Industrial Heating August 2011

August 2011

Process Control Dividends p.3 p.35 Large Ring Induction Large-Ring I duction Hardening p.38 Hardness-Testing Automation p.42 Electron Beam Technology p.45 ASM HTS insider p.48

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Publication Official publication of ASM’s Heat Treating Society Online 24/7 at www.industrialheating.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]

A game-changing technology coming soon...

Yeah, it’s kinda like that.

Ipsen delivers innovation.

www.IpsenUSA.com/innovation

Industrial Heating’s Web Search Power Pages ALLOYS/CASTINGS & FABRICATIONS Steeltech Ltd. Our Alternative Energy Saving Alloy Tube Assemblies can reduce your energy usage up to 50%. This technology enables your radiant tube assemblies to operate at the same temperature using half the energy. Contact: 616-243-7920 www.steeltechltd.com Wirco, Inc. For 65 years, Wirco has been the leading supplier of heat-resistant castings and fabrications to the thermal-processing industry. Our website features many of our quality products. Contact: 800-348-2880 www.wirco.com

BURNERS & COMBUSTION EQUIPMENT Hauck Manufacturing Co. Hauck Manufacturing Company offers a wide range of combustion products including burners, blowers and controls and Kromschroder burners and control products. Contact: Michael Shay, 717-272-3051 www.hauckburner.com

CONTROLS, INSTRUMENTATION & TESTING EQUIPMENT Applied Test Systems Applied Test Systems is a leading manufacturer of process heating and materials testing equipment designed for creep and tensile testing, burst testing, sealant testing, asphalt testing and a variety of process heating applications. Our products are supported by our A2LA-accredited service and calibration department. Contact: [email protected]; 724-283-1212 www.atspa.com Clemex Technologies: Hardness Testing Clemex CMT.HD is a field-proven hardness testing solution that offers unparalleled image quality and capabilities. www.clemex.com Proceq, Inc. Proceq makes and sells the EQUOTIP, EQUOSTAT and Equopen portable hardness testers. Highly accurate with excellent value. Contact: Tom Ott, 724-512-0330 www.proceq-usa.com Struers Inc. Worldwide leader in materialography providing an entire range of equipment and consumables for specimen preparation; extensive line of hardness testers and microscopes providing a full range of comprehensive lab solutions. Contact: Bill Thompson, 888-STRUERS (787-8377) www.struers.com Super Systems: Furnace Control & Instrumentation At Super Systems Inc., we specialize in delivering products and services to the thermal-processing industry. Our products include oxygen probes, single-loop and programmable controllers, atmosphere analyzers including 3-gas NDIR, dew point, multipoint data logger (AMS 2750D compliant) SCADA software packages and engineered systems. Contact: Herb Bond, 513-772-0060 www.supersystems.com

4 August 2011 - IndustrialHeating.com

Yokogawa The UTAdvanced is Yokogawa’s newest controller that combines PID control and ladder logic. The universal flexibility and ample communication protocols makes the UTAdvanced the most efficient and easy-to-use hybrid controller. Contact: 800-258-2552 www.yokogawa.com/us

FURNACES & OVENS Can-Eng Furnaces, Ltd.: Furnaces, Heat Treating Leading North American designer and manufacturer of heattreating equipment for ferrous and nonferrous metals. Products include furnaces, auxiliary equipment, atmosphere generators and process-control systems. Quality management system is registered to ISO 9001:2000. Contact: Steve Cropper, 905-356-1327; [email protected] www.can-eng.com G-M Enterprises: Heat-Treating Furnaces G-M manufactures a wide range of furnaces, including vacuum, box, bell, batch and continuous. Contact: Suresh Jhawar, 951-340-4646 www.gmenterprises.com Ipsen Inc.: Heat-Treating Equipment Ipsen manufactures, retrofits and services vacuum and atmosphere thermal-processing equipment for TurboTreater, TITAN, MetalMaster,VFS HEQ/HIQ/VDS, aluminum brazers, vacuum carburizing, vacuum oil quench, Ivadizer and atmosphere products. Contact: Mark Heninger, 815-332-2512 www.ipsenusa.com Solar Manufacturing: Vacuum Furnaces Solar Manufacturing has more than 100 combined years of experience in vacuum furnace design. Featured are improved graphite insulation materials, curved graphite heating elements, tapered gas nozzles, high-velocity gas quench systems and more. Contact: 267-384-5040 www.solarmfg.com Surface Combustion, Inc.: Heat-Treating Furnaces Industrial manufacturer of heat-treating furnaces, including controlled carburizing, nitriding and vacuum carburizing. Surface Combustion offers continuous or batch furnaces with atmosphere gas generators and process controls. Contact: Daniel E. Goodman, 419-891-7150 www.surfacecombustion.com Wisconsin Oven Corp.: Ovens Wisconsin Oven offers: custom and standard models; gas or electric; temperatures to 1400˚F; factory tested and adjusted. Contact: Gary Hanson, 262-642-3938; [email protected] www.wisoven.com

HEATING ELEMENTS INEX INEX offers a wide range of composite radiant tube shapes including straight-through, U-tubes, closed-ended and segmented in various lengths and diameters. Contact: Mike Kasprzyk, 716-537-2270 www.inexinc.net

Industrial Industrial Heating’s Heating’s Web Web Search Search Power Power Pages Pages INDUCTION HEATING EQUIPMENT Ajax TOCCO Magnethermic Ajax TOCCO induction heating technology and equipment is ideal for applications requiring fast, localized heat such as brazing, curing, annealing, hardening, seam annealing, melting and forging. Contact: George Welch, 330-372-8511 www.ajaxtocco.com CEIA USA CEIA manufactures induction heating generators, controllers and pyrometers that enable closed-loop feedback for precision heating. Designed for seamless integration into automation, CEIA’s generators can handle endless applications. Contact: 330-405-3190 www.ceia-usa.com

REFRACTORIES & INSULATION SGL Carbon Group SGL is a full-service material supplier specializing in hightemperature applications and customer support. Contact: Lee Young, 610-670-4070 www.sglcarbon.com Unifrax High-temperature insulation products including Fiberfrax ceramic fiber, Insulfrax and Isofrax soluble fiber, and Foamfrax thermal insulation. Contact: Virginia Cantara, 716-278-3832 www.unifrax.com

THERMOCOUPLES Induction Tooling, Inc.: Induction Equipment & Services Induction Tooling is widely recognized as the premier manufacturer of tooling for induction hardening. Our excellent reputation is the result of building high-quality inductors. Contact: David Lynch, [email protected] www.inductiontooling.com Inductoheat, Inc. - An Inductotherm Group Company Inductoheat, Inc. is one of 40 companies making up the Inductotherm Group and is leading the world in induction heating technologies. Inductoheat can solve your most challenging heating, heat-treating and forge heating problems with our wide range of induction heating equipment and services. Contact: Tim Boussie, sales application manager, 248-688-3121 www.inductoheat.com

Furnace Parts LLC Furnace Parts is an industry leader in the manufacture of specialty thermocouples and temperature sensors. Our expertise includes a full line of assemblies. Contact: John Popovich; [email protected] www.furnacepartsllc.com

VACUUM PUMPS Edwards We are at the forefront of vacuum technology for all industrial applications providing high quality, reliable and cost-effective solutions with reduced environmental impact. Contact: Dave Sobiegray, 716-440-2442 www.edwardsvacuum.com

GET CONNECTED www.industrialheating.com/connect

Now it's easier than ever to stay connected to the best source of news and technology in the industry! IndustrialHeating.com - August 2011 5

TECHNOLOGY CONTINUOUS FURNACES

NITRIDING FURNACES

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Gas Nitrider Designs 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

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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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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. Q

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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

CONTENTS

August 2011 • Vol. LXXIX • No. 8

On the Cover:

A R T I C L E S

A fully automated traversing Rockwell hardness testing system from Wilson Hardness is shown testing multiple samples.

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Advanced Process Controller Improves Refractory Production Steve Maus – West Control Solutions; Gurnee, Ill. In today’s cost-conscious environment, metal producers, heat treaters and their suppliers are looking for every possible edge. A small investment in improved process control can pay big dividends.

Induction Heat Treating

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Induction Hardening of Very Large Rings and Bearings Otto Carsen, Stefan Dappen and Dirk M. Schibisch – SMS Elotherm GmbH; Remscheid, GERMANY Translated and adapted by George Burnet – SMS Elotherm North America When the going gets huge, heavy and hard … very large bearings and rings are required to carry high loads and their resulting torques. These components are highly stressed and are, therefore, induction hardened to increase their dynamic strength and wear resistance.

42

F E A T U R E

Process Control & Instrumentation

Materials Characterization & Testing

Automated Hardness Testing Improves Productivity, Accuracy, Efficiency Bill O’Neill – Wilson Hardness; Norwood, Mass. Hardness testing is a fundamental characteristic in analyzing component properties. As an important materials-testing tool, this critical parameter can be performed and measured by a multitude of methods and techniques.

45

Melting/Forming/Joining

Ebeam 2010 Conference Review Robert Bakish – Bakish Materials Corp.; Englewood, N.J. Ebeam 2010 featured 19 speakers and was attended by 60 companies from Brazil, Canada, Czech Republic, Kazakhstan, Russia, Ukraine and the United States. Learn more about this technology, including research updates from around the world.

IndustrialHeating.com - August 2011 7

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COLUMNS 14 Editorial Skills Deficit In spite of a recession of epic and global proportions, the manufacturing skills deficit continues to be a problem. The key cause of the problem is twofold: the retirement of baby boomers and the college-only tracking of students. Meet August’s Facebook friend here as well.

16 Federal Triangle How to Sell our National Birthright Barry Ashby sheds light on a Chinese builder’s plan to buy land in Idaho to build a city and industrial park modeled after special economic zones that currently exist in China.

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18 The Heat Treat Doctor™ Hot Gaseous Corrosion The effects of corrosion on engineered materials are well documented. The focus for most corrosion engineers is on aqueous corrosion. As heat treaters, however, the effects of hot gaseous corrosion in our heat-treat furnaces are of more immediate concern.

22 MTI Profile – Induction Heat Treating Corp. 24 IHEA Profile – THERMPROCESS a Success for IHEA

18 DEPARTMENTS 26 Industry News

53 IH Economic Indicators

33 Industry Events

54 The Aftermarket

51 Literature Showcase

56 Classified Marketplace

52 Products

62 Advertiser Index

SPECIAL SECTION N HTS Names New Board Members

48 HTS insider News from the ASM Heat Treating Society

Liquide where she directed eral indus the busin tries in ess devel the emer ern Europ

opment op ging econo e and Russia for sevMetals mies of . Previo The HTS Awards market 2011 HTS/ Central/Ea usly, she for Air and Nominatin strongly manage stProdu g Committee board members, ged the involved Heat Trea Bodycote Best named new Global including Roger with Cente cts and Chem a found Paper ting Awa (Athens, Ala.) as ical Meri icals. Jones to serve in president for the The winne r for Heat rded start-up engineer/coop ing member, as vice 2011-2013 term; r of the was Treating and as planteratio He has served manager William Flower, 2011 HTS/B topher Klaren Paper in a busin Excellence n with(1988-94 in different positions and Meri Lazar Chrisess leade E national ). Heat Treati (U.S./ odycote as ous facilities, including atCana the company’ to serve on the r she advo for the 2011-201 Heat Treati Best ng Awar da), AFS s vari-and local socie HTS Board plant manager d is “Intel 4 term; and cated (France), ng: Simul (U.S.), ties 1994-96), start-up (Grand Brett Carlson ligent student board Process,” CTIFRapids, ation of engineer/plantmem (France)Mich.;MPIF (U.S.), ASME such as: CCM to serve as member for the Carburizat by A manager and AWT 1995-97), vice ber of (Holland, 2011-2012 term. T (Aus begin Sept. 1, (Austria), Wei, Ph.D. (primary autho ion ASM president of operation Mich.; (Germ The terms 2011. Leaving Heat r) Ms. Yingy ATTT has serve student, land, Athens, and s (Grand Rapids, Treating Socie any). Meri has the board are Sisson Jr., FASM engineerin ing materials h been Elkhart, Ind.; 1997-200 d in vario Dr. Richard ty for over us Hol(past president) g, Worc science a ident (2004-11 4), senior vicecapacities. , Fred Specht tute. The ester Polyte Michael Wright and 15 yyears ) and president Brett pres(member), awar (member), Roger and chnic since April 2011. d will be to develop the HTS Gene coming vice president) Jones (elected on isBill next-generation and Carls intends presented Insti- Winner of the HTS/ as infrom ral Mem , Dr. Soraya managem currently succession planning, Rapid City, at the Bodycote ent isteam through Nov. 1, Benitez (young sional board bership 2011 mentoring Schoo a member) and 2011 S.D., profesjunio Meeti and training; , at the implement integrated John Metzger l of Mines ng on Best Paper at South Exposition member). Terrence to developr and HTS Confe in (student board Dakota IT systemsing and Techn in Cinci Brown remains rence and Treating AwardHeat for a process cess managem degreecontrol and nnati, 31, 2011, and president through The ASM ent; to integrate ing. , Ms. in meta pro-ology, pursuThomas Clements Yingying Aug. Heat Treati Ohio. a lean/six llurgi Brett sigma-bas ity culture; and Wei. in Heat Sept. 1, 2011. becomes president participateed qual-cal engin ng Socie to continue to Scien Treating eeron move ce d in the ty estab tainable, process toward Award Found represents “green,” lished the Continuing board National ation Resea or susin 1997 technology. for advancem Best Paper members include Undergrad to recog rch motes heat (FASM), Dr. B. ent in Dr. Subi Dinda Lynn Ferguson 2010, where uates in the Experience heat-treati nize a paper Christopher (FASM), Michael clear adva treating in some that der (FASM), Dale ng techn summer he resea M. Klaren is const J. Schneisubstantia ncement ology, of Weires, John general rched ructed pervisor/b suing. The proin mana historical l way or R. Keough (FASM) Ralph Poor. a furna usiness unit manager award The new board repor ging the ce for the represents direct iron and of t.heatincludes treat operation He is the will begin its term endowed business process 2011. a reduction, s at Deere andarship a plaqu recipient on Sept. 1, by of heat e and a Company , the ,South of the D.W. and wrote a techn Waterloo Tractor treatwww.asmin Bodycote Therm $2,50 Works, Iowa.SDSM Dakota al Proce Fuerstenau ical ternationa He graduT Tech Oppo ated from the ss – North 0 cash prize l.org/hts Roger A. Jones MET Schol University of Dubuque Sch America. a Materials Challenge Schol rtunity Scholar to read is corporate president 1977, earned Award and Robert Visit inAdva the winni of Solar Atmosphe his M.S. ntage Stude arship. He also Gaster ng pape res Inc. After Rece is a mem the Iowa State University in metallurgy from r. Distingui nt Chap graduating from Hocking ber of ter. shed Serv ives CHTE in 1979 and joined Technical College, the company Robert ice Awa joined ABAR Corp. he as process metallurgi Gaster, rd in 1975. In 1978, senior st in its heat-treat tions. For the staff engin joined Vacuum he next 16 years,Bern operaeer for Furnace Systems ard Rece he worked materials Waterloo facility’s in Corp., all which was founded areas ives engin heat-treatTrea the 2011of eering ting Achie processes by his father, Geor the Deere appointed leader . In 1995, at liam R. Jones, WilvemeChris was ge Bodeen of the Heat Willia & Comp FASM. In m Manufactu Treat J. Berna ring nt Award Heat Moline any ing Group and found Solar Atmosphe 1983, he helped rd Jr., presid Technology Engineerto his currentof Surfa positioncein Comb res Inc., serving novation heat-treat organizati In1998.ustion fore becoming as vice president Chris ledent Ohio), is Center, theand CEO on through president in 1993 bethethe was presented Westfield Ave. redevelop (Maumee, recipientment Inc. and corporate 2001. He has site in Waterloo H. from of the the Cente president in been a member Bode2003-200 for Heat en Heat 6, of the 2011 ital project that of the Metal Treating r since 1983, serving a large cap- George resulted in Awar Treating Treati Institute d. improved ng Achie on the Board cellence Exefficiencies and processes, equipmen of and 2009-pres (CHTE) operations safety. EstabMore t, vement ent) and as president Trustees (1998-2004 Distinlishedrecently, guished a new capacity-e been a member in 1996 (2004-05). Roger he, manages Service xpansion ogniz es in distin of ASM Philadelph project Awar has this at the increased customer heat guish treat ed since 1983 and ia Liberty Bell to respondaward CHTE meeti d contribution recdemand. to Chapter served as chapter and Chris has held in ng the Northeast s president (1993-94 was chair of the the fiaeldmember signifi May fi Iowa Chapter manageme tobeen ASM Heat Treating of heat of cant ). He of ASM nt ter Polyte at the Metal Proce board member, since or engin treating 1979, Society (HTS) Immediate Needs Committe chnic Institu serving as mercial vice chairman ssing Institu eering through e and the HTS andimpa porters, devel chairman. He in revising the te. Amon leadership, Education Committe te (MPI) on the Nominatin Gaster participatedopment of outstanding ct. Berna ASM Handbook at Worc g CHTE e, served served g Committee for substantial Volume 4: Heat rd is recognized with the es’s most ods of Measuring in sever two separate terms a member of the Treating, center. comand “for innov ment manu vision ardent al capa Case Depth passioMethHTS T&P Committe He was and is and presented sselection supcities durin ative n as facturing papers Heat Treating chair of e. He was elected HTS Board in committee commitmen Society Conferenc g his tenur for the heatat ASMan entrepreneu thinking, 2005. the board to the ccommittee. es. t to and e r of equip treating and the Presenting served on CHTE The awar educating the projectApelian, A next gener marketplace and ’s strate Meri Lazar is the awar William D. Flower director, Membersh d presentation gic-planni ation of for an internation d are (from MPI; Bob will director-atdi al businessis president of heat treate ip Meeti ng development advisor left to right) cialty Heat Treating SpeGaster; ng on Nov. be made at the rs.” large. Socie withing and Roge Diran a deep ty Inc. He earned HTS 1, Confe interest in 2011, at the critical link General r Fabian, B.S. in mechanic rence and his between technolog the ASM al engineering CHTE Exposition Heat Treaty and research, operation in 1979 from Western in Cinci s and marketing Michigan University nnati . is , She a Ohio. graduate engineer and a graduate degree in metallurgy from in finance in 2005 ASM INT Romania, with from Chicago Graduate industry experience Join ASM ERN ER RNA School of Business. ATIO A gained T while I O working and living Today: was president NAL –Th NAL of Material Damage He ww www e Hea ww..asm tries. Meri’s experience in various counHe t Trea asmiinte Consultants Inc. (1982-88 nterrnat includes leadership ting Soci natiiona ) before joining uide Group and onal.org roles in Air LiqSpecialty Heat ety Air Products and Treating 48 August 2011 > Sele Chemicals Inc. returned to the - IndustrialHeating.com ct "Membe She recently U.S.Treat from an overseas Heat Insider.. rship" appointment with indd 49 Air

