A custom-built vacuum induction melting (VIM) equipment is set to expand thermal processing for a manufacturer, whose operations already has two VIM solutions.
The furnace will be fabricated at the Buffalo headquarters of Retech, a SECO/WARWICK Group subsidiary, to capitalize on available schedule improvements. As custom equipment, the subsidiary’s furnaces are not dependent on assembly-line style construction, so they can be fabricated and assembled just in either location.
While this client prefers not to divulge this VIM’s application, Retech’s solution can handle casting a wide range of materials used in applications from automotive and consumer products to critical, high-value equiaxed, directionally solidified, or single-crystal aerospace parts. Almost every furnace Retech makes is modified to meet the specifications and associated applications of its clients.
VIM from the Retech Buffalo, NY location.
Source: SECO/WARWICK
What is the most common scenario for a eutectic reaction? And (for that matter) what constitutes a eutectic reaction?
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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.”
A hot isostatic press will add a new capability to the research infrastructure already in place at the Sydney Manufacturing Hub (SMH), the advanced manufacturing research facility at the University of Sydney, Australia.
Hot isostatic pressing (HIP) has become a critically important technology for the densification of unconventional microstructures associated with additive manufacturing (AM) across a broad spectrum of industries. It has proven of particular value in developing high-performance materials and building advanced metallic structures for mission-critical applications, for example within the aerospace, hypersonics, defense, biomedicine, energy, mining & minerals, and oil & gas sectors.
According to Professor Simon Ringer, Pro-Vice-Chancellor (Research Infrastructure) at University of Sydney, the SMH (as a research facility) is focused on offering the broadest possible range of advanced manufacturing capabilities, aiming to support the entire AM workflow from design right through to final part conformity in one facility.
“This [Quintus Technologies] hot isostatic press delivers enormous uplift in our university’s contribution to the national advanced manufacturing capability,” states Prof. Ringer. “It aligns critically with our own initiatives such as at the Sydney Biomedical Accelerator and our Net Zero Initiative. Moreover, this is a nationally significant capability that will allow our researchers to partner with industry to blaze new trails in manufacturing-related R&D.”
The Quintus Hot Isostatic Press going to the Sydney Manufacturing Hub is equipped with URQ® and URC® technology. Source: Quintus Technologies
The SMH selected the press model QIH 15L M URQ® + URC®, equipped with several proprietary features that streamline the HIP process and produce finished 3D printed parts with maximized theoretical density, ductility, and fatigue resistance. Uniform Rapid Quenching® (URQ) delivers an impressive cooling rate of 103K/minute while minimizing thermal distortion and nonuniform grain growth. HPHT™ (High Pressure Heat Treatment) combines stress-relief annealing, HIP, high-temperature solution-annealing (SA), high pressure gas quenching (HPGQ), and subsequent aging or precipitation hardening (PH) in one integrated furnace cycle.
Quintus’s strong focus on materials science and materials processing research, exemplified by the URQ functionality, was of special interest to the Sydney hub, Prof. Ringer relates. He also cites the intrinsic safety of the vessel and yoke design, along with the rapid cycle time for processing AM parts, as major benefits for the facility, which is geared to enable concept-to-production demonstration capabilities.
“Our new HIP capability will address a significant gap in the AM community in the Australian region and further offer the potential for SMEs (small and medium enterprises) and start-up companies to access this critical process,” Prof. Ringer adds.
SMH’s broad user base extends from its own researchers to those from other local universities and research organizations to private industry and collaborations with international institutions.
Jan Söderström CEO Quintus Technologies
“As the industry leader in advanced hot isostatic pressing technology for over 70 years, we have noted exceptional interest in new manufacturing approaches that improve quality, lower cost, and reduce environmental impacts,” says Jan Söderström, CEO of Quintus Technologies. “We are excited to work with the talented researchers at the Sydney Manufacturing Hub to deepen their expertise and refine processes for pressure-supported heat treatment, laying the foundation to advance both productivity and sustainability for operations in Australia and its neighbors.”
The hot zone of the model QIH 15L M URC® measures 7.32 inches (186 mm) in diameter and 19.7 inches (500 mm) high. The press operates at a maximum pressure of 207 MPa (30,000 psi) and a maximum temperature of 2,552°F (1,400°C). It will be installed in the Hub’s purpose-built facility on the University of Sydney’s Darlington campus in January 2025.
