May 2011
June 28 - July 2, 2011 • Düsseldorf, Germany
Induction Modeling p.41 Selective Laser Melting p.47 All About Gas Nitriding p.53 Heat-Treat Automation p.59
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CONTENTS
May 2011 • Vol. LXXIX • No. 5
On the Cover:
A R T I C L E S
Rex Heat Treat's 15-foot vertical gantry furnace transferring a hardening load into the oil quench. Read more about Rex Heat Treat on p. 28.
41
F E A T U R E
Computer Modeling of Induction Heating: Things to be Aware of, Things to Avoid Dr. Valery Rudnev – Inductoheat, Inc.; Madison Heights, Mich. Computer simulation of induction heating has gone from “useful” to “necessary.” Modern computer simulation is capable of effectively simulating electromagnetic and thermal phenomena for many processes, including those that involve electromagnetic induction. Sintering/Powder Metallurgy
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New Ground in Metal-Powder Additive Manufacturing Rob Snoeijs – LayerWise; Leuven, BELGIUM Selective laser melting (SLM) is a powerful technology that shapes any desired metal part geometry by melting metal powder layer by layer. Digital production of functional metal models yields distinct product improvements and economic advantages.
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4 May 2011 - IndustrialHeating.com
Induction Heat Treating
Vacuum/Surface Treating
Principles of Gas Nitriding (Part 2) Daniel H. Herring – The HERRING GROUP, Inc.; Elmhurst, Ill. This is article is actually the third in a series that included an online exclusive in April. The gas nitriding process, including the applicable equations and other specifics, will be discussed here. Check out all three parts for a full treatment of the process.
59
Process Control & Instrumentation
Implementing Process Controls and Automation in Heat Treating Jim Oakes – Super Systems Inc.; Cincinnati, Ohio In heat treating, automation is approached in categories. The types of processes and equipment may only have certain capabilities when it comes to mechanically automating a process, forcing heat treaters to look at nontraditional types of automation.
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COLUMNS 14 Editorial All About Automotive We review the lightweighting of cars with high-strength steel or aluminum, fuel economy, the impact of the tsunami on the auto industry and the future of automotive materials.
18 Federal Triangle Return of the Small Modular Reactor According to Barry Ashby, America’s nuclear-power future appears healthier than expected. He discusses the small modular reactor (SMR) and why he feels that both the U.S. and the world would benefit from what they have to offer.
20 The Heat Treat Doctor™ The Role of Metallurgical Analysis in Solving Heat-Treat Problems What do heat treaters need to provide to the metallurgist to assure that accurate information and reliable facts result from whatever testing or analysis is performed, upon which we can make informed decisions.
24 Now You Know Bearing Balls, Not Ball Bearings Have you ever wondered how the balls in a ball bearing are made? Although they look simple and are an uncomplicated shape, the production process and requirements are a bit more challenging.
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©2010 Babcock & Wilcox Nuclear Energy, Inc. All rights reserved.
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26 IHEA Profile – IHEA Develops Strategic Plan 28 MTI Profile – Rex Heat Treat
DEPARTMENTS 30 Industry News
66 Products
38 IH Economic Indicators
70 Aftermarket
39 Industry Events
72 Classified Marketplace
63 Literature Showcase
78 Advertiser Index
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Industrial Heating is the official publication of ASM’s Heat Treating Society and official media partner of ASM’s HT Expo & Conference.
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Online Exclusive An 80-Year Legacy of Thermal Processing In case you missed it last month, Industrial Heating’s look back at thermal-processing history is still available online. This article pulls quotes and other content from the pages of past issues.
