To that end, the company recently expanded yet again, adding another 30,000 square feet of production space. Furthermore, all of Certiﬁed Metal Craft’s 30 employees are committed to a common goal of customer support based on the work ethic of a family-owned and operated business. Ownership is sincere in its belief that nothing is more important that what comes to people’s minds when the name “Certiﬁed Metal Craft” is mentioned. As a Nadcap-accredited supplier serving all industries and prime contractors throughout the U.S. and Mexico, Certiﬁed Metal Craft strives to supply the best service possible in its continued efforts to be a one-stop shop. As for the future, the company is currently exploring options to expand into different markets, not only in the San Diego area but in southern California and beyond. For more information, visit www.certiﬁedmetalcraft.com.

See Us at Booth #1723

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

IHEA Making Things Happen Internationally

T

• Ted Jablkowski, Fives North American Combustion • Dan Curry, Eclipse Inc. • John Clarke, Diamond Engineering

he U.S. Technical Advisory Group (TAG) to the International Standard Organization (ISO) Technical Committee (TC) TC244 – International Standard for Industrial Furnaces and Associated Processing Equipment has been very busy. Since the May 2011 Working Group (WG) meetings in Belgium, the U.S. TAG’s task group has developed numerous Comments, which are formal proposals for changes, to the Committee Drafts (CDs) and Draft International Standards (DIS). In the pursuit of the development of an International Standard (IS), the Working Groups (WG) develop a Working Draft, then Committee Draft (CD), then a Draft International Standard (DIS), then a Final Draft International Standard and ﬁnally an IS with sequential and successful ballots by the Principal members of the various TAG’s representing countries around the world. The U.S. has the following experts working to develop various ISO documents:

Recent work of the U.S. TAG to ISO TC244 culminated in: • U.S. TAG ballot for Disapproval with Comments on CD 13577-1 from ISO/TC244/WG 1 – General safety requirements • U.S. TAG ballot for Disapproval with Comments on CD 13574 from ISO/TC244/WG 4 – Vocabulary • U.S. TAG ballot for Approval with Comments on DIS 135791, -2, -3, -4 from ISO/TC244/WG 3 – Method of energy balance and efﬁciency • U.S. TAG ballot for Disapproval with Comments on CD 13577-2 from ISO/TC244/WG 2 – Safety requirements for combustion and fuel handling systems (ballot pending vote of U.S. TAG)

ISO/TC244/WG 1 – General safety requirements • Kevin Carlisle, Karl Dungs Inc., convener for WG-1 • Ted Jablkowski, Fives North American Combustion • Mark Stender, Surface Combustion • Dan Curry, Eclipse Inc. • Bill Rucki, Fives North American Combustion • Elliott Davis, Selas Heat Technology Co. and Pyronics Inc.

The U.S. TAG met Sept. 28 Pittsburgh, Pa., to prepare for the upcoming WG meetings in Paris and to further develop our country’s positions on WG 13577-4 from ISO/TC244/WG 1 – Protective Systems. Any persons interested in joining the U.S. TAG to ISO TC244 are asked to contact Ted Jablkowski of Fives North American Combustion, U.S. TAG chair, at ted.jablkowski@ﬁvesgroup.com.

ISO/TC244/WG 1 – Protective systems • Kevin Carlisle, Karl Dungs Inc., convener of WG-1 • Ted Jablkowski, Fives North American Combustion • Mark Stender, Surface Combustion • Dan Curry, Eclipse Inc. • Bill Rucki, Fives North American Combustion • Elliott Davis, Selas Heat Technology Co. and Pyronics Inc. ISO/TC244/WG 2 - Safety requirements for combustion and fuel-handling systems • Kevin Carlisle, Karl Dungs Inc. • Ted Jablkowski, Fives North American Combustion • Dan Curry, Eclipse Inc. • Elliott Davis, Selas Heat Technology Co. and Pyronics Inc. • Bill Rucki, Fives North American Combustion ISO/TC244/WG 3 - Method of energy balance and efﬁciency • Kevin Carlisle, Karl Dungs Inc. 34 October 2011 - IndustrialHeating.com

ISO TC244 members meet on a regular basis, including at IHEA’s 2011 Annual Meeting last April.

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Equipment News Vacuum Furnace Wall Colmonoy installed a Centorr Workhorse® vacuum-brazing furnace at its Los Lunas, N.M., facility. The new furnace, customized for Wall Colmonoy’s speciﬁc needs, is able to process material under high vacuum and partial pressures with excellent process control. It has an effective hot-zone size of 12 inches x 12 inches x 12 inches and a maximum temperature of 2400°F. The Yokogawa processcontrol system with HMI interface will help technicians maintain effective operation and control of the furnace as well as provide data with which to make operational decisions. Engineers and technicians will use the furnace to continually test braze quality. According to Wall Colmonoy, the furnace is expected to increase throughput by a factor of two. Used for product development, application development and research testing, this increased capacity will allow the company to keep pace with requirements. The model includes a Varian VHS – 6 diffusion pumping system, Leybold rotary-vane roughing pump and a water-cooled diffusion pump bafﬂe allowing for processing of materials at very low vacuum levels. www.centorr.com

Coil Annealing Furnace Nichols Aluminum, a subsidiary of Quanex Building Products, purchased a Vortex® Jet Heating coil annealing furnace from SECO/ WARWICK. The furnace, which incorporates SECO/WARWICK’s patented, state-of-the art Vortex jet nozzle system, will be used for processing aluminum sheet at Nichol’s Lincolnshire, Ill., facility. The nozzle system produces high heat-transfer rates without creating hot spots at the impingement point. The result is uniform heating with a reduced cycle time compared to other high-velocity convection and mass-ﬂow alternatives. Nichols Aluminum is an environmentally friendly aluminum sheet producer. This furnace will increase the plant’s efﬁciency and productivity. www.secowarwick.com

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36 October 2011 - IndustrialHeating.com

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

Industry News

Oven Lucifer Furnaces delivered a large ﬁber-lined, forced-air recirculating oven to The Lincoln Electric Company in Cleveland, Ohio. With chamber dimensions of 24 inches high x 24 inches wide x 36 inches long, the oven features a uniformity of +/-15°F between 200°F and 1200°F. Constructed with ceramic-ﬁber insulation for energy savings and faster heating and cooling cycles, the oven includes a stainless steel roller hearth for ease of loading/unloading. It also includes a Honeywell over-temperature controller and chart recorder. Heating elements located on the side walls are designed from heavy-gauge resistive element wire mounted over ceramic tubes for full radiation from the coils for rapid heat. Each element is mounted individually for easy, low-cost replacement. A high-volume stainless steel fan assembly with heat slinger circulates air around the alloy liner, past the heating elements and through the chamber, providing uniform heat to the workload. A safety micro switch automatically shuts off power to the fan and heating elements when the door is opened. www.luciferfurnaces.com

Vacuum Furnace Ipsen, Inc. shipped a 2-Bar TITAN® H6 to California Brazing/Nevada Heat Treating. The TITAN H6 has a 36-inch x 36-inch x 48-inch work area and will be used to perform both commercial and Nadcap-accredited brazing processes. The TITAN is an all-new, modular, standardized, skid-mounted heat-treating system that can be installed in just a few days. Its control system supports multiple languages, provides real-time data acquisition and stores up to 1,000 recipes. TITAN’s small footprint, manufacturing versatility, operational simplicity

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38 October 2011 - IndustrialHeating.com

and ﬁnancial ﬂexibility (purchase, lease or rent) add up to greater proﬁtability and response time. www.ipsenusa.com

Vacuum Furnace Solar Atmospheres of Western PA will install a custom-built horizontal 20-bar vacuum furnace at its Hermitage facility. The furnace, which was designed and built by sister company Solar Manufacturing, measures 40 inches wide x 50 inches deep x 36 inches high and has a 3,500-pound maximum load. The excessive pressure and high-speed gas velocities of the 20 bar simulate the beneﬁts of oil quenching. Using inert gas as an alternative to oil minimizes distortion and provides a much cleaner process. The new furnace will allow Solar Atmospheres to better serve customers requiring vacuum carburizing by increasing core hardnesses of large cross-sections. www.solaratm.com

Industry News

Box Furnaces L&L Special Furnace Co. manufactured two high-uniformity box furnaces for a U.S.-based manufacturer of wind-turbine components with facilities in Germany and Japan. The primary purpose of the furnace is to remove a cutting residue left on turbine parts after machining. The parts are placed in the furnace and heated to 1000°F. The furnaces, which are also used for tempering and other thermal processes up to 1875°F, have a work envelope of 48 inches wide x 60 inches high x 60 inches deep. There is a cast alloy hearth and hydraulic loader for easy loading and unloading. The furnace has an automated variable-speed controlled exhaust system. At a certain point in the process, when the cutting residue is at a critical temperature, the exhaust system activates. A series of slide dampers under the furnace open and allow fresh air into the furnace while exhausting the cutting-residue fumes. The furnaces are heated from four sides and have lightweight highdensity castable piers for hearth support. www.hotfurnace.com

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

See Us at Booth #2035

Global Heat Treating Partners Visit us at booth #2111 at the ASM International onal show to discuss your heat treating needs.

Lindberg/MPH and Solo Group continue to provide innovative solutions to the global heat treating and heat processing marketplace. Lindberg/MPH 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 See Us at Booth #2111

40 October 2011 - IndustrialHeating.com

Industry News

Ask the Expert Steve Ruoff Commercial Technology Manager, Metals Processing

Q

For our vacuum furnace, how can we get adequate gas pressure to quench at pressures up to 20 bar?

A

There are a number of ways to address the challenge of high pressure gas quench—and a variety of factors to consider to achieve the most economical high pressure gas supply solution. Air Products applications engineers can help you fully understand your furnace and its backﬁlling gas volume, and then properly size the surge tank pressure, volume and usage which are the key to ... ... read Steve’s full answer at www.airproducts.com/J56 or give us a call at 800-654-4567 (press 1 and mention code 883). Don’t miss us at the Heat Treat Show November 1-2, in Cincinnati, Ohio. Visit booth 1823 to learn how our experience in gas supply, applications development and safety can help you improve product quality, reduce operating costs, increase production and optimize gas usage.

Nitriding System Nitrex Metal received an order from China’s Xi’An Aero-Engine Group, a manufacturer of turbojet and turbofan engines and gas turbines. The Nitreg®-S type nitriding system will be used for processing stainless steel aero parts as well as Nitralloy and alloy steel components. The furnace, with a work zone measuring 32 x 59 inches, has a maximum load of 3,300 pounds and is equipped with an ammonia dissociator for delivery of process gases and a neutralizing system to meet emission standards. The system, which will be delivered in the second half of 2011, complements a previous system delivered to Xi’An nine years ago and will support the company’s production expansion efforts. www.nitrex.com

Business News Eclipse Acquires CEC Combustion Safety Eclipse Inc., a provider of products, systems, and services for industrial heating and drying applications, acquired CEC Combustion Safety (CEC). Eclipse intends to operate CEC as an independent organization, providing the CEC business with the infrastructure and resources to signiﬁcantly grow their market position in safety-related combustion services. CEC will continue to operate out of its Cleveland, Ohio, facility. According to Rockford, Ill.based Eclipse, the acquisition adds leadership in combustion safety as an integral part of the company. According to CEC, Eclipse gives it the scope and scale to take the CEC value proposition to unsurpassed levels in the combustion industry. John Puskar, president of CEC, will continue to lead the business unit.

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tell me more www.airproducts.com/J56 © Air Products and Chemicals, Inc., 2011 (33885) J56

See Us at Booth #1823 42 October 2011 - IndustrialHeating.com

Call for our free catalog on CD-ROM or shop online anytime!

The right parts, on time, every time. ™

See Us at Booth #2005

Industry News Quality Heat Treat Equipment & Atmosphere Generators

THERMO TRANSFER INC. Cosma International Acquires Grenville Castings

Radiant Tube Heated Roller Hearth Furnace

Our Gas Fired Roller Hearth Furnaces incorporate the latest features in furnace design including atmosphere, temperature and PLC controls. We offer complete design, manufacturing, installation and service for all of your heat processing equipment needs.

Roller Hearths Mesh Belts Box Furnaces Car Bottoms Catalyst

Tip-Ups Atmosphere Equipment Replacement Parts Complete Rebuild Services Repairs

For more information, write or call: Thermo Transfer Inc. 1601 Miller Ave. • Shelbyville, IN 46176 (317) 398-3503; Fax (317) 398-3548 Website: www.thermotransferinc.com

Cosma International, a global automotive metal-forming supplier and an operating unit of Magna International Inc., acquired Grenville Castings, a structural casting supplier of aluminum components for the automotive, heavy truck and recreational markets. Grenville Castings, headquartered in Perth, Ontario, is a niche production and development company with a focus on complex structural casting. Its core technology includes thin-wall and hollow-core low-pressure casting. With the combination of Cosma’s global footprint and the technical expertise gained from Grenville Castings, the acquisition positions Cosma to become a leading global manufacturer of aluminum structural castings in all major geographic markets. The acquisition will also support Cosma’s global launch of an automotive chassis program scheduled to start production in 2014. Production will be supported through both existing and new manufacturing facilities.

Timken May Invest in Ohio Steel Plant The Timken Company is considering investing $225 million at its Canton, Ohio-based Faircrest Steel Plant to increase capacity, expand product range and strengthen competitiveness of its alloysteel bars. A ladle reﬁner and large-bloom continuous caster would be central to the investment, targeted to begin production in 2014. The investment would increase Faircrest’s shipped capacity by 25%. A team from Timken is beginning discussions with suppliers and government ofﬁcials.

See Us at Booth #1831

QUICK TURNAROUND, QUALITY SERVICE REDUCE YOUR INVENTORY AND ADD TO YOUR BOTTOM LINE Count on Furnace Parts, LLC, to meet all your needs for Industrial Thermocouples and Temperature Sensors. We offer a full range of products and services, including: • • • • •

Mineral Insulated Metal Sheathed Thermocouples (MgO) Noble Metal and High Temperature Thermocouples––Types S, R, B and C Base Metal Thermocouples—Types J, K, N, T and E Insulated Thermocouple and Extension Wire NIST Traceable Calibration Services

ISO 9001:2008 and ISO/IEC 17025:2005 accredited since 2000. 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 www.furnacepartsllc.com for information.

Proud member of:

See Us at Booth #2218

44 October 2011 - IndustrialHeating.com

Quality stock

castings available directly from Wirco. IMMEDIATE DELIVERY! C A S T T R AY S

ISO 9001 Certified: 2008

PUSHER HEADS ROLLER RAILS CHAIN GUIDES

F U R N A C E FA N S For a complete listing of stocked parts go to:

wirco.com See Us at Booth #1935

To place an order from our stocking program call: 1.800.348.2880 email: sales @ w i r co.com or contact: your local sales representative All parts are common for 30 x 48, 36 x 48 and 36 x 72 Batch IQ Furnaces.

MADE IN AMERICA

Industry News

Carpenter to Build Facility Focused on Premium Products Carpenter Technology announced that it will construct a new 400,000-square-foot state-ofthe-art manufacturing facility in response to strong customer demand for premium products primarily in the fast-growing aerospace and energy industries. The new facility, which is expected to be operational in approximately 30 months, will ultimately be capable of producing approximately 27,000 tons per year of additional premium product. It will include

CFC, Carbon Carbon Composites

remelting, forge and associated ﬁnishing and testing capabilities. The facility will be built on one of several 200-acre greenﬁeld sites currently under consideration and will cost approximately $500 million. The investment will enable Carpenter to support the increased demand related to the Latrobe (pending), Amega West and Oilﬁeld Alloys acquisitions. It will also support increased demand expected from the sales of new technologies the company plans to commercialize over the coming years.

Cabot to Sell Supermetals Business

Cast Tray

135 lbs. Total Weight

Cabot Corp. entered into an agreement to sell its Supermetals business to Global Advanced Metals (GAM) for a minimum of $400 million in total cash consideration. The transaction is subject to regulatory approval and is expected to close by the end of the calendar year. GAM is a global leader in the supply of tantalum ore, a raw material used by the Supermetals business in the manufacture of high-end products to the aerospace, electronics and other industries. Cabot will maintain its mining operation in Manitoba, Canada, where the company mines cesium for its Specialty Fluids Business and tantalum.

Evraz to Expand Portland Tubular Operations

CFC Tray

30 lbs. Total Weight Highly stable, No distortion

Improved Cost Performance for Heat Treat Operations From CFC Fixturing to Hot Zone materials, ACROSS can provide energy-efficient high-temperature material solutions for the vacuum furnace and heat treating industry

ACROSS USA, INC. Phone: 310-635-3555 [email protected] See Us at Booth #2106

46 October 2011 - IndustrialHeating.com

THE NEXT MATERIAL WORLD www.acrosscc.com

Evraz Group plans to expand Evraz Inc. NA’s structural tubing facility in Portland, Ore., to add capacity to manufacture American Petroleum Institute certiﬁed (API) pipe. This multi-million dollar investment is scheduled for completion by August 2012 and will bring the mill’s total capacity from 120,000 short tons up to 250,000 short tons of API pipe and structural squares, rounds and rectangles. Evraz will supply steel for the API pipe from its sister steel mill next door. The facility will continue to support the structural tubing market in addition to the new OCTG product line.

Stackpole International Acquired by Sterling Group Stackpole International, a manufacturer and sole-source supplier of highly engineered oil pumps and powderedmetal components to automotive original equipment manufacturers, was acquired from Gates Canada by the Sterling Group, continued on page 48

Advancements in Gear Hardening

GEAR HARDENING

Single Precise Frequency Profile Hardening. Recognizing the demand for greater equipment simplicity has motivated Ajax TOCCO to develop and refine a customer driven innovative system based on the use of a specifically precise selected single programmed frequency. This frequency is used to produce the required diametrical pitch gear tooth profile hardened pattern. This is just one of the numerous advancements Ajax TOCCO is producing for the future. For more information, please visit our website or call Ajax TOCCO.

Ajax TOCCO Magnethermic® Corporation 1745 Overland Ave Warren, OH 44483 Tel: 800-547-1527

THE GLOBAL FORCE IN INDUCTION TECHNOLOGY See Us at Booth #1901

Tel: 330-372-8511 Fax: 330-372-8608

www.ajaxtocco.com

Industry News 73)NNOVATION4HENEW732%+5-!43 WITHGAPFLOWHEATEXCHANGER.EXTGENERATION TECHNOLOGYOFHIGHPERFORMANCE73BURNERSYSTEMS a Houston-based private equity investment ﬁrm, for $285 million. Headquartered in Ancaster, Ontario, Stackpole currently has 12 manufacturing facilities and technical centers in North America, Europe, China and Korea. Stackpole, which was founded in 1952 and acquired by Gates in 2003, is a market leader in both oil pumps and powdered metals.

Horsehead to Build New Production Facility

-AXIMIZEDEFFICIENCY T H E N E W B U R N E R G E N E R AT I O N 73)NCÀ7EST%RIE!VENUEÀ,ORAIN /(53! 0HONE À&AX % MAILWSINC FLOXCOM 737iRMEPROZESSTECHNIK'MB(ÀD 2ENNINGEN'ERMANY

See Us at Booth #2110

IFI 48 October 2011 - IndustrialHeating.com

Horsehead Corporation announced that it plans to build its new, state-of-the-art zinc and diversiﬁed metals production facility in Rutherford County, N.C., near the municipality of Forest City. The new plant is expected to employ approximately 250 people once it is fully operational. According to Horsehead, the facility will produce zinc at much lower costs and provide opportunities for the company not only to serve its traditional hot-dip-galvanizing market but also to serve the broader market for special highgrade zinc and the continuous galvanizing market. Horsehead anticipates capital costs for the new plant, which will be capable of producing special high-grade zinc and continuous-galvanizing grade in addition to the Prime Western grade that the company currently produces, to be more than $350 million. Construction of the facility could be completed as early as the third quarter of 2013. The existing smelter in Monaca, Pa., will continue to operate until the new plant is fully commissioned. Horsehead plans to continue non-smelter operations in Monaca and is exploring alternative uses for the facility.

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Industry News/Events

People in the News Katanya Jaworek (left) has been added to SECO/WARWICK’s Thermal Team sales staff as a sales application engineer. Ms. Jaworek responsibilities will include presenting and negotiating custom-engineered furnace proposals with customers and developing project concepts and project proposals to solve customer needs.

ALD Thermal Treatment, Inc. Providing the fi nest metallurgical services in a wide variety of markets through Vacuum Treatments and specialized gas quenches.

LEADERS IN THE CONTROL OF DISTORTION Vacuum Carburizing with High Pressure Gas Quenching Plasma CARBURIZINGs Vacuum High-Temperature 3OLUTION.ITRIDINGs Vacuum HarDENINGs Vacuum Brazing ANNEALINGs.ORMALIZINGs#ryogenic Treatments Measurement and Testing

GLOBAL SERVICE CENTERS

Ed Ridge (center) has been named chief operating ofﬁcer for Aerobraze Engineered Technologies, a division of Wall Colmonoy. Mr. Ridge has extensive experience leading manufacturing engineering companies to strong operational and ﬁnancial results. Gary Peterson (right) has been named operations manager at Wall Colmonoy’s Los Lunas, N.M., facility. Mr. Peterson is an expert in global supply-chain optimization. He will focus on applying lean manufacturing practices at Los Lunas.