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AWARDS

Heat Treat Insider.indd

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ating.com

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

8 August 2011 - IndustrialHeating.com

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

Anytime, Anywhere

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

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

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

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Everyday Metallurgy Boring Made Interesting A tunneling project to extend a subway line created interest in the large Tunnel Boring Machine being used. Just how does this 23-footdiameter machine with a length of 200 feet and a weight of 1.2 million pounds cut 35 feet of tunnel every day? And how does thermal processing play a role?

Product of the Month

Online Exclusive Interview with Bodycote’s Tracy Glende Industrial Heating recently had an opportunity to interview Tracy Glende, president of Bodycote’s Aerospace, Defense and Energy division. The U.K.based company, which is the world’s largest provider of thermal-processing services, issued several press releases at the 49th International Paris Air Show in late June. Glende took some time to answer questions pertaining to the releases and also responded to general questions about the economy and Bodycote. To read this interview, visit www.industrialheating.com/ bodycote or click on this Mobile Tag.

The Raytek MI3 sensors are now compatible with the Modbus and Profibus network protocols, allowing them to be used in a wide range of applications requiring digital communication for field devices. See page 52 for more details.

Webinar Temperature Sensing/Control: The Right Tools Save You Money Aug. 18, 2:00 p.m. Dr. Rick Martin of Martin Thermal Engineering will review the present state of temperature technology. Click this Mobile tag for more information.

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.

10 August 2011 - IndustrialHeating.com

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

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

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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: Timothy A. Fausch 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

12 August 2011 - IndustrialHeating.com

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

Skills Deficit

I

n spite of a recession of epic and global proportions, the manufacturing skills deficit continues to be a problem. We have discussed some of the reasons for this in the past, but the key cause of the problem is twofold: the retirement of baby boomers and the college-only tracking of students. The problem with the first factor is that boomers will be retiring from now until about 2030. The recession might have absorbed some of these early retirees, but what will we do when business is going well and the largest part of our workforce continues to retire? Do you have a plan? Do you have people in the pipeline, training to take the place of these older stalwarts? We can’t wait until they leave to begin thinking about it. A number of programs exist to connect students to manufacturing. Some involve younger children – middle and high schoolers – while others connect universities with industrial partners. One such program is a partnership between Western Kentucky University (WKU) and Logan Aluminum. Back in February, Logan Aluminum donated $300,000 to create the Logan Aluminum Industrial Partnership Program and to fund an endowment for the Logan Aluminum Student Fellowships. The program will provide students at WKU’s Department of Engineering with access to industry-based projects, summer work, special assignments and a cooperativeeducation program. More and more companies are taking the same approach. Advanced Technology Services Inc. (ATS) of Peoria, Ill., helps pay for 40-week community-college training programs, and it funds scholarships for engineering students at universities. Two ATS managers spend most of their time with high schools, attending career days, conducting plant tours and meeting with guidance counselors. A recent WSJ article highlighted some of the issues challenging manufacturers in their search for qualified people. It said that “the U.S. education system isn’t turning out enough people with the math and science skills needed to operate and repair sophisticated computer-controlled factory equipment, jobs that often pay $50,000 to $80,000 a year, plus benefits.” A spokesman for Lehigh Heavy Forge said that he needs people who understand the intricacies of $1 million lathes and other metalshaping equipment. Because the school systems are not doing it, some companies have developed their own apprenticeship programs to train people for their industry-specific needs. An example is the Apprenticeship 2000 program started by a North Carolina manufacturer, Blum Inc. In the program, apprentices receive 8,000 hours of training in manufacturing skills – classroom as well as hands-on. A dedicated lab with $1.8 million in training equipment is utilized. Graduates receive an associate’s degree in manufacturing technology and a journeyman certification from the North Carolina Department of Labor. They also earn a paycheck while they learn. Training includes career paths for tool and die makers, electronics technicians, CNC machinists, machine technicians, mold/plastics technicians and welding fabricators. Other local companies, such as Timken and Siemens, are also participating in the program. The bottom line is that your company will be faced with this issue sooner or later. What can you do now to prepare yourself? How can you help students to see that manufacturing offers a viable career path? IH 14 August 2011 - IndustrialHeating.com

onth Friend of the M

Theresa O Fallon

Process Engineer North American C onstruction Services, Ltd. (NAC S)

T

heresa was an intern at NACS in Birmingham, Ala., for the past year. NACS specializes in designing/ engineering/building/maintaining/ retrofitting furnaces and optimizing thermal processes. NACS is a part of Fives North American Combustion.

College: Recent graduate of the University of Alabama at Birmingham (UAB) Degree: B.S. degree in Material Science Engineering B.S. degree in Chemistry Career Note: Theresa’s senior design project – an iron-melting cupola furnace with a heat exchanger – won the 2010 ASM International Undergraduate Design Competition. Activities: Exploring, biking, swimming and rock & mineral collecting IH Reader: Theresa has been reading Industrial Heating online for a couple of years and recently subscribed to the print edition. Find us on www.industrialheating.com/facebook

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

How to Sell our National Birthright

I

t all began innocuously. There were announcements last autumn that Sinomach, a Chinese builder, wanted to buy land near Boise, Idaho, to build a 30,000-acre city and industrial park modeled after special economic zones (SEZ) that exist in China. We find with some investigation that state-owned Sinomach (China National Machinery Industry Corporation), established in January 1997 and active in 130 countries, is managed by the Communist Party of China (CPC). In a May 26, 2009, description by Dr. Xu Dixin, Chinese Academy of Social Sciences and CPC master theoretician, as printed in Beijing Review, SEZs closely adhere to former Soviet leader Vladimir Lenin’s “new economic policies” defined in the 1920s. With a bit more checking we find that the U.S. government has already set up 257 “foreign trade zones” nationwide and, would you believe, the SEZ fits exactly into that definition. Then we find with more checking that these planned SEZ sites are only a “beachhead,” as specifically stated by Governor Butch Otter and his Commerce Secretary Don Dietrich. Know that the dictionary definition of beachhead is “an area on a hostile shore occupied to secure further landing of troops and supplies.” It is now evident that Sinomach is looking at similar sites in Ohio, Pennsylvania and Michigan. I am not a conspiracy theorist, but it is evident that China wants to buy U.S. property and build city and industrial establishments within U.S. borders that are outside both individual state and federal controls. It also appears that governments (state and local) are complicit to ensure that this happens. The political establishment believes that the CPC is benign in intent and does so at YOUR peril. Several politicians, including former governors (Huntsman of Utah and Locke of Washington), publicly stated that “China is more capitalist than the U.S.” This is a gross lie. The CPC has an agenda to defeat America, and the approach described here just might be it. The CPC controls a large portion of U.S. debt, so they can call the shots. Remember that in 2010 China had a “current account balance” of $272 billion (the largest in the world) and the U.S. had negative $561 billion, nine times larger than any nation 16 August 2011 - IndustrialHeating.com

on the planet. This means that America sells the national birthright when a foreign, adversarial state controls such assets within our Republic. China has the means to command this outcome and projects a suspicious agenda. When I say adversarial, let me be specific. Chinese military officials constantly talk about coming conflict between China and the U.S. They now have as many attack submarines as the U.S. Their newest fighter jet (introduced a few hours before Secretary Gates retired at the end of June as a show of “in-your-face”) more than rivals the F-22 Raptor – it is larger, carries more fuel, flies higher and faster, and has better anti-detection stealth. On June 27, the Senate passed a resolution that “deplores China’s use of force” against neighbors in the South China Sea. The Chinese Foreign Minister immediately said that the resolution “did not hold water” and that the U.S. “should not interfere.” Analyses by Australia’s Lowy Institute address China’s military risk-taking behavior as raising the chances of armed conflict and that China’s “frictions with the United States are likely to persist and intensify.” It is notable that China has been practicing this art of “industrial city building” and has several cities fully constructed. Vacant towns, each capable of housing more than 1 million people with contained industrial plants, are scattered throughout the Chinese boondocks. Some existing SEZ cities are in Zhuhai, Shantou, Xaimen and Shenzhen, which has grown to 14 million people from nothing 30 years ago. A new city at Ordos and several others are totally empty. The intent is to create new industries because China has more people than jobs. Furthermore, China has already exported this concept. In Sudan, for example, Chinese financing, weapons and prison labor operate the oil industry for the local (incompetent and corrupt) government. Extend all of this and imagine a bit of downtown Communist China right there in Idaho. Delightful. While preparing this article, I contacted Idaho Senators Mike Crapo and Jim Risch, Congressmen Raul Labrador (1st) and Mike Simpson (2nd), and Governor Otter (all Republicans) and asked about their position on this subject. The most complete reply I obtained was from a press secretary: “He only knows what he reads in the newspaper.” Unbelievable! IH

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

Hot Gaseous Corrosion

D

a and information on the effects of corrosion on ata engineered materials are available in many forms e and from many sources.[1–15] The focus for most cora rosion engineers is on aqueous corrosion, an imporr tant topic in and of itself. As heat treaters, however, the effects of hot gaseous corrosion in our heat-treat furnaces are of more immediate concern. Let’s learn more.

• • • • • • • •

Corrosion Basics We begin with the realization that all materials are chemically unstable in some environments, and corrosive attack will occur. It can often be predicted or modeled by studying thermodynamic data and knowing which of the many corrosion-related chemical states are active. In the real world, however, it is important to recognize the various forms of corrosion: Uniform (or general) attack Intergranular attack Galvanic (or two-metal) action Erosion Dezincification (or parting) Pitting Stress corrosion Electrolytic (or concentration) cells

When it comes to corrosion, the greater the metal’s solubility, the greater the degree and severity. There are many important variations on the above, and two of the most important are (a) localized corrosive attack (e.g., pits, intergranular attack, crevices, galvanic action) and (b) interaction with mechanical influences (e.g., stress, fatigue, fretting). These actions are frequently very rapid and have catastrophic effects.

Fig. 1. Pusher-furnace alloy fan and shaft assembly

18 August 2011 - IndustrialHeating.com

There are also a number of ways to combat corrosion, including: alloying to produce better corrosion resistance; cathodic protection (via sacrificial anodes); coatings (metallic or inorganic); organic coatings (e.g., paints); metal purification; alteration of the environment; nonmetallics and design (i.e. physical) changes. Heat-Resistant Alloys Furnace interiors contain numerous examples of heat-resistant iron-nickel-chromium (Fe-Ni-Cr) alloys for such items as radiant tubes, fans, heating elements, roller rails and rollers, chain guides, and atmosphere inlet tubes to name a few. Baskets, grids and fixtures are other examples. These alloys are normally selected based on their strength (at temperature) and resistance to corrosive attack. Since these heat-resistant alloy parts are often the most expensive furnace components, heat treaters should have an understanding of how they can be attacked and what can be done to extend their life by minimizing or preventing it. Gas-Solid Reactions A chemical reaction involving a solid and a non-equilibrium gas or gas mixture can be classified as a gas-solid reaction. Examples of intermediate and high-temperature reactions of this type include oxidation, sulfidation, carburization, nitriding, chloridation and the like. The principles are the same for all these types. Only the details differ. As heat treaters, our interest is in controlling, retarding or suppressing these reactions to prevent unwanted corrosion, gasification or embrittlement of the furnace alloy or materials being processed. Examples of Catastrophic Carburization (a.k.a. Metal Dusting) Metal dusting (Fig. 1) is a hot gaseous corrosion phenomenon in which a metallic component disintegrates into a dust of fine metal and metal-oxide particles mixed with carbon.