This press release is available in its original form here.
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An electric box furnace, currently headed to a Midwest equipment provider, will ultimately be installed at a Snap-on production facility that services tool and die support within the company’s production line.
The model QDD29 economical dual-chamber heat treating and tempering oven from L&L Special Furnace has a compact over/under design that saves floor space and provides reliable heat treating in-house.
QDD29 economical dual-chamber furnace (Source: L&L Special Furnace)
The top chamber is primarily deployed for heat treating tool steels at temperatures up to 2200°F; the tempering chamber is suited to temperatures up to 1250°F and has a recirculation baffle that makes it suitable for small aluminum work as well. The hardening and tempering chambers have interior dimensions of 12” wide by 8” high by 24” deep, with total external dimensions of 55” wide by 70” tall by 56” deep.
The QDD29 is controlled with digital single setpoint controls along with overtemperature protection. Solid-state relays drive the heating elements in a control circuit.
This press release is available in its original form upon request.
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Robert (Bob) Hill, FASM President Solar Atmospheres of Western PA Source: Solar Atmospheres
Solar Atmospheres of Michigan has successfully relocated from the old Fraser and Warren facilities to a new location in Chesterfield, Michigan. All ten furnaces (both new and existing) are fully operational at the Chesterfield plant, heralding a new era of efficiency and productivity.
This spring, construction will begin on a 15,000 square foot expansion on an adjacent lot. The expansion will allow for the investment in cutting-edge vacuum furnaces from Solar Manufacturing.
Bob Hill, president of Solar Atmospheres of Michigan, states, “Our future is very bright in Michigan. The consolidation and expansion will allow us to elevate our service standards and meet the evolving demands of our clientele across Michigan and the surrounding states. Solar of Michigan remains steadfast in its dedication to innovation, service excellence, and customer satisfaction as it ventures into this new chapter of growth and expansion.”
This press release is available in its original form here.
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2024 is a big year for heat treaters who work for the DoD.AsJoe 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 inHeat 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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As heat treaters strive for a sustainable future, pressure mounts to make the right choices while running commercially viable operations. This guest column by Michael Mouilleseaux, general manager at Erie Steel, Ltd., explores how and why heat treat operations are now coming under the focus of the U.S. Department of Energy.
This informative piece was first released inHeat Treat Today’s March 2024 Aerospace print edition.
The iron and steel industry contributes approximately 2.1% of energy-related CO2 emissions from primary sectors in the U.S. These statistics may seem insignificant or far removed, but the federal government has now determined that heat treating is a significant contributor and has set in motion critical changes for U.S. heat treaters.
Background
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On December 8, 2021, President Joe Biden issued an executive order that committed the federal government to “lead by example” in U.S. efforts towards carbon-free and net zero emissions solutions. Since then, the executive has delegated the Department of Energy (DOE) and the Environmental Protection Agency (EPA) to spearhead these initiatives aimed at reducing greenhouse gas emissions (GHGE) and promoting energy efficiency across various sectors of the U.S. economy. To support these efforts, $10,000,000,000 in incentives are being allocated for the DOE and EPA to investigate and promulgate regulations.
Specifically, the government sees the “industrial sector” as responsible for close to a quarter of all greenhouse gas emissions (GHGE); the five industries named within this sector are chemical processing, petroleum processing, iron & steel production, cement production, and food & beverage manufacturing. The DOE is leading the efforts of “supercharging industrial decarbonization innovation” and leveraging the potential of “clean hydrogen.”
Following these directives, the DOE unveiled the “Industrial Decarbonization Roadmap” in September 2022. This strategic plan will guide decarbonization efforts of the five key industrial sectors to mitigate GHGE. The four pillars are:
Energy efficiency
Industrial electrification (using green electricity)
Adoption of low-carbon fuels, feedstocks, and energy sources (LCFFES)
Carbon capture, utilization, and storage at the generated source (CCUS)
The DOE determined that process heating — accounting for 63% of energy usage within the iron and steel industry — would be the best opportunity to apply these four pillars. However, until May 2023, heat treating had not been explicitly mentioned as a target for decarbonization efforts.
Why Should Heat Treaters Care?
In May 2023, the Industrial Efficiency & Decarbonization Office — an office within the DOE’s Office of Energy Efficiency & Renewable Energy — held a symposium to refine its commitment to the decarbonization of the industrial sector. It was then that heat treating was specifically defined as a process targeted for the reduction of GHGE in the steel, aluminum, and glass manufacturing industries.