Events OCTOBER

Oct. 30-Nov. 4 AVS 58th International Symposium and Exhibition; Nashville, Tenn. www.avs.org

Oct. 31-Nov. 2 ASM Heat Treating Society Conference and Exposition; Cincinnati, Ohio www.asminternational.org

Limbach - Oberfrohna Germany Port Huron, Michigan USA Ramos Arizpe, Coahuila Mexico

NOVEMBER

10 FORGExpo – A free international virtual event; 7 a.m.-1 p.m. ET www.forgexpo.com

www.aldtt.net www.ald-vt.de Photo: Buderus Edelstahl GmbH

Michael Pode (Sales) 803-546-6686 or [email protected] Robert Peters 803-600-8052 or [email protected] 50 October 2011 - IndustrialHeating.com

10-12 Aluminium India 2011; Mumbai, India http://www.aluminium-india.com/ 11 Free Webinar, hosted by Industrial Heating – “Secrets of Hardness & Mechanical Testing” www.industrialheating.com

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65

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See Us at Booth #2324

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See Us at Booth #1801 IndustrialHeating.com - October 2011 51

MO L YBD EN UM & TUNG STEN. Elmet Technologies is a world-class supplier of mill products and machinefabricated furnace components. • • • • • • •

HOT ZONE COMPONENTS AND ASSEMBLIES FURNACE RACKS FASTENERS, SPACERS, HANGERS, CROWNS ROD (THREADED, GUN-DRILLED) HEATING ELEMENTS (WIRE, ROD, MESH) SHIELDING (COMPONENTS AND ASSEMBLIES) CRUCIBLES, BOATS, CARRIERS

• CUSTOM-DESIGNED HARDWARE

Elmet. We fabricate Molybdenum and Tungsten products for innovative companies worldwide. See Us at Booth #1927

+ 1 2 0 7 . 3 3 3 . 61 0 0

e ti sa l e s@ e l m et t ech.co m

www.elmet t echno lo g ies.co m

COME SEE US AT HEAT TREAT 2011 IN CINCINNATI, OCT. 31–NOV. 2, BOOTH #1927

FEATURE | Heat Treating Fig. i . 5.. HybridCarb y i C ® installed on a furnace

Greener Thermal Processing Leads to a Greener Bottom Line Aymeric Goldsteinas and Jim Grann – Ipsen, Inc.; Cherry Valley, Ill. Most thermal-processing companies turn green at the thought of going green. It can be very overwhelming when you consider changing technologies, retooling operations and production practices at a cost that often takes years to recover. Sustainability, grid parity, subsidies, LEED certiﬁcation … What does it all mean when it comes to the bottom line?

0.40 %F %C

Carbon Potential, %

0.60

0.20 0.00

08:22:00

07:24:20

06:26:40

05:26:00

04:31:20

03:33:40

EndoGas 02:36:00

0.00

0.80

01:38:20

08:22:00

07:24:20

06:26:40

05:26:00

04:31:20

03:33:40

02:36:00

01:38:20

00:40:40

23:43:00

22:45:20

21:47:40

HybridCarb

1.00

00:40:40

0.20

%F %C

insulation, furnace cycle optimization, high-efﬁciency combustion systems and gas ratios paired with concern for uniformity, repeatability and overall product quality. If you know you have a tight furnace and optimized cycles, you’ve done all you can do, right? Not so fast. Our research and development team – Team Innovation – is busy every day

23:43:00

0.40

Fig. 1. Photo of HybridCarb®

1.20

22:45:20

0.60

Temperature, ˚F

0.80

Carbon Potential, %

1.00

2000 1800 1600 1400 1200 1000 800 600 400 200 0

21:47:40

1.20

20:50:00

Temperature, ˚F

2000 1800 1600 1400 1200 1000 800 600 400 200 0

Twain, “If you stand still, you fall behind.” The thermal-processing industry must remain innovative in order to keep moving forward. In today’s atmospheric gassing systems using endothermic gas or nitrogen/methanol, only 2% of the gas is actually diffused into the workpieces – 98% remains unused and is burned off and released into the atmosphere. This is not only questionable from an environmental standpoint but also represents a squandering of resources, resulting in unnecessary costs. For atmospheric furnaces, there are many factors to consider for increasing your “green-ness.” These factors include

20:50:00

A

l lthough many companies across the globe have n managed to become much m greener and in the process g have begun saving, it usually takes a signiﬁcant investment of both time and money and is often a very difﬁcult transition. Change can be painful and cumbersome to production, and in heat treating, slowing production can be extremely detrimental to the bottom line. At Ipsen, we believe that innovation drives excellence, and that excellence includes being more environmentally friendly. Heat treatment is an energyhungry business, and in the words of Mark

Fig. 2a and 2b. These charts show that the furnace temperature and carbon potential of the HybridCarb® system (2a) is comparable to that of an endothermic generator (2b), but recycling the process gas provides better carburizing efficiency and reduced cost savings. IndustrialHeating.com - October 2011 53

EG-III

Depth

0.058

0.054

0.050

0.046

0.042

0.038

0.034

0.030

0.026

0.022

0.018

EndoGas 0.014

0.058

0.054

0.050

0.046

0.042

0.038

0.034

0.030

0.026

0.022

0.018

0.014

0.010

HybridCarb

EG-II

0.010

HRC

HC-III

EG-I

0.006

HC-II

64 62 60 58 56 54 52 50 48 46 44

0.002

HC-I

0.006

64 62 60 58 56 54 52 50 48 46 44

0.002

HRC

FEATURE | Heat Treating

Depth

Fig. 3a and 3b. These charts show hardness uniformity from the same furnace with identical sample coupon material and placement. Uniformity is much tighter with HybridCarb® (3a).

dreaming the future. When they looked at atmospheric technologies, they saw a huge opportunity hiding in a dinosaursized carbon footprint – endothermic generators, one of the largest culprits of energy consumption in thermal processing. Endothermic generators get the job done but often lack the adjustment capabilities to efﬁciently handle the ﬂuctuations of demand at the generator, furnace and

ever-changing natural gas suppliers, not to mention the waste of burning off the process gas during generation. New Process-Gas-Recycling Technology Ipsen’s new process-gas-recycling technology saves energy and resources by decreasing energy consumption and carbon footprint, resulting in immediate cost savings

without the hassle of major changes in operations. HybridCarb® is a gassing system that provides precise process gas control. Instead of burning it off, the process gas is recycled, reconditioned and reused, which increases efﬁciency up to 90%. The HybridCarb system allows for a reduction of more than 40 tons of CO2 per year – the equivalent of planting 220 new trees a year!

P ulse F iring S ystem S olutions F eaturing K romschröder Combustion C ontrols

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

• • • •

Fuel savings up to 30% Excellent temperature uniformity Versatility of control scheme

• Lower NOx • Improved turndown • Heating and cooling cycles

High-low or on-off control

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

www.hauckburner.com

See Us at Booth #1822

54 October 2011 - IndustrialHeating.com IH06084Hau.indd 1

5/6/08 10:14:51 AM

How it Works

The Ipsen HybridCarb system replaces endothermic generators and other similar gassing systems with a more efﬁcient system that not only generates the process gas but also recycles it, resulting in signiﬁcant cost savings. Using this system, process gas is recovered and used for further heat treatment. Thanks to this processgas recycling, the carburizing efﬁciency is enormously increased, which is a beneﬁt not only for the environment but also for our operating efﬁciency. The unique design of the HybridCarb system has a more efﬁcient gas injection method than that of an endothermic generator, which allows for a better distribution of carbon, resulting in tighter hardness uniformity. During HybridCarb’s recirculation phase, the process gas is not directed to the burn-off system. Instead, after transferring carbon into the load, the process gas is guided back through the system in order to be reconditioned and reused. This gassing method offers the possibility of saving 90% of the process gas during the carburization cycle, thus reducing the exhausting of carbon dioxide (CO2) caused during the process-gas burn-off. The combination of the precise control enabled by HybridCarb along with the process-gas injection method provided by the Trunk Module (patent pending) has delivered tighter hardness uniformity in several of our early beta testing sites. The unique HybridCarb design allows for precise process-gas control, which results in reduced heat-input requirements and can lead to better performance, while the gas burners on the furnace work less – all translating to less utility cost, faster recovery after transfers and reduced maintenance cost. Types of Furnaces Supported HybridCarb can be installed on batchtype furnaces (e.g., Ipsen type TQ- and RTQ- furnaces as well as similar furnaces from other manufacturers). Furnace integrity is a factor when considering the HybridCarb application. The furnace tightness must support a low, controlled leak rate and minimal pressure with a speciﬁed ﬂow rate in order to carry

out an efﬁcient recirculation and reconditioning of the process gas. Some furnaces may require slight modiﬁcations for maximum efﬁciency and control. Installation of HybridCarb

Unlike many green improvements, HybridCarb can be installed in hours. It is

intuitive, operator-friendly and its compact roll-in design ﬁts almost anywhere, taking up much less space than your typical endothermic generator. It does not require riggers, and it connects to the existing utilities while having almost no hardwire break-ins to the original controlling system. The original alarm and safety

We are Invensys Eurotherm Reduce energy costs and increase power control performance through the E-Power’s load management funtion..

Temperature Uniformity Survey Recorder

Expect more from your temperature controllers, bring them online.

Visit us at ASM 2011 - Booth #2011, to learn more about our products.

nanodac™, combining secure data and PID control now with setpoint programming.

www.Eurotherm.com

See Us at Booth #2011 IndustrialHeating.com - October 2011 55

FEATURE | Heat Treating

Fig. 4. Snapshot of HybridCarb savings calculator showing how it can save you thousands of dollars a year. Typical protective atmosphere volume required

750 CFH

24 x 36 x 24 load size furnace

500 CFH

36 x 48 x 36 load size furnace

750 CFH

Process factors that impact HybridCarb™ Furnace cycles per day

1.0

Operating weeks/year

51

Production hours/week

120

Production days/week

5

Furnace Tightness factor (0.4 to 1.0)

0.85

Process factors unique to nitrogen/methanol atmosphere Electric-heated furnace 1=On 0=Off

1

Gas-heated furnace 1=On 0=Off

0

Gas-heated combustion efﬁciency %

73%

Combustion efﬁciency "U"-tube burners

57%

Combustion efﬁciency "SERT burners"

73%

Common to all Atmospheres Enriching (carburizing) % of total cycle duration

0.75

Utility Costs Electric cost $0.00/KWH

$0.08

CH4 cost/Mtherm

$4.50

Nitrogen cost/100CF

$0.140

Methanol cost/gallon

$1.65

Note: Green highlighted values adjusted for each application

Maintenance labor rate/hr with burden

$75.00

HybridCarb® annual savings HybridCarb® vs. endothermic

$15,449 savings

HybridCarb® vs. nitrogen-methanol

$26,209 savings

HybridCarb® Annual natural gas cost

$1,848

Annual electric cost

$2,232

Annual operating cost

$4,081

Endothermic Atmosphere Annual natural gas cost

$12,631

Annual electric cost

$2,399

Annual maintenance parts

$1,500

Annual maintenance labor

$3,000

Annual operating cost

$19,530

Nitrogen-methanol atmosphere Annual nitrogen cost

$3,599

Annual methanol cost

$20,112

Annual natural gas cost

$775

Annual electric cost

$5,805

Annual operating cost

$30,290

56 October 2011 - IndustrialHeating.com

sequences are unaffected by the installation. This green technology offers a nearly hassle-free solution, using less ﬂoor space and less piping than endothermic generators, and it reduces costs immediately upon installation. HybridCarb interfaces with the existing gas safety panel. In addition, the installation of Ipsen’s Trunk Module into one of the sidewalls of the heating chamber is required. The Trunk Module extracts the process gas out of the heating chamber, sending it to be reconditioned, and then delivers the reconditioned gas back into the heating chamber as needed. The Trunk Module is designed to work in conjunction with the combustion blower of the heating chamber during the atmosphere circulation phase, which provides a sufﬁcient separation between extracted (used) gas and recycled (reconditioned) gas. The only change in the furnace controls is the installation of a manually operated switch in order to activate the HybridCarb system. This switch can also be installed directly into the control unit and includes an electrical bypass that monitors the amount of protective gas in the furnace’s gas safety panel when the system is activated. All other security queries of the existing furnace installation remain active and will not be affected by the start-up of the HybridCarb system. The existing furnace hardware and software – including all probes, sensors, analyzers and the furnace-gas safety panel – are still responsible for creating and executing the heat-treatment programs, temperature control and C-potential control in the heating chamber. In the same respect, all safety devices and original adjustments remain active on the furnace. Overall Benefits and Support

The beneﬁts of the HybridCarb system include: • Quick and easy connection using Ipsen’s patent-pending Trunk Module • Fast recovery of atmosphere after door movement and quenching operations • Less heat and atmosphere loss due to closed recirculation design • Improved hardness uniformity • Less chance of IGO formulations • Enhanced furnace pressure regulation • Signiﬁcantly less expensive to operate compared to the cost of running and maintaining an endothermic generator or nitrogen/methanol gassing system • One system per furnace prevents a single generator from bringing several furnaces to a halt • Shorter burner recovery time • Less natural gas consumption • Environmentally friendly and cost efﬁcient Ipsen’s world-class Aftermarket Support team provides support, prequaliﬁcation testing and installation of HybridCarb systems. Conclusions Making changes and improvements to be more green can be a hassle, but Ipsen’s HybridCarb gassing system is one of the few green technologies that is easy to implement, and it allows you to begin saving right away. So next time you feel yourself getting a little green around the gills about being more environmentally friendly, remember research and development teams, like our Team Innovation, are working hard every day to make green technologies more, well, company-friendly. IH For more information: Contact Ipsen, Inc., 984 Ipsen Road, Cherry Valley, IL 61016; tel: 815-332-4941; fax: 815-332-4995; e-mail: [email protected]; web: www.IpsenUSA.com. Author Jim Grann is senior technical manager and Aymeric Goldsteinas is product development manager.

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FEATURE | Induction Heat Treating

Computer Modeling Helps Identify Induction Heating Misassumptions and Unknowns Fig. 1. An appearance of skin effect when induction heating carbon-steel billets

Dr. Valery Rudnev – Inductoheat Inc.; Madison Heights, Mich. Whenever someone is discussing induction heating, reference is often made to the skin-effect phenomenon, which is a fundamental property of induction heating. It can be clearly observed during billet heating (Fig. 1). Skin effect represents a nonuniform distribution of an alternating current within the workpiece cross section.

Core I = Isurface

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1000 Temperature, ˚C

Surface

800 600 400

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200

Internal area 10

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Surface

CD

Internal area Surface

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with current penetration depth emphasizes the importance of having a clear understanding regarding skin-effect appearance during induction heating. Many times, engineers calculate the distribution of the current density along the workpiece thickness (radius) using Bessel functions or numerous charts that are readily available to determine values of b versus temperature when heating different materials using various frequencies. Unfortunately, many people are not aware that the widely used assumption regarding current and power distribution due to a skin effect is not valid for a great majority of induction surface-hardening applications. Computer modeling helps to unveil this common misassumption.

assumed to be exponentially decreasing from the surface into the workpiece. Figure 2 illustrates the skin effect, showing the commonly accepted understanding regarding current-density distribution being reduced from the workpiece surface toward the core. At a distance equal to one penetration depth (b) from the surface, the current magnitude will retain approximately 37% of its surface value. However, the power density retains only about 14% of its surface value because power relates to a current as I2R. From this, one can conclude that about 63% of the current and 86% of the induced power in the workpiece will be concentrated within a surface layer of thickness b. The fact that practically all induced power (heat source) is concentrated

Power density (heat source)

A

c ccording to the skin-effect phenomenon in induction p heating, eddy currents inh duced within the workpiece d will primarily ﬂow in the surface layer (the “skin”), where a majority of all induced power will be concentrated. This layer is called the reference depth or current penetration depth, b. The value of penetration depth varies with the square root of electrical resistivity and inversely with the square root of frequency and relative magnetic permeability.[1] In a great majority of publications devoted to induction heating and induction heat treating, distributions of current density and power density (heat source) along the workpiece thickness/radius are

12

14 16 Radius, mm

18

10

12

14 16 Radius, mm

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Fig. 3. Solid lines represent radial distribution of temperature (left) and power density (right) when induction surface hardening carbon-steel shafts using 10 kHz. Required case depth is 2 mm. The dashed black line in the graph at right is the commonly assumed exponential power-density distribution.[1,2] IndustrialHeating.com - October 2011 59

FEATURE | Induction Heat Treating

It is imperative to remember that the widely accepted assumption of exponential distribution of induced current and power is only appropriate for a solid body (workpiece) having electrical resistivity and magnetic permeability constant. Therefore, realistically speaking, this assumption can be made for only some unique cases of induction heating and heat treating, such as induction heating of non-magnetic materials to relatively low temperatures (i.e. preheating prior curing or bonding) or heating materials that exhibit insigniﬁcant changes in their electrical resistivity during the heat cycle. For the great majority of induction surface-hardening applications, the power density (heat source) distribution is not uniform, and there are always thermal gradients within the heated workpiece. These thermal gradients result in nonuniform distributions of electrical resistivity and, in particular, magnetic permeability within the heated workpiece. Presence of these nonlinearities leads to the fact that the common deﬁnition of current penetration depth does not “ﬁt” its principle assumption. Induction Hardening Speciﬁcs and Magnetic-Wave Phenomenon The aim of surface hardening of steels and cast irons is to provide a martensitic layer on speciﬁc areas of the workpiece to increase the hardness, strength, and fatigue and wear resistance while allowing the remainder of the part to be unaffected by the process. If the frequency has been chosen correctly, the thickness of the nonmagnetic surface layer – the layer that is heated to above the Curie temperature for austenization – is somewhat less than the current penetration depth in hot steel. The desirable frequency is often chosen in such a way that it produces a current penetration depth that will be 1.2-2 times the required case depth. In induction surface hardening, the power-density distribution along the radius/thickness has a unique “wave” shape [1,2] that differs signiﬁcantly from the commonly assumed exponential distribution. 60 October 2011 - IndustrialHeating.com

Here, the power density has its maximum value at the surface and decreases toward the core. But then, at a certain distance from the surface, the power density suddenly starts increasing again, reaching a maximum value before it starts ﬁnal decline (Fig. 3, right). Originally, a hypothesis regarding a “magnetic-wave” phenomenon was independently introduced by Simpson[3] and Losinskii.[4] They intuitively felt that there should be situations where the power-density (heat-source) distribution would differ from that of the traditionally accepted exponential form. Both scientists provided a qualitative description of this phenomenon based on their intuition and understanding of the physics of the process. At the time, a quantitative evaluation of this phenomenon could not be developed due to a limitation in computer-modeling capabilities and the lack of software that could simulate the tightly coupled electrothermal phenomena of induction hardening. Of course, it also was not possible to measure during heating the power/current density distribution inside the solid workpiece without disturbing an eddy-current ﬂow. To the best of my knowledge, the ﬁrst publication that provides a quantitative assessment of a magnetic-wave phenomenon was published in reference 2 with further research provided in references 1 and 5. Modern tightly coupled electromagnet-

Fig. 4. Selective areas of cup-shaped components required induction hardening.

ic-thermal numerical software enables a quantitative estimation of the magneticwave phenomenon based on its ability to properly simulate interrelated electromagnetic and thermal phenomena. An example is given in Figure 3, which shows the temperature proﬁle (left) and powerdensity distribution (right) along the radius of a 36-mm (1.42-inch) diameter medium-carbon steel shaft at the ﬁnal stage of heating (just before quenching would be applied) using a frequency of 10 kHz. For comparison, the dotted curve represents the commonly assumed exponential curve for power-density distribution, and the solid curve shows an actual magneticwave distribution obtained as a result of numerical computer modeling. The main cause of magnetic wave relates to the phenomenon in induction

Fig. 5. FEA mesh (left) and computer-simulated magnetic-ﬁeld distribution at the ﬁnal stage of heating (right) using two two-turn inductors and “U”-shaped magnetic-ﬂux concentrators when selective hardening of end regions of cup-shaped component. Due to the symmetry of the component, only the right half was modeled (courtesy of Inductoheat Inc.).