Fig. 2. 330-alloy radiant tube removed after six months of use (rotary retort furnace)

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Generally, metal dusting occurs in a localized area. How rapidly the disintegration progresses is a function of temperature, the composition of the atmosphere and its carbon potential, and the material. Other significant factors include the geometry of the system, reaction kinetics, diffusivities of alloy components, the specific volume ratio of new and old phases, and the ultimate plastic strain. Metal dusting usually manifests itself as pits or grooves on the surface or as an overall surface attack in which the metal can literally be eaten away in a matter of days, weeks or months. As an example, the writer has seen a 330-alloy plate mounted underneath a refractory-lined inner door of an integral-quench furnace (where atmosphere passes underneath the door and into the quench vestibule) reduced in thickness from 12.5 mm (0.5 inch) to less than 0.75 mm (0.03 inch) in a little over two months. In another example, a metallographic investigation of a failed wrought 330-alloy radiant tube (Fig. 2) was conducted. Optical microscopy of the inside (Fig. 3) and outside diameter surfaces in the attacked area revealed evidence of massive carbides. These carbides formed by the reaction of carbon with chromium, depleting the matrix of chromium in regions adjacent to the carbides. Grain detachment and subsequent failure by erosion then occurred. How does it occur? In general, catastrophic carburization of ferrous alloys proceeds via the formation and subsequent disintegration of metastable carbide. The first step in the process is absorption of the gaseous phase on the surface of the metal. The more reactive this phase, the easier it decomposes or is catalytically decomposed (in the case of iron) on the surface. This step is followed by diffusion of carbon atoms from the surface into the bulk metal. As a result, there is a continuous buildup of carbon within the surface layer. As this layer becomes saturated with carbon, a stable carbide, metastable carbide or an activated carbide complex forms. It then grows until it reaches a state of thermodynamic instability, at which point it rapidly breaks down into the metal plus free carbon. It’s at this stage that the metal disintegrates to a powder as the result of plastic deformation and subsequent fracture in the nearsurface layer. The process is controlled by internal stresses due to phase transformation. In other words, competition between stress generation and relaxation exceeds the ultimate strength in this near-surface layer and causes fracture to occur. In Fe-Ni-Cr alloys, the phenomenon occurs slower (but does not stop) since the disintegration leads to larger metal particles, which are less active catalysts for carbon deposition than the fine iron particles that form with ferrous metals. Therefore, the mass gain from carbon depositing onto high-nickel alloys is much lower. Also, the decomposition of high-nickel alloys occurs by graphitization and not via unstable carbides. Pourbaix-Ellingham Diagrams Thermodynamics can be applied to solid-gas reactions such as 20 August 2011 - IndustrialHeating.com

Fig. 3. Microstructural view – catastrophic carburization

oxidation, carburization, sulfidation and nitriding to obtain equilibrium dissociation pressures below which no reactions occur. Diagrams are available of the free energies of formation versus temperature for most metallic compounds. An interesting use of Pourbaix Diagrams (generally reserved for mapping out possible stable equilibrium phases of aqueous, electrochemical systems) as a predictor of stable alloy systems is found by superimposing the various elemental constituents. These diagrams are read much like a standard phase diagram (with a different set of axes). Final Thoughts Hot gaseous corrosion should be an area of focus in an effort to extend the life of alloy components, reduce downtime and save money. IH References 1. NACE International (www.nace.org) 2. ASM International (www.asminternational.org) 3. Uhlig, Hubert H., Corrosion and Corrosion Control, Wiley-Interscience, 2008. 4. Fontana, Mars G., and Norbert D. Greene, Corrosion Engineering, McGraw-Hill, 2008. 5. Nateson, K., Corrosion-Erosion Behavior in Metals, Metallurgical Society of AIME, 1980. 6. Gas Corrosion of Metals, National Bureau of Standards, 1978. 7. Herring, D. H., “What to Do About Metal Dusting,” Heat Treating Progress, August 2003. 8. Staehle, R. W., “Engineering with Advanced and New Materials,” Materials Science and Engineering A, Volume 198, Issues 1 – 2, 1995, pp. 245 – 256. 9. ASM Handbook Volume 13A - C: Corrosion, ASM International, 2003. 10. Oxidation of Metals and Alloys, ASM International, 1971. 11. Javaheradashti, Raza, Microbiologically Induced Corrosion, Springer-Verlag, 2008. 12. Pourbaix, Marcel, “Atlas of Chemical and Electrochemical Equilibria in the Presence of a Gaseous Phase,” NACE International, 1998. 13. Pourbaix, Marcel, “Atlas of Chemical and Electrochemical Equilibria in Aqueous Solutions,” NACE International, 1974. 14. Schweitzer, Philip A., Corrosion Engineering Handbook, Marcel Dekker, 1996. 15. Stempco, Michael J., “The Ellingham Diagram: How to Use it in HeatTreat-Process Atmosphere Troubleshooting,” Industrial Heating, April 2011.

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Induction Heat Treating Corp. Induction Specialists Since 1946

S

i ixty-fi ve years ago, an induction heating specialist at a General Electric established a small, independent business near Chicago. Omer Haimbaugh’s company b would soon be recognized as the country’s first comw mercial induction heat-treating plant. That same company, now known as Induction Heat Treating Corp., currently occupies a 35,000-square-foot facility in Crystal Lake, Ill., and employs 60 people over three shifts. Haimbaugh’s venture gained momentum during the Korean War, when it used two 15-KW high-frequency induction heaters primarily to induction harden fuse bodies for air-to-air missiles. The tip had to remain soft so that the missile would detonate upon contact. This process involved austenitizing the fuse body in nitrogen to prevent scale formation while heating. But that’s not all the company did. The early years also ushered in processes such as annealing (for Ford hub caps) and tin soldering (for bread pan corners). Other large-production jobs included the silver brazing of covers for temperature controllers, the soft soldering of gas tanks for lawn mowers and the case hardening of 12-foot steel bars. In 1972, the company name was changed from Induction Heating & Engineering Inc. to Induction Heat Treating (IHT) to reflect the desired future path of the business. Today, IHT serves a wide variety of industries – the most prominent being automotive, agriculture, military and construction – with an even wider array of services. IHT’s capabilities include induction hardening, induction annealing, induction scanning, induction brazing, induction shrink fitting, selective hardening, selective annealing, induction tempering and induction case hardening. In fact, there isn’t much that IHT can’t do. The company has 22 induction power supplies in the entire range of frequencies (1450 KHz) with customized work stations. This range of equipment allows for versatility in processing and allows IHT to process many

parts that other heat treaters aren’t capable of processing. Over the past year IHT has installed numerous new pieces of equipment, including: a 4-foot x 6-foot tempering oven, a glass bead blaster, a micro-hardness tester, three scanners and a portable ultrasonic hardness tester. IHT’s in-house tooling department enables it to successfully complete jobs other companies might not even attempt, saving customers both time and money. The maintenance staff – with more than 60 years of experience – is committed to keeping the tooling operation at full strength while continually searching for improvements. In addition to its process and equipment capabilities, IHT boasts a quality system that is unsurpassed in frequency of inspection, attention to detail, and efficiency of order retention and traceability. IHT, Industrial Heating’s 2010 Commercial Heat Treater of the Year, is both ISO and CQI9 certified. The company, which was also the first company to receive the Commercial Heat Treater of the Year award in 1995, has implemented a comprehensive employee training program that includes classroom instruction with written exams, a video library to offer visual aid and hands-on training. Weekly training meetings are held to discuss production issues and safety. IHT, which is still owned and operated by the Haimbaugh family, is not done investing and expanding. The company has recently remodeled its main office and plans on adding straightening and consulting services as well as possibly installing a new hardening furnace. Over the course of the IHT’s long history, business has shown to double every 20 years. With that goal in mind, adding a second facility in the Midwest is not out of the question. For more information, visit www.ihtcorp.com.

22 August 2011 - IndustrialHeating.com

Ensuring Certainty

Reaching new Heights in Hardness Testing DuraVision - Struers Newest Universal Macro Hardness Tester A fully automatic universal and macro hardness tester with innovative features and increased automation is a natural complement to any production environment testing large or heavy samples in cast iron, steel and aluminum. The DuraVision creates ef¿ciencies in a production environment. An entire test cycle of load application, indentation, focusing, illumination adjustment and hardness evaluation is now carried out automatically – thereby ensuring 100% repeatability in testing. It’s fast, simple and accurate.

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Telephone: 888.STRUERS (787.8377) | Email: [email protected] | Web: www.struers.com

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THERMPROCESS a Success for IHEA

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ew ventures often bring a lot of different emotions with them – uncertainty, excitement, anticipation, success. IHEA’s first Resource Center, in conjunction with Industrial Heating, at THERMPROCESS in Düsseldorf, Germany, was all of those and more. The Resource Center, with 10 sponsors, was very active throughout the week offering information on IHEA’s educational programs, resources and members as well as providing a place for sponsor presentations and for attendees, member companies and prospective members to gather and network. THERMPROCESS is held every four years in conjunction with three other trade fairs: GIFA (International Foundry Trade Fair), METEC (International Metallurgical Technology Trade Fair) and NEWCAST (International Trade Fair for Precision Castings). Post-show reports from organizers in Germany noted that this year’s events closed with a record high number of exhibitors and visitors – 1,958 exhibitors met with 79,000 visitors from 83 countries. With these results, the four events impressively confirmed their status as the leading trade shows for their respective sectors. The high percentage of international exhibitors and visitors reflects the global reputation these shows enjoy. More than 54% of the visitors travelled to Düsseldorf from abroad, with India, Italy, France, Austria and the U.S. having the highest percentage of foreign attendees. THERMPROCESS also received high marks from both visitors and IHEA Resource Center sponsors. A total of 98% of all attendees said they were pleased with their participation, and 97% reported that they accomplished their goals at the four trade shows. Some 80% of the visitors plan investments over the next two years, and the majority of them attended GIFA, METEC, THERMPROCESS and/or NEWCAST in order to prepare for this purpose. In addition, concrete business deals were concluded on site, including the $54 million deal between a German casting

Dan Goodman of Surface Combustion answers questions following his presentation in the Resource Center.

machinery manufacturer and a railway company. There is no doubt that THERMPROCESS attracted visitors that IHEA members wanted to see. “Attendees expect to do business at THERMPROCESS, not just look and see what’s being exhibited, said INEX’s Mike Kasprzyk. “They came with the mindset of doing business to purchase products or start the buying process.” And IHEA’s Resource Center was a success amongst members. “The Resource Center was far more successful than we could have expected,” said Elliott Davis of Selas. Surface Combustion’s Rowan Gwillim said that she loved the idea of having one place for everyone to come and get together. “It’s a great concept,” Gwillim added. Kasprzyk confirmed that IHEA provided a great networking opportunity for its members. The four trade fairs will again be held concurrently in summer 2015 in Düsseldorf. IHEA has already begun the process of organizing an even better Resource Center for that show. “A debriefing session with sponsors before departing Germany provided us with a wide range of ideas that we plan to implement at the next show to make the event even more valuable for IHEA members,” Anne Goyer said. “We look forward to taking many more IHEA members with us in 2015.” IHEA wishes to thank its 2011 Resource Center sponsors: Eclipse (Platinum); Fives North America, INEX, Selas and Surface Combustion (Gold); Dry Coolers and RAD-CON (Silver); and Elster Kromschroder, Vulcan Catalytic and Wellman Furnaces (Supporting). UPCOMING EVENTS

The Resource Center welcomed a Chinese delegation on June 28 for a reception.

24 August 2011 - IndustrialHeating.com

Sept. 19 IHEA Online Distance Learning Courses begin (registration now open) Sept. 27-28 42nd Combustion Seminar; Pittsburgh, Pa. Sept. 28-29 2011 Fall Business Conference; Pittsburgh, Pa. Visit www.ihea.org for complete details and/or to register.

Advancements in Gear Hardening

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Industry News

Equipment News Box Furnaces L&L Special Furnace Co. shipped five multi-purpose bench-mounted box furnaces to a leading steel manufacturer in the southern U.S.The furnaces are used in the laboratory department for testing sample blocks of steel. This is a critical part of the testing and quality department to ensure that manufactured products meet strict quality criteria. The Model GS1714 has internal

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26 August 2011 - IndustrialHeating.com

The Lanly Company designed, built and commissioned an aluminum-tube annealing oven for a metals processing company in Columbiana, Ohio. The oven can process aluminum tubes up to 20 feet in length. A high-volume cross-flow airflow design ensures even heat distribution throughout the oven and temperature regulation of +/-5°F at stabilized conditions. The oven has a maximum air temperature of 800°F and includes a temperature-profile controller with nine-point thermocouple feedback. A balanced, motorized verticallift door with a clamping mechanism for positive sealing is featured. Loading and unloading of the tubes is accomplished with a powered rail-car bottom that also doubles as the oven floor. The primary end use of the oven is for annealed aluminum used in the manufacture of collegiate and high school baseball bats. www.lanly.com

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Industry News

Car-Bottom Furnace Can-Eng Furnaces International delivered a 130-ton carbottom furnace to Edmonton Exchanger, a manufacturer of heavy-walled steel cylinder and dished head assembly units located in Edmonton, Alberta. The furnace, which is designed for stress relieving and reheating at temperatures up to 2000°F, is to be operated as a single 55-foot chamber or two independent heating chambers (24 feet and 31 feet) separated by an inner door. The dual door and two-car assembly gives Edmonton Exchanger the flexibility to utilize a smaller heated chamber as dictated by customer requirements. www.can-eng.com

Box Furnace Lucifer Furnaces shipped an HL7-A12 box furnace to SunCoast Automation 2000 Inc., which designs and builds automated systems for various industries. The furnace, which is ideal for annealing, brazing, hardening and normalizing, has heating elements located on both side 2300°F. e walls and reaches 2300 F. The heavy-gauge, low-watt, density-coiled y-coiled elements are housed in easy-to-replace holders. A 6-inch-high -inch-high x 6-inch-wide x 12-inch-long ng chamber is insulated with 2.5 inches of low-iron insulating brick ck as well as 2.5 inches of mineralralwool block for energy-efficient ent operation and low outside shell hell temperature. A 1-inch-thick hearth arth plates provides a strong work surface for parts. www.luciferfurnaces.com

Pit Carburizing Line Aichelin Heat Treatment Systems will manufacture a pit furnace line consisting of two pit carburizing furnaces, washer, temper and quench to be installed at Flame Metals’ Rogers, Minn., facility. Each pit furnace has a work zone of 78 inches in diameter x 98 inches deep with a maximum gross loading capacity of 30,000 pounds. The furnace line will use the latest Super Systems Inc. controls, which include CarbCALC II for online carbon diffusion, redundant carbon-probe technology, probe plus IR compensation utilizing four gas technology, programmable controls for recipe management and SuperDATA for plant-wide data collection and furnace management. www.aichelinusa.com

Nitriding System Nitrex Metal will supply a NX-811 Nitreg®-S type system to Wuhan Hangda, a leading MRO service provider for aircraft components in China. The packaged system comes complete with a vacuum purge system to accelerate the nitriding process and an INS series neutralizer to meet environmental compliance. The system also complies with Wuhan Hangda’s requirement for “zero white layer” nitriding of aftermarket aircraft parts made of Nitralloy and 17-7 PH stainless steels. Start-up is scheduled for the second quarter 2011. www.nitrex.com

28 August 2011 - IndustrialHeating.com

The Road to Quality... incorporated

Melting, Holding Furnaces Bricmont Inc., an Inductotherm Group Company, was awarded a contract to supply eight high-production-capacity round top-charge aluminum-melting furnaces and eight rectangular, tilting holding furnaces for Weiqiao Aluminum and Electricity Company’s new production facility in China’s Shandong Province. Bricmont will provide engineering, materials, procurement and field services for the furnaces, while Inductotherm Group China will provide local materials, installation and support services. The installation will include regenerative burners, electromagnetic stirring, in-bath metal refining and advanced controls. www. bricmont.com

Induction Hardening System

Business News Waukee Engineering Upgrades Lab

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andprovided Temperature vacuum Vacuum furnace. SSi immediate response, Programmable Controller turnkey installation, and some of the best support that we have ever experienced. The 9220 controller has tremendous allowing us to run Nitriding functionality, and Temperature Programmable Controller Bill Flower Senior VP

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Waukee Engineering Company, a member of United Process Controls, upgraded its ISO/IEC 17025:2005-certified in-house laboratory in Milwaukee, Wis. Along with remodeling the calibration laboratory, investments were made to upgrade to higher-accuracy testing instrumentation. Waukee renewed its ISO/ IEC 17025:2005 accreditation this past March. It provides validation that Waukee calibration and testing services are performed to appropriate standards and assures customers that the flow meters they purchase will meet their expectations and standard of quality. Waukee Flo-Meters™ are typically used in the measurement of industrial gases and liquids in the heat-treating industry.