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Editorial Reed Miller, Associate Publisher/Editor | 412-306-4360 |
[email protected] All About Automotive
A
r review of recent automotive news reveals several key k areas to cover. The lightweighting of cars with high-strength steel or aluminum is one important h initiative, which is related to another – fuel econoi my. The third revolves around the impact of the tsunami on the Japanese auto industry. Cut the Fat In just a week or so, the 10th Annual Great Designs in Steel (GDIS) seminar will be held in Livonia, Mich. At that venue, the FutureSteelVehicle (FSV) program presents production technologies and steel grades to the industry’s advanced high-strength steel (AHSS) products. Over the past decade, the use of AHSS by the auto industry has outpaced all other lightweighting options. Making vehicles lighter by using AHSS has an additive effect. As vehicles shed pounds, engines can be lighter because it takes less to power the lighter vehicle. Brakes can be lighter because it is easier to stop a lighter vehicle. Batteries for hybrids or electric cars can also be lighter as the vehicle sheds pounds. Needless to say, all of this trimming of the fat results in a more fuel-efficient vehicle. Experts predict that the use of lightweight steel will save 0.37 quad of energy by 2020. A quad is equivalent to over 8 trillion gallons of gasoline or nearly 300 trillion kWh of electricity. Five new 2011/2012 gas-powered vehicles are professed to reach the 40 MPG threshold by a variety of innovative techniques. Several specifically mention the widespread use of lightweight steel as one of the ways they got there. Obviously, aluminum usage is also important. Development continues on new and improved ways to make metals lighter. Researchers at the Polytechnic Institute of New York University have found a way to make metal lighter while recycling a toxic waste. Metal-foam composites have been created using fly ash – a toxic by-product of coal combustion – as an additive. The metal foam material can be used to replace solid aluminum and magnesium in certain automotive applications. While it’s likely these “inclusions” will not make the steel stronger, tests have found that the lightweight foams absorb more energy than the solid materials. 14 May 2011 - IndustrialHeating.com
What’s Happening? As I write this editorial, Toyota has announced that it is rationing aftermarket parts for dealers in the U.S. They also said that they expect “some production interruptions” at North American factories due to problems obtaining parts from Japan. Similarly, Honda said that it “will begin to adjust production levels, cutting hours at some plants in half.” Subaru cut shifts in half at its Lafayette, Ind., plant to conserve parts, and as of the day of this writing, Nissan is reassessing North American production. The tsunami effect has hurt domestic manufacturers that rely on Japanese-made parts as well. GM was forced to temporarily close a pickup factory in Shreveport, La., and a related engine line in Buffalo due to a lack of imported parts from Japan. Speaking of GM, they recently announced the sale of its share of Delphi Corp. back to its former parts subsidiary for $3.8 billion. This will result in a $1.6 billion gain in its first-quarter financial results. In March, Ford was expected to surpass GM, becoming the top U.S. auto seller. Industry experts say this has more to do with GM falling than Ford gaining. However, with two of the five 40 MPG models – 2011 Fiesta SE SFE and 2012 Focus SFE – Ford has positioned itself well for the higher-priced fuel we are currently experiencing. The Association of Global Automakers, a lobbying group representing Toyota, Honda, Nissan, Hyundai, Kia, Subaru, Mitsubishi, Suzuki and others has petitioned the U.S. government to require the continued availability of E10 fuel – 10% ethanol, 90% gasoline. The feds have approved E15 for 2001 and newer vehicles. Many have expressed concern that the E15 usability tests were not adequate and that prolonged use will damage fuel lines or the engines themselves. The Future A quick glimpse into future technology reveals that materials are a key component. The following list helps paint the picture: honeycomb-shaped, polyurethane-spoked tires; electromagnetic motors to replace shocks and springs; magnesium exoskeleton; graphene-based ultracapacitor for energy storage; aluminum-oxynitride windows, roofs and doors; carbon-fiber composites; lithiumion batteries; integrated solar panels; inflatable metallic structures for better crash protection; and enhanced turbocharger/supercharger technology to name a few. IH Concept car illustration courtesy of WorldAutoSteel www.worldautosteel.org
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Federal Triangle Barry Ashby, Washington Editor | 202-255-0197 |
[email protected] Return of the Small Modular Reactor
T