Heat time = 1.2 sec. 25kHz

Heat time = 2.23 sec. 25kHz

Heat time = 8 sec. 25kHz

Fig. 6. Computer simulation of the sequential dynamics of the induction hardening of selected areas of cup-shaped components using two two-turn inductors and “U”-shaped magnetic-ﬂux concentrators. Due to the symmetry of component, only the right half was modeled using FEA (courtesy of Inductoheat Inc.).

surface hardening that carbon steel retains its magnetic properties in the subsurface region, and the surface region is nonmagnetic being heated above AC2 critical temperature for austenitization. Note that this phenomenon can sometimes create the maximum heat source value below the surface of the workpiece and not at its surface. Further discussion regarding this phenomenon can be found in references 1, 2 and 5. Taking into consideration the wavelike distribution of power density is important when choosing the induction frequency necessary to provide the required hardness depth. In induction surface hardening, therefore, the selection of optimal frequency is not as obvious a task as it might appear using “rules of thumb” or as it was presented in a great majority of publications devoted to induction heating, based on the commonly accepted assumption of the heat-source distribution. It is important to be aware that the magnetic-wave phenomenon of powerdensity distribution does not only appear along the radius/thickness of the workpiece. It also occurs when studying powerdensity distribution in axial direction as it occurs in through-hardening of selected areas of the component. Causes for its appearance remain the same. Numerical computer modeling using appropriate software helps to reveal this appearance.

Case Study Induction hardening comprises three groups of applications: surface hardening,

through hardening and selective hardening. The goal of induction surface hardening is to provide a martensitic layer on sur-

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See Us at Booth #2241 IndustrialHeating.com - October 2011 61

FEATURE | Induction Heat Treating

face areas (external and/or internal) of the workpiece that allows improving certain properties of the part without affecting the rest of the part. This is accomplished by raising only the required surface depth of steel above the transformation temperature to a point where it transforms to austenite and is then rapidly cooled. In contrast to surface hardening, the goal of through hardening is to provide a martensitic structure throughout the entire workpiece. For this to occur, the entire cross section is raised above the transformation temperature and then rapidly cooled to produce a consistent martensitic structure through the entire cross section. The ability of the component to be through hardened depends upon the hardenability of the steel, the quenching conditions, grain size and the part’s geometry. Both induction through and surface

(case) hardening can be localized to a component’s unique geometry, a process often referred to as selective hardening. Figure 4 shows an example of a selective induction-hardening application – top and bottom end regions of the cup-shaped component required being selectively hardened. The area between those two regions should retain ductility, and its hardening was prohibited. Because of the symmetry of the component, only the right half was modeled using ﬁnite-element analysis (FEA). Figure 5 shows FEA mesh (left) and computer-simulated magnetic-ﬁeld distribution (right) at the ﬁnal stage of heating using two two-turn inductors and “U”-shaped magnetic-ﬂux concentrators. The frequency is 25 kHz. The plot of magnetic-ﬁeld distribution (Fig. 5, right) clearly indicates demarcation of the cup’s regions heated above the

See Us at Booth #1917

62 October 2011 - IndustrialHeating.com

Curie temperature and below it. Concentration of magnetic ﬁeld lines can be clearly seen. Magnetic-wave phenomenon appears at a magnetic/nonmagnetic border. Sequential dynamics of temperature proﬁles during induction heating are shown on Figure 6. Magnetic wave was not the only physical phenomena that needed to be taken into consideration in order to accurately simulate the process and determine an optimal coil design that results in a desirable temperature distribution. Some of those challenges were related to the following phenomena: From an Electromagnetic Perspective

It was necessary to assure the balance of the following three electromagnetic effects: proximity effect, “ring” effect and end effect. Each affects the distribution of the heat generation and temperature

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FEATURE | Induction Heat Treating

proﬁle. By determining an optimal coil design and process recipe, it was possible to balance the electromagnetic effects and obtain desirable ﬁnal temperature distribution. From a Heat-Transfer Perspective

During the heating cycle, the presence of colder neighboring areas creates a greater cooling effect (cold-sink effect) experienced by particular regions. This means that during the heating cycle, uneven amount of heat will be removed from different areas of the required heat zones due to thermal conductivity. This demands designing inductors that can intentionally distribute the power density nonuniformly, compensating for an intensive heatsink effect and producing the required temperature pattern at the end of heating.

From a Design Perspective

It is important to come up with a relatively simple, cost-effective and robust coil design that will induction harden selective areas of the component with high, repeatable quality and with minimum shape distortion. Computer modeling precisely addressed the presence of the reviewed process features and determined an optimal inductor design and process recipe, dramatically reducing development time. IH References: 1. Rudnev,V., Loveless,D., Cook,R., Black,M., Handbook of Induction Heating, Marcel Dekker, New York, 2003, 800p. 2. Rudnev,V., Cook,R., Loveless,D., Black,M.: “Induction heat treatment: basic principles, computation, coil construction, and design consideration,” Steel Heat Treatment Handbook, edited by G.Totten and

M.Howes, Marcel Dekker, p.765-872 (1997). 3. Simpson, P.G., Induction Heating: Coil and System Design, McGraw-Hill, NY, 1960. 4. Lozinski, M.G., Industrial Applications of Induction Heating, Pergamon Press, London, 1969. 5. Rudnev,V., Simulation of Induction Heat Treating, ASM Handbook Volume 22B: Metals Process Simulation, D.U.Furrer and S.L.Semiatin, editors, ASM Int., Materials Park, Ohio, p.501-546 (2010). For more information: Contact Dr. Valery Rudnev, FASM, Inductoheat, Inc., An Inductotherm Group Co., 32251 North Avis Dr., Madison Heights, MI 48071; tel: 248-629-5055; fax: 248-589-1062; e-mail: rudnev@inductoheat. com; web: www.inductoheat.com

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FEATURE | Process Control & Instrumentation

Are Your Industrial Controllers Fluent in (M)any Languages? Invensys Eurotherm; Ashburn, Va. Over 30 process-automation network protocols exist in use today. Why is this important, and how do you decide which ones are best for your heat-treatment application? Fig. 1. Nanodac

P

e eter Sherwin from Invensys s Eurotherm discusses this topic with Chris Mooney and t Mikael LeGuern (process exM perts in control and power) to understand applications and reasons for the different (language) protocols.

Overview of Network Protocols [Peter] Chris, why do we have network protocols, and how are they used in a heat-treat process? [Chris] Simply put, network protocols allow us to transmit data from point A to point B (or point C, D, E, etc.). This is relevant in heat treating because we can have a master programmer device sending out instructions to many so-called slave devices as well as communicating with a central SCADA unit. Most modern process equipment – from the industrial controller handling your furnace temperature to the PLC or PAC controlling your mechanical motion – can be outﬁtted with some manner of ﬁeldbus communications. [Peter] What is the current status of these protocols? [Chris] The older, costlier standard of retransmitting data with multiple 4-20mA signals is being replaced by Modern Industrial Communications. These newer networks allow a wide variety of information to be communicated from sources all over the plant ﬂoor, sometimes over a single network cable (signiﬁcantly reduc-

ing the cost and complexity of wiring). Whether you are reading the power-draw levels from a network of SCRs to calculate your power factor or the ﬂow from a ﬂow meter to monitor your gas usage, the data is available, accurate and does not suffer from the retransmit errors associated with nondigital communications. Industrial communications networks allow an engineer to connect dozens of ﬁeld devices and share data between devices for process-control purposes with corporate leadership who analyze this information to determine performance against a set criteria of KPIs (Key Performance Indicators). These communications networks all require some language, or protocol, to transfer data. Increasingly, Ethernet-

based communications are becoming more prevalent amongst the numerous protocols available to suit a wide variety of products and applications. [Peter] What are the main protocols in use today? [Chris] Among these various protocols there are two types that are most widely used: CIP and Modbus. CIP, or Common Industrial Protocol, was developed by Allen Bradley (of Rockwell Automation) and includes a number of network hardware types. CIP contains older serial hardware-based network platforms, with Controlnet and Devicenet being the most popular. But the most recent addition to the CIP family is EtherNet/IP, an Ethernet-based protocol.

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Modbus slave industry standard PLC Modbus Slaves 3504 2704

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Serial modbus RTU (port1) Serial modbus RTU (port2) Modbus TCP/IP

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IndustrialHeating.com - October 2011 67

FEATURE | Process Control & Instrumentation

Fig. 3. Single-loop controller

Fig. 4. Multi-loop controller

EtherNet/IP

Ethernet-based communications stems from the need for interconnectivity between wide varieties of networking platforms – both industrial and businessrelated. EtherNet/IP does not require its own independent network. It can operate under an established plant network. Functionally speaking, EtherNet/IP communication offers the ability to move

EtherNet/IP, or Ethernet Industrial Protocol, is an open network that makes use of most networking hardware available off the shelf, communication lines and physical media. What this means to a plant engineer is that a simple CAT5(6) cable is all that is needed to connect the devices on the network. The creation of

large amounts of data at very high speeds. This allows the passage of real-time information to all levels of an organization, from plant floor to top management. Like all of Allen Bradley’s protocols, EtherNet/IP is considered an “open protocol.” This means that it conforms to the Ethernet IEEE 802.3 and to the CIP standards. The CIP standards are governed by an organization called ODVA, which maintains all compliance standards. If a device wishes to be ODVA compliant, it must be tested and approved at an ODVA-approved lab. The benefits of open protocols provide users with the surety that connecting with other ODVA-compliant devices should be trouble free. But there are other protocols that offer similar advantages as alternatives to the CIP platform, such as the Modbus protocol.

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Modbus

Modbus was developed in the 1970s by the PLC manufacturer Modicon (now owned by Schneider Electric). Like CIP, Modbus is an open platform but is instead governed by the Modbus Organization. Like Allen Bradley’s CIP, Modbus has both a serial and Ethernet base. Modbus RTU is a serial platform that makes use of the widely available single-drop RS232 or multi-drop RS485 network. Presently, most Modbus networks operate on an RS485 network rather than 232 as it is faster and offers the ability to address multiple units on a network. While originally on serial links, Modbus is also available on an Ethernet-based network called Modbus TCP. Again, because of the ubiquitous nature of business networks, Modbus TCP can coexist on a plant network alongside normal network trafﬁc again allowing data ﬂow from plant bottom to top management.

Even though these two Ethernet-based protocols are as proliﬁc as they are, not all ﬁeld devices are available with both choices. As communications become more complex, many of the newer types of networked devices can operate multiple protocols from one Ethernet link. Data Capture

A primary use for these communications protocols is data transfer and collection. Additionally, ﬁeld devices can send process variables to controllers and monitor devices such as HMI panels and SCADA software packages. This data is ultimately collected, stored and either analyzed to make the process more robust and efﬁcient or saved for regulatory and customer-demand purposes. Depending on the level of security and regulation a company needs to meet, this data can be found in a few formats. Most data collected over these com-

munication networks can be viewed in an open CSV format. Once in this format, the data can be brought into SQL databases or imported into various analytical software packages. However, data security is a concern with this open format. From the moment the data is captured, there is no security. The data is free, open and can be tampered with without anyone’s knowledge. Many heattreating organizations follow strict regulations for data surety (e.g., AMS 2750D requirements), and storage in a CSV-like format is unacceptable. The good news is that there are a number of companies that now offer data-acquisition platforms (both hardware and software) for processes that need to meet strict tamperproof regulations. Included in this list is the nanodac Controller/ Recorder (Fig. 1) and 6000-series Chart Recorders from Invensys Eurotherm. For

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IndustrialHeating.com - October 2011 69

FEATURE | Process Control & Instrumentation

Mobile phone

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Remote programming control

Send and receive ﬁles via FTP Ethernet 2 Ethernet 1 CF card

PC Transfer logging

Fig. 5. EPower

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Mini8 controller

T2550 programmable automation controller

USB keyboard Drive

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Fig. 6. PLM logo

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the majority of products in this category, the data ﬁles are checked for attempted manipulation against some proprietary algorithm. This is critical to ensure that the data can be trusted implicitly. These historical records must also be kept for extended periods of time – even years – so it is important to question the memory capacity of these units.

Applications of Network Protocols with Power Controllers. [Peter] Mikael, your expertise in power controllers and knowledge of network protocols has promoted the use of a variety of network protocols within the latest Power Controllers/ SCR Technologies from Invensys Eurotherm. What practical advantage do these protocols offer a heat treater? [Mikael] Over the past few years, we have included network protocols in the latest EPower Power Controllers, especially Ethernet protocols like EtherNet/IP, Modbus TCP or Proﬁnet. While at the core these are still SCR units, the inclusion of protocol technology has allowed these devices to start communicating to each other and the outside world. To explain

[Peter] Chris, what protocol options do typical controllers have? [Chris] Serial communications (e.g., Modbus RTU) are typically found in the less expensive, smaller, singleloop controllers, but as you move up in complexity of control and have more information/data that can be passed from device to device, there tends to be a variety of protocols offered.

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the beneﬁts of this technology, we can think about splitting this into two areas: (1) communicating process, diagnostic and energy information to HMI or SCADA systems and (2) communication between devices to maximize energyefﬁcient usage. Communicating Energy Information to HMI or SCADA Systems

The electrical power controller is determining the use of energy in your process in KW/hour. In an energyintensive industry such as heat treatment, control, data capture and analysis of energy use is more important today than it has ever been in our history. The base of the power controller is the SCR technology acting as a fast electrical switch to allow electrical energy to ﬂow to the heating

Power Controllers/SCRs vs. Contactors

O

lder-style mechanical contactors have been used for many years in controlling the heat input to furnace heating systems. For high duty cycles, however, life of these contactors can be measured in months due to mechanical wear. Other drawbacks are their slow speed in switching cycles – typically not less than 30 seconds. The advent of power controllers and SCR technology has improved the life of the switching mechanism (these are fast electrical switches and do not suffer the mechanical wear), and their switching speed is measured in the low milliseconds rather than seconds. This precise control of the load results in holding tighter temperatures and typically provides the user with a more consistent and reproducible process cycle. Modern power controllers have the ability to operate with different ﬁring modes (even within a single cycle) gaining an optimum balance of energy costs through load balancing and shedding, speed of operation, power factor and harmonic disturbances. To read more about power controllers, please refer to the white paper “Energy Cost Reduction through Load Balancing & Load Shedding” by Mikael LeGuern at http://www.eurotherm.com/products/power-control/epower/.

70 October 2011 - IndustrialHeating.com

system of your furnace (see sidebar for Power Controllers/SCRs vs. Contactors). Today’s power controller not only acts as this fast switch but is configurable over a network. It also has the ability to monitor the electric usage and, using network protocols, can provide this data to a DataLogger, HMI or SCADA system. This data can be translated into information about energy use per process (particulary on a batchbased system), idling energy use and peak-demand information. This information can then be used to accurately predict future energy use running a specific process (helping pricing calculations) and also to give peak-demand information that can aid decisions in avoiding blackouts due to running over capacity. However, this information is after the fact. What can we do with current technology to act on data/information in real time? Communicating Between Power Controllers

Utilizing network communications, it is now possible to link power controllers together. Why is this important? If you have a multi-zone furnace or multiple furnaces with a number of power controllers, you can now have automated fast communication between these devices. This means you can schedule the firing of these units to avoid firing at the same time, thus minimizing the peak-load demand and also balancing the power across multiple controllers. Everything is done automatically at high speed with minimal configuration from the operator. Without rapid communication between the devices, the time lag would delay firing and impact heat-up times or, worse, impact the ability of the furnace to maintain process temperatures. Not only can you address issues with peak demand, if you have multiple processes using power controllers, you can use a shedding technique to keep below a user-defined set limit on power/current usage to prevent overloading the grid or to reduce cost of energy by limiting demand charge. Latest Network Technology and Freedom of Choice [Peter] One last question, Chris. What is the latest technology, and why is this important? [Chris] Although we have discussed numerous protocols and their availability in different products, typically for discrete controllers you have to select a particular protocol for an instrument rather than being able to use a variety of protocols in a single controller. Certain manufacturers still have a proprietary protocol system, which means if you select their system or have legacy products using that network, you don’t have the freedom to choose “best-in class” controllers or systems because you are tied into using their products to communicate over a network. Even worse, some of the legacy products are not supported or don’t have a migration path, so you have no option but to update your whole control system even if it’s only a single controller that requires replacement. Building on the open-networking environment that SCADA systems such as Invensys Wonderware offer with multiple protocols and built-in drivers, this open technology is now available in smaller systems such as the newer class of machine HMIs. This now allows the controls engineer to specify the best-in-class instrumentation and utilize the HMI to provide protocol translation between current and legacy products. Let’s hope the spirit of open communications continue into the future for all suppliers to offer the controls/maintenance engineer the greatest choice and the ability to specify best-in-class instrumentation whether looking at a new system or improving a part of a legacy system. IH For more information: Contact Peter Sherwin, business development manager – heat treatment, Invensys Eurotherm, 44621 Guilford Drive, Suite 100, Ashburn VA, 20147; tel: 703-724-7300; fax: 703-724-7301; e-mail: [email protected]; web: www.eurotherm.com. Chris Mooney, controls product specialist ([email protected]), served in the Air Force as an avionics specialist before joining Invensys Eurotherm. Mikael LeGuern, product marketing manager – power products ([email protected]), developed the EPower controller in Europe before joining the North American team four years ago. See Us at Booth #1611 IndustrialHeating.com - October 2011 71

FEATURE | Industrial Gases/Combustion

The Basics of Pulse Firing Dan Curry – Eclipse, Inc.; Rockford, Ill. Pulse ﬁring is a combustion heating-control method developed in Europe in the early 1970s. The number of pulse-ﬁred burner applications in North America has been growing steadily from the 1990s. This article discusses the basics of pulse ﬁring as it applies primarily to heat-treating furnaces.

T

h primary purpose of a furnace he is i to provide heat to the product u or load, so basic knowledge of o desired furnace heat-transfer characteristics helps in understanding why and how pulse ﬁring can be beneﬁcial.

Furnace Heat Transfer Thermal efﬁciency is a measure of getting heat from the burner to the load. It is important to isolate factors that are not related to the burner ﬁring method (pulse vs. amplitude modulation) when making comparisons. The Sankey diagram in Figure 1 highlights ways to increase efﬁciency that are not related to the burner ﬁring method, such as: • Reducing the exhaust losses with heat exchangers to preheat the combustion air of the burner • Reducing wall losses by increasing and maintaining wall insulation • Reducing opening losses by maintaining door seals and furnace pressure control • Reducing heat storage by installing low thermal-mass insulation in batch furnaces where the temperature cycles regularly The transfer of energy from the ﬂame and hot combustion gases to the load depends on the difference in temperature and the barriers that impede the transfer. So, efﬁciency gains that are related to the burner ﬁring method correlate to excess air and velocity. Excess Air

Excess air is the amount of air above what is required for complete combustion of the fuel. It can come from the burner, open-

rier. Therefore, reducing its thickness improves heat transfer. Another advantage of higher velocity is stirring of the furnace atmosphere to level the temperature throughout the furnace volume. This effect is demonstrated in Figure 2, where the high-velocity stream draws in surrounding air. The entrainment can be 10 times the volume for burner outlet velocity at 500 feet per second (340 mph or 150 meters per second). Production quality requires all parts of the load, no matter where they are located inside the furnace, to reach and stay at the desired temperature. Good proﬁts come from quick production throughput by rapidly heating the load to its desired temperature. Therefore, uniformity and high heat-transfer rates are important furnace characteristics.

ings in the furnace or it is purposefully injected to stir the environment to get uniform temperature throughout the furnace. Excess air acts as an additional heat load because it must also be heated. Therefore, more excess air requires more fuel. Excess air reduces the temperature of the ﬂame and products of combustion, and thus, the heat-transfer rate is also lowered. Velocity

Velocity is the speed of the products of combustion ejected from the outlet of the burner. Faster hot combustion gases deliver more heated mass across the load surfaces. The higher mass ﬂow carries more heat across the entire distance of the load before the stream cools, and as a result, the temperature differential and heat-transfer rate are increased. In some designs, the high velocity scrubs the load surface and reduces the thickness of the layer of dead air stuck by surface friction. This dead layer acts as an insulating bar-

Modulation The primary function of a combustion control system is to vary the heat input

Dry Add a heat exchanger

Wall loss (conduction)

Moist

Increase, maintain insulation Opening loss (radiation)

Gross heat input (HHV)

Use low thermal mass insulation

Net heat (LHV)

Available heat

Heat to load

Maintain door seals & pressure control

Heat storage to walls & ﬁxtures

Fig. 1. Efﬁciency gains outside of ﬁring method IndustrialHeating.com - October 2011 73

FEATURE | Industrial Gases/Combustion

to a process in order to sustain the desired temperature. The heat input is typically adjusted by two methods: amplitude or frequency modulation.