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Elotherm received an order for an automated induction hardening system. A U.S.-based manufacturer will use the turnkey process solution to make high-performance powertrain components. The system will enable reliable hardening of superior-quality parts with more than twice the throughput of conventional equipment. It will feature Elotherm’s patented inductor designs for hardening rotational parts as well as the company’s patented energy-monitoring technology for precise, real-time control of the manufacturing process. Commissioning is scheduled for 2012. www.sms-elotherm.com

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IndustrialHeating.com - August 2011 29

Industry News

V&M Star Building Tube Plant in Ohio V&M Star is building a new seamless tube plant in Youngstown, Ohio, located in Mahoning County between Pittsburgh and Cleveland. Commissioning of the facility, which includes a hot rolling mill, is scheduled for the first half of 2012. After its completion, the plant will be capable of producing 450,000 metric tons per year of high-quality seamless tubes within a diameter range of 60.3-180 mm with tolerances and mechanical properties according to international standards.

Timken to Acquire Philadelphia Gear The Timken Company announced an agreement to acquire the assets of Philadelphia Gear Corp., a provider of high-performance gear drives and components with a focus on value-added aftermarket capabilities in the industrial and military marine sectors, for $200 million. The acquisition brings proprietary power-transmission knowledge of premium gear drives, replacement products and services for markets including energy and infrastructure. Philadelphia Gear was recently awarded an $80 million contract to provide main reduction gears for the U.S. Navy.

Gerdau Announces New Branding As part of its 110th anniversary, Gerdau is introducing a new brand and visual identity. The long steel and special steel operations of Gerdau in North America, Gerdau Ameristeel and Gerdau Macsteel, will now be known as Gerdau. The descriptor for the long steel operations in North America, previously Gerdau Ameristeel, will be Gerdau Long Steel North America. Gerdau Special Steel North America is the descriptor for the company’s special steel operations, previously known as Gerdau Macsteel.

Ultra Low NOx Emissions of 20 ppm or Less

Bodycote to Open Heat-Treat Facility in Mexico Bodycote announced the planned opening of a new vacuum heat-treatment facility in northwest Mexico. The facility will provide outsourced specialist processing support to major aerospace and powergeneration suppliers in the area. The new plant, located in the city of Empalme in the State of Sonora, is a result of Bodycote’s recently signed long-term agreement with Trac Precision, a key supplier to Rolls-Royce and Siemens. Under this agreement, Bodycote will support Trac’s Mexico operations with vacuum brazing and heat treating. The facility, which is scheduled to open in the third quarter of 2011, will be a more cost-effective option for other aviation manufacturers within the region, enabling them to provide complete processing without transporting parts back to the U.S. The Mexico site will maintain full aerospace accreditation and prime approvals supported by Nadcap and AS9100. To read an interview with Bodycote’s Tracy Glende, where he discusses this new facility and much more, visit www.industrialheating.com/bodycote or click on this Mobile Tag. Get the free mobile app at http://gettag.mobi

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

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

30 August 2011 - IndustrialHeating.com

®

www.hauckburner.com

Industry News

Universal Stainless to Purchase Assets of Patriot Special Metals Universal Stainless & Alloy Products signed an agreement to purchase the assets of Patriot Special Metals of North Jackson, Ohio. Patriot Special Metals is a substantially completed greenfield facility that includes a state-of-the-art radial forge in the initial start-up phase and a vacuum induction melting (VIM) facility that is scheduled to be completed by Universal Stainless for production in the first quarter of 2012. The plant also includes two vacuum arc remelt (VAR) furnaces, scheduled for a fourth quarter 2011 start-up, and related equipment for heat treating and finishing long products. The transaction is expected to close by the end of July.

Carpenter Technology to Acquire Latrobe Specialty Metals Carpenter Technology Corp. and Latrobe Specialty Metals entered into a definitive merger agreement whereby Carpenter will acquire Latrobe in a transaction valued at approximately $558 million. According to Carpenter, the acquisition will provide needed capacity to meet customer demand for its products and improve its position in the aerospace and energy industries. Combining the two companies will improve product mix, lower cost and reduce required capital investments for future growth. The deal is expected to close by Sept. 30.

SECO/WARWICK Establishes Subsidiary in Germany The SECO/WARWICK Group established a new subsidiary in Germany operating under the name of SECO/WARWICK GmbH and having its registered office in Stuttgart. The main objective of SECO/WARWICK GmbH is to increase sales of products manufactured by the atmosphere and vacuum furnace segment of the Group, with focus on low-pressure carburizing with pre-nitriding using PreNitLPC® and FineCarb® technologies. The German subsidiary will offer furnaces produced by SECO/WARWICK S.A. and SECO/WARWICK ThermAL

32 August 2011 - IndustrialHeating.com

S.A. and will provide technical assistance to customers in Germany, Austria, the Netherlands, Switzerland, Liechtenstein and Slovenia.

OBITUARY Jeff Pritchard, CEO of VAC AERO International, passed away June 3, 2011, 13 days before his 54th birthday. Pritchard graduated from the University of Toronto with a degree in metallurgical engineering and soon after pursued a career in aerospace at VAC AERO. His contributions to the company, and to the heat-treating industry, are numerous. During his tenure as CEO, Pritchard helped VAC AERO become a more international business, placing the company on a strong foundation for years to come.

Industry Events

SEPTEMBER 12-15 Euromat 2011 – European Congress and Exhibition on Advanced Materials and Processes; Montpellier, France www.euromat2011.fems.eu 19-21 2011 Die Casting Congress & Tabletop; Columbus, Ohio www.diecasting.org/congress 20-22 Heat-Treatment 2011 – 5th International Specialized Exhibition; Moscow, Russia www.mirexpo.ru/eng

OCTOBER 11-13 Fundamentals of Brazing Seminar, hosted by Kay & Associates; Greenville, S.C. www.kaybrazing.com 16-21 MS&T 2011, in conjunction with ACerS 113th Annual Meeting; Columbus, Ohio www.matscitech.org 17-20 IFHTSE (International Federation for Heat Treatment and Surface Engineering) 19th Congress 2011; Glasgow, Scotland www.ifhtse2011.org 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

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FEATURE | Process Control & Instrumentation

Advanced Process Controller Improves Refractory Production Steve Maus – West Control Solutions; Gurnee, Ill. In today’s cost-conscious environment, metal producers, heat treaters and their suppliers are looking for every possible edge.

I

n the case of a manufacturer of proprietary refractory shapes, a small investment in improved process control is paying big dividends. By simplifying the operation of their firing furnace, the producer now enjoys improved yields, reduced equipment supervision and lower operating costs. The system changes and the resulting improvements are detailed in this article. The supplier offers refractory shapes (Fig. 1) for a variety of thermal-process industries, including metals production and heat treatment. The casting and curing operation includes a box-type, gas-fired furnace that uses profile control to execute cycles that can be over 80 hours long. The critical success factors in the economical production of this class of products are threefold: tightly controlled heating rates, correct process definition and prompt response to equipment issues. Driven by tightening margins and increased competition, the staff determined that replacingg the older-technology gy furnace controls would pay back handsomely if those factors tors could be optimized.

Fig. 1. Typical cast refractory shapes

Energy Services Group (ESG), a furnace builder and control-system integrator based in Channelview, Texas, was called upon to perform the controls upgrade. ESG controls engineer Mike Hunter analyzed the shortcomings of the original control system, surveyed current control technology and selected the West ProVU Advanced Process Controller as a powerful yet economical solution for the project. Specifically, Hunter recognized that a large number of outputs would be needed to improve process control and equipment monitoring. He also concluded that the profiling function of the ProVU would minimize the risk of mistakes in process definition and selection. Heating Rate Control By nature, cast refractory contains a high weight fraction of water. This makes precise control of heating rates at low temperatures absolutely critical, because overheating will damage the product if the retained water is vaporized too qquickly. p y Unfortunately, the original controller could not adequately manage the excess-

air burner system during the slow ramp-up from ambient temperature to the first soak at 300˚F. Furthermore, problems at the high end occasionally resulted in overheating. Even worse, the occasional damage caused by poor control could not be detected until the end of the run several days later when the product was cooled, removed and inspected. The impact of suboptimum control was costly in terms of lost time, wasted energy and material, and missed deliveries. The problem was solved by splitting the temperature range and using on-off control below 300˚F and proportioning control up to the maximum process temperature of 1500˚F. At low temperatures, as the profiling function ramps up the setpoint, a deviation band is used in combination with alarm contacts to cycle a burner control solenoid. Once the 300˚F crossover point is reached, the solenoid is disabled, and a linear actuator takes over for proportioning control. The result is optimum process control over the entire curing cycle, which is made ma possible by the flexibility of outputs p and a alarms in the controller.

Fig. 2. Display screen with plain text IndustrialHeating.com - August 2011 35 Indu

FEATURE | Process Control & Instrumentation

Process Definition While the curing cycles themselves are not complicated, they do vary considerably in terms of heating rate, soak time and temperature. In the previous setup, these cycles were listed on an operator sheet at the furnace control panel and were numbered 1 through 8 as dictated by the controller/ recorder/profiler. The procedure to add or change a cycle was cumbersome and, because of display limitations, programming errors were not easily detected. The results of simple mistakes were often dramatic: If a temperature or ramp rate was set incorrectly or if the wrong cycle was selected, a fourday run would result in a pile of ceramic shards instead of a set of precise shapes. The profiler utility in the new controller provided an elegant solution. The controller display screen uses clear, plain text rather than mnemonic codes to display information, which drastically reduces the risk of programming errors. Navigation between segments and within features of a segment is simplified, and once completed, the profile is saved with a plain-text name. The operator sheet is eliminated because the list of cycles is now on board the controller (Fig. 2), and the risk of choosing an incorrect cycle is all but eliminated. The result: higher yields and improved deliveries. An off-line engineering tool provides utilities for configuration, profile construction and visualization (Fig. 3), and simulation of controller behavior. Start-up risks are minimized because all aspects of the controller can be analyzed and tested virtually before committing equipment or product for real-world validation. In addition, the new controller has a sealed, front-mounted USB port that allows the user to back up the configuration of the device (inputs, outputs, alarms and events) as well as all of the programmed cycles. Conversely, data can also be uploaded from a standard USB memory stick if changes are desired or if another controller requires an identical setup. Once the work on the furnace was completed, the controller and profile data became part of the electronic file for the project. 36 August 2011 - IndustrialHeating.com

Fig. 3. Off-line engineering tool

Prompt Response Capability The older technology of the original control system did not allow for remote signaling of equipment conditions. Given that the furnace is located in a remote part of the manufacturing complex, stationing an operator nearby to constantly monitor it was not cost-effective. Because of the value of the product, however, it was often a necessary evil, especially on weekends when manpower was further reduced. Many of the problems with the initial system stemmed from poor temperature control. The instability of the burner system at low temperatures and the tendency to overshoot in the upper range required frequent attention and intervention. If the furnace was unattended, however, slow response and delayed corrective action could produce off-spec results. The new controller has sufficient capacity to dedicate individual outputs to specific equipment conditions in addition to all of the other tasks noted previously. By using these outputs in combination with a simple PLC and an integrated paging system, key personnel now receive a detailed text message whenever attention is required. Burner flame problems, temperature deviations and end-of-cycle conditions can be automatically reported, allowing immediate response. Even so, the improvements in burner control

noted previously have all but eliminated the need for urgent corrective measures. Compared to the old system, therefore, direct operator monitoring is reduced as is the turn time between furnace cycles. The result: reduced costs. Summary By making a small investment in improved process control and monitoring, significant savings are being realized in refractory production. The new system is simple to operate because of a plain-text controller display, an easily understood profiler utility that minimizes mistakes and an innovative USB feature. Temperature control is improved over a wide range because of the creative use of multiple controller outputs, and operating costs are reduced because of the resulting higher yields and reduced manpower for monitoring. IH For more information: Contact Steve Maus, heat treatment market manager, West Control Solutions, 1675 N. Delany Rd., Gurnee, IL 60031; tel: 317-626-6118; e-mail: Steve.Maus@ West-CS.com or visit www.West-CS.com.

Use this Mobile Tag to locate process controllers in our online Buyers Guide

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FEATURE | Induction Heat Treating

Induction Hardening of Very Large Rings and Bearings Otto Carsen, Stefan Dappen and Dirk M. Schibisch – SMS Elotherm GmbH; Remscheid, GERMANY Translated and adapted by George Burnet – SMS Elotherm North America When the going gets huge, heavy and hard … very large bearings and rings are required to carry high loads and their resulting torques. Typical applications include general machinery, mining, marine, military-aerospace and construction equipment, as well as onshore and offshore energy technologies. These components are highly stressed and are, therefore, induction hardened to increase their dynamic strength and wear resistance.

T

raditionally, case carburizing has been used to harden very large workpieces such as slewing rings, ring gears and bearing races. The carburizing process is straightforward and has been well understood for many decades. The Case for Induction Hardening A growing number of manufacturers, however, are augmenting or replacing their carburizing processes with induction hardening, in which the surface material’s metallurgical structure is transformed (hardened) through a precisely controlled sequence of rapid surface heating followed by rapid cooling (quenching). Practical advantages of induction hardening include: • Minimal workpiece distortion – Induction hardening heats the workpiece

surface. Through-heating is avoided. The rapid heating/quenching sequence minimizes distortion, thereby reducing requirements for expensive and timeconsuming secondary machining and straightening operations. • Superior metallurgical properties – Workpiece heating is limited to the surface area only, and the heating cycle is kept short. Unwanted grain growth is avoided. • Higher throughput – With short cycle times (minutes instead of hours or even days), induction hardening supports higher throughputs and streamlined manufacturing. • Compact machine footprint – Induction hardening requires less factory floor space. Processing the ring in a vertical or near-vertical plane further reduces the equipment footprint.

• Ability to harden extremely large workpieces – Induction hardening can treat very large workpieces (e.g., 6-meter-diameter rings). • Production scheduling flexibility – Like the microwave oven in your kitchen, induction heating is instant on/instant off, with no need for lengthy warm-up, cool-down cycles. Production planners have greater freedom when scheduling small lot sizes and one-off parts. • On-line quality control – Modern induction systems feature energy monitoring systems and hardness checkers for automated on-line QC of each and every workpiece while it is in process. • Reduced energy consumption – Induction hardening primarily heats the surface instead of the entire workpiece. The heating cycle is necessarily short, and total energy consumption is low.

¾

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38 August 2011 - IndustrialHeating.com

Fig. 2. Skin effect – Higher frequencies are used to concentrate heating near the surface and away from the core.

