FEATURED NEWS

High Pressure Prepares Parts for Space

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT TECHNICAL CONTENT, FEATURED NEWS, HIPING TECHNICAL CONTENT

Dive into the role and benefits of HIP and HPHT™ in the space industry, highlighting how these key processes are shaping the future of space applications.

This Technical Tuesday article by Andrew Cassese, applications engineer, Quintus Technologies was originally published in Heat Treat Today’s March/April 2024 Aerospace print edition.

The realm of space exploration and technology is rapidly evolving, pushing the boundaries of what’s possible in engineering and material science. Among the key players in this revolutionary change are hot isostatic pressing (HIP) and High Pressure Heat Treatment™ (HPHT™). These processes have become indispensable in manufacturing components that can withstand the harsh conditions of space. In this demanding environment, the longevity and reliability of components are paramount.

Reducing Risk

Space missions have put increasing focus on the need to minimize risk and improve mission safety. Some well-documented, safety-related events include:

  • Outer space
    • Soyuz 11 decompression in 1971
  • Earth’s atmosphere
    • Soyuz 1 parachute failure in 1967
    • X-15 controls failure in 1967
    • Space Shuttle Challenger launch
      booster failure in 1986
    • Space Shuttle Columbia re-entry
      disaster in 2003

Structural integrity is therefore in focus for every single component involved in space missions, with exacting demands on quality and function. Material failure is not an option, and therefore component qualification is one of the main areas of focus. Predictable properties that are reliable and with minimal variation are critical for mission safety. Hot isostatic pressing helps to guarantee this by reducing the spread and variation in mechanical properties.1 It works to do this by using high temperatures and pressures to close internal defects in mission critical parts after casting or additive manufacturing. This increases the density of components and gives them a more anisotropic microstructure which in turn results in more consistent mechanical properties.2

What Properties Are Most Important

The harsh environment of space demands components with exceptional properties. They must withstand extreme temperatures, resist radiation, endure vacuum pressures, and cope with mechanical stress from vibrations and accelerations. HIP processing plays a pivotal role in this, enhancing material properties to meet these challenges. Space manufacturers also must think about thermal expansion/contraction due to temperature variations, compressive stresses, irradiation, and space debris. All of these can affect mission success and can ultimately prevent loss of life, see Figure 1.

Figure 1. Challenges that space-bound materials must endure

Through HIP, components gain increased fatigue life, improved ductility, and enhanced fracture toughness, which are crucial for surviving in space.

Common Materials and HIP Processing Requirements

Materials commonly processed by HIP for space applications include titanium, aluminum alloys, nickel-based superalloys, refractory alloys, shape memory alloys, and ceramics. High-strength aluminum and titanium alloys are used due to their high strength to weight ratio which is key for space missions to conserve fuel efficiency, increase payload capacity, and improve maneuverability.3 Nickel-based superalloys are used in exhaust valves and turbine rotors due to their exceptional creep resistance properties at high temperatures. Refractory alloys like Nb-C103 and TZM are used in high-performance rocket nozzles because of their high melting point and excellent strength at high temperatures. Newer shape memory alloys developed by NASA can recuperate their original shape when heating above specific critical temperatures, and their applications are expanding beyond just actuators.4

As new alloys and materials are developed in the space industry, certifications and standards are necessary for their adoption. HIP effectively eliminates porosity in these materials, ensuring structural integrity and performance under the extreme conditions of space. This means HIP recipes need to be developed and optimized for materials to be tested with their greatest potential in mind.

Challenges in Processing Space Components

Processing components for space via HIP is not without its challenges. Th e extreme conditions required for HIP, including high temperatures and pressures, demand robust and sophisticated equipment. Quintus Technologies applications centers utilize a graphite furnace capable of heating to 3632°F (2000°C), while maintaining pressures of 30,000 psi (200 MPa). The process requires precise control to ensure uniformity of properties across the component. Specifically, the graphite uniform rapid cooling© (URC©) furnace can maintain temperature uniformity while controlling to a specified cooling rate.

Another challenge with processing space components in HIP can be oxidation of parts in the HIP furnace atmosphere. Niobium, for example, can suffer from substantial oxidation at elevated temperatures. In practice, tantalum foil is typically used to wrap the niobium components during HIP and to prevent oxidation from any residual moisture in the argon atmosphere. New products, like the Quintus Purus©, can reduce the amount of oxidation seen on parts aft er HIP while saving valuable time and resources by not having to wrap parts with getter materials like stainless steel, titanium, or tantalum.

Ongoing Research and Unknowns

Collaborations with universities and national labs on projects at low TRLs will help set the foundation for HIP in the space industry. Quintus Technologies, through its application centers, is actively engaged in research to further enhance the capabilities of HIP for space applications. Optimizing the HIP process to reduce costs and improve efficiency through HPHT is one area where the company has already found success, see Figures 2 and 3.