h nuclear disaster in Japan, continued growth in world he electricity demand (projected to rise 77% by 2030) and e aging power-generation infrastructures led to this coma mentary on the best means to satisfy national and inm ternational energy hunger. I attended a small modular reactor (SMR) seminar on March 28 and learned that America’s nuclear-power future appears healthier than expected. It is also headed in the right direction after decades of fear and loathing by a large part of the population. My unofficial count indicates there are 15 light-water designs, 10 liquid-metal-cooled, nine gas-cooled, three molten-salt-cooled and two fusion SMR power producers in development and in varying stages of commercialization. Recall that an SMR was the original – the first nuclear power output of 45 KWe (kilowatts electric) was done at an Idaho laboratory on Dec. 20, 1951, and hundreds of Navy nuclear vessels have since covered the ocean surface and depths for over 50 years. The definition of an SMR is generally accepted as electric output of up to 300 MWe, but the great majority of those cited as in development are in the 10 to 100 MWe range with some field portable units as small as 1.5 MWe output. What distinguishes the modern SMR is greater simplicity of design, economies of factory-built production and dramatically reduced siting costs. What differentiates manufacturing entities from former U.S.-dominated providers is that all have high foreign ownership. For example, GEHitachi is 50% Japanese owned; both Areva and Mitsubishi are 100% Japanese. Over half of those developing SMR concepts are American-owned firms. What this indicates is that participating American industry is concerned about an inhospitable tax and regulatory environment at home and that there’s clear recognition, as expressed by numerous at the seminar, that foreign markets are the preferred (and first) markets of choice. There are many aspects of SMR use that are quite different from other sectors. Previously, all reactors were built on location, were large to achieve economies of scale in financing and operation, and great care was devoted to facility safety and security to prevent theft and improper proliferation of radioactive materials. Today, the trends are to make components in a factory to halve costs and to cut total construction time by half and possibly reduce labor costs eightfold. Reactors housed in a sealed containment can be small enough to ship on a railcar or truck. Installation at many proposed 18 May 2011 - IndustrialHeating.com
sites are underground with all waste materials stored within the containment during a typical 60-year life with refueling every two to 10 years. The reasons for foreign markets being attractive to SMR makers are that many poor countries cannot afford the financing of the large, average-sized plant ($9-11 billion) and, further, that these countries do not have the needed grid infrastructure to distribute power from gigawatt power stations. It is also expected that the anticipated capital cost of these SMRs will be about $5,000 per KWe, or several hundred million dollars, rather than billions for the monolithic power stations. Another overlooked feature of SMRs is that they are indeed “modular” and can be linked together to increase output as demand in a locale changes. Inherent safety of SMR design has been a focus for developers to change the fuel cycles, to do everything from burning other “used fuels” and nuclear waste, and to limit the operating cycle so that “passive” control and cooling means are part of every plant. The object is for no SMR to ever run out of control. An assessment made two years ago by the International Atomic Energy Agency projects that 40 to 100 SMRs will be in operation worldwide by 2030 with the target being 96 units. None of these are predicted to be in the U.S. even though more than 120,000 Americans are in the U.S. civil nuclear workforce and are part of a civilian nuclear power sector that is estimated to reach $500-740 billion during the next decade. For comparison’s sake, 441 large reactors now operate in 35 countries supplying 15% of the world’s electricity. Of course, there is a lack of consensus about the positive outlook offered here. The Institute for Energy and Environmental Research, for example, has a bleak view of future SMRs’ ability to assist electric supply problems. But it is my conviction that SMRs offer an improvement to power-supply needs and that both the U.S. and the world would benefit from what they have to offer. As large consumers of electrical energy, it is in U.S. industry’s best interest to exercise rational support for the SMR avenues that are opening. It is also essential that industry advise the federal government to assist by allowing future opening of these avenues. IH If you would like to ask Barry Ashby a question, e-mail him at
[email protected]. You can hear him answer your query, and others, in our Talk Back to Barry podcasts, which are available at www.industrialheating.com.