• Low emissions – Induction hardening produces essentially no CO2 emissions. Principles of Induction Hardening Induction hardening is comprised of two process steps: heating followed by rapid cooling (quenching) with a quenching fluid. The heating is caused by alternating current flowing through a coil (sometimes called an inductor) that is sized and shaped according to the workpiece. The alternating coil current creates a corresponding alternating magnetic field that, in turn, induces eddy currents inside the workpiece. These eddy currents produce heat inside the workpiece. The heating depth is inversely proportional to coil current frequency. Higher frequencies produce shallower heating in the workpiece. This very useful phenomenon is known as the “skin effect.” Heat originates inside the workpiece and does not have to be transferred into the workpiece via radiation or convection at the surface. The heating period is therefore short (e.g., a few seconds), and unwanted core heating is avoided (Figs. 1 and 2). Before hardening, the steel workpiece surface contains a mixture of _-iron (ferrite) and cementite (Fe3C) at room temperature. The induction coil heats the surface material to a temperature of at

Fig. 3. Ring hardening machine for large bearings up to 6 meters (tilting design)

least 723°C (the eutectoid temperature), causing the ferrite to transform into a-iron (austenite). The steel is thus “austenitized.” At the same time, carbon from the available cementite dissolves into the austenite because carbon has a much higher solubility in austenite than in ferrite. This dissolved carbon is essential because a steel workpiece must contain at least 0.02% carbon to be hardenable. In the next process step – quenching – the austenitized steel is rapidly cooled at a controlled rate. This rapid cooling prevents the diffusion of carbon atoms and the reformation of original ferrite and cementite mixture. Dissolved carbon atoms are trapped in the ferrite, causing the ferrite body-centered cubic (BCC) crystal structure to deform into a body-centered tetragonal (BCT) structure called martensite. The temperature difference and the cooling rate, which can be controlled by selecting the right quenching medium (such as oil, or water with polymer additives), determine the level of martensite formation. Faster cooling below the transformation temperature produces more martensite. The fresh martensite is hard and brittle. Tempering (controlled heating to prescribed moderate temperatures for defined time periods) reduces this brittleness and gives the steel the desired combination of hardness, strength and toughness. Conventional Induction Hardening Methods for Large Rings and Bearing Races Single-Shot Hardening With single-shot hardening, either the workpiece rotates past one or more stationary inductors or a complete 360-degree ring inductor interfaces with the entire workpiece. The entire bearing surface (race) is heated to the appropriate austenitizing temperature followed by a quench of the entire surface. Quenching may be done by submerging the workpiece in a bath or by using spray nozzles that are integrated into the inductors and tailored for the process requirements. The single-shot process is best suited for workpieces with a diameter less than 2 meters. The induction heating electrical-power requirement grows quadratically with in-

creasing workpiece diameter. For example, single-shot hardening of a 2-meter-diameter ring would require about 1.6 MW of power. Compared to scan hardening, the single-shot process with its high power is very fast, typically measured in seconds. Scan Hardening with a Remaining Soft Zone Scan hardening with a remaining soft zone has been a standard process for hardening single raceway and multi-raceway large bearings. The inductor/spray head assembly is stationary while the ring rotates with a low, constant tangential velocity past the inductor. A small soft zone (unhardened area) necessarily remains at the end of the scan path. With 100 kW of power, a 3-meter-diameter bearing race can be hardened in less than one hour (Fig. 3). New Techniques for Scan Hardening with No Soft Zone With its residual soft zone, traditional scan hardening is inadequate for mission-critical components with stringent requirements for smoothness and heavy loads such as: • Ultra-low vibration systems (e.g., magnetic-resonance imaging, MRI, technology) • High mechanical-stress systems (e.g., tunnel-drilling machines) • Systems where continuous rotation is required or where challenging environmental conditions mandate maintenance-free systems with high lifetime (e.g., wind turbines, tidal plants and oil platforms) Carburizing is limited as a process alternative by furnace size and long process times. Single-shot induction hardening is impractical due to its high power requirement. A better hardening method is needed to efficiently and reliably harden very large, high-value rings. In response to this need, a process to scan harden arbitrarily large rings with no remaining soft zone has been developed and patented.[1] This process differs from conventional scan hardening primarily at the start and end location of the scan, where steps are taken to avoid unwanted tempering and changes in the hardened-zone microstructure. IndustrialHeating.com - August 2011 39

FEATURE | Induction Heat Treating

900 Centerline

800

Hardness, HV1

700 600

5 mm deep 0.5 mm deep

500 400 300 200 100 0

Fig. 4. Illustration of the inductor setup with flux concentrators and spray heads during the starting sequence

Comparing this process to singleshot induction hardening, a 6-meterdiameter ring can be processed with a 200-kW scanning system, which is 1/8th the power the single-shot process would require. In contrast to carburizing, which would require several hundred hours in the furnace, the time required for the induction scan-hardening process (less than two hours) is negligible. Moreover, the cost-intensive and time-consuming straightening operation to clean up the distortion caused by carburizing can be avoided altogether. Scan hardening and tooth hardening on both the inside and outside diameters of the workpiece can be done on the same induction machine with minimal setup times. Manufacturers of large ring bear-

0

20

40

60 80 Position, mm

100

120

Fig. 5. The polished section and hardening depth of a ring segment after the starting sequence shows uniform hardening with no soft zone.

Characteristics of Induction Scan Hardening with no Soft Zone Scan hardening with no soft zone requires two inductor assembles, each comprised of an inductor and a spray head. The inductors are narrow to create a compact hardening zone. Flux concentrators focus the magnetic field for one-sided hardening.

by-side in the same direction for a short distance. One of the assemblies reverses directions, so the inductor assemblies travel in opposite direction. This technique avoids the formation of a soft zone at the start location (Fig. 4). Figure 5 depicts the hardening result with the etched case and with two hardening passes along the workpiece axis at 0.5 mm and 5 mm depths after tempering. The start location is still recognizable, and one can see that the entire area has been hardened with a relatively constant case depth.

Start Sequence The inductor assemblies are brought together in a back-to-back orientation and are then energized with independent power supplies. Both assemblies travel side-

End Sequence Like the start sequence, the end sequence relies on precise control of the quenching sprays and the tight motion control of the inductors and sprays to achieve a uniform

ings with small production runs appreciate this flexibility and the freedom to process diverse workpieces while holding equipment costs at a minimum.

900 Centerline

800

Hardness, HV1

700 600

0.5 mm deep

500

5 mm deep

400 300 200 100 0

Fig. 6. Inductor movement and spray setup during the end sequence of induction hardening

40 August 2011 - IndustrialHeating.com

0

20

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60 80 Position, mm

100

120

140

Fig. 7. The result of the end sequence of induction hardening is uniform hardening with no soft zone.

case depth with no soft zone at the end location (Figs. 6 and 7). The resulting bearing surface meets stringent requirements for high loads and smooth operation. Summary Induction hardening has proven itself in the manufacturing of high-value, large ring bearings. Wind power certainly owes its success in part to surface-hardened bearing races and gear teeth. Construction and mining equipment would wear out quickly, and military and aerospace endeavors would entail unacceptable risks without the benefits of induction hardening. Alternative hardening methods for large rings and bearing races struggle with distortion, soft spots, grain growth, furnace dimensions, energy efficiency, emissions and extraordinarily long process times. Induction scan hardening with no remaining soft zone bridges the gap between conventional hardening methods and the growing demand for very large bearings with high load ratings, low noise and longer service lives. IH For more information: Contact George Burnet, general manager of SMS Elotherm North America at tel: 724-553-3471; e-mail: [email protected]. Otto Carsen is sales manager, hardening, for SMS Elotherm GmbH and Dirk M. Schibisch is vice president of sales.

References available online

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Fall 2011 On-Line Distance F Di t Learning L Courses Register Now! Registration Closes - Sept. 9 • Classes Begin - Sept. 19 R REGISTRATION OPEN NOW! • EARN CEU CREDITS! R 1 Fundamentals of Industrial Process Heating – and – 2 Advanced Industrial Process Heating In conjunction with the Emerging Technologies Applications Center of Northampton Community College.

FOR COMPLETE DETAILS AND TO REGISTER, VISIT: www.ihea.org Combustion Seminar & OnLine Distance Learning buttons can be found on the right side of the home page. Click them for information & to register. QUESTIONS: Call 859-356-1575

IndustrialHeating.com - August 2011 41

FEATURE | Materials Characterization & Testing

Automated Hardness Testing Improves Productivity, Accuracy, Efficiency Bill O’Neill – Wilson Hardness; Norwood, Mass. Hardness testing is a fundamental characteristic in analyzing component properties. As an important materials-testing tool, this critical parameter can be performed and measured by a multitude of methods and techniques.

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h some hardness-test hile types such as the Rockty well test will yield fast, w single-process results si based on indentation depth, many of the commonly used test types such as Vickers, Knoop and Brinell require a secondary process to determine the size of the indentation (in microns or millimeter) surface area. These secondary processes can be time consuming, inefficient and prone to subjective errors. One means of improving productivity while providing consistency to the process is through automatic indentation and impression reading utilizing image analysis. Significant improvements in recent years in hardness-testing instrumentation as well as computer hardware, electronics, imaging algorithms and software capabilities have opened the door to extremely precise and reliable testing processes that provide results more

quickly than ever before. These components and techniques have proven to be beneficial in raising efficiency, speed and accuracy to levels never before achieved. Why Automatic Hardness Testing? Two common hardness tests are Knoop and Vickers, which are used in micro and/ or macro testing to determine material hardness based on measuring the size of a diamond-shaped impression left from an application of a specified force. The Knoop diamond produces an elongated rhombic-based, diamond-shaped indent with a ratio between long and short diagonals of about 7 to 1. Knoop tests are typically performed at test forces from 10-1,000 g; are often referred to as micromicro hardness or microindentation tests; an and are best used in small test tes areas or on brittle materials material as minimal material defor deformation occurs on the short shor diagonal area.

Fi 1 Fig. 1. F Fully ll automated t t d ttraversing i K Knoop/Vickers /Vi k and dR Rockwell k ll hardness-testing h d t ti system t testing multiple samples (Top of page) Fig. 3. High-quality image of Vickers indentation on glass sample, previously not possible with older techniques

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The Vickers diamond produces a square-based pyramidal shape with a depth of indentation about 1/7th of the diagonal length. The Vickers test has two distinct force ranges – micro (10-1,000 g) and macro (1-100 kg) – to cover a multitude of testing requirements. Vickers tests are typically referred to as macroindentation tests and are used on a wider variety of materials including case-hardened and steel components. Vickers indents are also less sensitive to surface conditions than the Knoop test. The nature of these test types typically dictates a force consistent with the material being tested, usually resulting in extremely small impressions that must be measured at the micron level. Traditional techniques, still widely practiced today, involve microscopes with objectives of varying resolution integral to the hardness tester. The objectives are used to manually measure the impression through an eyepiece, based on human interpretation. Predictably, this is timeconsuming, inefficient and, in today’s fastpaced, extreme environment, it is increasingly unacceptable. It is not uncommon for a technician to produce and measure by eye many hundreds of indentations during a day, with fatigue likely compromising the measurement process as the indents increase in quantity. Add to this the need to produce a full analysis of a hardness traverse often consisting of more than 15 indents each (many times on a single sample) as well as the importance of accurate, well-reported results, and the need for more advanced, automated techniques becomes evident (Fig. 1).

Automatic Hardness-Testing Techniques Over the past several years and no doubt increasingly in the future, these manual processes have and will continue to rapidly give way to automation in every aspect of the testing process. New, extremely efficient techniques in material preparation and handling, mount fixturing, stage movement, results interpretation and analysis, and even reporting have been introduced to the hardness-testing industry. An important and productive technology being integrated into many hardness systems around the world is automatic stage traversing and image analysis of Knoop, Vickers and Brinell indentations. An automatic hardness system typically consists of a fully controllable tester, including an auto-rotating or revolving turret as well as actuation in the Z axis either from the head/indenter housing or from a spindle-driven system used for both applying the indent at a predetermined force as well as for automatically focusing the specimen. Add to this a standard computer with dedicated hardness software, an automatic XY-traversing motorized stage and a USB video camera, and the result is a powerful, fully automatic hardnesstesting system. After initial setup with samples and an applicable traverse and parameter program, the system can be left alone to automatically create, measure and report

Fig. 2. Fully automated traversing and image-reading Knoop/Vickers system testing four mounted samples at a time

on an almost unlimited number of indentation traverses (Fig. 2). This newer technology eliminates much of the hardware that in the past caused operational challenges and cluttered workspaces. For example, current-design stages are moved by a virtual joystick, and stage controllers are fully integrated into the stage assembly on some systems. Advances in stage-movement algorithms and mechanical design have made XY accuracy and repeatability better than ever, which is paramount in precision traverse requirements such as case-depth analysis. Image Analysis Image analysis is not new, but the technology driving it continues to advance. The indent measurement process is considerably improved from a more limited form with inadequacies measuring smaller indents and samples with fewer surface finishes. These high requirements in regard to surface preparation along with process restrictions meant previous systems were lacking in effectiveness as a complete solution. Now, for example, camera technology has evolved from frame grabber to IEEE Firewire to USB formats, eliminating additional hardware while at the same time increasing camera resolution and fieldof-view possibilities. The capabilities of current and developing cameras, coupled with the processing capacity of today’s PCs and continually improving software packages, have significantly improved the accuracy, repeatability and dependability of automatic indentation reading. All digital cameras have pixel arrays. Each pixel can be either on or off. If a black and white image is projected on the pixel array, the pixels in the dark areas will be off and the light ones will be on. By counting the number off, the size of the dark spot on the image can be determined and subsequently the image area. The size of any indent is used in combination with the indenter and applied force to determine hardness value. It is now possible to accurately and repeatedly read smaller-than-ever indents and locate and analyze indents

Fig. 4. Fully automated traversing Rockwell hardness-testing system testing multiple samples

on surfaces and materials previously not possible (e.g., glass). In addition, new developments in microscope objectives and digital zooming technology are allowing for wider magnification ranges than ever before (Fig. 3). Automatic Traversing Expanding productivity even further is the ability to utilize larger-size automatic-traversing XY stages capable of holding two, four or even six samples at a time in an array of fixturing types. Pre-programmed and saved traverses are opened, samples are aligned in holders and, with a single click, the indentation, reading and reporting of a multitude of traverses on each sample is initiated. Autofocus mitigates any compromise of indent clarity due to small parallelism position variation. Newer software even allows different scales, forces and microscope objectives within and between traverses, creating new possibilities in multi-sample and case-depth analysis. This fully frees the operator from manually moving the sample from test to test for both the indentation as well as the measurement process and quickly provides an ROI and benefit that is readily evident and clearly increases the ability to evaluate a variety of materials. Other Applications Automated testing is also increasingly beneficial for Rockwell hardness testing, IndustrialHeating.com - August 2011 43

FEATURE | Materials Characterization & Testing

Fig. 5. Automated Rockwell system testing multiple samples with nine indents on each sample

particularly in repetitive-pattern requirements such as Jominy testing, where a number of bars can be fully tested and reported, unmanned after one click of the mouse. The use of an automated stage and software integrated with a Rockwell tester capable of automatic actuation allows for multiple sample testing. In some cases manufacturers are automatically testing more than 15 parts on a stage with multiple indents on each part (Figs. 4 & 5). As in Knoop and Vickers testing, Brinell testing is by nature a laborintensive and manual process that, in its conventional state, requires constant human intervention and processing. Since the traditional Brinell test consists of a single, controlled test force made with a specified diameter tungsten-carbide ball, the resulting impression must be optically measured (diameter in mm) to determine the material hardness. This is typically performed using a low-power, handheld microscope, a process that is both laborious and subjective. As in Knoop and Vickers, fatigue-induced errors from performing measurements repeatedly are common, and the process itself can be inefficient and time-consuming. With many processes requiring 100% inspection and productivity that depends on quick turnaround, it is no surprise that a means to both accelerate the process and mitigate the possible manually 44 August 2011 - IndustrialHeating.com

induced errors is in demand. The method that may be most applicable is dependent on a variety of factors, including test-time requirement, specimen geometry, loading and unloading technique, material properties, ASTM standards requirements and adherence, and of course budgetary alignment. The production Brinell test is one unique method of automatically and accurately determining Brinell hardness in a production environment. Through the use of the Rockwell test principle of measuring depth of penetration to determine hardness, the production Brinell test eliminates the costly and time-consuming procedures associated with conventional Brinell testing. First, the part is pre-clamped with sufficient pressure to prevent it from moving during the test process. Next, the test is performed applying a pre and full test force for a specified dwell time. The part is unclamped upon dwell completion. The test result is obtained by measuring the difference between the reference depth and the final depth after recovery has taken place. An ASTM standard, ASTM E103 – Standard Test Method for Rapid Indentation Hardness Testing of Metallic Materials exists for this test type. This test method covers the procedure for rapid-indentation hardness testing of metallic materials as an alternative to ASTM Test Method E10 on standard Brinell hardness and includes methods for the verification of rapid indentation hardness-testing machines. Production Brinell systems can be integrated to production automation lines or stand alone to perform quick and consistent Brinell testing. They are available in a variety of formats and frame configurations and can be customized to meet an abundance of application requirements. If the test must adhere to the more common, optical Brinell standard, ASTM E-10, then other means of productively performing optical Brinell measurements are available. When using a conventional Brinell floor- or bench-model tester that performs the indent portion of the test only, an alternative to the handheld manual process involves utilizing a handheld digital camera that can accurately and efficiently

measure the diameter of the impression, automatically using image analysis techniques as described above. As a result, it has become relatively easy to measure Brinell indents through a camera. If a handheld imaging system, which requires manual intervention, is lacking in the desired production level, a fully automatic, optical Brinell system can provide adherence to ASTM E-10 while allowing for fully automated optical testing. A fully integrated automatic optical Brinell testing system can quickly and accurately perform the entire Brinell test process in accordance with ASTM E-10. This includes accurate indentation application and providing an imageanalysis system to autofocus on, identify and record indent size and hardness measurement. All of this, coupled with flexible user-friendly software, gives the operator extensive capabilities in generating tests, completing the analysis and generating reports. An operator only has to locate the sample in the tester and press the start button. Indentation is automatic as is the rotation of a revolver or turret-style system that turns the measuring objective/microscope into position. The automatic focus and imaging process is then initiated, and results are returned quickly in both indent diameter and Brinell hardness. Past limitations in regard to surface finish, lighting, preset calibration and pixel sizing have been mitigated and are continually undergoing improvement. The result is increased ability and dependence on “letting the instrument do the work,” contributing to substantial increases in throughput and consistency while freeing up the operator for other responsibilities. With a fully integrated system, the laborintensive, subjective and error-prone process is virtually eliminated and instead replaced with a significantly more accurate and productive process. IH For more information: Contact Bill O’Neill, sales manager, Wilson Instruments, 825 University Ave., Norwood, MA 02062; tel: 781-5757-5873; fax: 781-575-5770; e-mail: [email protected]. For automated hardness-systems information please visit www.wilson-hardness.com.