Figure 2. Typical thermal processes for additively manufactured parts
Figure 3. High pressure heat treatment with solution heat treatment (SHT) process for the same parts, using an integrated heat treatment approach

The HPHT process can combine stress relief, solution annealing, HIP, and aging into one cycle. Aft er a ramp up in pressure and temperature, the part is held for a specified amount of time before being rapidly cooled in the URC furnace. Aft er this, the temperature of the machine can be brought up to the aging temperature of the material for the completion of an in situ heat treatment.

A Space Case – Launcher Engine-2 Rocket Engine

Table 1. CuCrZr vs. GRCop-42: A Comparison

One application of this is on the Launcher Engine-2 (E-2) rocket engine.

Quintus Technologies, EOS Group, and Launcher worked together to develop a tailored HPHT cycle for Launcher’s 3D printed E-2, first vetted out in an applications center at small scale. The powder alloy in question, CuCrZr, was developed by EOS and printed on an AMCM M4K machine. EOS compared CuCrZr to the NASA alloy of GRCop-42 and found that the CuCrZr alloy was a more economically viable solution for thermal applications with lower strength requirements, see Table 1. The rapid cooling at 200°C/min in the QIH 122 URC furnace at Aalberts surface technologies allowed the team to HIP and solution heat treat the CuCrZr combustion chamber in a single step. The aging treatment was also performed in the QIH 122 directly aft er the solution.5

In October 2020, a full-scale test firing of the E-2 injector and combustion chamber was conducted at the Launcher NASA Stennis Space Center test stand. On April 21, 2022, Launcher’s E-2 liquid rocket engine was able to demonstrate full thrust. Continued tests from Launcher have been successful with performance boost testing
and the first fully integrated engine was ready for shipping on October 12, 2023.6

Figure 4. Aalberts QIH-122 MURC in Greenville, SC (Source: Aalberts Surface Technologies)

Conclusion

As humanity reaches further into the cosmos, the role of HIP and HPHT in manufacturing space-bound components becomes increasingly significant. These processes not only enhance the essential properties of materials for space applications but also address the unique challenges of manufacturing for an environment as hostile as space. With ongoing research and development, HIP and HPHT continue to evolve, promising to unlock new possibilities in space exploration and technology, and their contribution will ensure the success of space missions, safeguarding the lives of those who venture into the final frontier.

Figure 5. Test firing of the High Pressure Heat Treated Launcher Engine 2 produced using additive manufacturing

References

[1] Dominik Ahlers and Thomas Tröster, “Performance Parameters and HIP Routes for Additively Manufactured Titanium Alloy Ti6Al4V. EuroPM,” 2019. https://www.semanticscholar.org/paper/Performance-Parameters-and-HIP-Routes-fortitanium-
Ahlers-Tr%C3%B6ster/faeb46e6eb8ef3e30bc00b91cd1bd8a7c0619200.
[2] Jake T. Benzing et al., “Enhanced strength of additively manufactured Inconel 718 by means of a simplified heat treatment strategy,” Journal of Materials Processing Technology 322, (December 2023). https://www.sciencedirect.com/science/article/abs/pii/S0924013623003424?via%3Dihub.
[3] “Engineering Materials for Space Building Stronger Lighter Structures,” Utilities One, last modified November 2023. https://utilitiesone.com/engineering-materials-for-space-building-stronger-lighter-structures.
[4] Girolamo Costanza and Maria Elisa Tata, “Shape Memory Alloys for Aerospace, Recent Developments, and New Applications: A Short Review,” Materials (Basel) 13, no. 8 (April 2020): 1856. https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7216214/.
[5] Mahemaa Rajasekar, “Processing Copper Alloys with Powder Bed Fusion,” LinkedIn, last modified November 2022. https://www.linkedin.com/pulse/processing-copper-alloys-dmls-technology-mahemaarajasekaran/.
[6] LAUNCHER (@launcher), “The first fully integrated E-2 engine is ready for shipping to @NASAStennis for our upcoming full engine test campaign later this year. E-2 is a 22,000 lb. (10 ft) thrust LOX/Kerosene,” X post, October 12, 2023. https://twitter.com/launcher/status/1712636548997607752.

About the Author

Andrew Cassese, Applications Engineer, Quintus
Technologies

Andrew Cassese is an applications engineer at Quintus Technologies. He has a bachelor’s degree in welding engineering from The Ohio State University.

For more information: Read J Shipley, “Hot Isostatic Pressing in Space – Essential Technology to Ensure Mission Safety,” 2020. Contact Andrew at andrew.cassese@quintusteam.com.

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Tool & Die Capabilities Increase with Heat Treat Box Furnace

/ ALUMINUM PROCESSING NEWS, FEATURED NEWS, HARDENING NEWS, MANUFACTURING HEAT TREAT, OVENS-HIGH-TEMPERATURE, TEMPERING NEWS

An electric box furnace, currently headed to a Midwest equipment provider, will ultimately be installed at a Snap-on production facility that services tool and die support within the company’s production line.