Furnace atmosphere stirred by high speed gases 5-12 volume entrained

Amplitude-Modulating Control

With the amplitude-modulating control method, the burners are regulated between high and low ﬁre in a continuously variable manner, as depicted in Fig. 3. Normally, a butterﬂy valve or some type of variable ﬂow control adjusts the amount of fuel and air delivered to the burner, achieving a ﬁring rate (Btu/hr or kW) that maintains the temperature of the load. This traditional method requires burners with good turndown (high vs. low ﬁring rate) to meet the varying heat input of most applications. For large furnaces, a group of burners are ﬁred and controlled together. This approach offers good control and ﬂexibility for a reasonable price when burners with sufﬁcient turndown are used. Frequency-Modulating (Pulse) Control

In a frequency-modulating control method (pulse ﬁring), the burners are switched between two states, and the cycling of the burners controls the heat input to the process. The burners are ﬁred at high ﬁre for a certain time and then cycled to either low ﬁre (high-low control) or turned off (onoff control). This cycle is repeated quite frequently, and in some designs it is six seconds. Faster cycle rates improve temperature uniformity at the cost of reduced equipment lifetime. The minimum on and off times are dependent on the response times and delays of the control devices, such as the ﬂame safeguard, valve actuation and burner ignition. The heat-input demand determines the duty cycle, which is the length of time the burner is at high ﬁre and then at low ﬁre (or off). Figure 4 shows the timing of four burners – b1 through b4 – ﬁred in a pulse sequence at three different heat-input rates. Pulse ﬁring by the on-off control method allows the use of burners with limited turndown in systems requiring a larger turndown than is possible with amplitudemodulating control. With individual control valves at each burner, it is possible to 74 October 2011 - IndustrialHeating.com

Load

5-12 volume entrained

Fig. 2. Velocity entrainment

Valve almost closed Burner at low

Valve half open Burner at mid

Valve fully open Burner at high

Fig. 3. Varying amplitude Fig. 4. Fixed cycle time with duty cycle by heat demand 25% demand

50% demand

75% demand

b1 b2 b3 b4 Sec 10 20 30 40 50 60 70 80 10 20 30 40 50 60 70 80 10 20 30 40 50 60 70 80

cycle burners independently for the greatest control ﬂexibility. However, pulse ﬁring does come at a price and an increase in system complexity. A generalized comparison of modulation methods is presented in Table 1. These ratings are subject to debate, however, because speciﬁc features and control components can be added to any system to improve deﬁciencies. Safety and Codes There are two predominant application standards that must be considered when applying pulse ﬁring to furnaces. The U.S. follows NFPA 86 and the E.U. follows EN746-2. Other countries typically adopt these or develop similar standards. The standards should be examined prior to making design, purchase and operational decisions. The condition for concern with pulse ﬁring in the on-off mode is when the furnace is below 1400°F (750°C) and

the burners are off. During the off time, a valve failure could lead to a collection of unburned fuel. When all burners in a zone turn off, the standards normally require a purge before any burners can come back on. The European standard has speciﬁc exceptions to this purge for the case of pulse-ﬁring equipment. The American standard limits the off time based on a calculation of a deﬁned gas-valve leakage rate. Additionally, NFPA requires enhanced maintenance schedules and monitoring of usage. There is another concern with the cycle timings. The minimum on time is determined by the ﬂame safeguard. It may have a start-up delay time before it energizes the ignition and gas-valve outputs. The on time must be longer than the trial for ignition time (ﬁrst safety time) plus the ﬂame failure-response time. Otherwise, each subsequent attempt to light a burner that does not produce a ﬂame will allow discreet vol-

Table 1. Comparison of pulse modes and amplitude modulation Feature

On-off pulse

High-low pulse

Amplitude

Turndown

Best

Better, requires precision settings

Good, depends on burners per zone

Emissions

Best

Better, depends on burner low ﬁre characteristics

Good

Safety

Good, must determine codes and deal with hazard when all burners are off

Better

Best, traditional systems with user familiarity

Life & maintenance

Good, wear on all components for cycle rate

Better, fewer components cycling

Best, slower rates of change

Reliability

Good, more chances of failed ignition

Better

Best

Cost

High

High

Low

umes of unburned fuel to collect in the furnace without achieving a ﬂame-safeguard alarm and a lockout condition. Eventually, these pockets of unburned fuel could collect and mix with air in the furnace and cause an explosion. Equipment Selection Considerations At the heart of a pulse-ﬁring system are the valves on the air and gas lines to each burner. The valves selected need to be designed speciﬁcally for pulse-ﬁring applications. At a frequency of 10 cycles per minute, 12 hours per day, ﬁve days per week, the valves will be subjected to 36,000 cycles per week or 1.8 million cycles per year. Standard solenoid valves will last only about six months in these conditions. These high cycle rates also apply to the control devices and their contact ratings. The lifetime of a contact depends on the number of operations, the current ﬂow and the type of load. Unfortunately, loads such as solenoid valves and ignition transformers are highly inductive and create sparks on the contacts. These sparks erode the metal in the contacts and shorten their life. Contact life can be increased by installing arc suppressors. To ensure that air is ﬂowing through the burner at the time of ignition, the air valve needs to be mounted close to the burner air inlet. It is also critical to install a ratio regulator at each burner to minimize variations of the air-gas ratio. It is important that the main gas-supply regulator is properly sized. An excessive variation of the inlet pressure into the ratio regulator can affect ignition reliability.

A number of specialized controllers dedicated for a speciﬁc pulse conﬁguration are available. These controllers offer the advantages of a compact design, requiring minimum programming by the user. Many pulse-ﬁred burner-management systems are built with a programmable logic controller (PLC). These systems can offer more functionality and customization than the specialized controllers. A single PLC with enough processing power can control the pulse sequencing and also all other furnace functions. If the PLC is a brand commonly used throughout the plant, then the maintenance personnel will be trained and familiar with it. This makes set up and troubleshooting of this equipment much easier. With either a specialized controller or a PLC, adjustments should be made to reduce the accumulated number of cycles while maintaining an acceptable stability of the process temperature. Conclusion In speciﬁc applications, signiﬁcant advantages can be achieved when applying pulse-ﬁring technology correctly. As with any technology, a solid understanding of the basic concepts helps achieve successful implementation. This article introduces some of these concepts. It should be followed in conjunction with a strong working relationship between the end user and the equipment supplier. IH For more information: Dan Curry, product development manager – controls, Eclipse, Inc., 1665 Elmwood Rd., Rockford, IL 61103; tel: 815-637-7265; e-mail: dcurry@eclipsenet. com; web: www.eclipsenet.com

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Contact Susan Heinauer at 412-306-4352 [email protected] IndustrialHeating.com - October 2011 75

Innovative industrial furnace technology Tenova Core designs, supplies and delivers to the North American market, the cutting-edge technology of LOI Italimpianti, the furnace business of Tenova. Heat treating furnace designs include batch and continuous type furnaces as well as complete heat treating lines. We specialize in installing quality furnaces to process plate, pipe, tube, bar, wire, forgings, strip and automotive parts. Product uniformity, low fuel consumption, high quality construction and advanced custom designed process and automation control systems are just a few of the beneﬁts and features of our comprehensive furnace technology. Tenova Core, advanced furnace and metal making technologies.

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FEATURE | Ceramics & Refractories/Insulation

Ceramics for Industrial Heating David Watkins – KEIR Manufacturing; Brevard, N.C. KEIR Manufacturing has entered its 28th year of helping businesses innovate and thrive through the application of leading-edge materials for industrial applications. One of our best product lines has been a wide variety of furnace components to meet the needs of a competitive and evolving interest in high-temperature processing equipment. Fig. 2. Furnace components made from 99.8%-pure alumina ceramics

A

l lumina ceramics and steatites have primarily been a used in the furnace indusu try for electrical insulators t with advantageous structural properties at elevated temperatures. Steatites are better heat insulators but do not have nearly the strength or the suitability for hightemperature applications that alumina formulations have. Traditionally, steatites had a signiﬁcant cost advantage. However, that has narrowed in recent years as the processing costs have decreased. Alumina ceramics offer a high-strength, low-cost advantage over any other technical ceramic. As a result, the markets for applications of alumina continue to expand as engineers gain further positive experience with these materials. Why are there so many ceramic formulations, and how does one choose the most appropriate for the application? Remembering where the ceramics industry originated will give you a better understanding. Potters, tile makers and brick makers all used local sources of clay to produce their products. Like other artisans, they developed many unique techniques and methods that still are prevalent today, even by sophisticated industrial ceramic producers. Because each operation had their own formulations, their products would differ in physical characteristics even if they looked similar and met the same speciﬁcations. In the early

1970s, great strides were made to develop standards by which to specify and measure the typical physical properties of common ceramic formulations used in industry. These developments established common nomenclature and common quality measurement techniques. Today, for instance, it is pretty well established what to expect from a 94% alumina body versus 96% or 98% alumina. Many manufacturers offer several different formulations for the varied applications in which they are used (Fig. 1). In the 1980s, the rapid development and application of engineered or technical ceramics came about. Solid-state electronic components had been growing in volume, and ceramics were at the very center of that development. In the late 1950s, in order to make pure silicon wafers that could be sliced and diced for circuit boards, a clean environment with abundant, clean water was needed. There were few locales that met the qualiﬁcations. Brevard, N.C., where KEIR is headquartered, is one of them. As early as 1960, improved waterpuriﬁcation techniques as well as clean-

room technologies made it possible to locate almost anywhere. Hence, Silicon Valley bloomed out of the desert in northcentral California near where much of the electronic research was taking place. By the 1980s, high-purity technical ceramics (originally developed for electronics) were ﬁnding new applications as mechanical parts, in the cores of nuclear reactors, in space, in the automotive industry and for military applications. Technical ceramics (mostly high-purity oxides) compared to common refractories or porcelains and steatites, have enormous advantages in strength, uniformity, the ability to hold much tighter dimensional tolerances, and crack or fracture toughness. They are dense and, therefore, not good thermal insulators but have outstanding mechanical properties even at very high temperatures. Also, being nonporous, they do not absorb moisture or gas. In short, these high-purity oxide ceramics make terriﬁc mechanical components for furnaces. Because of their predictable physical characteristics, technical ceramics have

Fig. 1. Typical properties of impervious high-alumina ceramics Alumina content Flexural strength

103 psi

Compressive strength

103

Tensile strength

103 psi

Modulus of elasticity

106

Working temperatures

Deg. ˚F

psi

psi

80-90%

90-96%

96-99%

99%+

35-46

40-52

40-60

40-70

140-300

250-400

300-425

300-425

10-25

15-35

15-35

20-35

31-40

40-46

45-52

48-57

2,550-2,750

2,570-3,100

2,900-3,450

2,900-3,450

Source: Alumina Ceramic Manufacturers Association

IndustrialHeating.com - October 2011 77

FEATURE | Ceramics & Refractories/Insulation

several processing advantages that make them more cost-effective to manufacture. The leading cause of scrap in a ceramic processing plant is lack of uniformity. Great pains are taken within the ceramic industry to control materials and processes to reduce scrap losses and increase ﬁnal yields. Technical ceramics are far more predictable in many areas of processing, which leads to higher yields and better tolerances. Although the raw materials are more expensive by sometimes a factor of 10, the ﬁnal price to the customer is not nearly as high because of higher yields. Why are older ceramic compositions still made today? There are several good reasons why old formulas for ceramic compositions are still commonly produced and marketed today. One is that they perform reasonably well in many applications and are somewhat less expensive to produce. Another less-understood reason is that ceramic processing is very specialized and often capital intensive. Typically, expensive tools are designed and produced for each part. Processing equipment, as well as furnaces and kilns, are specially produced for speciﬁc cycles and temperatures. Since each formulation has a different shrinkage when ﬁred and ﬁre on different cycle times and temperatures, it is not possible to use the same tooling or often the same process to make parts from a newer or different ceramic formulation. The cost of making a wholesale change to a more modern formulation is prohibitive. The cost in-

Your Thermal Process Deserves Special Treatment.

vestment in the tooling alone could well keep companies bound to outdated but still reasonably good formulas. Newer Production Methods Lead to Advances in Quality, Delivery and Cost Like most industries, ceramic producers have experienced revolutionary change over the past 25 years with the computerization of machine tools, statistical process controls and lean manufacturing techniques. This has eliminated much of the waste while improving quality and delivery performance. In the mid-1980s, several ceramic companies made deliberate moves away from traditional forming methods that rely on permanent steel or carbide tools to make speciﬁc parts. They moved toward several ﬂexible methods of manufacturing that employ computer-controlled machine tools and far-fewer dedicated tools. This revolutionized their ability to quickly deliver parts designed and made for speciﬁc applications that would later be modiﬁed. This also made short production runs affordable, leading to greater innovation by the purchaser who could, for the ﬁrst time, cost-effectively experiment with different designs. Design engineers today have many material options open to them that were not available even a generation ago. High-purity alumina ceramics have become an intelligent choice in many situations where high strength, toughness, nonporosity and reasonable cost are desirable. This is what makes high-alumina ceramics a real value today. IH For more information: Contact Gordon Murray, sales & marketing specialist, KEIR Manufacturing Inc., 133 McLean Rd., Brevard, NC 28712; tel: 828-885-8444; fax: 828-884-7494; U.S. toll free: 800-992-2402; e-mail: [email protected]; web: www.keirmfg.com

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HIGH-TEMPERATURE TECHNOLOGY

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matched to your own particular requirements.

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We’ve been in the induction heating business for more than 50 years, developing systems to harden

These are just some of the things automakers and their suppliers insist upon. Which is why, when it comes to hardening auto components, many of them turn to EFD Induction.

valves, camshafts, crankshafts, balancing shafts, connection rods, starter rings and gudgeon pins. To learn more about EFD Induction — and how we can help improve your business — just contact

We design, make and maintain high-uptime induction hardening systems. In fact, we’re

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the world’s no. 1 induction hardening company — with plants and labs in the US, Europe and Asia. So wherever you are, there’s a good chance we’re in the neighbourhood.

Learn more about our products and services at the ASM Heat Treat Show 2011—visit us at Booth 2034.

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Putting the smarter heat to smarter use

New ASM HTS Board Starts Term The ASM Heat Treating Society is pleased to introduce its new Board, which started its term effective Sept. 1. Board members are: Mr. Thomas E. Clements, President Engineering Mgr. – Metals & Thermal Processes Caterpillar Inc.; Peoria, Ill.

Mr. Christopher M. Klaren, member Manager Heat Treat Operations Deere & Company; Waterloo, Iowa

Mr. Roger Alan Jones, Vice President Corporate President Solar Atmospheres Inc.; Souderton, Pa.

Ms. Meri Lazar, member Consultant; Philadelphia, Pa.

Mr. Terrence D. Brown, Past President Director – Commercial Bluewater Thermal Services; Greenville, S.C. Mr. Robert Hill, Board Liaison President; Solar Atmospheres Inc.; Hermitage, Pa. Dr. Subi Dinda, FASM, member Professor Consultant; West Bloomﬁeld, Mich.

Mr. Ralph P. Poor, member Director of Standard Products Surface Combustion Inc.; Maumee, Ohio Mr. Michael J. Schneider, FASM, member General Manager - Prod. Materials & Metallurgy The Timken Co.; North Canton, Ohio Mr. Dale J. Weires, member Technical Fellow Boeing Philadelphia; Philadelphia, Pa.

Dr. B. Lynn Ferguson, FASM, member President Deformation Control Technology Inc.; Cleveland, Ohio

Mr. Brett N. Carlson, Student Board Member South Dakota School of Mines & Tech; Rapid City, S.D.

Mr. Bill Flower, member President; Specialty Heat Treating; Grand Rapids, Mich.

Mr. Eric Young, Young Professional Board Member Plant Metallurgist; The Timken Co.; Union, S.C.

Mr. John R. Keough, P.E., FASM, member Chief Executive Ofﬁcer Applied Process Inc.; Livonia, Mich.

Mr. Randall S. Barnes, Executive Director HTS Senior Manager – Society Activities/Afﬁliates ASM International; Materials Park, Ohio

HTS Members Named 2011 ASM Fellows The honor of Fellow of the Society was established to provide recognition to members for distinguished contributions in the ﬁeld of materials science and engineering and to develop a broadly based forum for technical and professional leaders to serve as advisors to the Society. HTS members named 2011 ASM Fellows are: Mr. William J. Bernard Jr. – President & CEO Surface Combustion Inc.; Maumee, Ohio For innovation and advances in furnace technologies and for his leadership in support of education for the heat-treating industry. Prof. Donato Firrao Dean of Engineering 1; Professor of Technology of Metallic Materials Politecnico di Torino, Torino, Italy For his research on mechanical metallurgy and surface engineering with outstanding contributions in modeling steel microstructure-fracture mechanics as well as surface-layer characteristics in nitrided steels.

W. Bernard

D. Firrao

A. Swiglo

Mr. A. Alan Swiglo Associate Director Manufacturing Processes Research Northern Illinois University; Naperville, Ill. For seminal and proprietary advancements across four decades in gear metallurgy and heat treatment and the cost-effective application of surface-enhancement techniques. IndustrialHeating.com - October 2011 81

Desk Edition, featuring more than 2,800 pages of tables, graphs, property data, photos and illustrations.

FREE copy of Practical Heat Treating when you join ASM and the ASM Heat Treating Society by Nov. 1. Need access to the world’s most trusted heat-treating information? Want to network with the top names in heat treating around the world? The ASM Heat Treating Society can help! For a limited time, the ASM Heat Treating Society is offering a special opportunity to those who join by Nov. 1. In addition to your beneﬁts as a member, you will receive a copy of Practical Heat Treating: Second Edition (Jon Dossett and Howard Boyer, editors). This book describes heat-treating technology in clear, concise and non-theoretical language. It is an excellent introduction and guide for design and manufacturing engineers, technicians, students and others who need to understand why heat treatment is speciﬁed and how different processes are used to obtain desired properties. As a member of ASM and HTS, you will gain access to: A full year of Advanced Materials & Processes magazine. Get complete coverage of global news and articles on new materials and processes. Unlimited ONLINE access to our two most popular ASM Handbooks. Find the answers you need in our Metals Handbook Desk Edition and Engineered Materials Handbook

Access to the 10 journals online. As a beneﬁt of membership, ASM and HTS members receive full-text online access to two of the most respected journals in the materials ﬁeld, Metallurgical and Materials Transactions A&B, as well as 10 other highly respected Springer-owned journals. Other ASM journals are available by subscription at a special reduced price for members. Local contacts and networking opportunities through your local ASM chapter. There’s no additional charge for belonging to your local chapter – it’s included as part of your regular annual dues. Exclusive members-only discounts on a wide variety of products, services and events. Includes the world-renowned ASM Handbook series, ASM conferences and expositions, and ASM continuing-education programs. Access to Heat Treater’s Guides Online. ASM Heat Treater’s Guides Online contains recommended practices for heat treating a broad array of ferrous and nonferrous alloys. Access to this subset of ASM materials information has been developed as an exclusive beneﬁt of membership in the ASM Heat Treating Society. Discounts on group life insurance, auto insurance, credit card rates, magazine subscriptions, car rentals and more. ASM works with select providers to arrange special discounts for ASM members. This offer is only available until Nov. 1. To join today, contact our Member Service Center at 440-338-5151, ext. 0, and ask for the “PHT Special.”

Student Papers Sought for ASM HTS/Bodycote Best Paper in Heat Treating Contest The ASM Heat Treating Society established the Best Paper in Heat Treating Award in 1997 to recognize a paper that represents advancement in heat-treating technology, promotes heat treating in a substantial way or represents a clear advancement in managing the business of heat treating. The award is endowed by Bodycote Thermal Process-North America. The HTS/Bodycote Student Paper Contest is open to all students, in full-time or part-time education, at universities (or their equivalent) or colleges. It also is open to those students who have graduated within the past three years and whose paper describes work completed while an undergraduate or 82 October 2011 - IndustrialHeating.com

post-graduate student. The winner of the HTS/Bodycote Best Paper in Heat Treating Contest will receive a plaque and a check for $2,500. To view rules for eligibility and paper submission visit the Heat Treating Society Community Web site at http://hts. asminternational.org/portal/site/hts/HTS_Awards. Paper submission deadline is Dec. 15, 2011. Submissions should be sent to: Sarina Pastoric, ASM Heat Treating Society, 9639 Kinsman Road, Materials Park, OH 44073; tel: 440338-5151, ext. 5513; fax: 440-338-6614; e-mail: sarina. [email protected].

Visit www.afc-holcroft.com or call 248-624-8191 for more information. See Us at Booth #2205

CALL TO ACTION: ASM Heat Treating Handbook Being Revised Editorial plans are being developed to expand and update the ASM Handbook, Volume 4, Heat Treating, 1991. Multiple volumes being considered are: • Vol. 4a Heat Treating Fundamentals and Processes • Vol. 4b Induction Heating and Heat Treatment • Vol. 4c Chemical and Thermochemical Surface Treatment • Vol. 4d Heat Treating Equipment and Process Control • Vol. 4e Quenching and Quenching Technologies • Vol. 4f Quality Control & Performance of Heat Treated Parts Volume 4a Editors: Jon Dossett and George Totten Editorial Committee (with other invitations in progress): Hans Zoch John Keough Torsten Ericsson Ron Wallis Olaf Kessler Kiyoshi Funatani Dan McCurdy Peter Hodgson Michael Schneider John Hubbard Volume 4b Editors: Valery Rudnev and George Totten Editorial Committee: Dick Haimbaugh George Pfaffmann Bernard Nacke Stan Zinn Anyone interested in contributing as an organizer, author or reviewer should contact Steve Lampman at ASM at 440338-5151, ext. 5560, or e-mail at steven.lampman@ asminternational.org.

HTS EVENT 26th ASM Heat Treating Society Conference and Exposition – Oct. 31-Nov. 2, 2011 Duke Energy Convention Center • Cincinnati, Ohio ASM Heat Treating Society and American Gear Manufactures Association (AGMA) are co-locating at the 2011 HTS Conference and Exposition. The conference will feature more than 90 presentations. To view the technical program in detail, visit www. asminternational.org/content/events/heattreat/technical.jsp.