FEATURE | Melting/ Forming/Joining

Review of Ebeam 2010 Robert Bakish, Bakish Materials Corp.; Englewood, N.J. Ebeam 2010 featured 19 speakers from around the world and was attended by 60 companies from Brazil, Canada, Czech Republic, Kazakhstan, Russia, Ukraine and the United States. Ebeam is a biannual event that first convened in Reno, Nev., in 1983.

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h conference, which has behe come the signature event for c this technology, opened with t a presentation by H. Padamsee off Cornell ll University titled “Continuing Niobium Needs for Accelerator Cavities, Present and Future.” He began by stating that 40 tons of Nb cavities have been ordered for upgrades of the CEBAF accelerator in Virginia, the Spallation Neutron Source (SNS) in Tennessee and the new European X-Ray Free-Electron Laser (XCEL) in Hamburg, Germany. With the success of SNS highintensity proton accelerators for European Spallation Source (ESS) and proton injection upgrades at Fermi Lab in Illinois and CERN in Switzerland, near-future market demand will be 50 tons. Together with other projects this demand could go up to 150 tons. The far-future scenario will depend strongly if the LHC collider now operating at CERN will reveal dramatic new finds and could generate the need for another 500 tons of high-purity Nb in the next six years. The cost of Nb will play an important role. All of these requirements are met with existing technology. If an advanced technology such as multiwire ingot slicing (Fig. 1 - online) can be achieved to produce material for cavities, substantial savings could result.

High-Heat Studies The next three papers dealt with highheat furnace studies, guns as a source of surface heat load and high-heat-flux experiments. The first paper, by D.L. Youchison, describes Sandia National Laboratories’ high-heat-flux electron-beam experiments for the ITER. They applied 12,000 thermal fatigue cycles at 0.75 MW/m2 and higher to identify performance limita-

tions. Their dual gun von Ardenne EB system, EB 1200, used to perform these high-flux tests was described as was the use of thermal imaging for safety monitoring and data acquisitions. The second paper, by V. Kuznetsov from Russia’s D.V. Efremov Institute and M. Neumann of 2A in Germany, was titled “Melting Electron-Beam Guns Used as a Source of Surface Heat Load During ITER PFC Testing.” Various power guns were used, but the most recent tests were performed with the EB 800/60 von Ardenne melting electron gun (Fig. 2). The purpose of the facility is to test fullscale prototypes of the ITER director plasma-facing components as well as to test PFC during their serial production. The third paper, “High Heat Flux Testing of Components for Future Fusion Devices by Means of the Facility JUDITH 2,” was written by A. Schmidt of Germany’s Forschungszentrum and EURATOM-Association (Fig. 3). First wall elements of future fusion reactors like ITER or DEMO will suffer extremely high heat fluxes up to 20 MW/m2. In order to assure the performance of these components, EB facilities are used to simulate these high heat loads, specifically details on beam diameter diagnostics, simple beam scanning methods and calibration techniques. The generation of heating beam pattern is based on freely programmable figures, which consist of points with X and Y coordinates and different dwell times of the beam. The paper is a summary of all EB parameters of the maximum 200-kW beam power used in these simulations with different materials and geometries. Melting The next series of papers were devoted to melting, beginning with “Refining

Fig. 2. von Ardenne electron gun (EB800/60) powered installation at the Efremov Institute in St. Petersburg, Russia

of Silicon by Electron Melting” by C. Lehnert of ALD Vacuum Technologies and B. Scheffel of the Frauenhofer Institute for EB and Plasma Technology. High demand for solar-grade silicon by the photovoltaic (PV) industry requires development of a new and cost-saving process for the purification of metallurgical and upgraded metallurgical silicon. The authors collaborated on the potential of EB refining for the production of solargrade silicon. In the study, 99.97% silicon samples were melted and refined in an EB test furnace in a graphite crucible using a cold-cathode EB source, and 99.999 purity material was obtained. Results of this study with the novel ALD 400 source (Fig. 4) were presented in detail. D. Maijer presented a paper coauthored by S. Cockroft and S. Fox of the University of British Columbia titled “Evaporation During EB Casting of Ti6Al4V.” The presence of voids or loss of chemistry control at the end of the EBCHR casting process to produce Ti6Al4V ingots may result in significant productivity loss as the top of the ingot must be removed. Raising the shrinkagevoid location can be achieved by hot IndustrialHeating.com - August 2011 45

EB gun

FEATURE | Melting/ Forming/Joining

AI coated glass mirror for IR camera

Video camera port

IR camera port

~1789

Pyrometer port Vacuum chamber

1200

800

ie e Cooling circuit (25˚C and 100˚C, 30 bar)

Test component

600

Fig. 3. The JUDITH 2 test facility

topping after the termination of casting. This, however, can result in significant Al evaporation, leading to off-spec chemistry. A mathematical model of the hot top stage during EB ingot and slab casting of this alloy has been developed. The model solves the thermal-flow problem. Analytical data is generated to validate the model under various hot-topping conditions. E. Copland of Alvac (Monroe, N.C.) presented a paper titled “Improved measurements of the Vaporization Behavior of the Al(1) + Al2O3 System.” There appears to be little agreement in data on the vaporization of Al. Al2O3 seems to be the ideal container for Al, but studies indicate interpretation of results from vaporization studies have been hindered by Al2O3 condensation. The presence of Al2O, the dominant vapor at temperatures around 1600°, does not appear accurately accounted for in early studies. The vaporization studies are reviewed, and the ramification of improved thermodynamic data on the understanding of multi-component solution behavior and vaporization from vacuum conditions encountered during EB melting are discussed. S. Dobrussin of Ulba Metallurgical Plant (Kazakhstan) shared the podium with M. Neumann of von Ardenne Anlagentechnik for a presentation titled "New EB Melting Capability of ULBA.” It is a 1.600-MW furnace (Fig. 5 - online) powered by two 800-kW von Ardenne electron guns. It is complementary to 46 August 2011 - IndustrialHeating.com

Fig. 4. ALD 400 solar silicon melting unit

older equipment at Ulba that processes Ta and Ti among other materials. The next speaker, S. Ladokhin and Associates from the Physico Technological Institute of Metals and Alloys (PITMA) in Kiev, Ukraine, presented “New Electron Beam Technologies and Equipment for Zirconium Tube Billet Manufacture.” The use of high-voltage glow-discharge guns appears the most appropriate since they were developed to perform in processes with high gas-generation materials such as Zr. The specific molds developed for this purpose are also discussed. U. Biebricher of ALD next discussed the wide range of EB services available at the company. They include conventional drip melting, horizontal and vertical coldhearth refining, and floating-zone refining and casting. He summed up by stating that no other melting technology can provide such flexibility. The last melting paper, by Biebricher and J. Flinspach of ALD, reported on the melting and process development services with an in-house ALD furnace on a toll basis (Fig. 6). They are capable of processing a variety of refractory metals and alloys from small buttons to larger ingots. General Topics A session on a range of EB-related topics rounded out the conference. It began with a paper presented by M. Merkel on work done by associates (including Merkel) from FOCUS GmbH, Fraunhofer Institute for

Electron Beam and Plasma Technology and the Institute of Scientific Instruments of the ASCR. It discussed the electron beam as a tool of both nano-science and micro-technology from UHV evaporation to micro EB surface modification. The presentation started with a discussion of EFM3, an ultrahigh EB evaporator claimed to be the standard of the industry, and ended with a desktop-sized instrument that looks more like an electron microscope than a welder. It is capable of tackling a large range of micro joining and surface-modification tasks. Both the instrument and selected applications were discussed. Aren Paster and associates from Zak Inc. (Troy, N.Y.) discussed flow optimization for drilled water-passage copper products. These become parts of EB and other

Fig. 6. ALD EB furnace for toll melting

Double-side coating Pre-treatment

Winding system

Layer resistance Optical spectrometer Dual magnetron sputter system

"Easy Beam" EB Magnetron system PECVD

Hollow cathode plasma source Boat evaporator

Fig. 7. Drilled water-passage copper products

Fig. 8. 120-kW NWL high-frequency power supply

types of melting furnaces. Fig. 7 shows such components. G. Schubert of PTR Precision Technologies reviewed EB welding, its applications and recent developments in the next presentation. R. Guenther of NWL (Bordentown, N.J.) looked at high-voltage, high-frequency power supplies for EB processes. Highfrequency, high-voltage power supplies have been used for more than 10 years in electrostatic precipitators with over 1,000 operational units with ratings up to 120 kW/unit (Fig. 8). In the past year, NWL has expanded this technology to the EB market, specifically in curing, coating and melting applications. Power supplies act like a current source, they parallel very

easily and handle current without disruption. Modules of these power supplies allow systems up to 600 kW. This paper discusses the advantages of these power supplies. The next paper by F. Fischer and U. Hampel of FZD Research Center and G. Mattausch and F-H. Roegner of Fraunhofer Institute for Electron Beam and Plasma Technology, both in Germany, reported on ultra-fast CT X-ray imaging for dynamic process visualization in research and industry. There is growing demand for rapid high-resolution spatial imaging of objects and processes. X-ray computer tomography (CT) can, in principle, be used as a tool in their visualization tasks. Units developed for medical imaging are too slow for technical applications due to their mechanical inertia. FZD has recently carried out a number of projects to develop fast X-ray CT devices based on fast scanning, high-power-density EB for the tomography of technical two-phase flows in papers. The EB source of the scanner operates at 150 KV and focuses power of 10 KHZ to a 1-mm-diameter spot. G. Mattausch of the Fraunhofer Institute, next presented a paper titled “Cold Cathode Electron Beam Sources for High-Rate PVD and Beyond.” Established designs of high-power EB sources based on thermionic emitters as well as their supply and control systems are complex and expensive, preventing their applications in many thin-film processes. Alternative EB sources with cold cathodes have recently attracted much interest because of their

Fig. 10. Nb ingots produced at CBMM

Electron beam evaporator

Fig. 9. 30kV/60kW HVGD EB system

prospects as an economic beam source for a broader spectrum of applications, including PVD. An efficient and single cold-cathode, axial-type electron source has been developed and tested at FEP. Inside this gun, a high-voltage glow discharge (HVGD) is sustained. In addition to simplified mechanical designs and electrical supply circuitry, cost reduction results also from the fact that HVGD’s beam source needs no differential HV pumping and can be operated in a wide range of acceleration voltages. All of these issues have been addressed, and we have a report of coating plastic substrates with a thick copper layer utilizing a 30KV/60KW HVGD EB system (Fig. 9). The last paper in the conference by L. DeMoura and C. Sousa of CBMM (Araxa, Brazil) summarized highlights of Nb production since its first EB furnace in 1989 and their second furnace in 2003. The Nb ingot produced (Fig. 10) goes to a variety of applications, including extra-pure Nb for superconducting cavities and Nb-Ti for superconducting magnets and sputtering targets. The paper revisits the fully integrated CBMM process for Nb production and the accumulated experience of operating a 500-kW and a 1.8-megawatt EB furnace. IH For more information: The proceedings of EB2010 are available as a CD from von Ardenne Anlagentechnik. Mr. Bakish is principal of Bakish Materials Corp., P.O. Box 148, Englewood, N.J. 07631; tel: 210-5675873; fax: 201-567-6684; e-mail: bakishmat@ aol.com IndustrialHeating.com - August 2011 47

HTS Names New Board Members The HTS Awards and Nominating Committee named new board members, including Roger Jones to serve as vice president for the 2011-2013 term; William Flower, Christopher Klaren and Meri Lazar to serve on the HTS Board for the 2011-2014 term; and Brett Carlson to serve as student board member for the 2011-2012 term. The terms begin Sept. 1, 2011. Leaving the board are Dr. Richard Sisson Jr., FASM (past president), Fred Specht (member), Michael Wright (member), Roger Jones (elected as incoming vice president), Dr. Soraya Benitez (young professional board member) and John Metzger (student board member). Terrence Brown remains president through Aug. 31, 2011, and Thomas Clements becomes president on Sept. 1, 2011. Continuing board members include Dr. Subi Dinda (FASM), Dr. B. Lynn Ferguson (FASM), Michael J. Schneider (FASM), Dale Weires, John R. Keough (FASM) and Ralph Poor. The new board will begin its term on Sept. 1, 2011. Roger A. Jones is corporate president of Solar Atmospheres Inc. After graduating from Hocking Technical College, he joined ABAR Corp. in 1975. In 1978, he joined Vacuum Furnace Systems Corp., which was founded by his father, William R. Jones, FASM. In 1983, he helped found Solar Atmospheres Inc., serving as vice president before becoming president in 1993 and corporate president in 2001. He has been a member of the Metal Treating Institute since 1983, serving on the Board of Trustees (1998-2004 and 2009-present) and as president (2004-05). Roger has been a member of ASM Philadelphia Liberty Bell Chapter since 1983 and served as chapter president (1993-94). He was chair of the ASM Heat Treating Society (HTS) Immediate Needs Committee and the HTS Education Committee, served on the Nominating Committee for two separate terms and is a member of the HTS T&P Committee. He was elected to the HTS Board in 2005. William D. Flower is president of Specialty Heat Treating Inc. He earned his B.S. in mechanical engineering in 1979 from Western Michigan University and a graduate degree in finance in 2005 from Chicago Graduate School of Business. He was president of Material Damage Consultants Inc. (1982-88) before joining Specialty Heat Treating 48 August 2011 - IndustrialHeating.com