The model QDD29 economical dual-chamber heat treating and tempering oven from L&L Special Furnace has a compact over/under design that saves floor space and provides reliable heat treating in-house.

QDD29 economical dual-chamber furnace (Source: L&L Special Furnace)

The top chamber is primarily deployed for heat treating tool steels at temperatures up to 2200°F; the tempering chamber is suited to temperatures up to 1250°F and has a recirculation baffle that makes it suitable for small aluminum work as well. The hardening and tempering chambers have interior dimensions of 12” wide by 8” high by 24” deep, with total external dimensions of 55” wide by 70” tall by 56” deep.

The QDD29 is controlled with digital single setpoint controls along with overtemperature protection. Solid-state relays drive the heating elements in a control circuit.

This press release is available in its original form upon request.

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Thermal Processing for Space and Additive Manufacturing

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT TECHNICAL CONTENT, FEATURED NEWS, HIPING TECHNICAL CONTENT, SINTERING POWDER/METAL TECHNICAL CONTENT

The race to space is in full swing with public and private sector companies staking their claim in this new frontier. And breakthroughs in technology and materials offer the potential to propel humanity to unprecedented distances. Success hinges not only on the ability to discover novel solutions but also on the capacity to prepare those solutions for efficient, large-scale production.

This Technical Tuesday article by Noel Brady of Paulo was originally published in Heat Treat Today’s March/April 2024 Aerospace print edition.

Space Today: Making Life on Earth Better, Safer, and More Connected

Noel Brady, Metallurgical Engineer, Paulo
Source: Paulo

According to NASA, 95% of space missions in the next decade will stay in low Earth orbit (LEO) and geostationary orbit (GEO). Th at means the first wave of commercial activity in space will be largely focused on making life on Earth better.

Several worldwide broadband satellites are already in orbit, offering more consistent, reliable internet signals around the globe. Defense campaigns are using advanced satellite machine learning to improve asteroid and missile detection, along with revolutionary laser technology that has made intersatellite communication possible for the first time — and the travel of information faster. And to help make
life in space safe and successful, NASA is developing a scalable network of public GPS receivers for easy, short-range space navigation and tourism.

All this to say, parts are being developed for a wide range of applications, a huge portion of which are being additively manufactured.

Thermal Processing Standards Necessary for AM Adoption

However promising additive manufacturing is for space, the adoption of AM has still been limited due to the lack of standards for proprietary material and 3D printing applications. Many thermal processing experts are joining research institutions and OEMs in the drive to bring AM into mainstream manufacturing with new industry standards and production-ready solutions that help achieve ROI.

The R&D process for discovering these standards can be lengthy and expensive because it requires trial and error. A prototype or small run of parts must be manufactured, then heat treated, and tested for the desired properties. If a test part’s yield strength is not where it should be, for example, then the heat treating recipe is adjusted, perhaps by lowering the temperature and increasing the pressure, and can be tested again on a new batch of parts.

Coach vs. Custom Cycles

In heat treating, there are two different types of cycles, and it’s important to know the difference when you’re working with any commercial heat treater. Coach cycles tend to be more economical because these are shared cycles — existing recipes that are in high demand and run on a regular schedule — with the potential to have multiple clients’ parts in the furnace at once. For example, a heat treater may have a standard titanium coach cycle they run once a day. See Table A for several coach cycles run at Paulo.

Table A. Example of Coach Cycles for Space Alloys

Coach cycles use recipes that were designed for cast parts and have been around since before additive was a viable form of manufacturing. While it’s true that cast parts and AM parts have similarities, such as their high porosity, it doesn’t mean that the recipes are optimal for preparing today’s parts for heavy space applications. That’s where custom cycles come into play.

Custom cycles are ideal for new or proprietary materials that don’t yet have recipes defined or that are not commonly heat treated enough to run on a regular schedule. The distinction between the two is important because not all heat treaters are equipped to run both types. While you may be able to find a coach recipe that gets you close to where you need to be, it certainly may not be optimal, especially for parts that will have a heavy life of service.

Heat treaters with flexibility of custom and coach cycles, along with full-cycle data reporting, offer a high level of control that is vital for helping the industry progress and scale for production. This is also a big reason why some in-house heat treating operations may choose to outsource some of their work: first collaborating with experienced commercial heat treaters to prove the specification for a new part with custom cycles before scaling for production.

Common Cycle Adjustments for AM

There are five primary parameters that can be adjusted in the heat treating of AM parts to achieve the desired results: temperature, pressure, time, cooling rate, and heating rate. For AM parts, adjustments to the temperature and pressure are a go-to for achieving parts with higher yield strength. For example, running a cycle 50°F cooler, but at 5 ksi higher pressure may yield better results.

There may also be certain heating ramp rates and intermediate holds before parts get to the max temperature, to allow for consistent heating and enhance the material properties. The same goes for the cooling process: controlling the rate at which a part cools with specific holding times and intermediate quenches.