Conceptual drawing of B&W mPower™ nuclear reactor design. Illustration ©2010 Babcock & Wilcox Nuclear Energy, Inc. All rights reserved.
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[email protected] The Role of Metallurgical Analysis in Solving Heat-Treat Problems
A
s a young boy growing up in the neighborhoods of Chicago, one of the Heat Treat Doctor’s most trustC ed friends was a mythical conjuror by the name of e Mandrake, The Magician. If a task seemed impossiM ble to accomplish, or when all else failed, all one needed to do was summon Mandrake, and “voila,” the impossible became possible! As heat treaters, we often seek answers to processing problems or component part failures from the metallurgical community without fully understanding what they need to do their job properly. What do we need to provide, whether it be accurate background information, a representative set of samples (good and bad) for comparative analysis, or even something as simple as protecting the surface of the component to be analyzed from further damage? Often, we don’t communicate our expectations in precise terms and thus do not know what to expect from an analysis. It’s time for us to learn what we can do to assure that accurate information and reliable facts result from whatever testing or analysis is performed, upon which we can make informed decisions. Mandrake would be proud. Let’s learn more.
having a confidentiality agreement in place before you start. If it turns out that the component is being returned from the field, extreme care must be taken to ensure a representative sample and to avoid further damage (see “The Do’s and Don’ts of Field Failure Analysis,” Industrial Heating, January 2006). Incoming (Raw) Material Analysis Too often we are forced to begin an analysis making assumptions about the raw material. Provide the laboratory with a copy of the mill’s material certification sheets. In addition to the chemical constituents, the metallurgist will glean information based on the form of the raw material, its grain size, cleanliness and prior mill processing. Doing an actual chemical analysis is not necessarily redundant. For example, trace-element chemistry can play a significant role when investigating certain phenomenon, such as temper embrittlement.
Laboratory Procedures Discuss with your metallurgist or outside laboratory what type of tests will be conducted and in what order. Understand what will be achieved at each step in the analysis process so that you can ask questions or offer suggestions. (This will also help explain the time or expense involved.) In this way, you will be better able to interpret the final results. The Role of Photography Be aware there is nothing more frustrating in the laboratory In this day and age of digital photography, a picture can indeed be worth the legendary 1,000 words (or more). Provide photographs than to work hard on a job only to find out that it is not the right sample or that the damage observed was induced by extraof everything, from multiple angles, and remember to use good neous factors. This translates into lost time and money. Also, be lighting and high resolution. Handle parts carefully so as not to induce damage and resist the temptation to reconscious of the fact that once the investigator has begun to work on your project, it is fit mating fracture surfaces together. Note part best that the analysis move forward uninterorientation and other salient features. rupted. So be sure to define the scope of work and clarify the boundaries of what he or she Processing History/Background Information is allowed to do once the investigation is unDon’t assume that someone knows your process der way. (Oftentimes, a “not to exceed” figure or product, or its intended service application, works well for this part of the investigation.) better than you do. Communicate the history Selecting the proper tests may involve of the part or process; separate assumptions trade-offs due to cost or time. Be sure you unfrom facts; provide necessary drawings, includderstand the cost/benefit relationship of each ing mating components if appropriate as well test and what the expected outcome might be as required specifications; and explain in detail so that the right choices can be made. Insist the design requirements. In other words, take on specificity to avoid open-ended analysis efthe guesswork out of the analyst’s job. Docuforts. Here are some examples of what can be ment anything of importance and give this information to the metallurgist, even if it means Fig. 1. The Doctor’s boyhood companion done in the laboratory. 20 May 2011 - IndustrialHeating.com
QuantumQuench QuantumQuench
Variable Speed Directional Quench There are no moving parts within the vacuum chamber
