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How To Reduce Carbon Footprint During Heat Treatment

May 16, 2024 / CARBURIZING, CARBURIZING TECHNICAL CONTENT, HARDENING, HARDENING TECHNICAL CONTENT, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT TECH

Given changing ecological and economic conditions, carbon neutrality is becoming more important, and the heat treatment shop is no exception. In the context of this article, the focus will be on how manufacturers — especially those with in-house heat treat — can save energy by evaluating heating systems, waste heat recovery, and the process gas aspects of the technology.

This article, written by Dr. Klaus Buchner, head of Research and Development at AICHELIN HOLDING GmbH, was released in Heat Treat Today April/May 2024 Sustainable Heat Treat Technologies print edition.

Introduction

Uncertainties in energy supply and rising energy costs remind us of our dependence on fossil fuels. This underlines the need for a sustainable energy and climate policy, which is the central challenge of our time.

European policymakers have already taken the first steps towards a green energy revolution, and the heat treatment industry must also take responsibility. Many complementary measures, however, are needed that can be applied to new and existing thermal and thermochemical heat treatment lines.

Heat Treatment Processes and Plant Concepts

The heat treatment process itself is based on the requirements of the component parts, and especially on the steel grade used. If different concepts are technically comparable, it is primarily the economic aspect that is decisive, and not the carbon footprint — at least until now. Advances in materials technology and rising energy costs are calling for production processes to be modified.

Figure 1. Donut-shaped rotary-hearth furnace for carburizing with press quenching
Source: AICHELIN HOLDING GmbH

An example is the quenching and tempering of automotive forgings directly from the forging temperature without reheating, which has shown significant potential for energy and CO₂ savings. Although the reduced toughness or measured impact energy of quenching and tempering from the forging temperature may be a drawback due to the coarser austenite grain size, this can be partially improved by Nb micro-alloyed steels and higher molybdenum (Mo) contents for more temper-resistant steels; it may also be necessary to use steels with modified alloying concepts when changing the process.^{1, 2} AFP steels (precipitation-hardening ferritic pearlitic steels) and bainitic air-hardening steels can also be interesting alternatives, since reheating (an energy-intensive intermediate step) is no longer necessary.

Similar considerations apply to direct hardening instead of single hardening in combination with carburizing processes because of the elimination of re-austenitizing. Distortion-sensitive parts often need to be quenched in fixtures due to the dimensional and shape changes caused by heat treatment. Heat treated parts are often carburized in multipurpose chamber furnaces or small continuous furnaces, cooled under inert gas, reheated in a rotary-hearth furnace, and quenched in a hardening press. In contrast, ring-shaped (aka donut-shaped) rotary-hearth furnaces allow carburizing and subsequent direct quenching in the quench press in a single treatment step. Figure 1 shows a typical ring-shaped rotary-hearth furnace concept for heat treating 500,000 gears per year/core hardness depth (CHD) group 1 mm.

Table 1. Saving potential due to increased process temperature for gas carburizing (pusher type furnace, 20MnCr5, CHD-group 1 mm)
Source: AICHELIN HOLDING GmbH

This ring-shaped rotary-hearth concept can save up to 25% of CO₂ emissions, compared to an integral quench furnace line (consisting of four single-chamber furnaces, one rotary hearth furnace with quench press and two tempering furnaces as well as two Endothermic gas generators). Due to the reduced total process time (without reheating) and the optimized manpower, the total heat treatment costs can be reduced by 20–25%.

The high-temperature carburizing aspect should also be mentioned, although the term “high-temperature carburizing” is not fully accepted nor defined by international standards. As the temperature increases, the diffusion rate increases and the process time decreases. As shown in Table 1, the additional energy consumption is less than the increase in throughput that can be achieved. Therefore, the relative energy consumption per kg of material to be heat treated decreases as the process temperature increases.

There are three key issues to consider when running a high-temperature carburizing process:

Steel grade: Fine-grain stabilized steels are required for direct hardening at temperatures of 1832°F (1000°C). Microalloying of Nb, Ti, and N as well as a favorable microstructure of the steels reduce the growth of austenite grains and allow carburizing temperatures up to 1922°F (1050°C) for several hours.
Furnace design: In addition to the general aspects of the optimized furnace technology (e.g. heating capacity, insulation materials, and feedthroughs), failure-critical components must be considered separately in terms of wear and tear, whereby condition monitoring tools can support maintenance in this area.
Distortion: This is always a concern, especially in the case of upright loading of thin-walled gear sections. As such, numerical simulations and/or experimental testing should be performed at the beginning to estimate possible changes in distortion and to take measures if necessary.

Figure 2. Recuperative burner with SCR system for NOx reduction Source: AICHELIN HOLDING GmbH

Heating System

Based on an energy balance that considers total energy losses, and preferably also temperature levels, it can be seen that the heating system plays a significant role. In addition to the obvious flue gas loss in the case of a gas-fired thermal processing furnace, the actual carbon footprint must be critically examined.

In the case of natural gas, the upstream process chain is often neglected in terms of CO₂ emissions, but the differences in gas processing (which are directly linked to the reservoirs) and in gas transportation can be a significant factor.³ However, the analysis of energy resources in the case of electric heating systems is much more important. This results in specific CO₂ emissions between 30–60 gCO₂/kWh (renewable-based electricity mix) and 500–700 gCO₂/kWh (coal-based electricity mix). Therefore, a general comparison between natural gas heating and electric heating systems in terms of carbon footprint is often misleading.

Figure 3. Comparison of specific CO2 emissions Source: AICHELIN HOLDING GmbH

Nevertheless, in the case of gas heating, the aspect of combustion air preheating should be emphasized, as it has a significant influence on combustion efficiency. The technical possibilities in this area are well known and include both systems with central air preheating and decentralized concepts, where the individual burner and the heat exchanger form a single unit. Recuperator burners are often used in combination with radiant heating tubes (indirect heating) in the field of thermochemical heat treatment. With respect to oxy-fuel burners, it should also be noted that the formation of thermal NOx increases with increasing combustion temperature and temperature peaks. To avoid exceeding NOx emissions, staged combustion and so-called “flameless combustion” — characterized by special internal recirculation — and selective catalytic reduction (SCR) can be used. The latter secondary measure, together with selective non-catalytic reduction (SNCR), has been state-of-the-art in power plant design for decades and has become widely known because of its use in the automotive sector. This system can also be adapted to single burners (Figure 2). In this way, NOx emissions can be reduced to 30 mg/Nm3 (5% reference oxygen), depending on the injection of aqueous urea solution, as long as the exhaust gas temperature is in the range of 392/482°F (200/250°C) to 752/842°F (400/450°C).⁴

Whether electric heating is a viable alternative depends on both the local electricity mix and the design of the heat treatment plant, which may limit the space available for the required heating capacity. In addition to these technical aspects, the security of supply and the energy cost trends must also be considered. Both of these factors are significantly influenced by the political environment. Figure 3 shows an example of the specific carbon footprint per kg of heat treated material with the significant losses based on the example of an integral quench furnace concept in the double-chamber and single-chamber variants electrically heated (E) and gas heated (G). The electric heating is based on a fossil fuel mix of 485 gCO₂/kWh. Once again, it is clear that a general statement regarding CO₂ emissions is not possible; rather, the boundary conditions must be critically examined.

Waste Heat Recovery — Strengths and Weaknesses of the System

Although improvements in the energy efficiency of heat treatment processes, equipment designs, and components are the basis for rational energy use, from an environmental perspective it is important to consider the total carbon footprint. An energy flow analysis of the heat treatment plant, including all auxiliary equipment, shows the total energy consumption and thus the potential savings. Quite often the temperature levels and time dependencies involved preclude direct heat recovery within the furnace system at an economically justifiable investment cost. In this case, cross-plant solutions should be sought, which require interdepartmental action but offer bigger potential.

In addition to the classic methods of direct waste heat utilization using heat exchangers, also in combination with heat accumulators, indirect heat utilization can lower or raise the temperature level of the waste heat by using additional energy (chiller or heat pump) or convert the waste heat into electricity. The overview in Table 2 provides reference values in terms of performance class and temperature level for the alternative technologies listed.

Process Gas for Case Hardening

Case hardening — a thermochemical process consisting of carburizing and subsequent hardening — gives workpieces different microstructures across the cross-section, the key factor being high hardness/strength in the edge region. A distinction can be made between low pressure carburizing in vacuum systems and atmospheric carburizing at normal pressure. Both processes have different advantages and disadvantages, with atmospheric heat treatment being the dominant process.

Table 2. Overview of alternative waste heat applications^{5, 6}
Source: AICHELIN HOLDING GmbH

In terms of carbon footprint, atmospheric heat treatment has a weakness due to process gas consumption. To counteract this, the following aspects have to be considered: thermal utilization of the process gas — indirectly by means of heat exchangers or directly by lean gas combustion (downcycling); reprocessing of the process gas (recycling); reduction of the process gas consumption by optimized process control; and use of CO₂-neutral media (avoidance). This article focuses on avoidance by optimizing process gas consumption and using of CO₂-neutral media.

Typically, heat treatment operations are still run with constant process gas quantities based on the most unfavorable conditions. Based on the studies of Wyss, however, process control systems offer the possibility to adapt the actual process gas savings to the actual demand.⁷ In a study of an industrial chamber furnace, a 40% process gas savings was demonstrated for a selected carburizing process. In this heat treatment process with a case hardness depth of 2 mm, the previously used constant gas flow rate of 18 m3/h was reduced to 16 m3/h for the first process phase and further reduced to 8 m3/h after 3 hours. Figure 4 shows the analysis of the gas atmosphere, where an increase in the H₂ concentration could be detected due to the reduction of the gas quantities. With respect to the heat treatment result, no significant difference in the carburizing result was observed despite this significant reduction in process gas volume (and the associated reduction in CO₂ emissions). The differences in the carbon profiles are within the expected measurement uncertainty.