Hot Isostatic Pressing, Space, and Additive Manufacturing

Hot isostatic pressing (HIP) combines high temperature and pressure to improve a part’s mechanical properties and performance at extreme temperatures. The sealed HIP vessel provides uniform pressure to bring parts to 100% theoretical density with minimal distortion. The high level of control and uniformity has made HIP the gold standard for AM parts for space.

Similar to cast parts, 3D-printed materials tend to have porous microstructures that can compromise part performance. HIP is the only process that’s able to eliminate these pores without compromising the complex geometries and near-net dimensions that are achieved in the printing process.

Benefits of HIP for space parts include the following:

  • Better fatigue resistance
  • Greater resistance to impact, wear, and abrasion
  • Improved ductility

For this process, Paulo’s Cleveland division is equipped with a Quintus QIH-122 HIP vessel, which is specially modified with additional thermocouples for more precise temperature control and greater data collection. A higher level of accuracy allows us to iterate with confidence and find an efficient path to production-ready development.

One primary benefit of the Quintus QIH-122 HIP is the ability to have faster cooling at a controlled rate, which allows you to heat treat and solution treat in one furnace. This cooling rate allows great efficiency that cannot be seen with other HIP vessels on the market.

It is critical that heat treaters adapt to meet the needs of this fast-evolving industry. Many commercial heat treaters do not yet have the level of data or dynamic cycle offerings necessary and will only run HIP coach cycles with set parameters. In other words, many are not equipped to economically iterate and adapt heat treating recipes for new parts. Without custom cycles, controlled cooling, and a higher level of data, it is impossible to push the boundaries of what’s possible.

Space Parts Requiring Thermal Processing

The future of space travel requires parts that can not only perform under high levels of mechanical pressure and extreme temperatures but are also durable enough for long-range and repeat missions. Heat treatment is a critical step in preparing rocket engine components, among others, for commission. Other space components commonly heat treat treated are:

  • Volutes
  • Turbine manifolds
  • Bearing housings
  • Fuel inlets
  • Housings, support housings
  • Bearing supports
  • Turbo components

Since the inception of NASA’s Space Shuttle Program, Paulo has treated integral components for launch and propulsion, along with many parts currently in orbit on the International Space Station.

Materials Used in Space Parts

New materials and applications are being explored every day. Proprietary alloy blends bring unique properties and promising potential in the push for stronger, faster, longer-lasting parts. But with unique properties comes the need for unique heat treating processes. Several high-performance superalloys used for space include:

  • Inconel 718, 625
  • Titanium (Ti-6Al-4V)
  • Hastelloy C22
  • Haynes 214, 282
  • GRCop Copper

Inconel 718, a championed space alloy, was originally used as a premier casting material before being adopted for AM. This nickel-based material features an extremely high tensile and yield strength that makes it ideal for components taking on a high mechanical load in extreme environments ranging from combustive to cryogenic — making this a natural material to adopt for space in the early days of 3D printing.

Because casting and 3D printing both result in similar porous microstructures, the heat treating process used for Inconel castings could also be adapted. Finding new opportunities within existing alloys like this is a highly efficient way to gain material advantage in today’s race to space.

To learn more about adapting alloys and heat treating processes for AM parts, download the full space guide.

About the Author

Noel joined Paulo in 2011 and spent several years as quality manager before stepping into his current role as a metallurgical engineer. Noel holds a bachelor’s degree in engineering and metallurgy materials science, and he is responsible for thermal process development and hot isostatic pressing process development.

For more information: Contact Noel Brady at nbrady@paulo.com or visit this link to download the full space guide from Paulo.

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Endings . . . People We Lost

/ FEATURED NEWS

Beginnings and endings often come together. As we prepare to begin a new year next month, we want to pause to remember a few lives that came to an end. Although the following are by no means the only important endings, Heat Treat Today would like to honor the memory of the following individuals who left their mark in the heat treating world.

This article first appeared in Heat Treat Today’s December 2023 Medical and Energy print edition. Feel free to contact Bethany Leone at bethany@heattreattoday.com if you have a question, comment, or any editorial contribution you’d like to submit.

Scott Hoensheid, Commercial Steel Treating Corp. (c. 1959–2022)

Scott Hoensheid retired as the president of Commercial Steel Corp., a commercial heat treater based in Highland, MI. As president of Commercial Steel Corp. since 1979, he served the heat treating industry diligently for over 40 years. He leaves behind his wife, Anne, and two children, Allison (John) VanHaverbeke and Katherine Hoensheid.

(Source: dignitymemorial.com)

John “Jack” Marino, Hauck Manufacturing and Denton Corporation (c. 1938–2023)

Well-known as a capable educator through several online IHEA courses, Jack Marino was an industry expert with more than 40 years of experience in the heat treating industry. Jack became the president of not one, but two companies: Denton Corporation and Hauck Manufacturing. Throughout his career, he obtained six U.S. patents in combustion technology and was the author of Ok, You’re a New Executive. Now What? Jack leaves behind his wife, Jean, and six children.