For more information contact G-M Enterprises 525 Klug Circle, Corona, California 92880 Phone 951-340-GMGM (4646) • Fax: 951-340-9090
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TH
• Stereomicroscopy • Nondestructive testing • Eddy current • Ultrasonic • Pressure testing (hydrostatic, pneumatic) • Surface finish • Macroetching • Mechanical testing • Hardness/microhardness testing • Tensile testing • Impact testing (e.g., Charpy testing) • Fatigue testing • Torque/torque-tension • Shear and double shear strength • Torsion testing • Creep • Stress rupture and stress durability • Vibratory testing • Sample preparation • Unetched part examination • Etched part examination • Optical microscopy • Microstructural determination • Grain size • Micro cleanliness • Intergranular attack • Inclusion characterization • Alpha case • Image analysis • Plating depth (layer thickness) • Defect measurement • Grain size • Scanning electron microscopy • Fractography • Feature/character recognition • Energy-dispersive X-ray spectroscopy • Qualitative element analysis • Inclusion characterization • Elemental distribution (dot) mapping • Corrosion testing Selecting the Right Laboratory Not all laboratories are created equal, either in the talent of their researchers or in tools available to do the job right. Talk to people you trust in the industry to help in the selection process. Be aware that many labs are better at some things than others and subcontract certain tasks to other labs. Be sure that you understand when and why this is being done and determine if you are better off going direct. 22 May 2011 - IndustrialHeating.com
Machining Pre-Treatment • Parameters • Material Condition (Feeds & Speeds) • Stress State • Material Condition • Fixturing • Machine Factors (Part Support) • Lubricants • Heating • Tooling (Ramp Rate) • Human Factors
• Process • Atmosphere • Equipment • Process Parameters • Metallurgical Factors Hardening
• Part Design • Quench Method • Equipment • Type of Quench • Quench Variables Quenching
Comparative Analysis (Good vs. Bad) If good parts exist, they can be invaluable aids in understanding why a bad part failed. Taking the seemingly extra step (and expense) of testing a good part along with a bad one will yield tremendous insight into the problem at hand. Do this whenever possible. Timing In an effort to get answers, avoid the temptation to push the lab to the point where steps are skipped or time is not taken to investigate secondary factors that may prove to be major contributors. Ask for verbal reports at key milestones in the analysis work, but avoid taking up valuable analysis time by “checking in” too often. Meeting in person to begin a project is always beneficial. Lab Reports Metallurgists tend to write reports for other metallurgists, a noble but often frustrating problem for the heat treater. If you need the report “translated” into layman’s terms, be sure to tell the lab. Yes, there is a delicate balance here between the facts and their interpretation, but this can often be handled by placing the interpretation in a “Discussion” section of the report. The trend today, due to liability concerns, is to simply report the facts and rely on the client to interpret them. If necessary, hire outside experts to put the information in the proper context in order for you to determine the right course of action. There
Material • Chemistry • Metallurgical Factors • Form
Output: Management of Dimensional Variability • Grinding • Straightening • Stress Relaxation • Deep Freeze • Tempering Post Hardening
Fig. 2. Ishakawa diagram – quenching
is nothing worse than paying good money for a report you don’t understand. Root-Cause Determination “What caused the problem, and how can I avoid its reoccurrence” should be the objective of any analysis effort. There are often multiple contributory factors and removing any one of them might avoid a part failure, even though defects may still exist. While it may or may not be possible to establish the root cause, it should always be the goal. The use of Ishakawa (fishbone) diagrams (Fig. 2) or other diagnostic methods listing all of the variables impacting a successful outcome can be a big help. Sometimes it’s the thought process itself and a discussion among various company departments that leads to the solution to be implemented. The Bottom Line: To Analyze or Not to Analyze A cost/benefit analysis should be performed before and after any analysis/ testing work. Knowledge is strength, and assumption is weakness. When in doubt, do the metallurgical analysis. It will amaze you what can be revealed. And remember that Mandrake is alive and well, living within each and every metallurgist! IH
Use this Mobile Tag to see the Field Failure Analysis column referenced in this column.
Who will invest in developing the advanced technology you need to stay competitive?