Visit the Heat Treat Show Exposition Along with a wide range of exhibitors representing equipment manufacturers and suppliers, a new Heat Treating Solutions Center will offer exhibitor presentations focusing on realworld problem solving on speciﬁc manufacturing techniques, products and technologies. Presentations are scheduled Nov. 1-2 in the Heat Treating Solutions Center – a designated area located on the show ﬂoor. To register for the expo, visit www. asminternational.org/content/events/heattreat/index.jsp. 84 October 2011 - IndustrialHeating.com

Industry Presentations – Solutions Center Date/Time

Topic

Company

Tuesday, Nov. 1 10:30 a.m.

Gear Honing a High Economic Process

Gleason Corp.

11:00 a.m.

CHTE – The Collaborative Research Home for the Heat Treat Industry

Center for Heat Treat Excellence

11:30 a.m.

Shop Floor CMM and Gear Inspection

Koepfer America LLC & Zeiss IMT

1:00 p.m.

Optimized Hob Designs to Improve Hob Life, Part Quality and Cycle Time

Star SU LLC

1:30 p.m.

Keynote Presentation – To Be Announced To Be Announced

2:30 p.m.

Considerations for Optimum Methods of Gear Finishing

KAPP Technologies

3:00 p.m.

Gear Flame-Hardening: Case Studies

Flame Treating Systems Inc.

3:30 p.m.

Contour Hardening of Gear-Like Components

Inductoheat Inc.

4:00 p.m.

To Be Determined

Bourn & Koch

4:30 p.m.

Enabling Efﬁcient and Cost-Effective Heat Treatment Operations – A Discussion Invensys About the Latest Developments in Eurotherm Control, Data, and Energy Instruments

Wednesday, Nov. 2 10:30 a.m.

New Alternative for Integral Quenching Applications

Seco/Warwick Corp.

11:00 a.m.

Innovative Indexable Insert Solution for Hobbing of Medium Sized Gears

Sandvik Coromant

11:30 a.m.

Electric Power Savings in Vacuum Furnace Operations

Solar Manufacturing

1:00 p.m.

Precision Atmospheres May Reduce Heat Treating Costs

Praxair Inc.

2:30 p.m.

Custom Application of Shot Peening to Gearing

Metal Improvement Co.

3:00 p.m.

On-Site Hydrogen Eases Atmosphere Challenges

Proton Energy Systems

3:30 p.m.

The Integration of Induction Heating and Press Quench in the Manufacturing Cell Using Robotic Handling Techniques

EDMS Inc., division of SAET Group

4:00 p.m.

Multi-Processing: Turning and Hobbing

Koepfer America LLC & EMAG LLC

4:30 p.m.

Noncontact Temperature Measurement in Heat Treating Applications

LumaSense Technology

Thursday, Nov. 3 10:30 a.m.

Challenges in Nitriding of Gear

Nitrex Inc.

11:00 a.m.

Spline Rolling - a Design Development

Roto-Flo & U.S. Gear Tools

11:30 a.m.

What’s Better for Me – Face Hobbing and Lapping or Face Milling and Grinding?

Gleason Corp.

1:00 p.m.

Tooth Contact Analysis in an Integrated Software Package

KISSsoft AG

1:30 p.m.

China Gear Industry and Gear Manufacturing

LI Gear Inc.

2:00 p.m.

Honing and Cup Wheel Superﬁnishing – a Cost Effective and Higher Quality Alternative to ID and Face Grinding

Nagel Precision Inc.

See Us at Booth #1910

Tweet about the show using the hashtag #HTS2011. See p. 16 for details.

ASM Heat Treating Society 26th Conference and Exposition Oct. 31-Nov. 2 Duke Energy Convention Center Cincinnati, Ohio Exhibition Hours: Tuesday, Nov. 1 10:00 a.m.-5:00 p.m. 5:00 p.m.-6:00 p.m. Networking Reception, sponsored by Industrial Heating/FORGE

Wednesday, Nov. 2 10:00 a.m.-5:00 p.m.

The ASM Heat Treating Society and the American Gear Manufacturers Association once again are partnering to create an exciting mix of education, technology, networking and exposition opportunities – at Heat Treat 2011 and Gear Expo.

Exhibitors & Booth Descriptions (booth numbers as of Sept. 2 from ASM International)

IndustrialHeating.com - October 2011 87

BOOTH DESCRIPTIONS Abbott Furnace Company 1715 Abbott Furnace Company manufactures belt, pusher and batch furnaces for temperatures up to 2912°F designed for your speciﬁc time, temperature and atmosphere needs. Abbott also offers a complete line of spare parts, component fabrication, ﬁeld service and an accredited calibration lab. www.abbottfurnace.com ACROSS USA, Inc. 2106 See our ad on page 46 Manufacturer of CFC, Carbon/Carbon Composite, advanced engineering material made from carbon-ﬁber reinforced carbon. Compared to other materials such as ceramics, metal and plastic, it is light, strong and highly elastic, and it can withstand temperatures over 2000°C without any loss in performance. www.acrosscc.com Advanced Nitriding Solutions

1830

AFC-Holcroft 2205 See our ad on page 83 AFC-Holcroft designs and builds custom and standard heat-treating equipment, including universal batch systems, mesh/cast link belt,

continuous pusher, roller/rotary hearth, walking beam, car bottom, austempering systems, atmosphere generators, aluminum processing equipment and other systems. Also, spare parts, retroﬁts, rebuilds and upgrades. www.afc-holcroft.com

Aichelin Heat Treatment Systems 1819 In the last 30 years, the Aichelin group has built and put into operation more than 1,000 chamber furnaces. These numbers prove the permanent high-quality, reliability and economy of our units. www.aichelinusa.com

AFFRI, Inc. 1928 AFFRI’s hardness testing equipment can reduce testing costs up to 70% compared to traditional methods, increase product quality (100% inspection testing on production ﬂoor), reduce testing times by 90% (just 60 seconds of analysis time) and increase energy savings (no need for sample preparation equipment). There is also no need to separate material types. www.affri.com

Air Liquide Industrial U.S. LP

Agilent Technologies 2138 See our ad on page 29 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, knowledgeable customer/ technical care. www.agilent.com/chem/vacuum

Air Products and Chemicals, Inc. 1823 See our ads on pages 42 & 113 Air Products, a worldwide leading industrial gas supplier, brings signiﬁcant experience in gas supply, technical know-how, applications development and safety to help you increase production and optimize gas usage. We offer high-purity gases, gas handling equipment and technology, and global supply capability to help you succeed. www.airproducts.com/mp Airﬂow Science Corporation

2022

Ajax TOCCO Magnethermic Corp. 1901 See our ads on pages 47 & 112 Ajax TOCCO Magnethermic Corp. is a world leader in the induction heating, heat-treating and melting industries. Our proven applications

Vacuum Angle and Inline Valves for all vacuum ranges and applications

Better valves for less money

Reliable simple design Low cost Short lead time www.vatvalve.com See Us at Booth #1942

88 October 2011 - IndustrialHeating.com

2016

VISIT Revolutionary Products for the BOOTH Global Metals Industry. #2211 High Performance Formulated Fluids and Lubricants ®

Tenaxol represents Chemtool Incorporated, the world’s foremost manufacturer of metalworking lubricants and specialty greases. Breakthrough preventatives, cleaners and other solutions provide a complete and effective single source provider.

Non-Tacky Polymer Quenchant TENAXOL QUENCH ULTRA 1500 • TENAXOL QUENCH ULTRA 2000 • TENAXOL QUENCH ULTRA 2500 The newest entries into the Tenaxol® family line of products. These are aqueous solutions of water soluble organic polymer that incorporates a non-nitrite corrosion inhibitor, defoamer and biocide. This combination results in a non-tacky homogenous solution.

High Temperature Performance Grease TENAXOL THERMAL PLUS is the most complete multipurpose grease on the market today! It provides lubricity, mechanical and thermal stability that surpasses conventional greases.

Quench Oils TENAXOL QUENCH OIL 03A • TENAXOL QUENCH OIL 1128 • TENAXOL QUENCH OIL 521 Designed for quenching operations which require a high speed quenching oil in order to develop maximum hardness and minimal distortion. Minimal evaporation loss. These low viscosity oils are formulated with paraffinic base stocks fortified with non-shearing accelerating additives that are designed to meet the toughest industrial requirements.

High Performance Machining Fluids TENAXOCOOL 88 • TENAXOCOOL HO • TENAXOCOOL HP Completely new technology machining and grinding coolants, like no other metalworking fluids on the market today! Manufactured using a proprietary process that gives these products many unique characteristics that will promote very high productivity and minimal downtime for the end user.

CLEANERS TO REMOVE QUENCH OILS CORROSION INHIBITORS AND RUST PREVENTATIVES COOLING WATER TREATMENT AND HEAT TRANSFER FLUIDS See Us at Booth #2211

CALL 414.476.1400 FOR A FREE SAMPLE. WE GUARANTEE PERFORMANCE!

BOOTH DESCRIPTIONS include brazing, annealing, hardening, tempering, seam annealing, forging and melting. Through a commitment to research and development, Ajax TOCCO is dedicated to bringing new ideas to the world’s basic metal industries. www.ajaxtocco.com Alcon/Castalloy, Inc. 2144 Alcon Industries is your single-source for heatand corrosion-resistant alloy castings and fabrications, including furnace trays, radiant tubes, custom ﬁxturing, rod frame baskets, furnace rolls and fans. Alcon Industries also has a scrap recycling program. Alcon Industries is a licensed producer of nickel aluminide castings. www.alconalloys.com Ameco USA 1843 Alloy fabrication specialists that offer custommanufactured products used in extreme heat and high-corrosion applications. Products include radiant tubes, retorts, mufﬂes, annealing covers, pickling hooks, salt pots, racks and trays. www.ameco-usa.com Ameritherm – An Ambrell Company 1828 Ambrell is a leading provider of induction

heating solutions. Solutions are available for high-frequency and low-frequency applications, and they can be tested for no charge in Ambrell’s Applications Lab. Beneﬁts of induction heating include repeatability, speed, precision and energy savings. www.ameritherm.com

equipment is known industry-wide for steadfast performance, straightforward design, and quality workmanship. Our standard and custom products include IQ furnace lines as well as tip-up, pusher, pit, box and car-bottom furnaces. www.BeaverMatic.com J.L. Becker Co. 1824 J.L. Becker Co. will feature information on industrial heat-treating equipment, atmosphere generators, replacement component parts and industrial parts washers. Fully automated computer management systems for batch furnace lines, mesh-belt furnaces and atmosphere generators will be highlighted. www.jlbecker.com

Atmosphere Engineering Company 1802 Atmosphere Engineering is a ﬂow measurement and control company that specializes in gasdelivery systems for the heat-treatment industry. www.atmoseng.com Avion Manufacturing 2330 Avion Manufacturing is a distributor of recuperative burner ECOMAX, which offers high efﬁciency through its optimized recuperator shape. www.avionmfg.com

Bluewater Thermal Solutions 1924 Bluewater Thermal owns/operates 17 processing facilities in U.S./Canada. Our facilities provide engineered solutions to manufacturers requiring components/materials be processed for improved strength, wear or corrosion properties. Bluewater serves automotive, aerospace, energy and heavy-equipment needs. www.bluewaterthermal.com

BeaverMatic 2001 See our ad on page 16 BeaverMatic manufactures proven-performance atmosphere furnace systems. This statement is as true today as when Jack Beavers founded the company more than 50 years ago. Our heat-treat

Portable Metal Hardness Testing

0ORTABLEs0RECISEs0ROFESSIONAL Proceq‘s Equotip family offers hardness testing solutions for an extensive range of applications. Most of the devices operate according to the world famous rebound principle to permit Customer-Oriented Professional Parts Inspection! s s s s s s

globally recognized testing technique (e.g. DIN 50156 & ASTM A956) highly accurate, plus measuring statistics integrated for testing beyond direct and prompt conversion to all common hardness scales complemented by the powerful low-load tester Equostat standardization requirements high degree of reliance

For more information visit www.proceq-usa.com or contact: Proceq USA, Inc. 117 Corporation Drive Aliquippa, PA 15001 Tel: +1-724-512-0330 Fax: +1-724-512-0331 [email protected] ... more than 50 years of know-how you can measure!

90 October 2011 - IndustrialHeating.com

BOOTH DESCRIPTIONS Bruker

2418

Buehler 2322 For 75 years, Buehler’s consumables and equipment have provided unmatched consistency, quality, reliability and ease of use for microstructural analysis in metallurgical laboratories, quality-control departments and failure-analysis facilities around the world. www.buehler.com C.I. Hayes

2244

Can-Eng Furnaces 1723 See our ad on page 33 Can-Eng Furnaces has the depth of experience to custom engineer heat-treating equipment for the most demanding applications. Product lines include: continuous mesh-belt furnace systems, plate heat-treating systems, tube and bar heattreating systems and a basketless heat-treating system (BHTS) for treatment of aluminum automotive components. Can-Eng also offers an Aftermarket Support Team that delivers system upgrades, technical support and spare parts. www.can-eng.com Caskol, LLC

2233

Castalloy, Inc. 2023 Castalloy is a leading producer of high-alloy heatresistant castings. Manufacturer of cast products such as baskets, belts, chains, ﬁxture grids, rails, trays, radiant tube and screw assemblies to meet a broad range of applications throughout the thermal-processing industry. State-of-theart engineering design, nondestructive testing, machining and fabrication are also offered. www.castalloycorp.com Celem 2042 Celem develops, manufactures and sells highand medium-frequency power capacitors for induction heating, plasma processing, solar inverters, wireless power transfer and other highpower applications. www.celem.com Ceramic Solutions, Inc. 2324 See our ad on page 51 Ceramic Solutions is an industry-leading distributor of technical ceramic products. A large inventory available for all standard size furnace, feed through, support tubes, both open and closed one end tubes, plates, single bore and multi-bore insulators, rollers and Hexoloy protection tubes. We offer quick turnaround,

old-fashioned customer service at competitive pricing. www.ceramicsolutionsconroe.com CES Processing Solutions 1916 CES is your source for custom cryogenic metaltreating systems. The working temperature range of CES equipment is between -300°F to 1120°F. In addition, a wide range of system management and temperature controls units are available, from conventional to PLC. www.cesgroup.com Cleveland Electric Labs

2134

CMI Industry Americas Inc. 2027 Industrial furnace manufacturer offering EPC contracts, focused on complete shop erection. Our company is part of an international group with over 3,500 employees. Most advanced roller-hearth technology for bright annealing, normalizing and stress-relief anneal. Featuring advanced alloy construction, Jet Cooling, ultrahigh-efﬁciency burner systems and the latest in refractory systems. www.cmigroupe.com Conrad Kacsik Instrument Systems, Inc. 1930

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$SFBUJOH4PMVUJPOT GPS'VUVSF)FBU5SFBU5FDIOPMPHJFT )$4UBSDLTWBMVFBEEFEQSPEVDUTPMVUJPOTGSPN.P 8 5B BOEBMMPZT-BEPQFE.PMZCEFOVNBOE5;. BSFJEFBMGPSIFBUUSFBUJOH TJOUFSJOH BOOFBMJOH CSB[JOH BOEIJHIUFNQFSBUVSFGVSOBDFBQQMJDBUJPOTTVDI BTIFBUUSFBUJOHMBSHFBFSPTQBDFQBSUTJOWBDVVNGVSOBDFT CSB[JOHMBSHFWPMVNFTPGQBSUTJODPOUSPMMFE BUNPTQIFSFGVSOBDFT BOEBOOFBMJOHNFEJDBMBOEBFSPTQBDFQSPEVDUTUPDSJUJDBMTQFDJmDBUJPOT 'VSOBDF1BSUT )FBU4IJFMET 4JOUFSJOH#PBUT

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$POUBDUPVSLOPXMFEHFBCMFTUBõBU PSJOGP!IDTUBSDLDPN +PJO)$4UBSDLBU#PPUI "4.)FBU5SFBU&YQP See Us at Booth #2037 IndustrialHeating.com - October 2011 91

BOOTH DESCRIPTIONS Contour Hardening Inc.

1842

CoorsTek Technical Ceramics

1923

heat-treat applications. www.datapaq.com Deformation Control Technology, Inc. 2217

Cornerstone Systems Inc. 1942 See our ad on page 88 Visual Shop is the top-selling plant management software program for the commercial heattreating industry. It includes quotations, orders, certiﬁcations, expediting, scheduling, tracking, shipping, invoicing, A/R, sales analysis, web-based customer portal and more. Visit our website to arrange a demo. www.csivisualshop.com Custom Electric Manufacturing 1816 See our ad on page 8 The heat-treating industry has relied on the quality and performance of Custom Electric heating elements for 40 years. Original equipment and aftermarket elements are available for every type of furnace. We also offer a complete line of immersion heaters for die casting operations. www.custom-electric.com. Datapaq, Inc. 2124 Datapaq Furnace Tracker systems provide reliable and accurate in-process temperature proﬁling for

Delkic International Technical Ceramics

the cooling tower. Recover plant ﬂoor space, save on installation cost and enjoy high reliability cooling design and fabrication. Available with chillers, plate heat exchangers and accessory equipment. www.drycoolers.com

2223

DMP CryoSystems 2100 See our ad on page 106 DMP CryoSystems continues to offer customers maximum process ﬂexibility with its complete line of combination furnace/freezers and loaders. Full in-house design and ﬂexible manufacturing capabilities permit custom integration with existing production lines. Stop by booth 523 for a demonstration of our new Level 2 HMI control package, which offers recipe management, data logging and complete system integration. www.cryosystems.com Dry Coolers Inc. 1811 See our ad on page 17 TowerShed™ outdoor mechanical room - new concept in evaporative cooling tower packages engineered for space savings and noise reduction. All pumps, controls and ﬁltration are factory installed in a heated room underneath

ECM USA Inc. 1910 See our ad on page 86 ECM is prepared to provide the industry’s leading low-pressure vacuum carburizing equipment to the exacting heat-treating needs of the industry. Our new concepts and designs will improve throughput and outperform others in the industry. Our long list of customers/partners is proof of the leading position ECM has today. www.ecm-usa.com Edwards 2130 Edwards offers innovative products, ﬁrst-class service, a single source of technological expertise and customized systems for the semiconductor and vacuum technology industries. Our products include vacuum pumps, instrumentation, thin ﬁlm deposition systems and components for the scientiﬁc instrument, R&D, lens coating, industrial and chemical processing industries. www.edwardsvacuum.com

Furnace Muffles

• For all types and styles of continuous furnaces • All alloys, including: 309, 310, RA330, RA 253 MA, 600, 601, RA 602 CA • Fabricated to customer Specifications • Highest quality at a reasonable cost • High tech support available

Also specializing in: Radiant Heater Tubes, cast & wrought Retorts Furnace Rolls Furnace Fans Serpentine Trays Recuperators Corrugated Boxes All Alloy Fabrications Specialty Baskets

34250 Mills Road, Avon, Ohio 44011 • Phone: (440) 327-5000 F: (440) 327-5599 • Web: www.Qual-Fab.net • Email: [email protected] Sales Representatives Wanted See Us at Booth #2136

92 October 2011 - IndustrialHeating.com

Made

in

America.

World-Class Design.

Now, after more than 100 years of innovative vacuum pump technology, the KINNEY® brand from Tuthill Vacuum & Blower Systems introduces the newest dry screw vacuum pump made in the USA. Available for industrial or process applications, the new KDS425 provides the same remarkable durability and ease of service that are hallmarks of every KINNEY vacuum pump ever made. The KDS425 dry screw vacuum pump features include:

• Vertical cantilevered design – no seals or bearings on the suction side

• No external seals – ends leaky driveshaft mess

• Easy to clean and service – no special tools or moving the machine

• Industry leading performance near atmosphere

• Top down vertical flow aids in moving

particulates and condensation away from the rotor chamber

• No proprietary special electric motor – runs

Product shown is with housing lifted.

with a standard over the shelf electric motor

Call or log on today for complete information on the newest, highest quality dry screw vacuum pump made in the USA. 1-800-825-6937

vacuum.tuthill.com

Vacuum & Blower Systems Designed & Manufactured in the USA

BOOTH DESCRIPTIONS EFD Induction 2034 See our ad on page 80 EFC Induction has installed thousands of heating solutions for a wide range of industrial applications - bringing the beneﬁts of induction technology to leading manufacturing and service companies. www.efdinduction-usa.com Elmet Technologies 1927 See our ad on page 52 Elmet Technologies is a global leader in providing molybdenum and tungsten products and assemblies to the heat-treating industry. Elmet’s vertically integrated process begins with the metal powder to ensure quality, performance and traceability. www.elmettechnologies.com

Fluxtrol, Inc.