(Source: Lebanon Daily News)

Clint Ooten, Bluewater Thermal Solutions (c. 1971–2023)

Clint Ooten was an incredible resource to Bluewater Thermal Solutions where he used his background in human resources for skillful team building and management. Included in Clint’s impressive background were four years as an HR director at GE. He began his time at Bluewater Thermal Solutions as the director of HR, and later went on to become the President — Industrials. Surviving Clint are his three daughters.

(Source: cannonbyrd.com)

Ross Pritchard, VAC AERO (c. 1929–2023)

Ross Pritchard began his career in the heat treating industry with a metallurgical engineering degree. In 1959, Ross founded VAC AERO International, Inc., a provider of vacuum furnaces and a source of excellent technical content for those in the industry. Ross led the company through building new plants, expanding the workforce from two employees to 200+, and continually keeping up with the changing technology of the industry. He is survived by his three daughters.

(Source: Tribute Archive.com)

David Pye, Pye Metallurgical International Consulting (c. 1939–2023)

David Pye was the founder of Pye Metallurgical International Consulting, a company he began after years of practical experience in the heat treating industry, both in commercial and in-house environments. At the end of his life, David had amassed over 45 years of metallurgical consulting, and therefore helped countless clients and
friends throughout the industry, both in the U.S. and in the U.K. David was skilled not only in technical sales but also in metallurgical laboratory processes. He passed away on June 12, 2023, in Virginia.

(Source: Industrial Heating.com)

William Edward Terlop, Sr., Jackson Transformer (c. 1938–2023)

William (Bill) Terlop was part of the induction heating industry for over 68 years. Bill became both a friend and mentor to many others in the industry, always willing to share knowledge and advice on transformers and magnetics. His career in the industry began when he was a young man working for a company; through his R&D, Bill grew their magnetics products division. He later purchased this division in 1986, creating Jackson Transformer Company. Everyone at the company is proud to honor Bill by carrying on his legacy.

(Source: trinitymemorial.com)

James Joseph Van Etten, Alhern-Martin Industrial Furnace Company (c. 1944–2023)

The owner of Alhern-Martin Industrial Furnace Company for over 40 years, James Van Etten was dedicated to the heat treating industry and leveraged his knowledge and expertise to help clients with their equipment needs. His dedication grew the business to be the dynamic company it is today. James is survived by his wife, Sandra, and his
children, Julie and James. His son is currently the vice president of Alhern-Martin Industrial Furnace Company.

(Source: detroitnews.com)

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2 CAB Lines for American Auto Part Manufacturer

/ ATMOSPHERE AIR FURNACES NEWS, AUTOMOTIVE HEAT TREAT, BRAZING NEWS, FEATURED NEWS

A heat treat furnace manufacturer with North American locations will provide an American partner with two identical continuous CAB lines for brazing aluminum heat exchangers, specifically battery coolers. The furnaces will be used in Mexico and Spain.

The SECO CAB lines will be used for protective atmosphere brazing aluminum of heat exchangers. Such solutions are used by leading automotive parts manufacturers and are used for mass production of battery coolers among other types of heat exchangers. This purchase was preceded by tests in the R&D laboratory.

Piotr Skarbiński, Vice President of Aluminum and CAB Product Segments, SECO/WARWICK Group (photo source: secowarwick.com)

“The purchased CAB lines,” explained Piotr Skarbiński, VP of Aluminum and CAB Product Segments, SECO/WARWICK Group, “will be the first solutions of this type in the customer’s factories.”

This press release is available in its original form here.

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This Week in Heat Treat Social Media

/ FEATURED NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

Welcome to Heat Treat Today’s This Week in Heat Treat Social Media. We’re looking at some compelling developments in aviation manufacturing, sharing a few metallurgy quizzes, and of course, bringing some fun, social heat treat videos to you.

As you know, there is so much content available on the web that it’s next to impossible to sift through all of the articles and posts that flood our inboxes and notifications on a daily basis. So, Heat Treat Today is here to bring you the latest in compelling, inspiring, and entertaining heat treat news from the different social media venues that you’ve just got to see and read! If you have content that everyone has to see, please send the link to editor@heattreattoday.com.

1. The Power of Engineering vs. Gravity

We usually like to share something rich and technical, but check out this compelling video of dual F119 engines powering an F-22 in an attack maneuver.! “F-22 with a combat capacity of; 1× 20 mm M61A2 Vulcan rotary cannon, 6× AIM-120C/D AMRAAM or 4× AIM-120A/B AMRAAM 2× AIM-9M/X Sidewinder, 2× 1,000 lb (450 kg) JDAM or 8× 250 lb (110 kg) GBU-39 SDB, 4× under-wing pylon stations can be fitted to carry weapons, each with a capacity of 5,000 lb (2,270 kg) or 600 U.S. gallon (2,270 L) drop tanks”

2. It’s a Beautiful Day in the Heat Treat Neighborhood

What’s everyone been up to on the social channels?

