OP-ED

Merry Christmas from Heat Treat Today

/ OP-ED

Your Heat Treat Today team will be celebrating the holidays with our families, and our offices will be closed from December 21 to January 1. Look for your next Heat Treat Daily e-newsletter on January 2nd! Until then, we hope this message encourages you and directs you to the true source of hope during this season.

Room with Him

In the next few days, it’ll be easy to get overwhelmed with all the activities, the gatherings, the lights and colors, crinkly wrapping paper and Christmas songs . . . and the movies. Who doesn’t settle down at least once during the season to watch a favorite Christmas movie? Some folks prefer the classics like White Christmas or It’s a Wonderful Life. Others love the new seasonal specials, like Home Alone or Elf. Maybe it’s Rudolph the Red-Nosed Reindeer that reigns in your house. My family’s favorite is The Muppet Christmas Carol.

In most Christmas movies, there’s always a special scene that moves viewers, reinforcing the themes of Christmas: hope, love, hospitality, faith, generosity, thankfulness. One scene from Rudolph moves me more than most, but I bet it’s not the one you’re thinking of.

Do you remember the residents of the Island of Misfit Toys? Dolly, and Charlie-in-the-box, and the boomerang who wouldn’t come back — toys that weren’t wanted because they didn’t do what was expected of them, or they were a little different in their design. Exiled to the Island of Misfit Toys, they waited and hoped for a chance to be enjoyed, appreciated and loved. However, the island was so far off course that they were forgotten year after year, and they were never given the opportunity to brighten a child’s Christmas morning.

Disappointments, slights, brokenness are felt, even at this time of year. Dolly’s words resonate with us when she says, “I just don’t feel like I have any more hope left in me.” Our hearts are troubled, and our coordinates don’t register on the radar. We might feel lost and forgotten along with the misfit toys.

This season is about more than parties, gifts, and decorations, as we all know. Jesus, the Son of God, became man, taking the form of a baby and living as the God-man, the perfect redemption for the lost, the broken, the misfits.

It is striking that at the end of his ministry, as he was wrapping up his time with his disciples before he went to the cross, Jesus assured them, “In my Father’s house are many rooms. If it were not so, would I have told you that I go to prepare a place for you? And if I go and prepare a place for you, I will come again and will take you to myself, that where I am you may be also.” (John 14:2-3) Jesus wandered about without a place to lay his head, yet he is quick to promise his troubled people not merely shelter, any shelter, but a room in the Father’s house.

Although the Savior came to no room at his birthplace, he has gone on to prepare rooms for us, and it’s not just a room, that is, a designated space with measurements and coordinates. He will be there also. And not just a room with him there — that would be awesome enough, but he also prepares for us, his followers, to be with him, to abide with him, to reside in him. He is what makes up the features, the atmosphere, the feng shui of the room. He is home. He is the where of kicking off our shoes and settling down with a cuppa joe. He is comfort food, a soft blanket, and a wagging tail at the door. This is what Christians mean when we say Jesus is our Sabbath.

A popular saying at this time of year is “Make room in your heart for Jesus.” Notwithstanding we can’t make the room, but he must, the truer saying is that “Jesus has made room for us.”

Hear his tender words of encouragement, which come after his prediction that Simon Peter will fail and deny him, just as we do in unbelief and discontentment: “Let not your hearts be troubled.” What follows next is his exhortation: “You believe in God? Believe also in me.” (John 14:1)

He doesn’t leave us to our own devices or our own means of finding our way to him. He comes to dwell with us; he becomes our dwelling place. And now, he is preparing an eternal dwelling place for his people. That’s the hope he gives the disciples as their steps falter under the burden of their troubled hearts, “that where I am you may be also.”

Know Jesus, and we can be assured we won’t be left on this island of misfit toys forever. We have a home.

And that makes for a merry Christmas message!

Here at Heat Treat Today, we are looking to 2025 with much anticipation and hope for more opportunities to work together and challenge ourselves and others with new ideas in the North American heat treat industry. Thank you for the opportunities every day to serve and encourage you in our heat treat corner of the world.

From the entire Heat Treat Today team, we wish you a very joyous and restful Christmas celebrating the birth of Jesus Christ!

by Laura Miller

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Understanding Inductance in a Furnace Heating System

/ CONTROLS TECHNICAL CONTENT, Manufacturing Heat Treat Technical Content, OP-ED, VACUUM FURNACES TECHNICAL CONTENT

In this installment of the Controls Corner, we are addressing inductance in a furnace heating system, and the critical role it plays in various industrial systems, including furnace load systems. Impedance acts as a measure of how much a circuit resists the flow of AC current. In this guest column, Brian Turner, sales applications engineer at RoMan Manufacturing, Inc., explains how impedance applies in electrical circuits.

This informative piece was first released in Heat Treat Today’s November 2024 Vacuum Heat Treat print edition.

Inductance is a fundamental concept in electrical engineering, and it plays a critical role in various industrial systems, including furnace load systems. In furnaces used for heating, inductance is a key factor influencing the system’s electrical performance, energy efficiency, and overall operational behavior.