Figure 4. CO and H2/CO concentration at various process gas volumes Source: AICHELIN HOLDING GmbH

The carbon footprint of the process gas, however, must be fundamentally questioned. In the field of atmospheric gas carburizing, process gases based on Endothermic gas (which is produced by the catalytic reaction of natural gas or propane with air at 1832–1922°F/1000–1050°C) and nitrogen/methanol and methanol only systems have established themselves on a large scale. Methanol production is still mostly based on fossil fuels (natural gas or coal), the latter being used mainly in China. Although alternative CO₂-neutral processes for partial substitution of natural gas — keywords being “power to gas” (P2G) or “synthetic natural gas” (SNG) — have already been successfully demonstrated in pilot plants, there are no signs of industrial penetration. Nevertheless, there is a definite industrial scale in the area of bio-methanol synthesis, though so far, purely economic considerations speak against it, as CO₂ emissions are still not taken into account.

The question of the use of bio-methanol in atmospheric gas carburizing has been investigated in tests on an integral quench furnace system. A standard load of component parts with a CHD of 0.4 mm was used as a reference. Subsequently, the heat treatment process was repeated with identical process parameters using bio-methanol instead of the usual methanol based on fossil fuels. Both the laboratory analyses of the methanol samples and the measurements of the process gas atmosphere during the heat treatment process, as well as the evaluation of the sample parts with regard to the carbon profile during the carburizing process, showed no significant difference between the different types of methanol. Although this does not represent long-term experience, these results underscore the fundamental possibility of media substitution and the use of CO₂-neutral methanol.

Conclusion

Facing the challenges of global warming — intensified by the economic pressure of rising energy costs — this article demonstrates the energy-saving potential in the field of heat treatment. In addition to already established solutions, the possibilities of the smart factory concept must also be integrated in this industrial sector. Thus, heat treatment comes a significant step closer to the goal of a CO₂-neutral process in terms of Scopes 1, 2, and 3 regarding emissions under the given boundary conditions.

References

[1] Karl-Wilhelm Wegner, “Werkstoffentwicklung für Schmiedeteile im Automobilbau,” ATZ Automobiltechnische Zeitschrift 100, (1998): 918–927, https://doi.org/10.1007/BF03223434.
[2] Wolfgang Bleck and Elvira Moeller, Steel Handbook (Carl Hanser Verlag GmbH & Co. KG, 2018).
[3] Wolfgang Köppel, Charlotte Degünther, and Jakob Wachsmuth, “Assessment of upstream emissions from natural gas production in Germany,” Federal Environment Agency (January 2018): https://www.umweltbundesamt.de/publikationen/bewertung-der-vorkettenemissionen-beider.
[4] Klaus Buchner and Johanes Uhlig, “Discussion on Energy Saving and Emission Reduction Technology of Heat Treatment Equipment,” Berg Huettenmaenn Monatsh 168 (2021): 109–113, https://doi.org/10.1007/s00501-023-01328-5.
[5] Technologie der Abwärmenutzung. Sächsische Energieagentur – SAENA GmbH, 2. Auflage, 2016.
[6] Brandstätter, R.: Industrielle Abwärmenutzung. Amt der OÖ Landesregierung, 1. Auflage, 109–113, https://doi.org/10.1007/s00501 02301328-5.
[7] U. Wyss, “Verbrauch an Trägergas bei der Gasaufkohlung,” HTM Journal of Heat Treatment Materials 38, no. 1 (1983): 4-9, https://doi.org/10.1515/htm-1983-380102.

About the Author

Dr. Klaus Buchner Head of Research and Development AICHELIN HOLDING GmbH

Klaus Buchner holds a doctorate and is the head of research and development at AICHELIN HOLDING GmbH. This article is based on Klaus Buchner’s article, “Reduktion des CO2-Fußabdrucks in der Wärmebehandlung” in Prozesswärme 01-2023 (pp. 42-45).

For more information: Klaus at klaus.buchner@aichelin.com.

This article content is used with the permission of heat processing, which published this article in 2023.

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Sintering Considerations: Vacuum vs. HIP

May 15, 2024 / HIPING TECHNICAL CONTENT, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT TECH, SINTERING POWDER METAL, SINTERING POWDER/METAL TECHNICAL CONTENT, VACUUM FURNACES, VACUUM FURNACES TECHNICAL CONTENT

Source: TAV Vacuum Furnaces

When processing cemented carbide, there are a few considerations you need to understand to use the proper sintering equipment. One of the biggest factors is the actual material; what is the colbalt content level of the processed material?

In this best of the web article, walk through the steps of dewaxing, sintering for appropriate densification, and the processing temperatures that are required for sintering cemented carbide.

An Excerpt:

“Other than mechanical stresses due to the differential pressure between inside and ambient pressure outside the furnace, operating at relatively high temperatures with high pressure of gas would lead to significant dissipations of heat to the external environment. This is not only anti-economic from an efficiency point of view, but could also compromise the structural integrity of the water-cooled steel vessel of the furnace by overheating it.”

Read the entire article from TAV Vacuum Furnaces, written by Giorgio Valsecchi, by clicking here: “SINTERING OF CEMENTED CARBIDE: A USER-FRIENDLY OVERVIEW – PT.2“

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Heat Treating AM Components to Infinity and Beyond

May 9, 2024 / AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT TECHNICAL CONTENT, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT TECH, SINTERING POWDER/METAL TECHNICAL CONTENT

The amazing materials that are produced through additive manufacturing (AM) and 3D machining often require post-processing heat treatments before these become final components that launch into space. What are the trends of AM/3D outside our planet, and what technical resources are available to you as you make one step into this field? This original content piece from the Heat Treat Today editors will help you understand where technology stands in 2024.

Why Does AM/3D Go to Space?

A broad spectrum of industries have found the appeal of additively manufactured parts, industries ranging from mining to medical and automotive to space. Much of this has to do with complexity of components that new engineering techniques require, the desire to save on material costs, and the ability to condense lead time. For some, additive manufacturing is becoming essential to the space industry; as Tobias Brune, head of the Business Unit Additive Manufacturing at TRUMPF, has commented, “With our 3D printing technology, we are driving the commercialization of the space-travel industry. If you want to be successful in the space-travel industry today, you have to use additive manufacturing.”

When should you expect this transition? Now.

In January of this year (2024), the first metal 3D printer for space was launched to the Columbus module of the International Space Station (ISS). This is a very active, integrated sense of seeing AM in the aerospace industry, and test runs with this equipment will ensue.

Flight model of 3D Metal Printer Launched on NG-20
Source: ESA

The Exploration Company in Europe plans to use 3D printers from TRUMPF (laser specialist) to print core components in engines for spacecrafts. The intent: missions in Earth’s orbit and to the moon.

Heat Treat & thermal Processing Requirements of Post-Processing AM

If you are going to get involved in AM, it is essential to have the right equipment. One of the most talked about equipment is hot isostatic pressing (HIP) technology. Often, heat treat operations use HIP equipment for post-process heat treating in order to get the solid part they desire. For the most part, commercial heat treaters have positioned themselves to handle the R&D required to navigate the terrain of overcoming processing challenges of new/complex parts and creating standardizations. However, private R&D facilities and departments are also building out their capabilities to handle AM in HIP.

However, so also have vacuum furnaces been a key leader in heat treating AM components. Here, commercial heat treaters have also made moves to expand their equipment/process offerings to accommodate AM parts.

So also do atmosphere considerations need to be considered, with gasses like H2 competing trying to capture the limelight.

Continue the Exploration: AM/3D Articles for Space

Looking for an introduction to the AM/3D topic for heat treaters? Begin with this article by Animesh Bose, an engineering pioneer: “The Role Of Heat Treat in Binder Jetting AM for Metals.” The article uncovers the history of one of the most important types of AM/3D manufacturing — binder jetting AM.

Then, take a step over for an industry focus on what “heat treatments for space” look like. Mike Grande eloquently summarized the current processes needed in space in this editorial from the March 2024 Aerospace print edition. Read “The Role of Heat Treatment in Space Exploration” in the digital edition of the magazine.

In-house or commercial? This article presents critical considerations of space components — with a particular emphasis on the importance of AM/3D — when considering how to grow your processing expertise and capabilities. Several examples from the frontlines of R&D are presented by Noel Brady in his article. Read the editorial, “Thermal Processing for Space and Additive Manufacturing,” for excellent illustrations.

Finally, hone in on the topic with a case study about developments in HIP technology for space component post-processing. This article begins with context confronting issues of structural integrity, especially of complex space components, with HIP. Andrew Cassese gets to the case study towards the end of his article, “High Pressure Prepares Parts for Space.”

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Message from the Editor: Digitalization: An Ever-Expanding Frontier

May 2, 2024 / EDITOR, EDITORS PICK, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT TECH

Heat Treat Today publishes eight print magazines a year, and included in each is a letter from the editor, Bethany Leone. This letter first appeared in the May 2023 Sustainable Heat Treat Technologies print edition.

Feel free to contact Bethany at bethany@heattreattoday.com if you have a question or comment.

In order to create a more sustainable future for heat treaters, operators may be looking to “digitalization” as an immediate step for their heat treat systems. Digitalization is an amorphous term that can describe a few things.