Gamifying Quality?? Count Us In!

Marking Milestones

When Precision Meets Creativity

3. Learn with Us – 3 Quick Visuals

Sometimes, it’s the small things on social media that grab your attention or give you the “ah ha!” moment. Do any of these short posts make you say “eureka”?

Rotate Rotate Rotate Rotate. . .
Spring is Here, depending on the Temperature
Quiz Time

4. Open Your Ears: The Podcast Corner

You can’t read everything, we get it. Heat Treat Today is here to recommend one informative podcast to enjoy on your daily commute, suggest a quick video on laser heat treating, and put a comprehensive article on surface treatments for automotive on your radar!

Tune in to Listen to Heat Treat Radio #107! Not Your Average Painting Class
The “Dougs” Talk

a Brazing Celebrity

5. Post-March Madness

Ever wonder the manufacturing processes behind the jump shots? Take March Manufacturing Madness: The Quiz below!

Have a great weekend!

 

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Advantages of Laser Heat Treatment: Precision, Consistency, and Cost Savings

/ AUTOMOTIVE HEAT TREAT TECHNICAL CONTENT, FEATURED NEWS, HARDENING TECHNICAL CONTENT, OP-ED

Laser heat treating, a form of case hardening, offers substantial advantages when distortion is a critical concern in manufacturing operations. Traditional heat treating processes often lead to metal distortion, necessitating additional post-finishing operations like hard milling or grinding to meet dimensional tolerances.

This Technical Tuesday article was originally published in first published in Heat Treat Today’s January/February 2024 Air & Atmosphere print edition.

In laser heat treating, a laser (typically with a spot size ranging from 0.5″ x 0.5″ to 2″ x 2″) is employed to illuminate the metal part’s surface. This results in a precise and rapid delivery of high-energy heat, elevating the metal’s surface to the desired transition temperature swiftly. The metal’s thermal mass facilitates rapid quenching of the heated region resulting in high hardness.

Key Benefits of Laser Heat Treating

Consistent Hardness Depth

Laser heat treatment achieves consistent hardness and hardness depth by precisely delivering high energy to the metal. Multiparameter, millisecond-speed feedback control of temperature ensures exacting specifications are met.

Minimal to Zero Distortion

Due to high-energy density, laser heat treatment inherently minimizes distortion. This feature is particularly advantageous for a variety of components ranging from large automotive dies to gears, bearings, and shafts resulting in minimal to zero distortion.

Precise Application of Beam Energy

Unlike conventional processes, the laser spot delivers heat precisely to the intended area, minimizing or eliminating heating of adjoining areas. This is specifically beneficial in surface wear applications, allowing the material to be hardened on the surface while leaving the rest in a medium-hard or soft state, giving the component both hardness and ductility.

Figure 1. Laser heat treating of automotive stamping die constructed from D6510 cast iron material (Source: Synergy Additive Manufacturing LLC)

No Hard Milling or Grinding Required

The low-to-zero-dimensional distortion of laser heat treatment reduces or eliminates the need for hard milling or grinding operations. Post heat treatment material removal is limited to small amounts removable by polishing. Eliminating hard milling or grinding operations saves substantial costs in the overall manufacturing process of the component. Our typical tool and die customers have seen over 20% cost savings by switching over to laser heat treating.

Figure 2. Laser heat treating of machine tool
components (Source: Synergy Additive Manufacturing LLC)

Applicable for a Large Variety of Materials

Any metal with 0.2% or more carbon content is laser heat treatable. Hardness on laser heat treated materials typically reaches the theoretical maximum limit of the material. Many commonly used steels and cast irons in automotive industry such as A2, S7, D2, H13, 4140, P20, D6510, G2500, etc. are routinely laser heat treated. A more exhaustive list of materials is available at synergyadditive.com/laser-heat-treating.

Conclusions

Aravind Jonnalagadda CTO and Co-Founder Synergy Additive Manufacturing LLC Source: LinkedIn

Laser heat treatment is poised to witness increased adoption in the automotive and other metal part manufacturing sectors. The adoption of this process faces no significant barriers, aside from the typical challenges encountered by emerging technologies, such as lack of familiarity, limited hard data, and a shortage of existing suppliers. The substantial savings, measured in terms of cost, schedule, quality, and energy reduction, provide robust support for the continued embrace of laser heat treatment in manufacturing processes.

For more information: Contact AJ at aravind@synergyadditive.com or synergyadditive.com/laser-heat-treating.