1701

Furnace Control Corp., a member of UPC

1623

Furnace Parts LLC 2218 See our ads on pages 44 & 108 Furnace Parts LLC is an industry leader in the manufacture of specialty industrial thermocouples and temperature sensors. Our expertise includes a full line of assemblies, including base and noble metal, mineralinsulated, metal-sheathed (MgO), RTD, bare and insulated wire. www.furnacepartsllc.com Garden City Fan/Flaktwoods

Elotherm Induction Technology 2212 See our ad on page 99 Elotherm is a vertically integrated OEM offering a full spectrum of induction heating, heat-treating and welding systems. The company’s equipment and systems are used in the production of metals and metal products. www.sms-elotherm.com Flame Treating Systems, Inc.

2101

2344

GeoCorp, Inc. 2005 See our ads on pages 37, 39, 41 & 43 GeoCorp has anticipated the future demands of the heat treating industry by introducing its new GeoSpec™ Technology, which provides half limits of error material for thermocouple wire and thermocouple assemblies. This material will meet requirements for limits of error of ±2°F or ±0.2%, whichever is greater. www.geocorpinc.com

GH Induction Atmospheres

2102

G-M Enterprises 1711 See our ads on pages 23 & 105 G-M presents our unique vacuum-furnace technologies designed for low maintenance and high performance. Patented 2-point element support, high-velocity venturi gas-cooling nozzles, true convection heating and cooling with full gas exchange in/out of the hot zone, power feed-thrus and 12-bar furnace with advanced computerized control systems. www.gmenterprises.com Graphite Metallizing Corp. 1925 See our ad on page 111 GRAPHALLOY’s self-lubricating properties and low coefﬁcient of friction makes it suitable wherever high temperatures and extreme mechanical or chemical stresses exist. GRAPHALLOY® works up to over 1000°F, and it is dimensionally stable even when submerged, under load or experiencing wide temperature swings. Applications include: heat-treat ovens, furnaces, conveyors, dampers, kiln carts and mechanical linkages. www.graphalloy.com

GET CONNECTED www.industrialheating.com/connect

Now it's easier than ever to stay connected to the best source of news and technology in the industry! See Us at Booth #2326

94 October 2011 - IndustrialHeating.com

BOOTH DESCRIPTIONS H.C. Starck Inc. 2037 See our ad on page 91 Molybdenum Lanthanum doped alloy from H.C. Starck has extraordinary resistance to recrystallization and high-temperature creep deformation. ODS Mo-La extends the service for hot-zone shielding and heating elements in furnace applications by providing dimensional stability and resistance to creep at the highest temperatures above those for pure molybdenum and TZM. www.hcstarck.com H.E.F. USA 1829 HEF USA Surface Technologies is part of the global HEF Group, experts in the science of tribology (wear & friction), offering products and services including PVD coatings, liquid nitrocarburizing and patented bushing designs. HEF has facilities in 16 countries and applications in over 40. www.hefusa.net Hauck Manufacturing Company 1822 See our ad on page 54 Pulse ﬁring is a ﬁring method for multiple burner combustion systems that controls thermal input and results in: superior temperature uniformity, fuel savings, lower emissions, improved

productivity and unmatched versatility when compared to traditional combustion system control methods. www.hauckburner.com Heat Treating Services Unlimited, Inc. 1939-1941 Heat Treating Services Unlimited is a full-service company dedicated to the thermal-processing industry. We are ISO/IEC 17025:2005 accredited to perform calibrations on site or in our in-house metallurgical lab. Our services include complete pyrometry programs, equipment repairs, rebuilds and relocations, safety and equipment training, and various consulting (CQI-9 and AMS 2750D). www.htsu.com Heatbath/Park Metallurgical Corp. 1810 See our ad on page 19 Heatbath/Park Metallurgical will be showcasing NEW Enviroquench®, an environmentally friendly, water-based polymer quenchant. Enviroquench provides quenching response similar to fast quench oil but is far superior in both safety and environmental characteristics. Enviroquench is nonﬂammable, low foaming and economical with desirable cooling characteristics. www.heatbath.com

See Us at Booth #2417

96 October 2011 - IndustrialHeating.com

HEESS GmbH & Co. KG 2018 HEESS specializes in machinery for ﬁxture hardening with fully automatic or manual equipment. HEESS offers individual solutions for hardening, washing, storage, transport and handling devices, especially for transmission parts. www.heess.com Hind High Vacuum Company Ltd. 2039 HHV designs and manufactures vacuum furnaces for heat treatment, brazing and other metallurgical applications. We integrate quality and technology into our vacuum furnaces at a reasonable price. www.hhv.in Houghton International

1838

HydroThrift Corporation 1911 Manufacturers of closed-loop engineered industrial cooling and heating systems including closed-loop evaporative type, closed-loop air to liquid type, closed-loop liquid to liquid type, refrigerated chiller systems, steam to liquid heating systems, electric heating systems and heat recovery systems. www.hydrothrift.com

BOOTH DESCRIPTIONS Induction Systems, Inc.

2200

Induction Tooling, Inc. 2414 See our ad on page 106 We offer the following services: design, build and repair of selective hardening quick change inductors; reverse design, document, build and repair inductor tooling commonly called inductor coils; controlled documentation; OEM consulting, referral and tooling integration; materialhandling equipment design and manufacture; and laboratory prototype testing. www.inductiontooling.com Inductotherm Group 1611 See our ad on Back Cover We are Inductotherm Group: over 40 companies working around the world, and around the clock, to serve the metals and materials industry. Inductoheat: induction heating, heat-treating and forging equipment; Radyne: inductioncontrolled atmosphere and vacuum brazing systems; Thermatool: technologies for tube and pipe production; PV/T: vacuum heat-treating and vacuum brazing furnaces. www.InductothermGroup.com

Industrial Heating 2326 See our ad on page 125 Industrial Heating Is the largest and most comprehensive integrated media resource focusing on high-temperature thermal-processing technology and applications. www.industrialheating.com Industrial Heating Equipment Association 2216 The Industrial Heating Equipment Association (IHEA) is a voluntary national trade association representing the major segments of the industrial heat-processing-equipment industry. Established in 1929 to meet the need for effective group action in promoting the interests of industrial furnace manufacturers, the organization has expanded and currently includes designers and manufacturers of all types of industrial heatprocessing equipment used for the melting, reﬁning and heat processing of ferrous and nonferrous metals and certain nonmetallic materials and heat treatment of products made from them. www.ihea.org

INEX Incorporated 2206 See our ad on page 110 Composite radiant tubes (silicon/silicon carbide) suitable for a wide variety of heat-treat furnaces will be displayed including straight-through open-ended, single-ended recuperator tube sets, and U-tubes of various sizes. Reaction bonded silicon carbide burner and recuperator components. Special ﬁnned tubes, which reduce energy consumption, are featured. www.inexinc.net Invensys Eurotherm 2011 See our ad on page 55 Invensys Eurotherm’s nanodac™ recorder/controller offers the ultimate in graphical recording combined with PID control. The compact ¼ DIN panel mount offers four high-accuracy universal inputs for data recording and PID control. This secure data-recording device will bring a crystalclear operator interface to even the smallest of machines. www.eurotherm.com IQ Technologies, Inc.

2316

Tweet about the show using the hashtag #HTS2011. See p. 16 for details.

See Us at Booth #1623 IndustrialHeating.com - October 2011 97

BOOTH DESCRIPTIONS Ipsen, Inc. 2123 See our ads on pages 5 & 26-27 Ipsen, Inc. designs and manufactures industrial vacuum furnaces, atmosphere furnaces and supervisory control systems for a wide variety of thermal-processing markets, including aerospace, commercial heat treating, medical, nuclear, chemical, tool & die, and automotive. In addition, Ipsen employs the largest and most skilled aftermarket and service support team in the business to meet your needs for controls upgrades, replacement hot zones, parts, maintenance and service. www.ipsenusa.com

magnetics. Our products include transformers, chokes, and AC and DC reactors. www.jacksontransformer.com

Ipsen Roadshow See our ad on pages 5 & 26-27

2133

ISA Alloys

2146

Jackson Transformer Co. 2417 See our ad on page 96 Jackson Transformer is an ISO 9001:2008-registered company that has been developing, designing and manufacturing a wide variety of air-cooled and water-cooled magnetic products since 1955. Our electrical engineers possess a combined experience of more than 125 years in

Jensen Industries Inc. 2003 Jensen Industries has been pioneering industrial heat-processing equipment for over 70 years. We’ll help solve your production needs with our custom equipment. www.jensenind.com Johnstone Co., Inc.

1836

Kubota Metal Corp.

1827

Kureha America, Inc.

2126

Kurt J. Lesker Company 2241 See our ad on page 61 KJLC sells the basic components for generating vacuum, including a comprehensive range of ﬂanges, ﬁttings, pumps, ﬂuids, valves, feedthroughs and traps along with vacuum pump repair for most major brands and pump ﬂuid reclaim to save you money and help the environment. www.lesker.com

Pure Processes, Safer Solutions On-Site Hydrogen Generation

HOGEN® C Series

ProtonOnSite.com | facebook.com/protononsite | [email protected]

See Us at Booth #2115

98 October 2011 - IndustrialHeating.com

@protonenergy

L&L Special Furnace Co., Inc. 2306 See our ad on page 78 L&L Special Furnace Co. builds some of the ﬁnest precision heat-treating furnaces in the world. The most demanding customers in the world use our custom, high uniformity furnaces for critical processing of aircraft parts, super-conductors, satellite parts, optical glass, dental powders, gyroscope components, automotive parts and much more. www.hotfurnace.com Land, an Ametek Company 2024 Infrared temperature measurement, line scanners, infrared thermometers, on-line thermometers and systems. www.landinst.com LECO Corporation 1807 See our ad on page 101 Hirox digital zoom microscopes from LECO have the highest magniﬁcation (up to 7000X - FOV) currently available on the market for capturing, recording and measuring materials and then viewing these images in outstanding detail. Packages offer a variety of lenses with Hirox interface, CCD digital camera and ﬁber-optic illumination integrated into one system. www.leco.com

PA S S I O N f o r M E TA L S

Power. Precision. Productivity. Induction Technologies for Heating and Heat Treating

Heating > Welding > Stirring > Annealing > Heat Treating > Hardening > Coating

Committed to Manufacturing Excellence – Need a complete process solution, not just another machine?

– Want a technology partner with the technical & ﬁnancial strength to grow with you in good times & bad?

As a member of the SMS Group of companies, Elotherm is your reliable partner for high-performance induction solutions today, and in the decades to come.

– Expecting 24/7/365 service with guaranteed on-time deliveries? At Elotherm, we’re investing in high-performance, energy-saving induction solutions for the North American market with a fresh lineup of re-engineered products, comprehensive process development, rigorous project management and responsive tech support in the United States, Canada and Mexico.

World Headquarters Elotherm North America 210 West Kensinger Drive, Suite 300 Elotherm GmbH Cranberry Township, PA 16066 Tel: +49 2191 981 300 Tel: 724.553.3471 [email protected] Fax: 412.202.3313 (fax) [email protected] www.sms-elotherm.com Toll Free: 877 7ELOTHERM (877.735.6843)

As a vertically integrated OEM for induction process solutions, we do more than simply build great machines. We also deliver complete induction process solutions based on fundamental science and solid, real-world engineering that help you meet your goals.

Responsible Energy Stewardship Elotherm’s new generation of converters featuring LLC resonance circuits and '\QDPLF(QHUJ\0DQDJHPHQW set the new standard for energy efﬁciency with a power factor greater than 95% across the complete load range. For efﬁcient systems that can reduce your energy consumption up to 20%, call 877 7ELOTHERM (877.735.6843).

Elotherm Brazil SMS Elotherm Brasil Tel: +55 11 4191 8181 [email protected] Elotherm China Elotherm Induction Tech. Co. Ltd. Tel: +86 (0) 21 2408 6468 [email protected]

See Us at Booth #2212

BOOTH DESCRIPTIONS Lindberg/MPH 2111 See our ad on page 40 Lindberg/MPH (a division of SPX Corporation) is a continuing leader in the production of standard and custom industrial heat-treat furnaces, including pit, box, IQ, vacuum and belttype for the ferrous and nonferrous markets. Our customers cover a wide range of industries, including aerospace/military, energy/oil, electronics and forging. www.lindbergmph.com LumaSense Technologies, Inc.

2318

Luoyang Achemetal Co., Ltd.

2041

Marathon Monitors Inc., a member of UPC 1623 McDanel Advanced Ceramic Technologies 2114 McDanel Advanced Ceramic Technologies is a leading manufacturer of high-quality advanced ceramic tubes, sheaths and components. We have extensive capabilities for producing custom components. www.mcdanelceramics.com

100 October 2011 - IndustrialHeating.com

Metal Treating Institute 2416 The Metal Treating Institute (MTI) is a nonproﬁt trade association that was established in 1933. MTI represents the largest network of commercial heat treaters in the world. MTI also represents manufacturers with in-house heattreating operations and suppliers who serve both commercial and captive heat treaters. www.heattreat.net

Morgan AM&T 2013 Morgan AM&T develops, manufactures and markets technologically innovative carbon, graphite and silicon carbide products that enhance our customers’ products and processes. Our products include premium-quality insulations, heating elements and ﬁxturing for high-temperature furnaces. www.morganamt.com

Metallurgical High Vacuum Corp. 2315 See our ad on page 64 Metallurgical High Vacuum Corp. will display 300 cfm and 430 cfm rotary piston pumps at the show. Features include positive pressure lubrication and oil ﬁltration. These pumps are direct bolt-in replacements for a popular 300 cfm pump that is widely used in the heat treating industry. These pumps are manufactured in the United States. www.methiva+c.com

Morgan Thermal Ceramics

MetalTest Inc.

2231

Nabertherm, Inc. 2015 Nabertherm supplies furnaces globally with all manufacturing completed at our facilities in Germany. Our extensive product range supports laboratory, research and production projects for many diverse markets. We integrate excellent build quality with professional logistics and reasonable pricing. www.nabertherm.com

2140

Micropyretics Heaters International

2227

Mitutoyo American Corporation

1915

Newage, an Ametek Land Company 2024 Hardness testers for Rockwell, Brinell, Microhardness, Vickers, Knoop, Durometers and IRHD. www.hardnesstesters.com

BOOTH DESCRIPTIONS Nitrex Metal Inc. 1623 See our ad on page 38 Nitrex Metal is a leading developer and supplier of automated turnkey nitriding and nitrocarburizing systems to customers involved with the aerospace, automotive, machinery, gear manufacturing, tool and die, and commercial heat-treating industries. www.nitrex.com

Power Distribution, Inc. 1825 PDI is a specialized manufacturer of custom transformers and control systems for OEM applications in the heat-treat industry. With three

U.S. facilities and a manufacturing partner in China, PDI is poised to serve your international needs with a team of experts. www.pdicorp.com

North American Cronite Inc. 2029 See our ad on page 65 North American Cronite, Inc., a division of AFE Technologies, is a manufacturer and designer of cast and fabricated heat-resistant alloy furnace parts. The company specializes in handling ﬁxtures, cast base trays and baskets, radiant tubes, rolls and corrugated boxes. www.afegroup.com Oerlikon Leybold Vacuum 2142 See our ad on page 21 Visit with Oerlikon Leybold Vacuum to gain the latest information on vacuum pump systems used in heat-treatment, sintering, brazing, vacuum induction melting and re-melting applications. www.oerlikon.com/leyboldvacuum OmegaVac Vacuum Products 2229 OmegaVac Vacuum Products offers vacuum pumps and vacuum boosters, assembled and tested in the U.S. Additionally, we offer Televac vacuum gauges and replacement hot zones for your furnace regardless of manufacturer. We also rebuild vacuum pumps and boosters for one-stop shopping. www.omegavacinc.com Park Thermal International Corp. 1841 Park Thermal International is a leading North American supplier of thermal-processing technology with a proven track record of designing, manufacturing and installing industrial heattreating furnaces, ovens and thermal-processing equipment since 1938. www.parkthermal.com PLANSEE USA 1717 PLANSEE’S exclusive high-performance HYBRID hot zone design is gaining market share in the world of graphite hot zones. With an everincreasing need for a longer-lasting (2x-3x its full-graphite predecessor) hot zone that is energy efﬁcient and has a superior quench time, the PLANSEE HYBRID is becoming more and more the preferred alternative to the standard graphite design. The PLANSEE HYBRID provides a high emissivity and great insulation properties for energy efﬁciency. www.plansee-usa.com

Tweet about the show using the hashtag #HTS2011. See p. 16 for details. See Us at Booth #1807 IndustrialHeating.com - October 2011 101

BOOTH DESCRIPTIONS Praxair, Inc. 1800 Praxair is third largest global supplier of industrial gases and process technology. Praxair has a core competency in gases and technical support for atmosphere applications including annealing, brazing, carburizing, neutral hardening and tempering. www.praxair.com

variety of materials for construction options and design speciﬁcations. Our experience in design and fabrication of quality valves has gained worldwide customer acceptance. www.pdcvalve.com

Precision Alloy Services

Protection Controls, Inc. 2035 See our ads on pages 40 & 110 Protection Controls Inc. offers a comprehensive service manual covering all PROTECTOFIER combustion safeguard units. It provides important and valuable information on installation, service guides, testing and troubleshooting, as well as speciﬁcations, features and applications on Protection Controls’ single and multi-burner units. www.protectioncontrolsinc.com

2210

Procedyne 2245 See our ad on page 114 For more than 45 years, Procedyne has been a leading supplier of specialized thermalprocessing products, systems and engineering/ technical services to heavy industries located throughout the world. These offerings include ﬂuidized bed reactors, ﬂuidized bed furnaces and ﬂuid bed dryers. www.procedyne.com Process Development & Control, Inc. 2219 Process Development & Control is a leading manufacturer of industrial butterﬂy valves for HVAC, furnace, power, blower and exhaust airtransfer systems in addition to special service applications. PDC offers customers a wide

Process-Electronic, a member of UPC 1623

Proton OnSite 2115 See our ad on page 98 Proton OnSite is a global leader in hydrogen energy and innovative gas solutions. Since 1996, we have been developing and applying hydrogen technology in creative and practical ways that best meets the diverse requirements of our customers. www.protononsite.com

Qual Fab, Inc. 2136 See our ad on page 92 Qual-Fab, Inc. specializes in all types of stainless fabrications for the heat treat industry including radiant tubes of all styles and sizes, both cast and fabricated, stainless and high nickel alloys. The company also produces furnace mufﬂes, rolls, serpentine trays, corrugated baskets, mufﬂes, retorts, fans and furnace ﬁxtures. QualFab’s experience guarantees quality products at competitive prices. www.qual-fab.net Quality Solutions

2103

Raytek Corporation 2122 See our ad on page 36 Raytek will feature the new MI3 1M and 2M hightemp, miniature infrared sensors with extended temperature ranges up to 3632°F. Come see what’s new in ﬁxed thermal imaging. www.raytek.com Rhenium Alloys Inc.

2112

Rohde GmbH 1817 Rohde manufactures heat-treatment equipment

Sharpen your heat treating skills. ASM instructors are industry experts with years of practical industry and teaching experience. Choose from top-rated classroom and laboratory courses. • Increase your knowledge and performance • Keep up with all the latest technical advances • Improve productivity Keep learning…for yourself and for the future. Visit www.asminternational.org/education for course locations and pricing Or call Member Service Center at 1.800.336.5152, ext. 0

102 October 2011 - IndustrialHeating.com

Classroom and Laboratory Classes

Date

Practical Induction Heat Treating

October 24-28, 2011

Introduction to Heat Treating

November 7-9, 2011

Advanced Heat Treating

November 10-11, 2011

Introduction and Advanced Heat Treating Take Both and SAVE!

November 7-11, 2011

Heat Treating for the Non-Heat Treater

December 5-7, 2011

Corrosion

December 12-16, 2011

Online and Self-Study Learning Fundamentals Of Brazing Online

Anywhere, anytime!

Induction Heating Self-Study (10-Lesson Series)

New, reduced price!

Metallurgy of Welding and Joining (13-Lesson Series)

New, reduced price!

Practical Heat Treating (15-Lesson Series)

Save up to 40%!

Maintenance of Heat Treating Equipment (6-Lesson Series)

New, reduced price!

Advanced Heat Treating (6 Lesson Series)

New, reduced price!

Heat Treating Quality & Inspection (14-Lesson Series)

New, reduced price!

Introduction to Heat Treating (9 Lesson Series)

New, reduced price!