One definition of digitalization curated for the heat treat industry is: the integration of advanced digital technologies (like cloud technologies, 3D visualization, simulation, analytics and collaboration tools, and even robotics) with heat treat equipment and all other aspects of production (order fulfillment, certifications, communication systems, etc.) to create a “digital twin” — that is, a holistic virtual representation of heat treat operations. By transitioning analog data and manual operations to a digital system, the end goal of creating a “digital twin” of all heat treat operations can be actualized, allowing heat treaters to monitor and analyze in real-time and create simulations and predictions about equipment performance.

This term tends to be broader than just “digitization” — the act of digitizing analog technologies to digital form — though the two terms are often used interchangeably.

An interest in digitalization makes a lot of sense. For one, updating manufacturing plants with digital practices is a huge draw for young people: “People want to work for a technologically advanced company that they can feel good about,” according to Josh Hale, managing recruiter at International Search Partners, when he spoke on Heat Treat Radio . Additionally, Covid-19 labor constraints accelerated adoption of IIoT (industrial internet of things) technologies — digitalization being just one of many. But there are also several intrinsic promises that digitalization has to offer manufacturers, for example:

Efficiency: creating efficient operations that streamline business processes
Accuracy: increasing accuracy by achieving precise control over temperature, atmosphere, and other process parameters
Data and Analytics: real-time monitoring/data collection and rapid data analysis
Safety: reduced need for manual interventions, thus avoiding accidents and improving operator safety

From a sustainability perspective, digitalization means heat treaters can monitor, analyze, predict, test, and adapt energy efficiencies in their operations. This magazine features a conversation with experts in heat treat with an eye for energy, and they’ve commented on this specific topic. “With higher computational capacity on the controllers on a per furnace basis,” John Clarke, technical director at Helios Electric Corporation notes, “we have the ability to start executing real-time analysis on the furnace and potentially implement a thermodynamic model of the furnace and how it’s operating.” Several representatives from Watlow illustrate this point: “Poor thermal uniformity can lead to scrap and rework of material, which both result in excess energy consumption.” Read the eight-page conversation with six international expert contributors on page 19.

But there are drawbacks to adopting this new technology, and in the midst of all of this “good,” I do wonder how difficult this transition has been — or can be — for some in-house heat treaters. Challenges when considering this technology include:

Initial Investment. The initial investment in new technology is always present, and so is the question of who will “dish out the dough.” Will the furnace supplier try to absorb upgrading expenses? Or does it fall to the end-user buying the furnace or upgrade?
Operational Complexity. However easy to operate a technology is now, it was not always the case. I once thought typing at a computer was the most difficult thing in the world. Now, I’m so familiar with a keyboard that I can look over at my husband texting on his phone and know (to a degree) the message he is typing, just by watching his thumb position. What skills does your team have to learn a new system? How much time will it take to train 50%–75% of them? How long until you feel confident in the process?
Overdependence on Technology. We depend on digital technologies for many things (thank you, alarm clocks!), but is the level of dependence compromising something valuable? And to what degree? When it comes to cybersecurity threats, for example, what type of dependence on technology exposes you to more risk versus fortifying your internal systems?

The promises and challenges of digitalization will continue to face-off in offices and plant floors. While the boundary line of digital acceptance may shift, this new frontier towards creating “a holistic virtual representation of heat treat operations” means new technologies and processes that will be tested and adopted by heat treat pioneers, possibly you.

As with any frontier, there are known and unknown dangers. Let us know how your company is considering digitalization and what opportunities are golden nuggets or simply fool’s gold: editor@heattreattoday.com.

Special thanks to Mike Löpke (head of software & digitalization at Nitrex Metal) and Jeffrey Halonen (CEO of Steelhead Technologies) for their insights.

Bethany Leone, Managing Editor, Heat Treat Today

Contact Bethany Leone at bethany@heattreattoday.com.

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Heat Treat Radio #108: Heat Treat NextGen Humberto Ramos Fernández

April 25, 2024 / HEAT TREAT RADIO, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT TECH

A leading heat treat and HIP processing director, Humberto Ramos Fernández has overcome business and technologic challenges to make HT-MX the successful commercial heat treat company it is today.

In this NextGen profile on Heat Treat Radio — with host and Heat Treat Today publisher, Doug Glenn — we’re learning the heart of an engineer, from early education and metallurgy interests to cycling and how-to-start-a-business.

Below, you can watch the video, listen to the podcast by clicking on the audio play button, or read an edited transcript.

HTT · Heat Treat Radio #108: Heat Treat NextGen Humberto Ramos Fernández

The following transcript has been edited for your reading enjoyment.

Meet Humberto (00:00)

Doug Glenn: Well, welcome everyone to another Heat Treat Radio episode. We have the great privilege today of having another one of our 40 under 40 award recipients here to tell us a bit about himself.

So, Humberto, I would like for you to tell us your name and tell us a little bit about your upbringing. Where were you educated, for example?

Humberto Ramos Fernández: My name is Humberto Ramos Fernández. I'm born and raised here in Chihuahua, Mexico. I've spent my whole childhood living here, and when I went to college, I moved to , Mexico, had my degree there, and then spent a few years working around there. For a little while, I lived in Houston, Texas. I also lived in Australia for a little bit. I spent a few months in Argentina as well, and then got back to working in Monterrey, and eventually moved back to Chihuahua, where I'm currently living. I am very happy to be here, actually.

Doug Glenn: Do you have a family? I know you have parents, obviously. But married, kids, the dog, a cat. What do we have actually?

Humberto Ramos Fernández: I am actually engaged. I am about to get married in September later this year.

Humberto shares about coming from a family of engineers.

Doug Glenn: Congratulations! Very nice, very nice. Yeah, best to you. That's great.

What was it that first made you think about metallurgy or heat treatment, that type of stuff?

Humberto Ramos Fernández: Well, I always knew I would want to be an engineer. My dad's an engineer. My brother is an engineer. Since a very young age, I've always been into cars and racing and stuff like that. So, engineering and mechanical engineering was kind of an obvious choice for me when deciding my degree after high school.

I never really thought of metallurgy as a career; it was kind of more of a business choice or business decision. When I started as a mechanical engineer I was very interested in the mechanical aspect of the parts and design more than the metallurgy.

But eventually, while still working in Monterrey, I had the opportunity to come back home in Chihuahua and visit for a weekend. I got submerged in the environment of business leaders where there were a lot of opportunities for businesses — one of those was heat treating.

That's when my real interest in it started. It's been around 13 years or so since then. I've learned a lot. I mean, there's a lot to learn yet.

But I'm happy in what I'm seeing and what I'm learning.

"The decision to go into metallurgy and heat treat adventure was a decision I made alongside my dad. You know, we decided that this was a good business opportunity for both of us."

- Humberto Ramos Fernández

Doug Glenn: I do want to mention that besides being one of Heat Treat Today’s 40 Under 40 recipients, you've also authored a couple of articles with us as well. Obviously you're learning. It's been going well, and you've been contributing, giving back to the industry, which is really good.

Family (05:20)

What did your family think of your decision to go into heat treatment and metallurgy?

Humberto Ramos Fernández: The decision to go into metallurgy and heat treat adventure was a decision I made alongside my dad. You know, we decided that this was a good business opportunity for both of us. Even though he's never been involved in the day-to-day operations, he's been very supportive, and he's the actual president of the board at HT-MX.

We started this business together, and he's been with me all the way. We've had some very dark periods within the last 10 years. Pretty much everything that could happen did happen — a pandemic and multiple industry crises and everything.

He's been very supportive. One of the main reasons we've had some success, and I've been able to lead this company through some hard periods is because of his support and his knowledge. It's a very valuable thing to have, and I'm very grateful for sharing the experience with him and still having him give so much.

HT-MX (07:04)

Doug Glenn: Tell us a little bit about HT-MX. I don't think we've really mentioned it in particular. Did it exist before you started, or did you start it from scratch?

Humberto Ramos Fernández: After I graduated as a mechanical engineer, I got a job at GE Oil & Gas. I worked at this facility where we were manufacturing and oil and gas equipment. I spent a couple of years there. I learned a lot on the engineering side of it.

I got to work in the corporate offices in Houston, TX, for a while, and this led me to realize that there were a lot of supply chain gaps in the Mexican industry. There were heat treaters, but none like the ones we were looking for from the quality side of the requirements.

Being from the engineering side of things, I would visit some of these suppliers and realize that there were opportunities everywhere for more .

While that was happening, there was this pretty cool idea here in Chihuahua: A group of businessmen got together and organized a visit “from Chihuahua to Chihuahua,” trying to understand all the manufacturing happening here. A lot of people didn't really know. Over here, there are four OEMs. There's aerospace OEMs. There's a Ford engine plant. There's a lot of industry happening here. They defined several supply chain gaps, and one of that was heat treatment.

One weekend I was here visiting my parents, and we got to talk about the potential opportunities. We just decided to go for it. We started the company officially in 2010, 2012. We've been operating since.

We have a business partner as well. And I think we made a pretty cool team. And you know, we've survived a lot of things throughout this.

What Is the Most Enjoyable Part of HT-MX? (10:04)

Doug Glenn: What's been the most enjoyable part? What do you really enjoy about it?

Humberto Ramos Fernández: I really enjoy whenever we have and then trying to translate that into an actual service — looking at the potential growth and the equipment requirements and the pyrometry and all that.

I think that's what we take a lot of care for at HT-MX, and I think that's one of the parts I enjoy the most.