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3 Heat Treat Furnaces for Annealing Aluminum

/ ALUMINUM PROCESSING NEWS, ANNEALING NEWS, FEATURED NEWS, MANUFACTURING HEAT TREAT

Jupiter Aluminum Industries (JUPALCO), a newly established aluminum factory which will be part of the Jupiter Group in India, has ordered three furnaces for annealing aluminum coils from a heat treat furnace manufacturer with North American locations.

The equipment ordered by the Jupiter Group from SECO/WARWICK includes three Vortex® 2.0 furnaces for aluminum annealing, two cooling chambers, and one loader. A system configured in this way will ensure the optimal production volume of the Indian rolling mill.  

The aim of JUPALCO’s new plant will be to achieve the highest level of domestic aluminum production in history and to create an ecosystem of comprehensive aluminum-based solutions. This is the first cooperation between SECO/WARWICK and the Jupiter Group.

The three Vortex furnaces are effective systems for annealing aluminum coils. In the Vortex 2.0 version, a system of straight nozzles has increased the heat transfer efficiency. The systems key feature is the increased heat transfer coefficient, achieved by directing high-velocity air to both sides of the coil. This allows air to flow over the coil edges, not just through its outer layer.

Piotr Skarbiński, Vice President of (Source: secowarwick.com)

With the use of patented air flow technology, the aluminum coil annealing systems operate with process cycles that are significantly shorter. This in turn ensures energy savings, increased efficiency, and improved surface quality of the finished coils.

“In the case of coil annealing,” commented Piotr Skarbiński, VP of the CAB and Aluminum Products Segment at the SECO/WARWICK Group, “the challenge is to optimize the process by reducing the cycle time as much as possible while maintaining the desired metallurgical properties throughout the entire load.”

The Jupiter Group plans to recycle over 50,000 tons of aluminum scrap every year once fully operational. This scrap will come from both in-house and customer scrap, purchased scrap, and recycled cans/foils etc. The new rolling mill in India will help the Group expand its footprint in the aluminum industry and produce Made in India products which will be known for its quality and reliable products and services. 

“Since the 1990’s,” says Mr. Sandeep Bajaj, CMD of Jupiter Aluminum Industries, JUPALCO, “the Jupiter Group processes aluminum as a partner of the converting and packaging industries. Ecology is an important value for us. It is included in our mission, just like our Partner’s. The rolling mill in India will be one of the most modern facilities of this type in this region, which is why we are equipping it with the best solutions available on the market.”

This press release is available in its original form here.

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Sustainability Insights: How Can We Work To Get The Carbon Out Of Heating? Part 2

/ BULK GASES & SYSTEMS TECHNICAL CONTENT, BURNERS & COMBUSTION SYSTEMS TECHNICAL CONTENT, FEATURED NEWS, MANUFACTURING HEAT TREAT TECH, OP-ED

The search for sustainable solutions in the heat treat industry is at the forefront of research for industry experts. Michael Stowe, PE, senior energy engineer at Advanced Energy, one such expert, offers some fuel for thought on the subject of how heat treaters should prioritize the reduction of their carbon emissions by following the principles of reuse, refuel, and redesign.

This Sustainability Insights article was first published in Heat Treat Today’s January/February 2024 Air & Atmosphere print edition.

Reduce

Michael Stowe
PE, Senior Energy Engineer
Advanced Energy

We explored why the question above has come to the forefront for industrial organizations in Part 1, released in Heat Treat Today’s December 2023 print edition. Now, let’s look at the four approaches to managing carbon in order of priority.

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The best way to manage your carbon footprint is to manage your energy consumption. Therefore, the first and best step for reducing your carbon footprint is to reduce the amount of energy you are consuming. Energy management tools like energy treasure hunts, energy assessments, implementation of energy improvement projects, the DOE 50001 Ready energy management tool, or gaining third party certification in ISO 50001 can all lead to significant reduction in energy consumption year over year. Lower energy use means a smaller carbon footprint.

Additionally, ensuring proper maintenance of combustion systems will also contribute to improved operational efficiency and energy savings. Tuning burners, changing filters, monitoring stack exhaust, controlling excess oxygen in combustion air, lubricating fans and motors, and other maintenance items can help to ensure that you are operating your combustion-based heat treating processes as efficiently as possible.

Reuse

Much of the heat of the combustion processes for heat treating goes right up the stack and heats up the surrounding neighborhood. Take just a minute and take the temperature of your exhaust stack gases. Chances are this will be around 1200–1500°F. Based on this, is there any effective way to reuse this wasted heat for other processes in your facility? One of the best things to do with waste heat is to preheat the combustion air feeding the heat treating process. Depending on your site processes, there are many possibilities for reusing waste heat, including:

  • Space heating
  • Part preheating
  • Hot water heating
  • Boiler feed water preheating
  • Combustion air preheating

Refuel

Once you have squeezed all you can from reducing your process energy consumption and reusing waste heat, you may now want to consider the possibility of switching the fuel source for the heat treating process. If you currently have a combustion process for a heat treat oven or furnace, is it practical or even possible to convert to electricity as the heating energy source? Electricity is NOT carbon free because the local utility must generate the electricity, but it typically does have lower carbon emissions than your existing direct combustion processes on site. Switching heating energy sources is a complex process, and you must ensure that you maintain your process parameters and product quality. Typically, some testing will be required to ensure the new electrical process will maintain the metallurgical properties and the quality standards that your customer’s specific cations demand. Also, you will need a capital investment in new equipment to make this switch. Still, this method does have significant potential for reducing carbon emissions, and you should consider this where applicable and appropriate.