The DOE’s refined commitment focuses on two things: reduce GHGE attributable to “process heating” by 85% by 2035 and achieve net-zero CO2 emissions by 2050. To reach these ambitious goals, the DOE emphasized the importance of adopting LCFFES, green electrification, and implementing strategies that promote industrial flexibility, advanced heat management, smart manufacturing, and alternative technologies.
The potential ramifications of the DOE’s efforts on the heat treating industry are momentous. With the development of regulations to support these efforts, businesses within this sector must prepare for significant changes. The focus on green hydrogen, biofuels, and electrification, coupled with advanced technological solutions like ultra-efficient heat exchangers, artificial intelligence, machine learning, and alternative no-heat technologies, are strategies being considered for potential regulation.
Conclusion
The heat treating industry stands at a crossroads, with the DOE’s decarbonization initiatives signaling a shift to adopt cleaner energy practices. As these regulations take shape, businesses will need to adapt, investing in new technologies and processes that align with the nation’s clean energy goals. In the next column, we’ll address potential ramifications of the DOE effort for industrial decarbonization in the heat treating industry to help you be better informed and prepared.
About the Author:
Michael Mouilleseaux General Manager at Erie Steel, Ltd.
Michael Mouilleseaux is general manager at Erie Steel, Ltd. He has been at Erie Steel in Toledo, OH since 2006 with previous metallurgical experience at New Process Gear in Syracuse, NY, and as the director of Technology in Marketing at FPM Heat Treating LLC in Elk Grove, IL. Michael attended the stakeholder meetings at the May 2023 symposium hosted by the U.S. DOE’s Office of Energy Efficiency & Renewable Energy. He will be speaking on the MTI podcast about this subject on March 5, 2024, 2:30 EST, and will present on this topic at the April 3, 2024, MTI Mid-West chapter meeting.
For more information: Contact Michael at mmouilleseaux@erie.com.
Attend the SUMMIT to find out more about the DOE’s actions for the heat treat industry.
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Welcome to Heat Treat Today’sThis Week in Heat Treat Social Media. We’re looking at some compelling developments in aviation manufacturing, sharing a few metallurgy quizzes, and of course, bringing some fun, social heat treat videos to you.
As you know, there is so much content available on the web that it’s next to impossible to sift through all of the articles and posts that flood our inboxes and notifications on a daily basis. So, Heat Treat Today is here to bring you the latest in compelling, inspiring, and entertaining heat treat news from the different social media venues that you’ve just got to see and read!If you have content that everyone has to see, please send the link to editor@heattreattoday.com.
1. The Power of Engineering vs. Gravity
We usually like to share something rich and technical, but check out this compelling video of dual F119 engines powering an F-22 in an attack maneuver.! “F-22 with a combat capacity of; 1× 20 mm M61A2 Vulcan rotary cannon, 6× AIM-120C/D AMRAAM or 4× AIM-120A/B AMRAAM 2× AIM-9M/X Sidewinder, 2× 1,000 lb (450 kg) JDAM or 8× 250 lb (110 kg) GBU-39 SDB, 4× under-wing pylon stations can be fitted to carry weapons, each with a capacity of 5,000 lb (2,270 kg) or 600 U.S. gallon (2,270 L) drop tanks”
2. It’s a Beautiful Day in the Heat Treat Neighborhood
What’s everyone been up to on the social channels?
Gamifying Quality?? Count Us In!
Marking Milestones
When Precision Meets Creativity
3. Learn with Us – 3 Quick Visuals
Sometimes, it’s the small things on social media that grab your attention or give you the “ah ha!” moment. Do any of these short posts make you say “eureka”?
Rotate Rotate Rotate Rotate. . .
Spring is Here, depending on the Temperature
Quiz Time
4. Open Your Ears: The Podcast Corner
You can’t read everything, we get it. Heat Treat Today is here to recommend one informative podcast to enjoy on your daily commute, suggest a quick video on laser heat treating, and put a comprehensive article on surface treatments for automotive on your radar!
Tune in to Listen to Heat Treat Radio #107! Not Your Average Painting Class
The “Dougs” Talk
a Brazing Celebrity
5. Post-March Madness
Ever wonder the manufacturing processes behind the jump shots? Take March Manufacturing Madness: The Quiz below!