Also, you know, just walking through the shop and seeing the furnaces — the floor being clean and organized. That’s just relaxing at some point.

“After lunch I used to drive around some of the old neighborhoods where there's these machine shops, and a single part gear or a shaft, and then go and do the heat treatment. And now we're doing hot isostatic pressing for airplane engine parts.”

Doug Glenn: It's got to be relatively satisfying for you to know that you started from zero.

Humberto Ramos Fernández: When we started, during the first few months, after lunch I used to drive around some of the old neighborhoods where there's these machine shops, and a single part gear or a shaft, and then go and do the heat treatment. And now we're doing hot isostatic pressing for airplane engine parts. So that's a big jump, you know.

It’s very satisfying. But at the end of the day, we still have a lot of challenges and a lot of things to do. So it's never about focusing on what we've already done, but what can be done and what lies ahead.

A bigger business also brings extra worries, you know.

More About HT-MX (11:58)

Doug Glenn: Little business, little problems; big business, big problems. Not a lot of people in the world have built a business from the ground up, so I'm sure it's worth taking some time, and just acknowledging that accomplishment.

So how furnaces? How many HIP units? How many employees do you have?

Humberto Ramos Fernández: Since the pandemic we went through an evolution. We refocused our company and became much more focused on the aerospace industry.

We were running high volume, automotive parts, and oil and gas parts. Since the pandemic and the increase in energy prices and a lot of the inflation issues that we had here in Mexico — especially with the energy costs — we were forced to focus on what we believe is the real volume behind a heat treatment. Which is, in my opinion, the engineering of aspect of it.

We started focusing on these clients where their requirements were higher and where we would be able to better service them with what we had. So, we refocused. We're currently running around eight furnaces and one HIP unit.

We’re expecting to add a couple of furnaces this year and we're in the process of adding a couple of other additional services.

So, we're growing. We kind of moved away from the high volumes work, and we're focusing more on more aerospace industry and work.

Top Industry Resources (13:55)

Doug Glenn: What are some of the resources that you use to help yourself stay well informed?

Humberto Ramos Fernández: I guess the Internet, obviously.

Heat Treat Today is one of the main sources. There are other sites out there where heat treatment is focused on that I follow. And I talked to colleagues. I'm very involved in the aerospace cluster here in Chihuahua, also in Aerospace Federation in Mexico, and with the Chamber Commerce in Chihuahua — also federally in Mexico as well.

Nowadays with the Internet, and all that kind of stuff, there's a lot of information around. The key aspect is to kind of know how to filter the good info from the bad info.

“We started focusing on these clients where their requirements were higher and where we would be able to better service them with what we had. So, we refocused. We're currently running around eight furnaces and one HIP unit.”

- Humberto Ramos Fernández

Rapid Fire Round (14:56)

Doug Glenn: Let me ask you a couple of rapid fire questions, just to kind of get to know you a little bit more as a person, if you don't mind.

Are you a Mac or Apple user, as far as your computer goes? Or are you a PC guy?

Humberto Ramos Fernández: No, I'm an Apple user.

Doug Glenn: Is that right? You have an Apple computer.

Humberto Ramos Fernández: Yeah, I'm actually on an Apple computer right now.

Doug Glenn: Are you more of a digital person? Do you like hard copy print, or digital, or both, or neither?

Humberto Ramos Fernández: I grew up reading physical magazines, and I still really enjoy car magazines and stuff like that. But other than that, books and podcasts and all, it's on digital.

Doug Glenn: So I don't know if this applies so much to you, because you own the company. Do prefer a flexible work schedule or a high paying job? Being the owner of the company, you have neither, so maybe you would take either.

Humberto Ramos Fernández: I'll take whatever I can get. I think that the flexibility is a very, very valuable part of any kind of work. And I try to offer that to the people that we work with. But also, you need to have high pay to retain the good employees and the good engineers. We are trying to balance both.

Doug Glenn: Tell me about your car passion. Are you still doing anything with your car passion here? You like car magazines and stuff like that?

Humberto Ramos Fernández: I have a couple of old cars I like to work on. I work with my brother on restoring as well. I still keep that passion going. It's something that I really enjoy.

Doug Glenn: So you gotta tell us: What's the 40 year old car?

Humberto Ramos Fernández: It's a 1983 BMW 320I.

Humberto’s big interest is working on old cars, especially a 1983 BMW 320I.

Doug Glenn: If you could travel somewhere else that you haven't already been, where would you go, and why?

Humberto Ramos Fernández: I haven’t been to Japan. And I would love to experience the culture. I feel fascinated by their history and their culture and even their food. So that would be one of my first options.

Doug Glenn: What was it about Japan in the past that caught your attention?

Humberto Ramos Fernández: Those kind of cultures that are so radically different from what we experience here in Latin America are very interesting to look at and to visit.

I've been through China. I've been through other Asian countries. And you know I've been through some other countries in Europe. So considering that I've never been, never been there I would definitely choose Japan.

Doug Glenn: What do you do with your free time? Assuming you have any?

Humberto Ramos Fernández: I like to spend my weekends cycling. I do a lot of road cycling as well. Endurance sports, mostly cycling. So recently, I've done a lot of long, long days out there on the bike. I love the weather here, and here in Chihuahua, we're close to some very nice mountains and the canyons are absolutely beautiful places to go and visit on your bike.

Doug Glenn: What’s your favorite app on your phone or movie or magazine?

Humberto Ramos Fernández: My favorite movie I think it would be the Shawshank Redemption.

Doug Glenn: What future plans do you have for your company and life? Obviously, I know you're getting married. So that's one. But company life, generally speaking, what are you looking forward to?

Humberto Ramos Fernández: I'm looking forward to a period of continuous growth in the company, and where we can stabilize the operation and allow me to explore new and bigger opportunities within the heat treatment industry. I think there's a lot to be done here, and I think as a country and as a state, we're coming into a very good period of time.

Personally, I feel optimistic of what we can achieve here, and that still drives me every day to try and improve our company and continue to learn and to establish ourselves as a reliable and valuable heat treater for our clients.

Doug Glenn: That's great, Humberto. It's been a real pleasure to talk with you. Thanks for spending some time with us.

About the Expert

Humberto Ramos Fernández is a mechanical engineer with a master’s degree in Science and Technology Commercialization. He has over 14 years of industrial experience and is the founder and director of HT-MX Heat Treat & HIPing, which specializes in Nadcap-certified controlled atmosphere heat treatments for the aerospace, automotive, and oil and gas industries. With clients ranging from OEMs to Tier 3, has ample experience in developing specific, high complexity secondary processes to the highest requirements.

Learn more at ht-mx.com.

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The Melting Point: Lesson on Eutectic Reactions

April 18, 2024 / MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT TECH, VACUUM FURNACES, VACUUM FURNACES TECHNICAL CONTENT

What is the most common scenario for a eutectic reaction? And (for that matter) what constitutes a eutectic reaction?

If your heat treat operations involves vacuum heat treatments, you may already be familiar with this term. With the ability to truly make a bad day worse, this paper uncovers several examples of eutectic reactions, the costs that this “metallurgical experiment” can have on your load and furnace, and what steps you should take to prevent two mating metals from melting together. In this best of the web article, read about the eight examples of how barriers are used in real-world applications.

An excerpt: “To many people, the term ‘eutectic’ is not well understood. The best way to think of a eutectic is a metallurgical meltdown. A eutectic reaction occurs when two components with different melting points and surfaces free of oxides come in contact with each other in the vacuum furnace. This can create an atomic diffusion. For some materials, when a specific atomic composition is reached, they will melt at a temperature much lower than the melting point of the individual metals. If that temperature is reached or exceeded during the heat treating cycle, melting will occur at the contact points. This is referred to as a eutectic melt.”

Read the entire article from Solar Atmospheres, by clicking here: “Preventing Eutectic Reactions and Diffusion Bonding in Vacuum Processing“

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CUI Considerations for the Heat Treating Industry

April 11, 2024 / MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT TECH, OP-ED

2024 is a big year for heat treaters who work for the DoD. As Joe Coleman, cybersecurity officer at Bluestreak Consulting, explains, Controlled Unclassified Information is a key topic you need to understand if you want to maintain or grow contracts with the DoD this year.

This Cybersecurity Corner installment was released in part in Heat Treat Today’s March 2024 Aerospace print edition.

If you are a prime contractor for the Department of Defense (DoD) or a subcontractor, then you have CUI in one form or another whether it is in paper or digital format. Learn what is, and is not, considered Controlled Unclassified Information (CUI).

What Exactly Is Considered CUI?

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The DoD handles CUI in many forms across its operations. CUI includes sensitive information that requires safeguarding but does not meet the criteria for classification as classified information. Examples of DoD CUI include:

Click image to download a list of cybersecurity acronyms and definitions.

Export Controlled Information (ECI): Information that is subject to export control laws and regulations, such as technical data related to defense goods and services.
For Official Use Only (FOUO): Information that is not classified but still requires protection from unauthorized disclosure for official government use.
Critical Infrastructure Information (CII): Details about critical infrastructure elements like facilities, systems, networks, and assets that are essential for national security, economy, or public health.
Privacy information: Personal information of individuals (e.g., Social Security numbers, medical records) that needs to be protected under privacy laws and regulations.
Sensitive But Unclassified (SBU) Information: Information that, although unclassified, is sensitive and requires protection due to its potential impact if disclosed.
Contract-related information: Non-public details within contracts, such as proprietary information, financial data, or technical specifications.
Proprietary information: Data owned by an entity and protected by intellectual property rights or confidentiality agreements.