BOOTH DESCRIPTIONS and salt-recovery units for the recovery of quench salts from washing-water to obtain saltfree water and clean reusable quench salt in liquid or solid form. www.rohdetherm.de Rolled Alloys 1727 See our ad on page 12 Since 1953, Rolled Alloys has been providing specialty alloys to the thermal-processing industry. Offering proprietary alloy RA330 and a diverse mix of heat-resistant alloys that provide both excellent strength and oxidation resistance for equipment that operates in the 10002250°F range. www.rolledalloys.com SAET Group - EDMS 2012 EDMS created in 1996 and specialized in press quenching and induction heat treat solutions is the North American branch of the SAET Group. Based in Tennessee, we design, manufacture and service induction heating solutions for the automotive, construction machinery, metalworking and aerospace industries. www.saetgroup.com Sandvik Heating Technology USA

2118

Schunk Graphite Technology 1940 See our ad on page 31 Schunk Graphite Technology is part of the Schunk Group, which is a world leader in C/C and graphite products used in the high-temperature furnace industry. We supply custom furnace ﬁxtures and hot-zone components to customers across North America. www.schunkgraphite.com SECO/WARWICK 1804 See our ad on page 25 SECO/WARWICK provides industrial metal heat-treatment furnaces used in a variety of processes for material ﬁnishing and component manufacturing applications. We supply furnaces to customers involved with steel and aluminum production, aluminum recycling, forging, automotive, aerospace, commercial heat treating, HVAC/R, electronics, wind energy, medical equipment and nuclear industries. www.secowarwick.com Signature Vacuum Systems, Inc. 2010 Signature Vacuum Systems designs and manufactures a broad range of standard and custom vacuum furnaces and ovens. www.signaturevacuum.com

Snecma Propulsion Solide

2319

Solar Manufacturing 2305 See our ad on page 13 Solar Manufacturing’s customers have come to depend on us to match the right furnace to their needs. Heat treaters from a variety of industries worldwide trust in our experience for their vacuum heat treating, brazing, carburizing, nitriding and sintering furnaces. Our vacuum furnaces provide maximum value through rugged, energy-efﬁcient hot zone designs, advanced furnace controls and innovative gas-quench systems achieving the highest performance results. www.solarmfg.com Stand Energy Corporation 1814 Stand Energy provides natural gas and expert energy-management services to commercial, industrial and government facilities. www.standenergy.com Struers, Inc. 2113 Struers Inc., a recognized leader and innovator in the materialographic community, supplies equipment and consumables for materialographic specimen preparation, as well as an extensive line of hardness testers and microscopes, to provide customers with a full range of comprehensive lab solutions. www.struers.com

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IndustrialHeating.com - October 2011 103

BOOTH DESCRIPTIONS Super Systems, Inc. 1801 See our ad on page 51 Super Systems, Inc. (SSi) develops and manufactures analyzers, sensors, controls and data-acquisition products for the heat-treating industry. You can always count on SSi’s innovative technology to address your speciﬁc heattreating requirements. Looking to retroﬁt your existing furnace cost-effectively with current technology? See how SSi instruments control the most sophisticated processes in nitriding, ferritic nitrocarburizing, carburizing and vacuum heat treating. www.supersystems.com Surface Combustion Inc. 1605 See our ad on pages 6-7 Surface Combustion will present its diverse product offering used in thermal processing of ferrous and nonferrous materials. These range from the most basic designs to high-tech automated furnace lines. New and updated designs include our ﬂameless Allcase® furnace, pit carburizing system, nitriding furnace, and controls for Triniding™ and ferritic nitrocarburizing (FNC) furnaces will be featured. www.surfacecombustion.com

Suzhou Advanced Rare Metal Co., Ltd. 2204 Tech Induction 1835 Tech Induction is a leader in engineering induction tooling. We also refurbish/build machinery and rebuild transformers. www.techinduction.com Televac

1906

Tenaxol Technologies 2211 See our ad on page 89 Dow Chemical UCON® quenchants are sold and serviced exclusively by Tenaxol Technologies in North America. We also market worldwide to commercial and captive heat treaters. www.tenaxol.com Tenova Core 2117 See our ad on page 76 Tenova Core designs and supplies heattreating, reheating and specialty furnaces. Representatives will be available to discuss our high-quality heat-treating furnaces for plate, pipe, wire, strip steel, forging and specialty applications. Designs include a wide range

of batch and continuous furnaces as well as complete heat-treating lines. www.tenovacore.com

Thermal Care, Inc. 2017 Thermal Care is a leading manufacturer of process-cooling equipment and systems for applications worldwide. As an ISO 9001:2008-certiﬁed manufacturer, we provide heat-transfer equipment for over 50 industries and specialize in meeting the speciﬁc needs of our customers by offering both standard and custom-designed process-cooling solutions. www.thermalcare.com Thermo Transfer Inc. 1831 See our ad on page 44 Thermo Transfer personnel will be on hand to discuss recently introduced circular integralquench furnace design, as well as recently completed projects in the areas of mesh-belt brazing, atmosphere tempering, roller hearths and atmosphere generators. TTI’s capabilities include rebuild and repair projects for all types of heat-processing equipment. www.thermotransferinc.com

Long Lasting

Won’t Rust or Corrode Avoid Down Tme Save on Maintenance

15-Year Shell Warranty

Not Harmed by H2O Chemical Treatments

The Greatest Thing Since a Delta Cooling Tower. Delta Cooling Towers designed the first engineered plastic (polyethylene) cooling tower in 1971. Since then we’ve improved and expanded “The Most Durable Corrosion-Proof Cooling Towers Available” to a full line, factory assembled and ready for any application. Visit us at www.deltacooling.com, or call 1.800.289.3358.

104 October 2011 - IndustrialHeating.com

QuantumQuench QuantumQuench

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

For more information contact G-M Enterprises 525 Klug Circle, Corona, California 92880 Phone 951-340-GMGM (4646) • Fax: 951-340-9090 See Us at Booth #1711

BOOTH DESCRIPTIONS Thermo-Calc Software, Inc. 2107 Thermo-Calc is a powerful, ﬂexible, easy-to-use software package for thermodynamic calculations for multi-component systems. DICTRA is a unique tool for accurate simulations of diffusion in multi-component alloys. www.thermocalc.com Throughput/Bluestreak 1926 Bluestreak MES, a powerful Manufacturing Execution System, is a best-of-breed solution designed exclusively for the metals-treating services industry. Manage critical, real-time information across all of your service processes while enjoying total visibility into operations and performance. www.go-bluestreak.com Toyo Tanso USA 2038 Toyo Tanso manufactures isostatically molded carbon and graphite products. We offer a wide range of graphite grades and properties in sizes to accommodate your heat-treating needs. We offer machined graphite and C/C composite products for the vacuum furnace industry. www.ttu.com

Tucker Induction Systems 2128 For 35 years, Tucker Induction has been providing world-class quality, service and support. We have over 200 years of combined experience in the manufacture of all types of induction tooling. www.tuckerinductionsystems.com United Process Controls 1623 See our ad on page 97 United Process Controls is an alliance of four companies, all with a strong presence in heat treating and combustion, whose aim is to provide prime control solutions through their worldwide sales and services network with easy-to-access local support. United Process Controls includes Furnace Control Corp., Marathon Monitors, Process-Electronic and Waukee Engineering. www.group-upc.com VAC AERO International, Inc. 1818 See our ad on page 11 A pioneer vacuum heat treater since 1959, VAC AERO offers a wide range of vacuum furnace systems and controls to ﬁt the stringent requirements of diverse applications in the aerospace, power-generation, medical, nuclear, tool & die, research and other high-tech industries worldwide. www.vacaero.com

Vulcan Steel Products

2104

Waukee Engineering Co., Inc., member of UPC

1623

Wellman Furnaces Inc. 1917 See our ad on page 62 For over 25 years, Wellman Furnaces has supplied radiant coil furnace systems for use in the polysilicon manufacturing process for making computer chips and solar panels. These systems are used to heat process streams of both silicon tetrachloride (SiCl4) and hydrogen. Systems with total outputs as high as 3 MW have been supplied. www.wellmanfurnaces.com Williams Industrial Service 1931 Williams Industrial Service features our line of custom and standard heat-processing equipment. Our products include internal-quench furnaces, spray dunk washers, draw furnaces and charge cars. www.wisfurnaces.com

Tweet about the show using the hashtag #HTS2011. See p. 16 for details.

The Retained Austenite Solution and More. Quench to freeze and back to temper with one profile. Eliminate multiple handling operations and increase product throughput.

For over 15 years we have provided our customers maximum process flexibility and dependability with our complete line of combination furnace/ freezers with temperature ranges between +1200°F and –300°F. Full in house engineering and flexible manufacturing capabilities permit custom integration with existing lines.

www.CryoSystems.com See Us at Booth #2414 106 October 2011 - IndustrialHeating.com

See Us at Booth #2100

915.351.8500

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

T-M Vacuum Products, Inc.

1-856-829-2000

www.tmvacuum.com

OF VACUUM

[email protected]

IH11084TM.indd 1

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

GET CONNECTED www.industrialheating.com/connect

Now it's easier than ever to stay connected to the best source of news and technology in the industry! See Us at Booth #2326 IndustrialHeating.com - October 2011 107

Professional Support Services to Industry

BOOTH DESCRIPTIONS Wirco, Inc. 1935 See our ads on pages 45 & Inside Back Cover Wirco Inc. is the industry leader in the design and production of heat-resistant castings and fabrications. For over 65 years, we have been providing quality stainless steel baskets, cast trays, furnace parts, mesh products, radiant tubes and custom ﬁxtures to our customers. www.wirco.com

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

Education/Training

Consulting • HT/Met

Process Analysis

Problem Solving

Furnace Diagnostics

Marketing Studies

WS Thermal Processes Technology, Inc. 2110 See our ad on page 48 WS will feature its high-efﬁciency self-recuperative burners and REKUMAT C ceramic radiant tubes for temperatures up to 2300°F with tube life up to 10 years. WS offers solutions for new equipment as well as furnace upgrades with proven technology that will reduce fuel consumption up to 50% while increasing available heat. www.ﬂox.com Yokogawa Corporation of America 1705 Yokogawa is a world leader in industrial automation and control. Our expertise and focus on the customer have made us a trusted partner since 1915. Yokogawa will display their solutions for the heat-treat industry and show their new controller line – The UTAdvanced. www.yokogawa.com/us Zircar Refractory Composites, Inc. 2304 We manufacture high-performance, high-temperature structural insulation products including refractory sheet boards, cylinders and custom shapes for thermal, structural and electrical insulation applications. www.zrci.com

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

PLATINUM GOES GREEN Save GREEN and go GREEN with the Furnace Parts LLC Platinum Thermocouple recycling program. When you purchase new Types S, R and B Platinum Thermocouples, we’ll recycle your used Platinum Thermocouples. The program reduces your total cost and saves the environment. And with our quick delivery, we’ll save you time too! Standard lead times are just 3-5 days, preventing the need for you to hold onto costly inventory. Contact a Furnace Parts LLC customer service specialist for more details. Call 800-321-0796 or visit www.furnacepartsllc.com.

See Us at Booth #2218

108 October 2011 - IndustrialHeating.com

The Pressure’s On. Raise the bar in Cincy. October 31-November 2, 2011 Duke Energy Convention Center • Cincinnati, Ohio USA

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

Media Sponsor:

Media Partner and Reception Sponsor:

Literature/Website Showcase Thermocouples & Atmosphere Analyzers Thermocouples/Temperature Sensors Furnace Parts LLC For 35 years, Furnace Parts LLC has excelled in the field of temperature measurement. Our corporate-capabilities brochure highlights our expertise in noble and base metal, MgO and RTD assemblies. For more information, contact us at 216-676-5005. www.furnacepartsllc.com

Thermocouple Product Line GeoCorp, Inc. GeoCorp’s new brochure provides information on its extensive temperature control product lines including thermocouples, thermocouple wire (survey, extension and bare wire), protection tubes and a wide selection of pyrometry supplies, recording chart paper and marking products, hardness testing supplies, heat treating accessories, chart recorders, instrumentation and controls. www.geocorpinc.com.

Thermocouple Handbook

See Us at Booth #2035

ATTENTION

Nanmac Corporation A new, user-friendly, free resource for temperature measurement is available on CD from Nanmac Corporation. Including a complete photo index, application guide, interactive resource center featuring scientific calculators, technical papers and more. Request your free copy at www.nanmac.com/ free, send a note to [email protected] or call 1-800-786-4669 in the U.S. or 001-508-8724811 worldwide.

Data Logger

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

See Us at Booth #2206

110 October 2011 - IndustrialHeating.com

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

Process Controller United Process Controls The PROTHERM 455 next-generation controller combines control and graphical recording capabilities with touch-screen technology. It is designed as a drop-in replacement for Marathon's CarbPro, DualPro, MultiPro and Carb PC. Easy-to-use interface introduces enhanced features that simplify operations in the field. Redundant probe feature is standard. www.group-upc.com

Literature/Website Showcase Industrial Gases/Atmospheres | Burners & Combustion Equipment Solutions for Metals Treatment Air Products and Chemicals, Inc. Air Products’ atmosphere supply, processes and technologies, and services can help you optimize your metal-manufacturing operation. Learn how we can help you maximize uptime, lower costs, increase throughput and improve quality control. Call 800-654-4567, code 716. www.airproducts.com/metals

Process Heating Equipment Eclipse Comprehensive brochure presents the entire line of process heating equipment and systems from the Eclipse family of brands. Our global powerhouse of industry-leading products includes combustion burners, packaged burners, integrated combustion systems, shut-off valves, valve trains, flame monitoring, recuperators and standby fuel systems. www.eclipsenet.com

Pulse Firing Hauck Manufacturing Company Pulse firing is a specialized type of combustion system control that offers significant process and productivity benefits. The brochure features Hauck burners and Kromschröder controls suitable for the high cycle demands of pulse firing. www.hauckburner.com

Temperature Measurement Handbook Omega Engineering Volume MMXIV Omega Temperature Measurement Handbook 7th Edition offers detailed information and specifications on more than 40,000 products for process measurement and control featured on over 2,000 color pages. The New 7th Edition contains the latest technology and new products in sanitary temperature sensors and devices, thermal imagers and infrared temperature products, and much more. www.omega.com/literature

Burners and Radiant Tubes WS Thermal Process Technology, Inc. Specializes in industrial burners with integrated heat exchangers (recuperative or regenerative) and radiant tubes. Burners and radiant tubes are available in alloy material and SiC-ceramic. Great efforts are made to provide the highest efficiency and lowest NOx emissions currently available on the market. www.flox.com

GRAPHALLOY BEARINGS CAN TAKE THE HEAT. ®

HANDLE HIGH TEMPERATURE AND HARSH OPERATING CONDITIONS WITH EASE GRAPHALLOY® bushings, bearings and components: • Survive when others fail • Run hot, cold, wet or dry • Excel at -450°F to 1000°F • Corrosion resistant • Self-lubricating • Non-galling • Low maintenance • Ovens, dryers, pumps, valves, turbines, mixers, conveyors

GRAPHITE METALLIZING CORPORATION Yonkers, NY 10703 U.S.A. ISO 9001:2000 H06

TEL. 914.968.8400 • WWW.GRAPHALLOY.COM/IH

See Us at Booth #1925 IndustrialHeating.com - October 2011 111 IH02072Gra.indd 1

1/17/07 4:57:19 PM

Engineered Solutions for Induction Heating Heat Treating • Scanning and single shot • Part development services

Forging

INDUCTION HEATING

• Billet and bar end heating

Steel • Quench and temper lines for bar, pipe, and tube • Strip heating • Coating and curing • Bar and slab heating for rolling

Ajax TOCCO Magnethermic® Corporation 1745 Overland Ave Warren, OH U.S.A. 44483 Tel: +1-330-372-8511 ®

THE GLOBAL FORCE IN INDUCTION TECHNOLOGY

Fax: +1-330-372-8608

www.ajaxtocco.com Call 1-800-547-1527 24/7 for assistance See Us at Booth #1901

Products

Ask the Expert Ask the Expert Anna Wehr-Aukland Ph.D., Senior Principle Research Engineer

Product of the Month Process Imaging Solution Raytek Raytek announced an enhanced version of its ThermoView™ Pi20 process imager with DataTemp® Pi (DTPi) software. This rugged, yet easy-to-operate thermal imaging solution includes two additional cameras, a new enclosure and C++ software development kit (SDK), allowing for use in a wide range of industrial environments. Designed for automated monitoring and control of continuous or stationary targets, the ThermoView Pi20 ﬁxed-mounted process imager provides an automated view of your process, allowing plant operators to shorten process start-up times and lower production line changeover costs. The camera is paired with the intuitive DTPi software, which minimizes or eliminates the long learning curve associated with manyy process imaging The ThermoView p g g systems. y Pi20 is now even more robust and versatile satile with the addition of two 45-degree remote focus cameras and a new “outdoor” ennclosure. This solution is ideal for appliications ranging from furnace refracctory monitoring to semiconductor/solar ar manufacturing. Customized solutions ns are also available for engine testing, steel el coating, metal forming, materials testing, g, solar module testing and automotive ve fabrication. www.raytek.com

Cables Omega Engineering The new E32 series of shock and vibration resistant cables for ﬁber-optic sensors are CE-compliant and can withstand temperatures up to 660°F. Since the ﬁber optic cables only transfer light, they are unaffected by electrical noise. The E32 comes in throughbeam or reﬂective sensing style to adapt to design requirements, are cut-to-length for custom ﬁeld installations and feature side-view sensing heads for right angle detection. The E32, ideal for the automotive industry, senses the presence of parts in assembly lines. Spot diameter lenses are available. www.omega.com

Blast Machine Guyson Corp. The Model GWB-702T – a rotary table wheel-blast system with one blast wheel over each half of a 4,000-pound-capacity, 70-inch-diameter turntable – is especially suitable for batch processing of work pieces that are essentially ﬂat or have limited vertical surfaces. Each blast wheel is directly driven at a speed of 3,000 RPM by a 10-HP motor and is capable of throwing approximately 220 pounds of metallic media per minute in an extended blast pattern up to 36 inches long. The blast pattern of the individual blast wheels is adjustable, so the twin wheels are aimed to provide rapid and thorough coverage of components on the entire surface of the turntable. GWB702T wheel-blast machines come standardequipped with an enhanced shot reclamation system that includes a tunable cascade airwash separator to remove dust from the working media mix as well as an independently adjustable cyclone separator to capture and reuse good shot or grit that would otherwise be carried over to the dust collector. The sensitive multi-stage reclaim enables the use of microscopic shot media for nondestructive cleaning applications. www.guyson.com

Q

What’s the best approach to select the hydrogen concentration for our nitrogen-hydrogen atmosphere for bright annealing of steels?

A

You can use the Ellingham diagram to predict the conditions that will be reducing to iron oxides and the oxides of the alloying elements added to steels. Alternatively, you can use more accurate and convenient diagrams for steels that were calculated using modern databases and computer programs. These techniques will help you troubleshoot and optimize your annealing operation by balancing hydrogen usage versus product quality. To learn more about these methods, read Anna’s full answer at www.airproducts.com/J57 or give us a call at 800-654-4567 (press 1 and mention code 882). Don’t miss us at the Heat Treat Show November 1-2, in Cincinnati, Ohio. Visit booth 1823 to learn how our experience in gas supply, applications development and safety can help you improve product quality, reduce operating costs, increase production and optimize gas usage.

tell me more www.airproducts.com/J57 © Air Products and Chemicals, Inc., 2011 (33887) J57

See Us at Booth #1823 IndustrialHeating.com - October 2011 113

Products

Borescope Camera

High-Temperature Air Ampliﬁer

Extech Instruments Designed for use in practically any environment, the durable HDV600 high-deﬁnition borescope camera series features a 5.7-inch color display for bright outdoor sites or poorly lit facilities. Optics include 4 mm-6 mm LEDilluminated camera probes, and SD memory stores 15,000 JPEGs or video – plus audio annotations. Glove-friendly controller handsets with 320-degree articulated probes and wireless connectivity simplify inspections. HDV600 videoscopes are designed for ruggedness, upgradeable versatility and high-deﬁnition clarity. www.extech.com

Exair Corp. The new High-Temperature Air Ampliﬁer offers a simple, low-cost way to move volumes of hot air to surfaces requiring uniform heating while in a furnace or oven. The High-Temperature Air Ampliﬁer ampliﬁes airﬂow up to 18:1 at outlet. It is the most efﬁcient for pushing high volumes of hot air to points that typically remain cool. This special design is rated for environments up to 700°F, and its surface is protected from heat stress by a mil-spec coating process, allowing easy disassembly for changing shims or cleaning. There are no impellers or moving parts to wear out, and the sound level is low (72 dBA). The High-Temperature Air Ampliﬁer is perfect for corrosive applications. www.exair.com

Wearing Compound ITW Devcon New DFense Blok™ Quick Patch is the only ceramic bead-ﬁlled wear and abrasion epoxy formulated for emergency repairs to processing equipment, even in severe conditions. With a working time of 4 minutes and an exceptionally fast cure time (functional cure in just 30 minutes), DFense Blok Quick Patch is ideal for the emergency patching and repairing of holes, leaks and cracks. By protecting against wear, abrasion and corrosion, it extends the equipment’s service life and minimizes downtime. A non-sagging, alumina ceramic bead-ﬁlled epoxy compound, DFense Blok Quick Patch can be used at thicknesses up to 1 inch on vertical surfaces and ¾ inch on overhead surfaces. Available in a 1-pound container, it is ideal for repairing, rebuilding and protecting a variety of equipment. www.devcon.com

Professional Support Services to Industry A Fluidized Bed Furnace Leader

Presents

®

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

Education/Training

Consulting • HT/Met

Process Analysis

Problem Solving

Furnace Diagnostics

Marketing Studies

The Procedyne NitroBlack Process A Breakthrough in Heat Treating Parts Improved Wear and Corrosion Performance

In addition, the NitroBlack® process produces parts which have attractive black matte surface Ànishes.