(Athens, Ala.) as start-up engineer/plant manager (1988-94). He has served in different positions at the company’s various facilities, including plant manager (Grand Rapids, Mich.; 1994-96), start-up engineer/plant manager (Holland, Mich.; 1995-97), vice president of operations (Grand Rapids, Holland, Athens, and Elkhart, Ind.; 1997-2004), senior vice president (2004-11) and president since April 2011. Bill intends to develop the next-generation management team through succession planning, mentoring and training; to develop and implement integrated IT systems for process control and process management; to integrate a lean/six sigma-based quality culture; and to continue to move toward “green,” or sustainable, process technology. Christopher M. Klaren is general supervisor/business unit manager of heattreat operations at Deere and Company, Waterloo Tractor Works, Iowa. He graduated from the University of Dubuque in 1977, earned his M.S. in metallurgy from Iowa State University in 1979 and joined the company as process metallurgist in its heat-treat operations. For the next 16 years, he worked in all areas of the Waterloo facility’s heat-treat processes. In 1995, Chris was appointed leader of the Heat Treat Manufacturing Engineering Group and to his current position in 1998. Chris led the heat-treat organization through the redevelopment of the Westfield Ave. site in Waterloo from 2003-2006, a large capital project that resulted in improved processes, equipment, efficiencies and operations safety. More recently, he manages a new capacity-expansion project in heat treat to respond to increased customer demand. Chris has been a member of the Northeast Iowa Chapter of ASM since 1979, serving as board member, vice chairman and chairman. He participated in revising the ASM Handbook Volume 4: Heat Treating, Methods of Measuring Case Depth and presented papers at ASM Heat Treating Society Conferences. Meri Lazar is an international businessdevelopment advisor with a deep interest in the critical link between technology and research, operations and marketing. She is a graduate engineer in metallurgy from Romania, with industry experience gained while working and living in various countries. Meri’s experience includes leadership roles in Air Liquide Group and Air Products and Chemicals Inc. She recently returned to the U.S. from an overseas appointment with Air

Liquide where she directed the business development for several industries in the emerging economies of Central/Eastern Europe and Russia. Previously, she managed the Global Metals market for Air Products and Chemicals. Meri was strongly involved with Center for Heat Treating Excellence as a founding member, and as a business leader she advocated cooperation with national and local societies such as: CCMA (U.S./Canada), AFS (U.S.), MPIF (U.S.), ASMET (Austria), ATTT (France), CTIF (France) and AWT (Germany). Meri has been a member of ASM Heat Treating Society for over 15 years and has served in various capacities. Brett Carlson is from Rapid City, S.D., and currently is a junior at South Dakota School of Mines and Technology, pursuing a degree in metallurgical engineering. Brett participated in the National Science Foundation Research Experience for Undergraduates in the summer of 2010, where he researched historical direct iron reduction, constructed a furnace for the process and wrote a technical report. He is the recipient of the D.W. Fuerstenau MET Scholarship, the South Dakota Opportunity Scholar Award and the SDSMT Tech Challenge Scholarship. He also is a member of a Materials Advantage Student Chapter.

AWARDS Bernard Receives 2011 George Bodeen Heat Treating Achievement Award William J. Bernard Jr., president and CEO of Surface Combustion Inc. (Maumee, Ohio), is the recipient of the 2011 George H. Bodeen Heat Treating Achievement Award. Established in 1996, this award recognizes distinguished and significant contributions to the field of heat treating through leadership, management or engineering development of substantial commercial impact. Bernard is recognized “for innovative thinking, outstanding vision and passion as an entrepreneur of equipment manufacturing for the heat-treating marketplace and for commitment to educating the next generation of heat treaters.” The award presentation will be made at the HTS General Membership Meeting on Nov. 1, 2011, at the ASM Heat Treating Society Conference and Exposition in Cincinnati, Ohio.

2011 HTS/Bodycote Best Paper in Heat Treating Awarded The winner of the 2011 HTS/Bodycote Best Paper in Heat Treating Award is “Intelligent Heat Treating: Simulation of Carburization Process,” by (primary author) Ms. Yingying Wei, Ph.D. student, materials science and engineering, Worcester Polytechnic Insti- Winner of the HTS/ Bodycote 2011 tute. The award will be presented at the Best Paper in Heat HTS General Membership Meeting on Treating Award, Ms. Nov. 1, 2011, at the HTS Conference and Yingying Wei. Exposition in Cincinnati, Ohio. 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 some substantial way or represents a clear advancement in managing the business of heat treating. The award includes a plaque and a $2,500 cash prize endowed by Bodycote Thermal Process – North America. Visit www.asminternational.org/hts to read the winning paper. Robert Gaster Receives CHTE Distinguished Service Award Robert Gaster, senior staff engineer for materials engineering at the Deere & Company Moline Technology Innovation Center, was presented the Center for Heat Treating Excellence (CHTE) Distinguished Service Award at the CHTE meeting held in May at the Metal Processing Institute (MPI) at Worcester Polytechnic Institute. Among CHTE’s most ardent supporters, Gaster served in several capacities during his tenure with the center. He was chair of the board and the projectselection committee and served on CHTE’s strategic-planning committee. Presenting the award are (from left to right) Diran Apelian, director, MPI; Bob Gaster; and Roger Fabian, CHTE director-at-large.

ASM INTERNATIONAL –The Heat Treating Society Join ASM Today: www.asminternational.org > Select "Membership" IndustrialHeating.com - August 2011 49

Mark your calendars and plan to attend HT 2011 in Cincinnati, Ohio. Registration is now open. Visit www. asminternational.org/heattreat for more information.

HTS EVENT 26th ASM Heat Treating Society Conference and Exposition Oct. 31-Nov. 2, 2011 Duke Energy Convention Center, Cincinnati, Ohio USA The ASM Heat Treating Society and American Gear Manufactures Association (AGMA) are co-locating at HT 2011, and the 2011 HTS Conference and Exposition is shaping up to be a don’t-miss event. The conference will feature more than 90 presentations, including some of the latest developments in heat-treating processes currently being used to improve the quality and repeatability of gear heat treatment. Speakers representing commercial heaters, equipment suppliers, research centers and gear producers from around the world will present the latest technologies in areas such as: • Induction hardening and surface treatments • Immersion quenching and distortion issues • High-pressure gas quenching and metallurgical issues • Novel and emerging processes To view the technical program in detail, visit http://www. asminternational.org/content/Events/Heattreat/technical.jsp A Special Symposium on vacuum technology is planned in honor of William R. Jones, president and CEO of Solar Atmospheres Inc., who has made huge contributions to the heat-treating industry. Visit the Heat Treat Show Exposition Along with a wide range of exhibitors, a new Heat Treating Solutions Center will offer exhibitor presentations focusing on real-world problem solving on specific manufacturing techniques, products and technologies. Presentations are scheduled Nov. 1-2, 2011, in the Heat Treating Solutions Center, a designated area located on the show floor. To register for the expo, visit http://www.asminternational.org/content/Events/ Heattreat/index.jsp. Prime exhibit space, advertising and sponsorship packages are available. To reserve yours today, contact Kelly Thomas, national account manager, at 440-338-1733 or kelly.thomas @asminternational.org.

Heat Treat 2011’s Virtual Trade Show MyHeatTreatExpo.com is your quickest way to Heat Treat 2011! Don’t miss an opportunity to join the growing list of exhibitors and visitors. Attendees can browse the expo and search the show by product, booth number or company name. Exhibitors get early visibility to prospective customers, and they can showcase their products and services, reach customers and prospects worldwide, and increase exposure by driving traffic to their website. For more information, contact Kelly Thomas, national account manager, at 440-338-1733 or kelly.thomas@asm international.org. ASM PRODUCTS Metallurgy for the Non-Metallurgist, Second Edition Editor: Dr. Arthur C. Reardon Price: $149 Member Price: $99 Prepublication prices good through Oct. 15, 2011 This completely revised second edition provides a solid understanding of the basic principles and current practices of metallurgy. The new edition was extensively updated with broader coverage of topics, new and improved illustrations and more explanation of basic concepts. It is a “must-have” ready reference on metallurgy! Contact MemberServiceCenter @asminternational.org.

Don’t Forget to Check Out ASM International on Facebook. Facebook is an alternative way for members and customers to interact. We encourage wall postings, discussions, member experiences, reviews of our products and services, photos from events, “happy-member” photos, best-practices, etc. Find out what’s going on at ASM (you’ll need a FB account), and stay in touch with your society and your colleagues on Facebook. 50 August 2011 - IndustrialHeating.com

Literature/Website Showcase Process Controls | Induction Heating/Melting | Miscellaneous Thermocouples/Temperature Sensors

Induction Heating Systems

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

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

Thermocouple Handbook

Induction Tooling Facility

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.

Induction Tooling, Inc. Induction Tooling, Inc. is the world's premier induction tooling facility celebrating over 30 successful years. We specialize in the design, build and repair of selective hardening inductors. Our quick-change designs have become the standard in the industry. www.inductiontooling.com

Data Logger

Leading the World in Induction Heating Technologies

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

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

Digital Indicating Controllers

Induction Systems

Yokogawa The UTAdvanced is Yokogawa’s newest controller that combines PID control and ladder logic. The universal flexibility and ample communication protocols makes the UTAdvanced the most efficient and easy-touse hybrid controller. www.yokogawa.com/us

SMS-Elotherm SMS-Elotherm engineers and manufactures high-performance induction systems to heat, weld, anneal, harden, temper and cut bars, billets, crankshafts and other shapes. In business for more than 70 years, the company has locations in the United States, Germany, France and China. www.sms-elotherm.com

Induction Heating Systems

Lit/Web Showcases

August 2011

Ajax TOCCO Magnethermic Corporation Ajax TOCCO Magnethermic Corporation is a world leader in the induction heating, melting and forging industries. Our proven applications include brazing, annealing, hardening, tempering, seam annealing, shrink fitting, curing, forging and melting. Regenerative vs. www.ajaxtocco.com

Process Control Dividends p.35 Large-Ring Induction Hardening p.38 Hardness-Testing Automation p.42 Electron Beam Technology p.45 ASM HTS insider p.48

Oxyfuel Burners p.41 Cutting Electric Costs p.45 Insulation for Efficiency p.51 Optimizing Alloy for Conservation p.57 A

FREE for Advertisers The most active literature showcase section in the industry. Every month, Industrial Heating provides a way for you to get your literature or CD into the hands of the entire industry. Qualifying advertisers get a FREE literature showcase! Paid showcases are always available for $695/month for a fullcolor brochure cover reproduction. Max. 40 words.

Publication Official publication of ASM’s Heat Treating Society Online 24/7 at www.industrialheating.com

IndustrialHeating.com - August 2011 51

Products

Product of the Month Infrared Temperature Sensors Raytek The Raytek MI3 sensors are now compatible with the Modbus and Profibus network protocols, allowing them to be used in a wide range of applications requiring digital communication for field devices. The updated thermometers now offer a low-cost, multi-channel noncontact temperature measurement solution with network communications capability. The MI3 Series represents a new generation of performance and innovation in noncontact temperature monitoring for Original Equipment Manufacturer (OEM) applications and manufacturing processes. These high-performance IR sensors reduce energy costs by allowing tighter process control and more efficient process heating. Improved control performance usually results in less product variation, higher product quality and increased throughput. The MI3 Series sensors combine a rugged IP65 (NEMA 4) stainless steel sensing head with a separate communication module. They offer a choice of scalable 0/4 to 20 mA and 0 to 5/10 VDC analog outputs or Type J, K, R or S thermocouple outputs, as well as an optional RS485 network interface. www.raytek.com

Flow Controller Waukee Engineering, a member of United Process Controls The Valve-Tronic Plus™ is a next-generation flow controller developed for demanding industrial applications that require accurate measurement and flow control. It is designed for practically maintenance-free reliability and can operate as a standalone solution for basic applications, or it can be integrated with a process control system or SCADA for automatic flow control. Features include: built-in web interface for easy access to parameter settings, event logs and troubleshooting; proprietary magnetic flow-sensing technology; standard Modbus TCP for easy integration with control systems; and advanced polynomial calibration for high accuracy over the entire range of the meter. www.waukeemeters.com

BOLTT is drilled or ratchet-driven through the new hot face and into the backup lining. STELBOLT will easily penetrate wallpaper, modules and low-density board linings. To improve lining efficiencies that have degraded after months or years of service the STELBOLT simplifies the “veneering” process. Apply one or two layers of new blanket and drill the STELBOLT through to a tightened position. www.stellarcanada.com

High-Temperature Metal Filler Thermal Imaging Camera Land Instruments The new Arc cameras – a series of thermal imaging cameras rugged enough for heavy industrial applications and compact enough for use in R&D and automation – have high-resolution radiometric imagers and field-of-view options that can view targets at any distance e with high clarity. They operate over a wide temperaturee range (-20° to 1000°C) and do not need to be connected to a PC. Available options include two temperature ranges, four lenses, two frame rates and three software variants. www.landinst.com

Infrared Temperature Sensor Omega Engineering The new noncontact infrared sensor with wireless transmitter er features remote IR sensor and radio wireless transmitter in a NEMA enclosure. Each unit transmits process temperature, ambient bient temperature, signal strength and battery status. This unit features es an adjustable emissivity from .10 to 1.0, and one receiver has the ability bility to work with up to 48 transmitters. Package comes with free software re that converts your PC into a multi-channel chart recorder or data logger. gger. It also interfaces with other Omega products, including the UWTC-REC1 EC1 for multi-channel PC chart recording and data logging. www.omega.com .com

Refractory Repair Stellar Canada STELBOLT was designed to both repair and compliment existing furnace linings. It can easily penetrate and hold onto a refractory fiber, insulating firebrick or lightweight monolithic lining. For repairs, a blanket patch can be placed over a damaged area and very simply the STEL-

52 August 2011 - IndustrialHeating.com

Alvin Products Hi-Temp Lab-metal® is a single-component metal putty that can withstand temperatures up to 1000°F. It requires no mixing, applies easily and can be sanded and then powder coated or painted. Hi-Temp Lab-metal can be applied directly from the can using a putty knife and provides excellent adhesion to any cast or machined metal surface. Once heat hardened, it can be machined, ground, drilled and sanded to a smooth finish that can be powder coated and painted for repairing parts used at high temperatures. www.alvinproducts.com

Products

Economic Indicators

REQUEST FOR QUOTE

High-Temperature Bushings Graphite Metallizing Corp. GRAPHALLOY® 453 self-lubricating bushings are intended for use

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in severe industrial applications where temperatures reach 750°F (400°C) or higher. GRAPHALLOY graphite/metal alloy bushings are designed to operate without lubrication and have proven to be successful in a variety of high-temperature applications, including heat-treat ovens and furnaces. Among their many advantages, GRAPHALLOY bushings operate at longer intervals without the need for maintenance, which reduces downtime. They are an excellent choice for applications where service and maintenance tasks are cumbersome or difficult to perform. Additional benefits include a low coefficient of friction and dimensional stability. www.graphalloy.com

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Temperature Calibrator E Instruments Group The MTC 650 microprocessor-based based temperature calibrator is a portable source that offers fast temmperature calibration in an easy-to-use design for temperatures up to 1202°F. The MTC 650 is ideal for fast site calibration of thermocouples, resistance thermometers and temperature e transmitters. www.einst.com

Induction Heating System Ambrell The EKOHEAT 250/10 – with 250 kW of power and a center frequency of 10 kHz – is ideal in a wide range of applications, including shrink fitting pipe, annealing wire and preheating steel bars prior to welding. Other successful EKOHEAT 250/10 applications include hardening, preheating for forging and crucible heating. The system is a flameless, noncontact method that’s fast, precise, energy efficient and conducive to process repeatability. www.ambrell.com

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

Replace This Tube...