In the heat treating industry, DoD CUI might include various sensitive details related to heat treatment processes, materials, or specifications used in defense-related applications. Here are some potential examples of DoD CUI within the heat treating industry:

Material specifications: Specifications for heat treated materials used in defense equipment, weapons systems, or components. This could include details about specific alloys, heat treatment methods, tempering, or hardening processes required for certain applications.
Process documentation: Detailed procedures and technical information regarding heat treatment processes employed in the production of defense-related materials or components. This might involve specific temperature ranges, cooling rates, or other proprietary methods used in heat treating.
Quality control data: Information related to quality control measures specific to heat treating in defense-related manufacturing. This could involve data on testing methodologies, inspection techniques, or standards compliance for heat treated materials used in critical defense systems.
Research and development (R&D) information: Research findings, experimental data, or proprietary knowledge related to advancements in heat treatment technologies tailored for defense applications. This may include innovative heat treatment methods for enhancing material properties, durability, or performance in defense systems.
Supplier information: Details about suppliers providing heat treatment services or materials to the defense industry, including contractual agreements, proprietary processes, or specifications specific to DoD projects.
Cybersecurity measures: Information about cybersecurity measures employed within heat treatment facilities that handle DoD contracts or projects to safeguard sensitive data from cyber threats.
Facility security protocols: Details regarding security protocols, access controls, and clearance requirements within heat treating facilities handling defense-related projects to prevent unauthorized access to sensitive information.

Other items that may be identified as CUI provided by the DoD or generated in support of fulfilling a DoD contract or order include, but are not limited to (in both paper and digital formats):

Research and engineering data
Engineering drawings and lists
Technical reports
Technical data packages
Design analysis
Specifications
Test reports
Technical orders
Cybersecurity plans/controls
IP addresses, nodes, links
Standards
Process sheets
Manuals
Data sets
Studies and analyses and related information
Computer software executable code and source code
Contract deliverable requirements lists (CDRL)
Financial records
Contract information
Conformance reports

What Is Not Normally Considered CUI?

Here are several examples of items that may not typically fall under DoD CUI for the heat treating industry:

General industry standards: Information related to commonly accepted industry standards, processes, or procedures that are widely available and not specific to defense-related applications.
Non-proprietary heat treatment techniques: Basic information about standard heat treatment methods or techniques that are publicly known and not proprietary to a particular organization or application within the defense sector.
Publicly available research: Scientific or technical research findings, publications, or data that are publicly accessible, not subject to proprietary rights, and not specifically tied to defense-related advancements.
Commonly shared best practices: Information regarding widely accepted best practices in heat treating that do not involve proprietary or classified techniques applicable solely to defense-related materials or components.
Non-sensitive business operations: Routine business operations, administrative documents, or general non-sensitive communications within the heat treating industry that do not pertain to defense contracts or projects.
Information approved for public release: Data that has been officially approved for public release by the DoD or other relevant authorities, ensuring it does not contain sensitive or classified details.
Basic material specifications: Information about materials, alloys, or heat treatment processes widely used in commercial applications and not specifically tailored or modified for defense-related purposes.

I hope this information has been helpful to you. Please contact me with any questions and for a free consultation, with a complimentary detailed compliance ebook.

**For more information:** Contact Joe Coleman at joe.coleman@go-throughput.com.

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

March 26, 2024 / 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.

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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Heat Treat Radio #106: Heat Treat Legend Doug Peters

February 22, 2024 / HEAT TREAT RADIO, MANUFACTURING HEAT TREAT TECH

“Don’t lose sight of who you are . . . .” In an industry where passion to create, help, and discover can become all-consuming, Doug Peters’ drive and dedication to the heat treat industry has not compromised his care to family, employees, and the joys of life. As the founder and CEO of Peters’ Heat Treating, this Heat Treat Legend joins Heat Treat Radio host, Doug Glenn, in a special episode.

Below, you can watch the video, listen to the podcast by clicking on the audio play button, or read an edited transcript.

HTT · Heat Treat Radio #106: Heat Treat Legend Doug Peters

The following transcript has been edited for your reading enjoyment.

Meet Doug Peters (01:05)

Doug Glenn: Doug, it’s really good to talk with you. We’ve known each other for many, many years, but it’s really nice to get a chance to sit down with you here on Heat Treat Radio’s Heat Treat Legend — it’s an appropriate title for you. I’m really glad you took the time to talk to us. Welcome to the episode.

Doug Peters: Thanks, I appreciate it.

Doug Glenn: The first thing we do in these episodes, Doug, is just kind of give people a sense of you, the person, before heat treat. How did you get into the industry and a little bit of the history of your experience? Why don’t you start with where you are located, as well?

Doug Peters: We’re located in Meadville and McKean, Pennsylvania; we have two plants. The total square footage in the plants is probably roughly 70,000 square feet.

My history goes clear back to my farm days. Our family farm, which has been in our family since 1885, opened a retail milk store in 1963. My mother had no babysitter, so I had to go to work with her. During that time, I was taught how to prepare a storefront, and by the time I was 12, she had me cashing out the cash register, and reconciling all receipts at the end of the day. When “Mrs. Brown,” who was elderly, pulled up out front, you went out and met her at the car and got her bottles for her, and helped her in and out of the store. A good amount of my business acumen, believe it or not, came from my mother and that experience.

Doug Peters, a true Heat Treat Legend
Source: Peters’ Heat Treating

I graduated from Penn State University with a degree in business but, enroute, tried to be a pharmacist, so I ended up with 40 credits in the sciences. I went into the insurance business because I felt as though I needed some toughening up, people-wise. I ended up being an insurance agent for three years and had one question that I always asked customers and that was: “If I’m a genie and I can grant you one wish, what would it be?” And every tool shop I called on said, “We need a good heat treater.”

I had worked for my wife’s father in a tool and die shop, in the summers, as a saw boy, etc., so I sort of knew what heat treating was. Well, I went and discussed it with my wife’s father, and he gave me the name of a gentleman who had just retired from Talon after 32 years in their heat treating department. I called him on the phone, I paid him under the table, and he taught me the trade. Without him, I wouldn’t be sitting here today.

Likewise, my father-in-law bought us a building and gave it to me one-year rent-free, and my father, who was a railroad engineer, showed up every day after a full shift, and helped me fix the old broken-down equipment that I had bought to start the business.

Then there was Jackie, sitting behind the scenes. She did all the books. She was a full-time schoolteacher. I went three years, to the day, without a paycheck. My first paycheck was $100.

That’s how I got started.

Doug Glenn: What year did you actually start the heat treat?

Doug Peters: 1979, October of 1979.

Doug Glenn: October of ’79 you started the heat treat. Wow. And there is great family involvement too, right? Your dad, your father-in-law, Jackie . . .

Doug Peters: Yes. You know something? You certainly can’t accomplish anything by yourself. Without those guys and Jackie, we would not have been able to do what we did.

Doug Glenn: That’s great stuff.

Help me with the math. How many years was that ago?

Doug Peters: In October 2023, it would have been 44 years ago.

Major Accomplishments (04:40)

Doug Glenn: So, in the 44 years, what are the highlights? Are there one or two, or two or three, major accomplishments that, when you look back, you say, “You know what? This was a major accomplishment or something pretty significant.”

Doug Peters: I think probably the most satisfying thing to me are the families of the employees that we’ve had over the years. I’ve watched them get married, buy homes, have children, have grandchildren, and we’ve been very lucky to keep a very tenured staff over the years. Being involved with not only the employees but our customers within the community. Being able to contribute and help people as a result of what we do here in the heat treat — it’s really been the most satisfying thing for me.

Doug Glenn: I don’t want to underemphasize that. I think that’s a classic Doug Peters answer too. You know, you are one of the most “people oriented” people I know, which is great. I told my wife, when we were starting Heat Treat Today: You know what I’m looking forward to, is paying people. I don’t know why I was looking forward to it, but I was. So, I appreciate that perspective.

Does anything jump to your mind as far as actual business accomplishments? Is there anything that happened over the years, like, for example, opening the McKean plant?

Doug Peters: Yes, I suppose, if you look at those things. To me, those were just normal forces of business to better serve customers.

We started out with four little box furnaces with maximum capacity of 20 pounds. My first employee was my loyal dog. As we moved forward, I was lucky enough to work for a very innovative group of customers. We were on the cusp of tool and die morphing with the advent of computers into enabling (or demanding) us to really do more than traditionally what heat treating had been responsible to do.

For instance, one of the early things we did was we learned how to not control size, but influence size on a particular part and design to eliminate hard finish time on tooling. That was one of the things we did a lot of work in. We did a lot of work in straightening.

Early cryogenics work. I mean, back in 1980 and 1981, I bought a machine that would take gaseous CO₂ and compress it into very pithy dry ice. Then, utilizing ethyl alcohol as a catalyst, I could drive temperatures to -70/-75 degrees. Experimenting with that, we found that we could improve the stability of materials that were being manufactured in the shops, but most of all, improve part life. So, that was the advent of us getting into liquid nitrogen cryogenics, in the very early ‘80s.

From there, we graduated into vacuum furnaces. We have nine vacuum furnaces, presently. In 2006, we bought 20,000-pound nitriders that can do up to 138 inches in length. Then, of course, the specification requirements grew and grew, as we moved forward.