WILL. Inductotherm Group: Many companies. One mission. To design and manufacture the most advanced thermal processing systems to help your company succeed. No matter what metal you melt, heat treat, hot forge or process, the Inductotherm Group will put our shared knowledge, global reach and unparalleled technology to work for one company. Yours. INDUCTOTHERMGROUP.COM
Visit us at Thermprocess/GIFA Hall 10, Stand 10B24 June 28th – July 2nd Düsseldorf, Germany
Now You Know Thermal Processing & Metals in Everyday Life
Bearing Balls, Not Ball Bearings
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ften, when bearings are discussed, people call them ball bearings. In truth, there are several other types of bearings that don’t even use balls. The most common of these is a roller bearing. Also a misnomer is when people refer to the balls in bearings as ball bearings. The balls are just a component of a ball bearing, which may also contain an outer race, an inner race and a retainer (cage). This discussion is all about the balls used in ball bearings. Have you ever wondered how the balls are made? Although they look simple and are an uncomplicated shape, the production process and requirements are a bit more challenging. Balls can be made from a variety of materials, including (but not limited to) tool steel, stainless, brass/bronze, titanium, Stellite, Teflon, and even ceramics such as aluminum oxide and silicon nitride. The material is chosen based on the application of the bearing. Regardless of the material, the manufacturing process is similar for metal balls. We will focus our discussion on through-hardened steel balls. Perhaps surprisingly, balls begin life as a piece of wire. The steel wire is typically annealed coil stock of a diameter appropriate for the final ball diameter being manufactured. The wire is fed into a machine that cuts off a measured piece and smashes both ends toward the middle. This is called cold heading because no heat is used in this process, which leaves a bulge or flash around the middle of the ball. The next step in the process is the deflashing operation. The balls are placed in rough grooves between two cast-iron disks. One disk rotates while the other is stationary. After deflashing, the balls are soft ground. This is a process similar to deflashing, but grinding stones are used to improve the precision. Balls remain oversize so that they can be ground to their finished size after heat treatment. Heat treatment is often performed in a rotary-retort furnace,
24 May 2011 - IndustrialHeating.com
depending on the specification requirements. If an application, such as aerospace or automotive, requires AMS 2750 temperatureuniformity survey (TUS) requirements, heat treatment will generally be performed in a batch furnace. TUSs are very difficult to do in a rotary retort. Small parts, particularly precision parts such as bearing balls, require good heat-treat control. Load sizes are determined by the surface area of the balls based on the maximum surface area that can be quenched in a load. Soak times are determined not by the diameter of the balls in the load, but by the packing height of the balls in the basket. The hardening process typically involves the following: • Preheating • Austenitizing (hardening) • Quenching • Subcooling (deep-freezing) • Tempering (based on final hardness requirement) Following heat treatment, the balls undergo several finishing operations. Descaling is followed by hard grinding, which is a slow and meticulous process that produces diameter tolerances as close as +/-0.0001 inch. Lapping and other finishing operations follow, most of which are proprietary in nature. These are particularly important for high-precision balls, but all balls need to be sized very precisely. Why? Ball bearings are designed with the assumption that all of the balls in the bearing are carrying an equal load, which means they must be the same size. If, for example, one or two balls were slightly larger, the load would be carried only by the larger balls, and the others would be free spinning. This would result in premature bearing failure. Balls are manufactured in accordance with ABMA (American Bearing Manufacturers Association) standards. The ABMA grade is designated by a number, which indicates a specific combination of dimensional form and surface roughness. Grades 3 to 50 are considered “precision” balls, and grades 50 and 100 are semi-precision. The normal range of sphericity for precision balls is +/-0.000003 for grade 3 and +/-0.00005 for grade 50. From here, the grading and specifying requirements get even trickier and are better left for a more detailed treatment of the subject. Bearing ball manufacture was undertaken in space aboard the shuttle. Molten blobs of steel were released into the zero-gravity atmosphere. Because a sphere has the lowest surface area of any form, the molten blobs form perfect spheres while they cool and possibly harden (depending on the material). Since space travel is expensive and the space-shuttle program is coming to an end, it’s likely that bearing balls will continue to be made using the tried-and-true manufacturing method discussed here for years to come. IH
IHEA Profile Industrial Heating Equipment Association | 859-356-1575 | www.ihea.org
IHEA Develops Strategic Plan
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u uring the past 12 months, IHEA has developed and begun implementing a new strategic plan. Part of b that plan included cultivating knowledge-base ret sources that the industry can rely on for information. s IHEA is pleased to announce that the beginning of its knowledge base can now be found on its website under RESOURCES, where you will find links to a wide variety of content for the following subjects: • Application videos • Energy efficiency • Innovations • Books • Software • Manufacturing careers • Manufacturing-related sites • Furnace market statistics • Government regulations/legislation • Environmental • Business • Social Media • Industry publications • Industry trade associations This will be an ever-expanding section of our website as we locate additional information that is important to the process heating industry. You can help us grow this area by telling us about important resources you use in your business.