Redesign

Finally, when the time is right, you can consider starting with a blank sheet of paper and completely redesigning your heat treating system to be carbon neutral. This, of course, will mean a significant process change and capital investment. This would be applicable if you are adding a brand-new process line or setting up a new manufacturing plant at a greenfield site.

In summary, heat treating requires significant energy, much of which is fueled with carbon-based fossil fuels and associated-support electrical consumption. Both combustion and electricity consumption contribute to an organization’s carbon footprint. One of the best ways to help manage your carbon footprint is to consider and manage your energy consumption.

For more information:
Connect with IHEA Sustainability & Decarbonization Initiatives www.ihea.org/page/Sustainability
Article provided by IHEA Sustainability

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Keep Your Roller Hearth Rolling at Peak Production

/ ATMOSPHERE AIR FURNACES TECHNICAL CONTENT, FEATURED NEWS, MANUFACTURING HEAT TREAT

Now that a new year is in full swing, it may be time to consider that all of the heat treating equipment that’s currently in the workplace has aged along with us. Without proper maintenance in place, you may start to see signs of age, wear, and tear on the high output furnaces that this industry relies on.

This Technical Tuesday, was originally published in Heat Treat Today’s January/February 2024 Air and Atmosphere Heat Treat print edition.

Jacob Laird
Mechanical Engineer
Premier Furnace Specialists, Inc./BeaverMatic
Source: Premier Furnace Specialists, Inc./BeaverMatic

Most companies have a “workhorse” furnace which is run exhaustively, and even new furnaces that run this way can start looking quite worn after just months of use. Yet decades-old equipment remains in regular use across the country, thanks to knowledgeable maintenance personnel. Since there is somewhat of a void in personnel for this position, here are a few ways to make sure your furnaces keep running into old age.

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For roller hearth or belt furnaces with rollers, there can be an extensive number of points in the drive which may facilitate misalignment. Most maintenance crews know to keep chains and sprockets in alignment and to keep bearings well-greased to avoid seizing, but these may not be enough for the high temperatures at which these furnaces typically run. Even though they are turning at slow speeds, the roller’s bearings should be filled with high-temperature grease which is designed not to break down and leak despite the heat constantly being transferred through the roller to the external trunnions (shaft ends). If the bearing already has standard grade grease, it needs to be fully pumped out of the bearing with new high-temperature grease to avoid contamination or reactions between the two which could cause leaking or seizing.

Roller hearth furnace system

For driven rollers, it’s only necessary to “lock-down” the drive side of the roller’s components using cone or dog point set screws (sometimes both) and thread locking compounds. As the furnace heats up, the rollers will expand. By leaving the idle end “free,” it allows a path of least resistance for growth, which allows for the best chance to keep drive mechanisms in-line.

An infrared (IR) thermometer can be a useful tool for diagnosing heat leaks around any furnace and avoiding burns while doing so during operation. It’s important to note that on stainless steel components and the glossy enamel coatings on some furnaces, IR temperature readings likely will not be exact. Quality IR thermometers have adjustable emissivity settings which greatly reduce the error caused by these highly reflective surfaces, but readings still should be used simply as reference points.

FCE insulation

It’s a good idea to occasionally check the furnace case for “hot spots,” and this tool allows it to be done without much effort. These are areas which have a higher than typical temperature compared to the rest of the furnace. This can be one of the earliest signs that insulation quality in that spot has issues. The insulation can be checked and repaired rather than waiting until the furnace’s case steel begins to turn white and burn away, leading to more costly repairs. For brick-lined furnaces in particular, one ideal time to perform this check is during the lengthy dry-out procedure to ramp up to operating temperature after a shutdown. The idle time at low temperatures helps to catch issues before high operating temperatures quickly make them worse. For roller hearth furnaces, simply checking the average temperature of each roller’s exposed trunnions and bearing housings can give insight into potential future issues if individual rollers run hotter than others.

As they say, “The best time to start was yesterday. The next best time is now.” Even a furnace that has seen better days can be maintained, repaired, or rebuilt to keep operations running smoothly and, most importantly, safely.

About the Author

Jacob Laird is a mechanical engineer at Premier Furnace Specialists. Jacob has a BS in both mechanical engineering and physics from South Dakota State University. Among many other things, Jacob is known for his skills in sizing/design of combustion systems, burner assembly, and electrical heating systems.

For more information: Contact Jacob at JLaird@premierfurnace.com.

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