Doug Peters with family. Left to right: Doug Peters, Diana Wilkosz, Jackie Peters, and Andy Wilcosz, with three grandkids interspersed.
Source: Peters’ Heat Treating

At this point in time — and I’ve got to give my son-in-law, Andy, my daughter, Diana, and his staff a lot of credit — Jackie and I had a company that was ISO, and we could work the ASM2750 pyrometry specifications. When Andy and Diana came on board, they took us to Nadcap. Andy just put in a destructive testing laboratory. For instance, we just had our first AS audit, so those capabilities are now online.

And we’ve grown to nearly 80 employees. When you look at the major accomplishments over the years, a lot of the technical-credit goes to the people out on the shop floor who really put their shoulder on the wheel and pushed with us to go through the disciplines that are required to gain those things.

The Metal Treating Institute (09:18)

Doug Glenn: I’d like you to address two other questions on accomplishments, if you don’t mind, Doug. You and I have had a long history in the Metal Treating Institute. I’d just like you to have a comment about your activity there, including the fact that you were a president. Then, also, would you be comfortable commenting on Laser Hard?

Doug Peters: Sure!

As far as MTI, our company would not be successful without MTI — or as successful as it is. We’ll give Jackie the credit.

In 1984, I bought a fluidized bed from Wally Bamford. As we sat at dinner, after we had signed the purchase orders that evening, Wally shoved an application for MTI under my nose, and he said, “You’ve got to join this organization.” I asked him what it was about, and he told me, so Jackie and I joined. But we didn’t do anything for four years, except look at the sales reports and everything else.

Well, my wife signed us up for our very first meeting in 1989. Once we got there, I went, “Oh my goodness, have I been missing out on how to grow the company?” It was at that meeting that I met Chet Walthall and Roger Keeran, who ended up being wonderful mentors and friends of mine. I treasure those guys so much.

The other fellow that I met through that journey was Jack Ross who owned Ironbound. Jack would allow you to come into his plant and he’d share anything, as long as you were an MTI member — that was his only requirement.

Lance Miller was our executive secretary, at that point. My first involvement at MTI was getting a call from Chet Walthall congratulating me because I was on his education committee. Then, with forward planning — which is now strategic planning — I called Lance and asked if I could go to the meetings being held in Pittsburgh. I was not on the committee but my contention to him was, as a forty-something, I really thought that somebody younger should be on the committee that was planning the future in the institute. So, that’s my involvement, and it just mushroomed from there.

I was the millennial president in 1999 and 2000. I have been on numerous committees, chaired the Education Foundation’s institution with Norm Graves; Norm was the treasurer.

Well, yes, of course, my wife, Jackie, who was our president in in 2015. It was my pleasure to carry her briefcase that year and watch her. Her tenure, at the board level and through the chairs, was longer than mine. She served on numerous committees and she’s received a few awards, and she’s so deserving.
Doug Peters, Founder & CEO, Peters’ Heat Treating, Inc.

Doug Glenn: In fact, if I may interrupt, you were one of the founders of that Educational Foundation, if I’m correct.

Doug Peters: That is correct. And, you know, there were other people on our committee too, but to be able to see what the education foundation has grown to and how it will support the industry moving forward, I am very pleased to have been a part of that.

Doug Glenn: And we’ve got to make another note here, since we mentioned Wally Bamford: It wasn’t long ago that Wally made a very significant contribution to that foundation.

Doug Peters: Well, you’re doggone right.

Our initial bogey was a quarter of a million dollars. We weren’t going to take a nickel out until we got to $250,000. We pushed it over $250,000 and that’s when I stepped aside and we had different folks take chairs. Then we pushed it to $450,000, and now we’re giving scholarships. As a matter of fact, we had a recipient, here at the heat treat, to the Founders Scholarship. Then, of course, Wally, at our 90^th anniversary, gave us a million dollars.

Doug Glenn: Canadian!

Doug Peters: Canadian, yes, yes! And I’m going to call Wally to make sure that he listens to this podcast, Doug.

Doug Glenn: It was so typical Wally Bamford, right? He’s up front, he’s talking, and he says, “I’d like to donate a million dollars,” and everybody is oohing and aahing, and he leans in and says, “Canadian” in a deep voice, into the mic. It was classic. Wally needs a lot of credit there.

One other question, before we get off of MTI. Have any other people in your family been the president of MTI that you’d like to talk about?

Doug Peters: Well, yes, of course, my wife, Jackie, who was our president in in 2015. It was my pleasure to carry her briefcase that year and watch her. Her tenure, at the board level and through the chairs, was longer than mine. She served on numerous committees and she’s received a few awards, and she’s so deserving.

Doug Glenn: We share quite a bit in common, right? First off, we have the same names: Doug and Doug. We also have wonderful wives and, if you’re like me, people in MTI can tolerate you, but they really like your wife. That’s the way it works on my side.

Doug Peters: Absolutely. Everybody says “hi” to her before they say “hi” to me.

Doug Glenn: Exactly. We both married well!

So, as far as MTI, thank you for commenting on that. I just felt that was important. That’s one of the reasons why I think both you and Jackie really are kind of heat treat legends. You’ve been very active in a lot of different things, MTI especially.

Laser Hard (14:12)

Tell us briefly about Laser Hard.

Doug Peters: Laser Hard has been a joint family venture. Good friends of ours (and customers), the Learn family has been doing laser welding and cladding for a good number of years and are principals in Alpha Laser in North America. The patriarch, Blair Learn, gave me a call and said, “I want to show you something.” So, I went down and looked at it and, when all was said and done, we decided to partner. He knew lasers and I knew heat treating and we felt as though there was a real need.

The things that we’ve done with Laser Hard, in solving issues that cannot be solved in traditional heat treating, do not cease to amaze me on a daily basis. The type of customers that we’re attracting, including large toolmakers (Tesla, Ford) there are all kinds of people that have come and worked with us on applications that we have had an opportunity to pioneer, literally.

It’s just been a wonderful partnership. I can’t say enough good things about Phoenix Laser, Inc.; that is the formal name of our partner’s company, and the Learn and Peters connection continues to thrive.

Doug Glenn: That’s great, that’s great. If anyone wants additional information on Laser Hard or Phoenix Laser, Inc., we can certainly get in touch with them.

I want to make sure people know a couple of names we’ve thrown out there, just for reference. Obviously, you’ve mentioned Jackie is your wife, and you’ve also mentioned Andy and Diana Wilkosz. Diana, of course, is your daughter, and Andy is now the plant manager/president.

Doug Peters: He is the president of the company.

Doug Glenn: Very good. A little kudos out again, back to the MTI relationship. Andy did a good bit of interning, I think, down at Texas Heat Treating, Inc. with Buster Crossley, if I remember correctly.

Doug Peters: That is correct. He worked out at Buster’s plant for three years before he came up.

Doug Glenn: Not that my opinion counts, but both Diana and Andy seem to be very accomplished folks; they represent Peters well in the industry.

Influential People (16:30)

You had mentioned, Doug, a couple of names that had a major influence or that were helpful to you, people that you want to maybe give some credit to. You mentioned about the guy at Talon. Is there anybody else, as you look back on your career, that has had a significant impact on you and helped you along the way?

Doug Peters: There have been so many people, I almost feel remiss in naming only a few names, in case I forget somebody. Obviously, Mr. Weller Gregg, who was that Talon guy (who was the head of heat treating), that gave me the start.

The young Doug Peters
Source: Peters’ Heat Treating

My two dads. And my two moms. Jackie’s mom taught me one of the most valuable lessons in business that I tell people about and that I carry forward. Every Thursday, Jackie’s mom would watch our children, when they were young, so Jackie could come to the shop and do payroll. Then she started having us up for dinner after work.

I was up there one evening and she sensed that I was a little troubled with something, and she said, “You have something on your mind, today,” and I said, “Yeah, I have a few things going on at work,” and she said, “Well, might I suggest something? I have a question: Can you do anything about them, right now?” and I said, “Well, no,” and she said, “Well, I suggest that you worry about them when you can do something about them.”

It was absolutely the best piece of advice I ever got because I learned how to put some of those things on a shelf and deal with them when I could deal with them. I think it saved me a lot of grief and a lot of stress, over the years.

Obviously, Chet and Roger. They gave me the confidence to think that I was good enough to do this. Jim Balk, up at Hansen/Balk, was a real mentor, and he gave me the confidence that I was heading in the right direction, and we shared many of the same philosophies about how you take care of customers.

I’ll talk about Lance Miller who really put the love of the industry inside of me; I can’t say enough about Lance.

And then you look down through that long list of the notables in the industry: A shoutout to Roger Jones who’s going through a battle, right now, with cancer. Roger, we love you and we hope that everything comes through for you. John Hubbard, who’s a really good friend of mine and who was an industry giant with his career and his seat at Bodycote. Like I said, Jack Ross, and just the different people, Doug, that I’ve met over the years who were just phenomenal people.

MTI, right now, I believe, is in very capable hands with Tom Morrison and his staff. I feel very good to still be part of MTI.

Life Lessons (19:15)

Doug Glenn: Any lessons that you’ve learned, like the one that your mother-in-law gave you, which I think is a valuable one: “Don’t worry about it until you can do something about it.” Is there anything else that you’ve learned, as a “senior” in the industry, that you think is worth discussing?

Yes, I did just call you a senior!

Doug Peters: My parents stuffed a lesson right inside of me: be a finisher. Put all the tools away where you found them.

One of things from being in business that I can tell you is very valuable — when your name is on the sign, you accept all blame. I’ve never, in 44 years, ever thrown one of my employees under the bus to a customer. I accept the blame. Because, when something goes wrong in this building, it is something that I take responsibility for. You do not ever throw somebody under the bus; you go back and you work with them to perhaps correct the behavior, the execution, or something.