Have a great weekend!
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Guangdong Tayo Motorcycle Technology Co. Ltd., a Chinese manufacturer of motorcycles and bicycles, has invested in a nitriding/nitrocarburizing system, increasing sustainability and growth for its new production facility in Jiangmen City, located in southern China’s Guangdong province.
Heat treat solutions company Nitrex was commissioned to deliver a comprehensive turnkey system, geared towards enhancing the performance and durability of multiple components within Guangdong Tayo Motorcycle, including those for the brands Haojiang, Daye, Shengshi, and Qidian.
Nikola Dzepina Nitrex Regional Manager – Asia Source: NITREX
Nikola Dzepina, Nitrex account executive, said, “Our partnership with Guangdong Tayo Motorcycle Technology Co. Ltd. will help them in fulfilling their mission of delivering top-notch, highly durable, and reliable motorcycles and bicycles to their global customer base.”
As part of their development strategy, Guangdong Tayo Motorcycle has placed sustainability, product quality, service excellence, and market expansion at the heart of their mission. Paving the way for superior motorcycles and bicycles, the company evaluated various options and ultimately selected Nitrex for its precision-controlled processes, process stability and repeatability, equipment longevity and reliability, and commitment to environmental friendliness.
Nitrex pit furnace Source: Nitrex
The turnkey system comprises a large pit-type furnace, model NX-1225, with a 4000-kg load capacity and the Nitreg® controlled nitriding and Nitreg®-C nitrocarburizing technologies. These surface treatments augment the properties of motorcycle and bicycle metal components, significantly enhancing wear resistance and providing protection against rust and corrosion. Additionally, the system features an ammonia dryer and accelerated cooling system, facilitating the delivery of high-purity ammonia and fast cycle times to optimize production efficiency.
Tao Liu, sales manager at Nitrex China, emphasized, “This system’s exceptional reliability, engineered for longevity with minimal maintenance requirements and low utility and production media consumption costs, aligns perfectly with Guangdong Tayo Motorcycle’s vision for a sustainable future.”
This press release is available in its original form here.
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Jupiter Aluminum Industries (JUPALCO), a newly established aluminum factory which will be part of the Jupiter Group in India, has ordered three furnaces for annealing aluminum coils from a heat treat furnace manufacturer with North American locations.
The equipment ordered by the Jupiter Group from SECO/WARWICK includes three Vortex® 2.0 furnaces for aluminum annealing, two cooling chambers, and one loader. A system configured in this way will ensure the optimal production volume of the Indian rolling mill.
The aim of JUPALCO’s new plant will be to achieve the highest level of domestic aluminum production in history and to create an ecosystem of comprehensive aluminum-based solutions. This is the first cooperation between SECO/WARWICK and the Jupiter Group.
The three Vortex furnaces are effective systems for annealing aluminum coils. In the Vortex 2.0 version, a system of straight nozzles has increased the heat transfer efficiency. The systems key feature is the increased heat transfer coefficient, achieved by directing high-velocity air to both sides of the coil. This allows air to flow over the coil edges, not just through its outer layer.
Piotr Skarbiński, Vice President of (Source: secowarwick.com)
With the use of patented air flow technology, the aluminum coil annealing systems operate with process cycles that are significantly shorter. This in turn ensures energy savings, increased efficiency, and improved surface quality of the finished coils.
“In the case of coil annealing,” commented Piotr Skarbiński, VP of the CAB andAluminum Products Segment at the SECO/WARWICK Group, “the challenge is to optimize the process by reducing the cycle time as much as possible while maintaining the desired metallurgical properties throughout the entire load.”
The Jupiter Group plans to recycle over 50,000 tons of aluminum scrap every year once fully operational. This scrap will come from both in-house and customer scrap, purchased scrap, and recycled cans/foils etc. The new rolling mill in India will help the Group expand its footprint in the aluminum industry and produce Made in India products which will be known for its quality and reliable products and services.
“Since the 1990’s,” says Mr. Sandeep Bajaj, CMD of Jupiter Aluminum Industries, JUPALCO, “the Jupiter Group processes aluminum as a partner of the converting and packaging industries. Ecology is an important value for us. It is included in our mission, just like our Partner’s. The rolling mill in India will be one of the most modern facilities of this type in this region, which is why we are equipping it with the best solutions available on the market.”
This press release is available in its original form here.
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