THE HERRING GROUP, Inc. 11 Industrial Drive, New Brunswick, NJ 08901 Tel: 732-249-8347 • Fax: 732-249-7220 www.procedyne.com • Email: [email protected]

See Us at Booth #2245

114 October 2011 - IndustrialHeating.com

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

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The Aftermarket Parts, Services & Consulting Resources

THE AFTERMARKET

$

125 pparts arts

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Single or NEW DOUBLE Aftermarket Cards Big Impact for a Small Price! Starting at $125 per month for a black & white card 116 October 2011 – IndustrialHeating.com

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Ź Problems in temperature uniformity Ź Quality problems Ź Production bottlenecks

SERVICE

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Ź Preventative maintenance agreements Ź Relines, upgrades & repairs Ź Service available in your factory or ours Ź Temperature & process control upgrades Ź Modiﬁcations and conversions

Ask us how we can improve the operating ope o efficiency of your equip pm equipment: (269) 849-2700

Genuine Lindberg Parts

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

IndustrialHeating.com – October 2011 117

The Aftermarket Parts, Services & Consulting Resources

Qual-Fab Inc. Quality Stainless Steel Fabrications for the Heat Treat Industry Aftermarket Services for Induction Equipment

• Radiant Heater

s s s s s s s s

• •

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www.qual-fab.net Rates Per Column Inch 1x=$125; 3x=$115, 6x=$100 and 12x=$95. No additional charge for bold print Blind box numbers available = $15 per issue

HELP WANTED

“Nadcap and You… Achieving Excellence Together.” Build Your Career with a Global Industry Leader. Performance Review Institute is seeking Aerospace experienced consultant auditors for the Nadcap Heat Treating program. As a Nadcap auditor, you will perform heat treating audits, complete audit reports, and have the opportunity to train associate auditors. The ideal candidate will possess the following general background: • Bachelor’s Degree in a technical field • Understanding of General & Aerospace quality systems (ISO, AS/EN/JISQ9100) • Familiarity with General Consensus specifications and Aerospace Standards • Computer skills in word processing, spreadsheets, email and internet • Desire to travel • Multi-lingual a plus • Strong interpersonal skills

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WWW.WONDERWELD.COM

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Industrial Heating

REPRINT PLAQUES ARE NOW AVAILABLE An excellent marketing opportunity

The following are specific criteria for Heat Treating: • Five (5) years “hands-on” experience (preferably in the aerospace industry) with the following processes: Aluminum Heat Treating, Titanium Heat Treating, Heat Resisting Treating, Heat Resisting Alloys, Brazing Alloys • Understanding of AMS2750 or Pyrometry specification As an innovative industry leader, we are proud to offer our auditors: • Flexible Schedules • Competitive Daily Rate • Paid Travel & Living Expenses • Paid Annual Training • No Need to Relocate See why Nadcap has been attracting & retaining some of the best professionals in the industry! Apply on-line today, via our application website, www.eAuditStaff.com. Determine your area of auditor expertise in one or more of these specific disciplines: Chemical Processing, Coatings, Composites, Conventional Machining, Elastomer Seals, Electronics, Fluid Distribution Systems, Heat Treating, Materials Testing, Non-Metallic Materials Testing and Manufacturing, Nondestructive Testing, Nonconventional Machining, Sealants, Surface Enhancement and Welding. For more information on PRI and the Nadcap program, visit our website, www.pri-network.org. Nadcap is administered by the Performance Review Institute, an equal opportunity employer, who values the diversity of our work force and the knowledge of our people.

118 October 2011 – IndustrialHeating.com

Contact Becky McClelland at 412-306-4355 for details

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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 OPPORTUNITIES

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Commercial Heat Treat Shop for Sale 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. For $25.00 We Will Post and Link Your Ad Online Visit industrial heating online at www.industrialheating.com

Forge company specializing in shallow cavity closed die forging of carbon and stainless steels seeking sales representation throughout the US.

Send agency profile and line card to: Box 725 c/o Industrial Heating Magazine 1910 Cochran Road, Suite 450 Pittsburgh, PA 15220 or reply by email to: [email protected]

FOR SALE HELP WANTED

Sales and Marketing Manager Pelican Wire Company, a growing manufacture of specialty wire and cable products, is seeking a full time marketing and sales manager. Located in Naples, Florida the company supplies numerous wire products into the electrical heating and temperature measurement industries. Pelican Wire offers a competitive package of benefits including health, life, vision, dental, long term disability, paid-time-off (vacation, holidays, and sick leave), professional development, and education assistance. In addition, Pelican Wire is a 100% employee owned allowing all employees to share in the long term financial success of the business.

Job Description: Seeking a full time marketing and sales manager that will be responsible for leading our sales staff and marketing efforts, with some direct account responsibility. Responsibilities will include the acquisition and management of new accounts and opportunities, the generation of estimates and proposals, and contract development. Position responsibilities will also include the management of various budget accounts, development of and tracking against forecast goals, and other administrative functions. This position will be responsible for the development of the skills and knowledge of the sales staff, and directing the marketing efforts of the company. Some national travel is required. The ideal candidate will have 10+ years in business to business technical sales, and 5+ years leading a sales team, preferably at a growing company. Experience in the wire and cable field is preferred, as is experience in electrical heating, temperature measurement, plastics, or medical device manufacturing. BSEE, BSCE, BSME, or BSBA preferred. Strong technical background and demonstrated ability to learn new technical data is a must. Candidate must be able to read and understand specifications and technical drawings, be fluent in the use of Excel and CRM tools, and familiar with cost modeling techniques.

Please send your resume in confidence to [email protected]

FOR SALE Surface Combustion 3 Chamber Furnace 48 x 36 x 24" Nitrogen and Oil Quench New Moly Hearth 412-781-3553 [email protected]

PROCESS HEAT

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Upgrade your LE to a Next Generation LHS air heater today www.leisterusa.com Toll-free: (855) Leister [email protected] IndustrialHeating.com – October 2011 119

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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

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

120 October 2011 – IndustrialHeating.com

Densification

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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

Classiﬁed Marketplace

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.

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

EQUIPMENT FOR SALE

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

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

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

For more information, please call 1-877-834-4328 (HEAT) 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]

HELP WANTED

ZF Group is a Leading Worldwide Automotive Supplier for Driveline and Chassis Technology. With total sales of euro 12,9 billion in 2010 and 70,000 employees at 117 production companies in 26 countries, ZF is among the top ten companies on the ranking list of the largest automotive suppliers worldwide. We are seeking the following positions for these locations. ZF Wind Power, LLC is building a new manufacturing facility in Gainesville, GA that will produce gear boxes for wind turbines. Heat Treat Team Leaders and Met Lab Techs are needed for this start up facility. Interested candidates should submit a resume to [email protected]. ZF Transmissions Group is building a new manufacturing facility in Upstate South Carolina to produce 8-speed and 9-speed transmissions. We are looking for a Metallurgist for this start up facility. Candidates interested in this position should submit their resume to [email protected]. ZF is offering a relocation package to bring these candidates into Gainesville, GA and Upstate South Carolina. Associates are eligible for major medical, dental and vision coverage, STD/ LTD insurance, voluntary life, AD&D, 401-K, life insurance, paid holidays, paid vacation, and tuition reimbursement.

FOR $25.00 WE WILL POST AND LINK YOUR AD ONLINE

ZF Group is an EEO/M/F/D/V IndustrialHeating.com – October 2011 121

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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 C A 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 –––––––––– 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 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 –––––––––– 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 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 –––– 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

122 October 2011 – IndustrialHeating.com

–––––––––– MISCELLANEOUS ––––––––– 30” × 48” Lindberg Charge Car (double-ended) 4000# Accurate — Skip Hoist (NEW) 30"× 48"× 30" Dow Washer (D&S) Elec New Carbon Probes 36" × 48" Surface Roller Tables 30" × 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 ––––––– 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" × 20" × 20" Gruenberg (Solvent) Elec 450˚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 Elec 500˚F 24" × 36" × 24" Demtee (N2) 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" × 36" × 48" 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 1250˚F 38" × 28" × 28" Trent (Top load) Elec900˚F 48" × 24" × 48" Blue-M Elec600˚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 Elec450˚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 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

SIVE ADHE

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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

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http://twitter.com/IndHeat http://www.facebook.com/IndustrialHeating

FOR SALE

FOR SALE New Design

SPARK IGNITER

FOR SALE

Used for the automatic ignition of recuperative burner systems.

Ipsen Horizontal Front Loading Cold Wall Vacuum Furnace *Diff erent Leng ths A vailab le

• • • • • 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

EQUIPMENT FOR SALE

Mowry Enterprises, Inc. New

Used

Rebuilt

Solutions

•

For Sale

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

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

FOR SALE

VACUUM OIL QUENCH CARBURIZER: C.I. Hayes: 24” x 24” x 24”, Still installed, 2 chamber with isolated oil quench, complete with water recirc system and alloy grids. Heat Chamber is 24 24 36. Quench chamber can be modiÀed for this larger load. VFS HL 36: 2500 F, 24” x24” x38” graphite hot zone, High vacuum, PLC/ touch screen controls, Pressure Quench

STANDARD & CUSTOMIZED HEAT TREAT FURNACES

VFS HL 50: 36” x 30” x 48”, graphite hot zone, high vaucum, 1200 CFM external quench, 2650 F 2 BAR: 10” x 10” x 20” hot zone, Graphite. Mech pump and blower, built in 1999. TM 12 x 12 x 20: graphite hot zone, high vacuum, internal quench, 5 psig positive quench ABAR 48 x 48 bottom load: graphite hot zone, high vacuum, external quench, PLC/ touch screen controls

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

• • • • •

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

WWW.LUCIFERFURNACES.COM • Phone: (800) 378-0095 • Fax: 215-343-7388 IndustrialHeating.com – October 2011 123

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Industrial Heating

REPRINTS An excellent marketing opportunity!

If it’s been printed in Industrial Heating, you can have it reprinted by Industrial Heating. Feature Articles, Technology Spotlights, MTI or IHEA ProÀles, Literature Features, and much more. Customize your reprints with your company’s ad, special message or even the cover of Industrial Heating.

Contact Becky McClelland at 412-306-4355 for details ONLINE AT: WWW.INDUSTRIALHEATING.COM

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

FOR SALE

FOR SALE All Surface Combustion Equipment: • Gas Fired Super Allcase Integral Quench Furnace 30” x 48” x 30”, 1750ÝF, with Top Cool, SBS chiller and controls. • Electric Super Allcase Integral Quench Furnace 30” x 48” x 30”, 1750ÝF, 140 KW with Top Cool, SBS cooler and controls. • Electric Super Allcase Integral Quench Furnace 30” x 48” x 30”, 1750ÝF, 180 KW with SBS cooler and controls. • Electric Tempering Furnace 30” x 48” x 30”, 1400ÝF, 81 KW with controls. • Gas Dunk Washer 30” x 48” x 30”, 180ÝF 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

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

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

“Featured Equipment” • Surface Combustion 6000 Endo, Gas Air Cooled • (2) available: Jensen doubledoor, walk-in batch oven. • Lindberg 24 " x 36 " x 18" Vacuum Furnace • Various pieces of Induction Equipment Enterprise Equipment Co., Inc. 6000 Caniff Ave.,Detroit, MI 48212 Ph: 313-366-6600 • Fax: 313-366-6603 Web: www.eecoinc.com Email: [email protected]

124 October 2011 – IndustrialHeating.com

• 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 • 36”W x 30”H x 48”L, Ipsen, I/O Internal Quench, Gas, 1850˚F, 2 Units • 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 • 30” x 48” x 30”H, Lindberg Batch Tempers, 1250˚F, 3 Available • 72"W x 6"H x 24' , Holcroft, Atmosphere, 1600˚F, Mesh Belt • 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 • Wheelabrator Spinner Hanger w/34"W x 52"H x 58"L opening.

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

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

Industrial Heating TRAINING 2011 Invest 60 Minutes and LEARN Secrets of Hardness & Mechanical Testing 2:00 p.m./November 11 This webinar will focus on hardness testing (e.g., Brinell, Rockwell, Rockwell Superﬁcial, Microhardness) and include examples of common testing problems encountered. The presenter will also discuss various other types of mechanical-testing methods, including fatigue, tensile strength, impact, shear and torsion testing. Other types of industry tests such as stress rupture, stress durability, pull-out/push-out, vibration, engagement, wear, microstructure, chemical analysis and corrosion will also be covered. Speak er: Dan Herring The Heat Treat Doctor© The HERRING GROUP, Inc.

ON DEMAND: Temperature Sensing/Control: The Right Tools Save You Money Original date: August 18 Topics to be covered include: Principles of temperature measurement; Types of sensors and suitable applications; Response, accuracy, and quality control; Non-uniformities, errors and numerical models; Indicators, switches, transmitters, telemetry; Sensors for safety, environmental control, process control. Sp e a ke r : Richard J. Martin, Ph.D., P.E., C.F.I. Martin Thermal Engineering

60 mins./webinar including Q&A. Sign Up TODAY Online At: webinars.industrialheating.com By the way, did we mention .... No software to install Industry expert speakers Live Q&A sessions

We send an e-mail reminder Two additional archived webinars All webinars are FREE!

Advertiser Website Index Page

COMPANY NAME

PHONE

WEBSITE ADDRESS

46 98 83 29 42,113 115 47,112 50 71 102,109 16 33 42 49,95 111 51 85 103 88 8 104 106 17 90 63 86 80 52 99 55 44,108 37,39,41,43 23,105 111 91 54 19 114 69 125 106 Back Cover 48 110 66 5 26-27 96 61 78 101 40 64 14,15 35 38 65 21 Inside Front Cover 100 114 90 40,110 98 57 92 36 12 104 68 31 25 79 13 58 51 6,7 89 76 44 107 93 Cover 97 11 88 62 45, Inside Back Cover 72 48

ACROSS USA, Inc. AEC Inc. AFC-Holcroft Agilent Technologies, Vacuum Products Div. Air Products and Chemicals, Inc. AIST Ajax TOCCO Magnethermic Corp. ALD Thermal Treatment, Inc. Alpha 1 Induction ASM International BeaverMatic, Inc. Can-Eng Furnaces International Ltd. Capitol Vacuum CEIA USA Ltd. Centorr Vacuum Industries, Inc. Ceramic Solutions Inc. Consolidated Engineering Co. Control Concepts Inc. Cornerstone Systems, Inc. Custom Electric Manufacturing Co. Delta Cooling Towers DMP CryoSystems Dry Coolers Inc. Duffy Co., The Eclipse ECM EFD Induction, Inc. Elmet Technologies Elotherm, SMS Group Eurotherm Inc., Invensys Furnace Parts LLC GeoCorp Inc. G-M Enterprises Graphite Metallizing Corp. H.C. Starck Inc. Hauck Manufacturing Heatbath Corp./Park Metallurgical Herring Group, The Huettinger Electronic, Inc. IH Training Induction Tooling Inc. Inductotherm Group Industrial Furnace Interiors Inc. INEX Incorporated International Thermal Systems Ipsen Inc. Ipsen Inc. Jackson Transformer Co. Kurt J. Lesker Co. L & L Special Furnace Co., Inc. LECO Corp. Lindberg/MPH Metallurgical High Vacuum Corp. Nanmac Corp. National Element Inc. Nitrex Metal North American Cronite, Inc. Oerlikon Leybold Vacuum USA Omega Engineering, Inc. Orton Ceramics Procedyne Corp. Proceq USA Inc. Protection Controls Inc. Proton PV/T Incorporated Qual-Fab, Inc. Raytek Corp. Rolled Alloys Rous Hi-Temp Product Co., Ltd. Saint-Gobain Ceramics, Structural Ceramics, Hexoloy Schunk Graphite Technology SECO/WARWICK Corp. SGL Carbon, LLC Solar Manufacturing Steeltech Ltd. Super Systems Inc. Surface Combustion Inc. Tenaxol Technologies Inc. Tenova Core Thermo Transfer, Inc. T-M Vacuum Products, Inc. Tuthill Vacuum & Blower Systems Unifrax, LLC United Process Controls Vac Aero International Inc. VAT, Inc. Wellman Furnaces Inc. WIRCO, Inc. Wisconsin Oven Corp. WS Thermal Process Technology Inc.

310-635-3555 847-273-7703 248-624-8191 800-882-7426 800-654-4567

www.acrosscc.com www.aecinternet.com www.afc-holcroft.com www.agilent.com/chem/vacuum www.airproducts.com/metals www.aist.org www.ajaxtocco.com www.aldtt.net www.alpha1induction.com www.asminternational.org www.beavermatic.com www.can-eng.com www.capvac.com www.ceia-usa.com www.centorr.com www.ceramicsolutionsconroe.com www.cec-intl.com www.ccipower.com www.ask4csi.com www.custom-electric.com www.deltacooling.com www.CryoSystems.com www.drycoolers.com www.duffycompany.com www.eclipsenet.com/serv5 www.ecm-usa.com www.efdinduction-usa.com www.elmettechnologies.com www.sms-elotherm.com www.eurotherm.com www.furnacepartsllc.com www.geocorpinc.com www.gmenterprises.com www.graphalloy.com/IH www.hcstarck.com www.hauckburner.com www.heatbath.com www.heat-treat-doctor.com www.huettinger.com www.industrialheating.com/ihtraining www.inductiontooling.com www.inductothermgroup.com www.iﬁ-inc.com www.INEXinc.net www.itsllcusa.com www.ipsenusa.com www.ipsenusa.com/HybridCarb www.jacksontransformer.com www.lesker.com www.hotfurnace.com www.leco.com www.lindbergmph.com www.methivac.com www.nanmac.com www.nationalelement.com www.nitrex.com www.afegroup.com www.oerlikon.com/leyboldvacuum www.omega.com www.temptab.com www.procedyne.com www.proceq-usa.com www.protectioncontrolsinc.com www.protononsite.com www.pvt-vf.com www.qual-fab.net www.raytek.com www.rolledalloys.com www.rous-hitemp.com www.hexoloy.com www.schunkgraphite.com www.secowarwick.com www.sglcarbon.com www.solarmfg.com www.steeltechltd.com www.supersystems.com www.surfacecombustion.com www.tenaxol.com www.tenovacore.com www.thermotransferinc.com www.tmvacuum.com www.tuthill.com www.unifrax.com www.group-upc.com www.vacaero.com www.vatvalve.com www.wellmanfurnaces.com www.wirco.com www.wisoven.com www.ﬂox.com

126 October 2011 - IndustrialHeating.com

800-547-1527 803-233-0660 800-991-2599 800-336-5152 815-963-0005 905-356-1327 800-237-3933 888-532-CEIA 800-962-8631 936-588-2646 770-422-5100 952-474-6200 800-275-4274 248-305-7700 800-289-3358 915-351-8500 800-525-8173 847-202-0000 262-925-6321 248-658-0700 207-333-6100 877-735-6843 703-724-7300 800-321-0796 419-433-1101 951-340-4646 914-968-8400 617-584-9322 717-272-3051 413-452-2000 630-834-3017 408-454-1182 440-237-0711 609-267-9000 586-726-2388 716-537-2270 414-672-7700 800-727-7625 800-727-7625 813-879-5811 800-245-1656 610-459-9216 800-292-6141 269-849-2700 269-543-4291 508-872-4811 800-600-5511 514-335-7191 800-243-4123 724-327-5700 203-359-1660 614-895-2663 732-249-8347 800-839-7016 847-674-7676 856-235-5400 440-327-5000 800-227-8074 800-521-0332 0086-533-3580575 716-278-6233 262-250-8869 814-332-8400 800-727-4474 215-258-3350 616-243-7920 513-772-0060 800-537-8980 414-476-1400 412-262-2240 317-398-3503 856-829-2000 800-825-6937 716-278-3800 800-547-1055 905-827-4171 781-935-1446 317-398-4411 800-348-2880 262-642-3938 440-365-8029

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CAST I N GS

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FABRICATIONS

MADE IN AMERICA BASKETS & FA B R I C AT I O N S

ISO 9001 Certified : 2008

C A S T T R AY S & F I X T U R E S

RADIANT TUBES & FURNACE ROLLS

FURNACE COMPONENTS To place an order or receive a quote:

call 1.800.348.2880 email our sales staff at [email protected] OR contact your local sales representative. See Us at Booth #1935

WIRCO, INC. : AVILLA, INDIANA www.wirco.com

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phone: 260.897.3768

ALLOY ENGINEERING & CASTING COMPANY : CHAMPAIGN, ILLINOIS

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800.348.2880

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fax: 260.897.2525

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sales @ wirco.com

Who can combine global expertise with local manufacturing, delivery and support?

CAN.

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

Visit Us At Heat Treat 2011/Gear Expo Duke Energy Convention Center Hall A, Booth #1611 Nov. 1 – 2, 2011 • Cincinnati, OH See Us at Booth #1611