But that one’s been really important to me because, you know, you do not tear down a person’s dignity, as you work with them, whether it’s a customer or one of the folks that you work with inside of your building. So, that one has been very, very important to me.

Doug Glenn: As you’ve worked, over the years, I’m sure the way you started working, back when you were a young man and as you’ve progressed up through, were there any disciplines you developed that really helped make you either a better person or a better businessman, or anything of that sort — anything that maybe even you continue, to this day, in disciplines?

Doug Peters: Number one is being up really early in the mornings, when you have personal time. Because a lot of people complain that they don’t have personal time. They lose themselves in their vocation. My father was a big contributor to that. Dad used to go to work at 7:00 in the morning. He was a railroad engineer so he’d get up at like 4:30/4:45am. I said to him one day, “Dad, why do you do that?” And he looked at me and he grinned and he said, “Because you’re not!” The point was that that was his time.

“I think you have to make family time. I don’t care how busy you think you are; you have to be able to create that balance, and you have to force that balance to happen.”
Doug Peters, Founder & CEO, Peters’ Heat Treating

And I think you have to make family time. I don’t care how busy you think you are; you have to be able to create that balance, and you have to force that balance to happen. For instance, I was home every night by 5:30pm: I had dinner with my children, I played with them, we worked on homework, and when they were young, I’d help bathe them. And if I needed to go back to work, I would kiss Jackie and go back out the door after the kids were snugged in their beds.

Jackie, on the other hand, used to bring the kids to the shop. In the early days, I’d be working weekends, and she’d pack up a whole dinner and she’d come over and she’d bring the dog and the picnic table and be outside and we’d have a family dinner together. But I think, when we were together, we never really tried to not talk business because we always had our family first, business second, so that made that formula easy.

The only goal that we ever had for the company, Doug, was to be with our children when we wanted to be with them. When Diana graduated from college, I looked at Jackie and asked, “What’s the goal now?” and she said, “To be with our children when we want to be with them.” At that point, that’s been the only major goal that Jackie and I have ever had with Peters’ Heat Treating.

Learning Through Difficulties (22:37)

Doug Glenn: That’s great.

Well, you’ve addressed the other question I was going to ask you and that was about work/life balance.

Jackie and Doug Peters receiving the Winslow Award
Source: Peters’ Heat Treating

As you know, 40 some years, not every day is sunshine and roses — sometimes there can be difficult times. Can you recall a difficult time and — if you’re comfortable talking about it — what was it and what did you learn from it?

Doug Peters: Well, we’ve had two fires, one in each plant. Each fire was not a result of anything that was a delinquency on our part. But having to take each one of those buildings and sift through the rubble and to rebuild each one of them certainly was, I think, a character tester.

Losing key employees at the wrong time. All it did was reinforce why you do contingency planning, why you cross train, etc.

The one thing Jackie always said was it was wonderful being married to somebody that liked what he did for a living because I seldom came home, downtrodden. There were a lot of nights, in the early days of building the company, I’d be crawling into bed at 10:30pm when the phone would ring and 3^rd shift would be calling off when we only had two guys up there, and I’d pull my pants back on and go back to work and then stay the whole next day. I did that numerous times as we built this company.

Those, somebody might say are “trials and tribulations,” but to me, it was just part of the job. It’s what I signed up to do and there’ll be no whining. You got your pants on, you went to work, and you were fortunate that you had a job to go to.

Career Highlights and Advice to the Next Generation (24:17)

Doug Glenn: Obviously, there were some valleys there, like the fires and things of that sort. How about the highlight? If you could pick one thing that was the highlight of your career, what would it be?

Doug Peters: There were a number of highlights: Watching the kids go through school and be successful in their respective careers, watching my wife be president of MTI in 2015 was a super, super highlight for me, and being fortunate to be asked to serve in the institute and to win the Heritage Award was something that was very special to me.

Here, in Meadville, we have what’s called the Winslow Award. It was started by Dr. Harry Winslow many, many years ago to go to the person that contributes the most to making sure that the Meadville economy is sound. I was the proud recipient of that in 2022. The list of names in that award, locally, is just amazing, too.

To not have made a bunch of enemies is something. You know, you have those instances where you’re in a difficult time — a job that’s gone bad or whatever. I’m very proud to say that, most of the time, when I see somebody that I haven’t seen in a while, I’m glad to see them and I think they’re glad to see me.

Doug Glenn: Last question for you, then: You and I both are getting up there as being “seniors” in the industry. Is there any piece of advice you would give to younger people?

Doug Peters: I think, first and foremost, don’t lose sight of who you are. I’ll go back to my father again. Dad looked at me one time and said, “Don’t become what your job is.” This all stemmed from him being a really beautiful woodworker. He could do woodworking that was gorgeous, and I asked him one time, “Why don’t you do this for a career?” and he said, “Well, it would be a job then!” And, in the course of that conversation, he looked at me and he said, “Don’t become what your job is. Be a great person that enjoys the job you chose.” I always tried to make sure that that’s who I was because I chose this vocation because I love to serve people, not because I loved to heat treat. It just so happened that heat treating was the vehicle that fulfilled my dream of serving people.

Doug Peters, Founder & CEO, Peters’ Heat Treating. Source: Peters’ Heat Treating

Dad was spot-on. Because, you know, when you retire, how many people do you see that are completely lost after they’ve walked out of their place of employment and they don’t know who they are? For me, that’s not been the case. I’ve been completely fulfilled. It was time. I’m happy to be on to the next stage in my life.

So, don’t become what your job is, is the first piece of advice I’m going to give these folks. Secondly, “Eat the frog.” Do the most unpleasant thing that you have to do every day, first, because your day is only going to get better. An MTI seminar that I went to gave me that piece of advice.

Last, but not least, take the three most important things you have to do tomorrow and write them down on a notebook and put them right in front of your computer at your desk at work so the next day when you walk in, there are only three things that are clouding your mind instead of list with 50 things. But if the day gets worse, turn the page, and write one down and take the other two off the list. It will help you focus and it will keep you moving forward.

Doug Glenn: That’s really good advice.

You know, you were talking about not becoming your job, which reminded me of a picture I saw of you, years ago, sitting behind a drum set. Tell us about that, just a little bit.

Doug Peters: I started playing the drums when I was in 8^th grade. My father was a drummer, and he was a USO drummer. He was a sergeant in the Transport Corp, during World War II, in the European theater, and dad taught me how to play the drums. I did take some lessons, for a short time, but not as long as I would’ve liked to have.

Then, I had a rock band, and I’ve continued to play, over the years, and I play with artists on records. I’ve played, pretty much, my whole life, and I’ve enjoyed it.

Doug Glenn: That’s the human side and that’s great.

Doug, thanks very much. I appreciate the time you’ve taken to visit with us.

Doug Peters: Well, thank you, Doug. It’s always a pleasure.

About the Expert

Doug Peters with his wife, Jackie (Kuhn) Peters, founded Peters’ Heat Treating company in 1979. Over his career, Peters has served on numerous community service and industry trade association boards. He is past president of the NW Chapter National Tooling and Machining Association as well as the millennial president of the Metal Treating Institute.

Contact www.petersheattreat.com

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Heat Treat Radio #106: Heat Treat Legend Doug Peters Read More »

Exo Gas Composition Changes, Part 2: Cool Down and Use in Heat Treat Furnaces

February 6, 2024 / ATMOSPHERE AIR FURNACES TECHNICAL CONTENT, BULK GASES & SYSTEMS TECHNICAL CONTENT, FEATURED NEWS, MANUFACTURING HEAT TREAT TECH

In Part 1, the author underscored the importance of understanding the changes in gas composition through three steps of its production: first, the production in the combustion chamber; second, the cool down of gas to bring the Exothermic gas (Exo gas) to below the ambient temperature; and third, the introduction of the gas to the heat treat furnace. Read Part 1, published in Heat Treat Today’s August 2023 Automotive Heat Treat print edition, to understand what Exo gas is and to learn about the composition of gas in the first step.

Harb Nayar
Founder and President TAT Technologies LLC Source: TAT

As the author demonstrated in Part 1, Exo gas composition changes in its chemistry for heat treatment; this first step is how the gas composition changes when it is produced in the combustion chamber. The composition of reaction products, temperature, Exothermic energy released, various ratios, and final dew point are all factors that need to be considered to protect metal parts that will be heat treated in the resulting atmosphere.

Now, we’ll turn to Steps 2 and 3.

Step 2: Composition of Exo Gas after Exiting the Reaction Chamber Being Cooled Down

The two examples that follow demonstrate how lean and rich Exo under equilibrium conditions change as they are cooled from peak equilibrium temperature in the combustion chamber down to different lower temperatures (Table B). This cool down brings the Exo down to below ambient temperatures to avoid water condensation.

Example 1: Lean Exo Gas with a 9:1 Air to CH₄ Ratio

The first column highlighted in blue shows the composition of the lean Exo gas as generated in the reaction chamber with an air to natural gas ratio of 9:1. The peak temperature as generated in the combustion chamber is 3721°F. The next four columns show how the composition changes when the lean Exo gas is slowly cooled from 3721°F to 2000°F, 1500°F, 1000°F, and 500°F under equilibrium condition. The following key changes take place as the temperature of the lean Exo is lowered from the peak temperature to 500°F:

Hydrogen volume almost triples from 0.67% to 1.97%.
H₂O volume decreases slightly from 19.1% to 17.5%, but still is very high at all temperatures.
Oxidation-reduction potential (ORP) changes as the H₂ to H₂O ratio increases from 0.035 to 0.111. At all temperatures, it is very low.
CO and the CO to CO₂ ratio drop in a big way, making lean Exo from being decarburizing at higher temperatures to being highly decarburizing at lower temperatures.
The percentage of N₂ remains at 70.34 at all temperatures.
There is no C (carbon, i.e., soot) or residual CH₄ at all temperatures.
For all practical purposes, at an air to natural gas ratio of 9:1, the Exo gas as generated is predominantly an N₂ and H₂ (steam) atmosphere with some CO₂ and small amounts of H₂ and CO.