the economy and health-care bill; how to attract and keep skilled workers; lengthy discussions on the implementation of IHEA’s strategic plan; and an entertaining motivational presentation on goals, attitude and behavior from keynote speaker Conor Cunneen. In addition, the TC244 Working Group 1 convened. THERMPROCESS 2011 With just a little over two months to go until the start of THERMPROCESS 2011 (June 28 in Düsseldorf, Germany), IHEA and Industrial Heating’s Resource Center has come together. Through the support of IHEA members and industry, this Resource Center will feature a presentation area, meeting rooms and literature from sponsoring companies. It will serve as a gathering spot for IHEA members exhibiting and visiting the show. Sponsorships for the Resource Center are still available. Benefits include access to food and beverage; use of meeting room; company name displayed in the Resource Center; and more. For a complete listing of sponsorships and the benefits included with each level, contact Anne Goyer at
[email protected] or 941-373-1830.
Annual Meeting IHEA’s 82nd Annual Meeting recently concluded four solid days of educational presentations, committee and ISO meetings, and networking opportunities at one of the biggest gatherings in years. More than 90 people made the trip to Florida, where members heard updates on
THE DIFFERENCE IS OBVIOUS. The Brightest Solutions Through Ingenuity
Solar stands out from the usual choices. 26 May 2011 - IndustrialHeating.com
Visit www.solarmfg.com to learn more.
PROUDLY MADE IN THE USA
MTI Profile Metal Treating Institute | 904-249-0448 | www.HeatTreat.net
Rex Heat Treat World-Class Heat Treater of Choice
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ex Heat Treat began as a two-man operation in a two-car garage over 70 years ago. Today, the commercial heat treater based in Lansdale, Pa., employs 90 people at three separate facilities. In 1938, the company’s first job was hardening a pair of chisels. During the late 1950s/early 1960s, what was known as J.W. Rex Company (named after founder J. Walter Rex) built three vertical gantry furnaces ranging in size from 15 to 30 feet tall for the Titan and Minuteman missile programs and became a major source for the heat treatment of ordnance shells. The company name was changed to Rex Heat Treat in 1999. The following year, a 30,000-square foot facility was added in Bedford, Pa. In 2005, the company expanded further with the addition of a facility in Anniston, Ala. Rex Heat Treat’s vertical gantry furnaces (15 and 20 feet high with maximum 65-inch-diameter work zone) are integral to its success. They permit parts to be suspended as required, providing a vertical orientation that takes advantage of gravity and reduces distortion during heat treatment. In addition, the rapid transfer from the furnace to the quench does not allow for any cooling of the load before being submerged in the quench bath. These furnaces offer marquenching, oil, water and air quenching. Rex Heat Treat has vertical capability for parts up to 24 feet long. The company provides a wide variety of other heat-treating services to industries including aerospace, military and power generation. It has large-volume horizontal capacity for annealing and aluminum processing. Rex Heat Treat boasts 19 Nadcap-certified furnaces with surveyed temperatures from 225˚F up to 2200˚F. This long-time MTI member also has pit furnaces from 8 to 25 feet deep and pusher furnaces capable of processing up to 110,000 pounds of parts daily. In addition, the company has substantial integral quench and austempering capacities at its Bedford and Anniston facilities.