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

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

IndustrialHeating.com - August 2011 53

The Aftermarket Parts, Services & Consulting Resources

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

Electric Heating Elements For a broad range of applications Find out more at… www.Duralite.com 54 August 2011 – IndustrialHeating.com

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

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

Single or NEW DOUBLE Aftermarket Cards Big Impact for a Small Price! Starting at $125 per month for a black & white card PARK THERMAL INTERNATIONAL (1996) CORPORATION New / Reconditioned Ovens Furnaces - Quenching Oils – Heat Treating Salts – Component Parts – Stainless Steel Foil – Refractory Products 62 Todd Road Georgetown ON L7G 4R7 Tel: (905) 877-5254 Toll Free: (877) 834-4328 (HEAT) Fax: (905) 877-6205 Email: [email protected] Web Site: www.parkthermal.com

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

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

Tubes Retorts Corrugated Boxes and Baskets Serpentine Trays Muffles Stainless Fixtures

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

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

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IndustrialHeating.com – August 2011 55

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Rates Per Column Inch

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HELP WANTED

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Field Service Engineer/Technician to serve as a company representative for Àeld installations, trouble shooting, service calls and preventative maintenance at customer facilities, with openings in Southern California, Texas, and Florida (Orlando). Experience/QualiÀcations: • Electrical/electronic background (must be able to read electrical line drawings) • Familiarity with Vacuum or Atmosphere Furnaces • Prior Heat Treatment shop experience a plus • Skilled in PLC Logic/Platform • Temperature control integration • Temperature proÀling and PID understanding • A/B Software knowledge - required • Wonderware, SCADA, SL/C5, RSLogics - a plus • Field wiring • Hydraulic and Pneumatic Experience Education: • 2-year degree preferred, or equivalent 2+ years of experience • Advanced technical education or combination of education and employment • Closely related equipment requiring the same skill sets will be considered QualiÀed candidate will be required to travel (domestic with a possibility of international), approximately 75% of time. Salary is based on experience and qualiÀcations.

Please send resumes to [email protected]

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

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]

POSITIONS AVAILABLE Tenova Core is an established leading industrial furnace and melt shop equipment engineering company. We are currently seeking qualified candidates for the following positions: • Combustion Engineer • Project Manager • Project Engineers • Mechanical Engineers • Automation Engineers • Software Leader • Piping Designer • Mechanical Designers Please submit resumes electronically to [email protected] or mail resume to:

Tenova Core Attn: Human Resources 100 Corporate Center Drive Coraopolis, PA 15108

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

www.heatbath.com ph: 413.452.2000

POLYMER QUENCHANTS • OIL QUENCHANTS 56 August 2011 – IndustrialHeating.com

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Ipsen Vacuum Furnace • Model #VFC 424 • ID: 24" W x 36" D x 18" H • Moly Lined – 2400˚F • Diffusion Pump • "Big Joe" Loader • Stokes 212H Mechanical Pump • Digital Controls Cleveland, OH Ph: 440-519-3800 Email: [email protected]

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

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

HELP WANTED

FURNACE DESIGN ENGINEER WANTED Midwestern Furnace Company Seeking Industrial Engineer Immediate Requirement For An Experienced, Self-Motivated Design Engineer Our company is a growing industrial high temperature furnace manufacturer. We provide batch & continuous furnaces, gas fired, electrically heated with air, inert, reducing and vacuum atmospheres. Our applications are very unique. Our equipment is provided to North American customers demanding exceptionally high temperatures, very tight atmosphere and temperature uniformity. The applicant would be required to work from our Wisconsin office. A highly competitive salary and benefits package is included. • Engineering BS or Masters Preferred • 8 to 10 Years Experience with High Temperature & Atmosphere Furnace Design • Strong Verbal and Written Communication Skills A Must • Proficient in Microsoft Office & AutoCAD (Solid Works 3-D a plus) • Confident with US and European Equipment Manufacturing Specs Ideal • Previous Management Experience Desired

Please send resumes to [email protected]

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

HELP WANTED

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

IndustrialHeating.com – August 2011 57

Classified Marketplace

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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 3000CFH Ammonia Dissoc. Drever Elec 3600CFH Endothermic Surface (3) Gas 5600CFH Endothermic Surface (5) Gas 6000CFH Gas Atmos. Nitrogen Generator Gas 10.000CFH Exothermic Seco/Warwick (2) Gas –––––––––– BOX FURNACES –––––––––– 8" × 12" × 6" Huppert Elec 2000˚F 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 Fce. Works (Muffle) Gas 2000˚F 12" × 24" × 8" 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 30" × 48" × 30" Surface (RTB-Atmos.) Gas 1750˚F 39" x 144" x 56" Nabertherm Kiln Elec 2450˚F R&G Elec 2000˚F 72"×72"×48" –––––––––– PIT FURNACES –––––––––– 22" Dia × 26"D L&N Elec 1400˚F 22" Dia × 26" L&N Nitrider Elec 1200˚F 28" Dia x 48" Lindberg Elec 1400˚F 40" Dia × 60"D L&N (steam) (2) Elec 1200˚F 48" Dia × 72"D Surface Gas (R.T.) 1850˚F 60" Dia × 144"D Lindberg Elec 1400˚F ––––––––– VACUUM FURNACES ––––––––– Elec 2400˚F 24" × 36" × 18" Ipsen VFC-424 –––– INTEGRAL QUENCH FURNACES –––– 8" × 18" × 8" Ipsen Gas 1850˚F 15" × 24" × 10" L&N Tricarb Elec 1850˚F 24" × 36" × 24" Lindberg (Top Cool) Elec 2000˚F 24" × 36" × 24" Surface Gas 1750˚F 30" × 30" × 30" Ipsen P-6 Pusher Gas 1850˚F 30" × 48" × 30" Surface Elec 1750˚F 30" × 48" × 30" Surface Gas 1850˚F ––––––– BELT FURNACES/OVENS ––––––– 24" × 5' × 6" Darvon (New) Elec 400˚F 12" × 15' × 4" Sgt. & Wilbur (1994) Muffle Gas 2100˚F 16" × 24' × 4" Abbott (Atmos.) Muffle Elec 2400˚F 24" × 17' × 28" Jensen – Dual Belt Gas 500˚F 24" × 19' × 30" Jensen Gas 500˚F Gas 500˚F 24" × 30' × 30" Jensen 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

58 August 2011 – IndustrialHeating.com

–––––––––– MISCELLANEOUS –––––––––– 30” × 48” Lindberg Charge Car (double-ended) 4000# Accurate — Skip Hoist (NEW) 30"× 48"× 30" Dow Washer (D&S) Elec New Carbon Probes 36" × 48" Surface Roller Tables 30" × 48" Surface Charge Car (System I) 30" × 120" × 12" Ransohoff Belt Washer/Dryer Gas 60" Diam Surface Rotary Hearth (RT) Gas Wilson Hardness Testers (RC) SBS Air/Oil Coolers 132" Diam. x 66" High Rad Con (Bell) Gas 1550˚F ––––––– OVENS/BOX TEMPERING –––––– 12" × 18" × 12" Surface Gas 1250˚F Elec 1250˚F 12" × 18" × 12" Lucifer 12" × 16" × 18" Lindberg (3) Elec 1250˚F 14" × 14" × 14" Blue-M Elec 1300˚F 14" × 14" × 14" Gruenberg (solvent) Elec 450˚F 15" × 24" × 12" Sunbeam (N2) Elec 1200˚F 15" × 24" × 18" Lindberg Elec 1250˚F Gas 1200˚F 18" × 36" × 18" Surface 18" × 48" × 18" Lucifer Elec 1400˚F 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 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 Elec 400˚F 36" × 24" × 24" Young & Bertke 36" × 24" × 48" Blue-M Elec 600˚F 36" × 36" × 36" Grieve (2) Elec 650˚F 36" × 36" × 36" Grieve Elec 500˚F 36" × 36" × 36" Trent Elec 1200˚F Elec 600˚F 36" × 36" × 48" Blue-M 37" × 19" × 25" Despatch Elec 850˚F 37" × 25" × 50" Despatch (3) Elec 500˚F 36" × 60" × 36" CEC (2) Elec 650˚F 36" × 36" × 60" Hevi-Duty Elec 850˚F Elec 450˚F 36" × 36" × 120" Steelman 38" × 20" × 26" Grieve Elec 850˚F 38" × 26" × 38" Grieve Elec 1250˚F 38" × 28" × 28" Trent (Top load) Elec 900˚F 88" × 38" × 38" Lydon Bros. Elec 1200˚F 48" × 24" × 48" Blue-M Elec 600˚F Gas 850˚F 48" × 30" × 42" Despatch 48" × 30" × 48" P-Quincy Elec 500˚F 48" × 48" × 48" Lydon Bros. Elec 1200˚F 48" × 48" × 72" Lydon Bros. Elec 450˚F 48" × 48" × 84" Gruenberg Elec 450˚F 48" × 72" × 72" Mich. Oven Elec 500˚F Gas 850˚F 50" × 50" × 50" Grieve 54" × 30" × 60" P-Quincy Elec 350˚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 Gas 750˚F 72" × 96" × 72" Despatch (2) 72" × 72" × 72" Mich. Oven Gas 500˚F 72" × 120" × 72" Grieve Gas 450˚F 72" × 144" × 42" Bowman (Car) Gas 1000˚F 84" × 96" × 72" Despatch (2) Gas 750˚F

SIVE ADHE

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

Resists Chemicals, Electricity, Molten Metals and Abrasion

2300 F O

FREE MATERIALS HANDBOOK

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

FOR SALE

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

FOR SALE

VACUUM PUMPS SALES AND SERVICE

CASHVAC INC. • • • • •

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

• FREE ESTIMATES AND DELIVERY

Factory Trained Stokes Pumps/Blowers

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

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

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

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

Classified Marketplace FOR SALE

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]

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

AFC Batch Integral Quench Furnace w/electric temper, spray/dunk washer, subzero freezer and charge car.

Lindberg Electric Rotary A-1 Condition FOR SALE

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 IndustrialHeating.com – August 2011 59

Classified Marketplace

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

FOR SALE

FOR SALE

FOR SALE

New Design

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

Singleton Corrosion Test Cabinet *Diff erent Leng ths A vailab le

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

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

*We offer both designs

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

EQUIPMENT FOR SALE

Mowry Enterprises, Inc. New

Used

Rebuilt

Solutions

For Sale VFS 6 BAR, 36 x 36 x 48: graphite hot zone, high vacuum, internal quench, 2650 F, PLC/ touch screen controls

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

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

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

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

Ipsen 224, 15” x 10” x 24” , 2002 control panel, rebuilt pump, graphite elements, mech pump/ diffusion pump VACUUM OIL QUENCH CARBURIZER: C.I. Hayes: 24” x 24” x 24”, Still installed, 2 chamber with isolated oil quench, complete with water recirc system and alloy grids. Heat Chamber is 24 24 36. Quench chamber can be modiÀed for this larger load.

FOR SALE Diffusion Bonding

VFS HL 36: 2500 F, 24” x24” x38” graphite hot zone, High vacuum, PLC/ touch screen controls, Pressure Quench VFS HL 50: 36” x 30” x 48”, graphite hot zone, high vaucum, 1200 CFM external quench, 2650 F 2 BAR: 10” x 10” x 20” hot zone, Graphite. Mech pump and blower, built in 1999. TM 12 x 12 x 20: graphite hot zone, high vacuum, internal quench, 5 psig positive quench ABAR 48 x 48 bottom load: graphite hot zone, high vacuum, external quench, PLC/ touch screen controls

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

60 August 2011 – IndustrialHeating.com

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Densification

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

FOR SALE

Classified Marketplace FOR SALE

FOR SALE

PROCESS HEAT

The Next Generation

All Surface Combustion Equipment:

LHS Air Heater

Built-in thermocouple with digital temperature readout

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

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

FOR SALE

• 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. • Electric 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 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]

• 28" Diameter x 72" Deep, Lindberg, 2000-F, Carburizer, Electric. • Stokes 412-11 Mechanical Pumps – Rebuilt – 2 Available • Stokes 1722 Package Systems – Rebuilt – 2 Available (412-11 w/615 Blowers) • Varian Leak Detectors – 4 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 • Progressive Technologies Rotary Index Shot Peeners • Induction Heating, 7.5 kW to 750 kW, 1 kHz to 450 kHz, 21 In Stock • 36” x 48” x 30”H, Surface Combustion Batch Tempers, 1400˚F, Gas • 59”W x 67”H x 50”L, Despatch, 1000°F, Atmosphere w/Forced Cooling, 2 Available • 8 Cubic Feet Jet Wheel Blast Multi Tumble Shot Blast Machines w/Loader, 2 Available • Dual Rotary Drum Washer, 2 Stage w/Blow Off, 23” Diameter x 15’L, Stainless Drums • SBS Air to Oil Heat Exchangers – 2 Available

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

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

IndustrialHeating.com – August 2011 61

Advertiser Website Index Page

Company

Phone

Website

25 41 37 62 15 11 26 32 10 19 30 12 41 28 Back Cover 53 3, 33 28 33 21 Inside Front Cover Inside Back Cover 27 23 29 6 9 34 31 13

Ajax TOCCO Magnethermic Corp. Applied Test Systems Inc. ASM International AVS 58th Symposium and Exhibition Can-Eng Furnaces International Ltd. CEIA USA CLEMEX Technologies Inc. Edwards Furnace Parts LLC G-M Enterprises Hauck Manufacturing IH Training IHEA Comustion Seminar & Exhibition Induction Tooling Inc. Inductoheat Inc. INEX Incorporated Ipsen Inc. Proceq USA Inc. Rous Hi-Temp Product Co., Ltd. SGL Carbon, LLC SMS Elotherm Induction Technology Solar Manufacturing Steeltech Ltd. Struers, Inc. Super Systems Inc. Surface Combustion Inc. Unifrax, LLC WIRCO, Inc. Wisconsin Oven Corp. Yokogawa Corp. of America

800-547-1527 800-299-6408 800-336-5152 212-248-0200 905-356-1327 888-532-CEIA 450-651-6573 800-848-9800 800-321-0796 951-340-4646 717-272-3051

www.ajaxtocco.com www.atspa.com www.asminternational.org www.avs.ort www.can-eng.com www.ceia-usa.com www.clemex.com www.edwardsvacuum.com www.furnacepartsllc.com www.gmenterprises.com www.hauckburner.com www.industrialheating.com/ihtraining www.ihea.com www.inductiontooling.com www.inductoheat.com www.INEXinc.net www.ipsenusa.com/ www.proceq-usa.com www.rous-hitemp.com www.sglcarbon.com www.sms-elotherm.com www.solarmfg.com www.steeltechltd.com www.struers.com www.supersystems.com www.surfacecombustion.com www.unifrax.com www.wirco.com www.wisoven.com www.yokogawa.com/us

62 August 2011 - IndustrialHeating.com

859-356-1575 440-237-0711 800-624-6297 716-537-2270 800-727-7625 800-839-7016 0086-533-3580575 800-727-4474 724-553-3471 215-258-3350 616-243-7920 888-787-8377 513-772-0060 800-537-8980 716-278-3800 800-348-2880 262-642-3938 800-258-2552

“ ingenuity ”

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

The Brightest Solutions Through Ingenuity

PROUDLY MADE IN THE USA

We give you the competitive edge by manufacturing accurately controlled, high quality induction heating equipment that produce superior long lasting parts time and time again.

‹ Hardening, tempering & annealing

Our team of scientists, engineers and maintenance experts blend a variety of techniques to establish the WLYMLJ[ OLH[PUN ZVS\[PVU ZWLJPÄJHSS` Z\P[LK MVY `V\Y production and thermal processing needs.

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‹ Billet & bar forging & warm forming ‹:OYPURÄ[[PUNZ[YLZZYLSPL]PUN WYLOLH[PUN ‹*VH[PUNJ\YPUNIVUKPUN IYHaPUN ‹¹VYSLZZZ[YPWHUKZSHIOLH[PUN

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Inductoheat, Inc. 32251 N. Avis Dr., Madison Heights, MI 48071