Table B. Air to Natural Gas at 9:1 and 7:1, cooled to various temperatures

Example 2: Rich Exo Gas with a 7:1 Air to CH₄

The column under ratio of seven is highlighted as red to show the composition of the rich Exo gas as generated in the reaction chamber with an air to CH₄ ratio of seven. The peak temperature is 3182°F — significantly lower than that for lean Exo. The next four columns show how the composition changes when the rich Exo gas is slowly cooled from 3182°F to 2000°F, 1500°F, 1000°F, and 500°F. The following key changes take place as temperature of the rich Exo is lowered from the peak temperature to 500°F:

Hydrogen volume almost doubles from 5.58% at peak temperature to 9.91% at 1000°F, and then it drops to 5.70% at 500°F. The overall volume of H₂ in rich Exo is significantly higher than in lean Exo.
H₂O volume decreases slightly from 17.9% to 15.1%, but it is still very high at all temperatures.
Oxidation-reduction potential (ORP) changes as the H₂ to H₂O ratio increases from 0.312 at peak temperature to 0.737 at 1000°F before decreasing to 0.377 at 500°F. Overall, ORP in rich Exo is significantly higher than that in lean Exo.
CO and the CO to CO₂ ratio drop in a big way, making it mildly decarburizing to more decarburizing
The percentage of N₂ remains at 65– 67%, which is lower than lean Exo.
There is no C (carbon, i.e., soot) at any temperature. However, there is residual CH₄ at 1000°F and lower. This increases rapidly when cooled slowly below 1000°F.
For all practical purposes, the rich Exo gas (at air to natural gas ratio of 7:1) generated is still predominantly a H₂
and H₂O (steam) atmosphere, but with more H₂; hence, it has somewhat higher oxidation-reduction potential (ORP) than lean Exo and a bit higher CO to CO₂ ratio (less decarburizing than lean Exo).

In summary, rich Exo as generated in the combustion chamber differs from lean Exo as follows:

It has a little less N₂ % as compared to lean Exo.
It has significantly more H₂ , but a little less H₂O than lean Exo. As such, it has a significantly higher H₂ to H₂O ratio (ORP).
It is decarburizing, but less than lean Exo.
It has residual CH₄ at temperatures below 1000°F. Therefore, it must be cooled very quickly to suppress the reaction of developing too much residual CH₄.

Discussion

Let us take the example of rich Exo (an air to natural gas of 7:1) exiting from the reaction chamber in Table B (see column highlighted in red). The total volume is 853.3 SCFH and has H₂O at 152.4 SCFH (17.9% by volume). This is equivalent to dew point of 137°F. Its H₂ content is 47.6 SCFH (5.58% by volume). And the H₂ to H₂O ratio is 0.312.

If this were quenched to close to ambient temperature “instantly,” this composition would be “frozen,” except most of the H₂O vapor will become water. Let us assume the Exo gas was instantly quenched to 80°F (3.6% by volume after condensed water is removed). Rough calculation shows that the final total volume of H₂O vapor has to be reduced from 152.4 SCFH to about 26.0 SCFH in order to meet the 80°F dew point goal. This means 152.4 – 26.0 = 126.4 SCFH of H₂O vapor got condensed to water.

Now the total volume of Exo gas after cooling down to 80°F= 853.35 – 126.4 = 726.95 SCFH, or almost 15% reduction in volume of Exo gas as compared to what was generated in the reaction chamber.

Of course, the composition of Exo gas will not be the same as calculated above. The exact composition after being cooled down depends upon the following:

a. Cooling rate of the reaction products from the peak temperature in the reaction chamber to some intermediate temperature, typically around 1500°F.
b. Cooling rate of the gas from the intermediate temperature to the final (lowest) temperature via water heat exchangers — typically 10–20°F below ambient temperature unless a chiller or dryer is installed on the system.

Depending upon the overall design of the generator, especially how Exo gas coming out of the combustion chamber is cooled and maintained during the period of its use, the expected Exo gas composition should be in the range of the light red columns in Table B — where temperatures are between 1500°F to 1000°F — however:

Total volume closer to 727 SCFH (since a major portion of H₂O was condensed out)
N₂ between 74–77%
Dew point between 80–90°F
CH₄. between 0.1–0.5%
H₂ percentage between 7–9%

Step 3: Composition of Exo Gas after Being Introduced into the Heat Treat Furnace

The cooled down Exo gas will once again change its composition depending upon the temperature inside the furnace where parts are being thermally processed.

As an illustration, let us assume the following composition of the rich Exo gas (with a 7:1 air to natural gas ratio) at ambient temperature just before it enters the furnace:

Total volume: 727 SCFH
H₂: 8% (58.16 SCFH)
Dew Point 86°F or 4.37% (31.77 SCFH)
CO: 6% (43.62 SCFH)
CO₂: 6% (43.62 SCFH)
CH₄ : 0.4% (2.91 SFH)
Balance N₂ (%)
75.23% (546.92 SCFH)

Table C shows how the composition changes once it reaches the high heat section of the furnace where parts are being thermally treated. The column highlighted blue shows the composition of Exo gas as it is about to enter while it is still at the ambient temperature. The next three columns show the composition of the Exo gas in the high heat section of furnaces operating at three different temperatures depending upon the heat treat application — 1100°F like annealing of copper, 1500°F like annealing of steel tubes, and 2000°F like copper brazing of steel products. The H₂ to H₂O ratio decreases as temperature increases.

Other general comments on Exo generators:

Generally, they are horizontal.
Size ranges from 1,000 to 60,000 SCFH.
Rich Exo generators use Ni as a catalyst in the reaction chamber. Lean Exo does not.
Lean Exo generators typically operate at a 9:1 air to natural gas ratio. There is no carbon/soot buildup.
Rich Exo generators typically operate at a 7:1 air to natural gas ratio. Below about 6.8 and lower ratios, soot/carbon deposits start appearing that require carbon burnout as part of the maintenance procedure.

Table C. Exo gas compositions in heat treat furnaces

Conclusions

A walkthrough of the entire cycle of gas production to cool down to use in the high heat section of the furnace clearly shows that as temperature changes, so does the Exo gas composition for any air to natural gas ratio.

Having a well-controlled composition of Exo gas requires the following:

Well-controlled composition of the natural gas used
Air supply with controlled dew point
Highly accurate air and natural gas mixing system
Highly controlled and maintained cooling system
A reliable ORP analyzer or the H₂ to H₂O ratio analyzer as part of the Exo gas delivery system.

Protecting metallic workpieces is paramount in heat treating, and in order to do this, the atmosphere created by Exothermic gas must be understood, both in the cool down phase and within the heat treat furnace. For further understanding of the good progress made in the improvement of Exo generators, see Dan Herring’s work in the reference section below.

References

Herring, Dan. “Exothermic Gas Generators: Forgotten Technology?” Industrial Heating, 2018, https:// digital.bnpmedia.com/publication/?m=11623&i=53 4828&p=121&ver=html5.

Morris, Art. “Exothermic Atmospheres.” Industrial Heating (June 10, 2023), https:// www.industrialheating.com/articles/91142-Exothermic-atmospherees.

About the Author

Harb Nayar is the founder and president of TAT Technologies LLC. Harb is both an inquisitive learner and dynamic entrepreneur who will share his current interests in the powder metal industry and what he anticipates for the future of the industry, especially where it bisects with heat treating.

For more information: Contact Harb at harb.nayar@tat-tech.com or visit www.tat-tech.com

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Exo Gas Composition Changes, Part 2: Cool Down and Use in Heat Treat Furnaces Read More »

MANUFACTURING HEAT TREAT TECH

Introduction

Heat Treatment Processes and Plant Concepts

Heating System

Waste Heat Recovery — Strengths and Weaknesses of the System

Process Gas for Case Hardening

Conclusion

About the Author

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Why Does AM/3D Go to Space?

Heat Treat & thermal Processing Requirements of Post-Processing AM

Continue the Exploration: AM/3D Articles for Space

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Meet Humberto (00:00)

Family (05:20)

HT-MX (07:04)

What Is the Most Enjoyable Part of HT-MX? (10:04)

More About HT-MX (11:58)

Top Industry Resources (13:55)

Rapid Fire Round (14:56)

About the Expert

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What Exactly Is Considered CUI?

What Is Not Normally Considered CUI?

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Reduce

Reuse

Refuel

Redesign

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Meet Doug Peters (01:05)

Major Accomplishments (04:40)

The Metal Treating Institute (09:18)

Laser Hard (14:12)

Influential People (16:30)

Life Lessons (19:15)

Learning Through Difficulties (22:37)

Career Highlights and Advice to the Next Generation (24:17)

About the Expert

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Step 2: Composition of Exo Gas after Exiting the Reaction Chamber Being Cooled Down

Example 1: Lean Exo Gas with a 9:1 Air to CH₄ Ratio

Example 2: Rich Exo Gas with a 7:1 Air to CH₄

Discussion

Step 3: Composition of Exo Gas after Being Introduced into the Heat Treat Furnace

Conclusions

About the Author

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