28 May 2011 - IndustrialHeating.com
Rex Heat Treat takes pride in its data-acquisition and process control systems (provided by Super Systems Inc.), which support its employees and shows the accuracy of its processes. These systems allow the company’s management team to remotely check, and modify as required, actual furnace runs and witness the quench on a computer, smart phone or tablet device. As a privately owned company, Rex Heat Treat is willing to invest in its employees, equipment and facilities as needed to support viable customer needs. Over the last two years, the company has reinvested $1.5 million back into its three facilities. The vast majority of this investment was new furnaces, major furnace rebuilds and facility infrastructure improvements. The future is bright for Rex Heat Treat. The company has just begun to penetrate the high-end markets it can support, and it will continue to earn opportunities with the global aerospace and defense industries. More importantly, Rex Heat Treat is keeping its options open for the addition of equipment and facilities to support future business levels. For more information, visit www.rexht.com
Celebrating 25 Years of Gears!
Indianapolis, Indiana
Since 1986, Contour Hardening has provided specialized automotive gear components using our patented computer-controlled induction heating technology. Our metal strengthening systems and processes have dramatically altered the traditional methods of manufacturing case hardened gears and other irregularly shaped, complex parts requiring a high degree of dimensional accuracy. This means our treated gears are stronger, more durable, and offer superior quality and better value than the competition.
Silao, Mexico
See you in Cincinnati for the ASM Heat Treat Show. #ONTOUR(ARDENING )NCr.ORTHWEST"LVD)NDIANAPOLIS ). rWWWCONTOURHARDENINGCOM
Industry News
Equipment News
load. The hot zone is an all-metal design incorporating molybdenum/stainless steel shields and molybdenum heating elements with a maximum operating temperature of 1000°C (1832°F). www.solarmfg.com
Vacuum Furnace Ipsen, Inc. shipped a 2-bar TITAN® V6 to the Texas plant of a global energy company. The bottom-loading furnace, with a 60-inch x 60-inch work area, was installed by Ipsen’s field-service team. The TITAN V6 offers energy efficiency and a reduced footprint. It features an easyto-remove hot zone and heat exchanger as well as loadproximity controls. This particular model included several standard options – all-metal hot zone, operator-access platform, 1,000-gallon backfill reservoir tank, controlled cooling using a variable-speed drive and 10-Torr hydrogen partial pressure. www.ipsenusa.com
Carbon-Fiber Process Line
Vacuum Furnace Solar Manufacturing received an order for a car-bottom-type vacuum heat-treating furnace from a major Chinese aircraft manufacturer. It is expected that the furnace will be used for the processing of various titanium aircraft parts and other related products. The Model HCB-120180-2EQ horizontal furnace incorporates a special motorized in/out front-loading system. Solar is modifying the design of its standard car-bottom loading system to uniquely suit the customer’s needs. The furnace work zone measures 99 inches wide x 48 inches high x 180 inches long and has a hearth designed to accommodate up to a 15,000-pound work-
Harper International finalized a contract with the United States Department of Energy’s (DOE) Oak Ridge National Laboratory (ORNL) for a full pilot-scale carbonfiber process line valued at approximately $12 million. The line is a custom-designed conversion process to support ORNL’s lowcost carbon-fiber research and technology transfer. The line incorporates Harper’s proprietary multi-flow oxidation oven technology, advanced LT and HT slot furnaces rated for 1000°C and 2000°C respectively, pre- and post-treatment fiber conditioning, gas treatment and handling, and materialtransport systems. www.harperintl.com
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