To talk about inductance, let’s first address impedance and how it applies:

In electrical circuits, impedance refers to the total opposition to the flow of alternating current (AC), which is a combination of both resistance (from resistors) and reactance (from inductors), essentially acting as a measure of how much a circuit resists the flow of AC current, taking into account both the resistive component (like a resistor) and the reactive component (like an inductor at a specific frequency) within the circuit.

Load configuration, power source (IGBT, VRT, ERT) to the furnace feedthrough
Source: RoMan Manufacturing Inc.

Inductance

Inductance is the property of an electrical conductor that opposes a change in the current flowing through it. It arises from the magnetic field generated around the conductor when an electric current passes through it. The unit of inductance is the Henry (H).

In an AC circuit, inductance creates a phenomenon known as inductive reactance, which resists the flow of current. Inductive reactance (XL) is given by the formula:

XL = 2πƒL

Where:
• XL is the inductive reactance (in ohms)
• f is the frequency of the AC supply (in hertz)
• L is the inductance (in Henrys)

This reactance influences how the current behaves in the system, which is particularly important in furnace load systems where high current flows are common.

Resistance

Electrical resistance is the opposition that a material offers to the flow of electric current. It is measured in ohms (Ω) and depends on factors such as the material’s properties, its temperature, and the geometry of the conductor (length, cross-sectional area). In heating systems like vacuum furnaces, resistance is harnessed to convert electrical energy into heat through Joule heating (also known as resistive heating).

The relationship between electrical power, voltage, current, and resistance is governed by Ohm’s law:

V = IR

Where:
• V is the voltage across the heating element(in volts)
• I is the current through the element (inamperes)
• R is the electrical resistance of theelement (in ohms)

The heat generated by the furnace’s heating elements is a function of the power dissipated in the resistance, given by the equation:

P = I2 x R

This shows that the heat produced is directly proportional to the resistance and the square of the current flowing through the heating elements

Close Couple

  • Reducing the material in the secondary* reduces resistance (HEAT = I2 x R)
  • Reducing the area in the secondary reduces inductive reactance increasing power factor

To be most efficient, use the shortest amount of conductor material from the electrical system secondary to the furnace feedthrough. Additionally, keep the distance between those conductors as small as possible.

Power Factor and Efficiency

Inductance in a furnace load system causes the current and voltage to be out of phase. This phase difference results in a lower power factor, which is a measure of how effectively the system converts electrical power into useful work. A lower power factor means that more apparent power (the combination of real power and reactive power) is required to achieve the same level of heating.

In practical terms, a furnace with a high inductive load will draw more current from the power supply for a given amount of heating, leading to increased energy losses and inefficiency.

In practical terms, a furnace with a high inductive load will draw more current from the power supply for a given amount of heating, leading to increased energy losses and inefficiency. Power factor correction techniques, such as the use of capacitors, are often employed to counteract the effects of inductance and improve system efficiency.

Conclusion

Inductance is a fundamental factor in the operation of furnace load systems, influencing everything from heating performance to energy efficiency and power quality. By understanding and managing inductance, furnace operators can optimize their systems for maximum performance while minimizing energy losses and operational costs. Controlling inductance is essential for ensuring that furnace load systems operate reliably and efficiently in demanding industrial environments.

*The connection from a vacuum power source to the furnace’s feedthroughs, this connection can be made using air-cooled cables, water-cooled cables, or copper bus.

About the Author:

Brian Turner
Sales Applications Engineer
RoMan Manufacturing, Inc.

Brian K. Turner has been with RoMan Manufacturing, Inc., for more than 12 years. Most of that time has been spent managing the R&D Lab. In recent years, he has taken on the role as applications engineer, working with customers and their applications.

For more information: Contact Brian at bturner@romanmfg.com.

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Cybersecurity Desk: CMMC vs. NIST SP 800-171: Understanding the Differences

/ CYBERSECURITY, OP-ED

In Department of Defense (DoD) compliance, many acronyms and standards define how businesses manage processes to stay compliant. In this Cybersecurity Desk column, which was first released in Heat Treat Today’s September 2024 People of Heat Treat print edition. In it, Joe Coleman, cybersecurity officer at Bluestreak Compliance, a division of Bluestreak | Bright AM™, discusses the similarities and differences between the Cybersecurity Maturity Model Certification (CMMC) 2.0 and NIST Special Publication 800-171 Rev. 2.

What Is CMMC?

The Cybersecurity Maturity Model Certification (CMMC) evaluates the maturity of an organization’s cybersecurity program. Developed by the DoD, it aims to equip over 300,000 Defense Industrial Base (DIB) contractors with robust defenses against cyber threats. Once formally published, CMMC 2.0 will be a mandated framework for private contractors and subcontractors seeking government contracts.

CMMC’s comprehensive approach includes NIST SP 800-171, NIST SP 800-172, and the Cybersecurity Framework (CSF), incorporating industry-leading practices. It ensures the effective implementation of critical controls and safeguards the integrity of the supply chain. CMMC 2.0 compliance certification has three levels:

  • Level 1: Foundational: For companies handling Federal Contract Information (FCI) but not Controlled Unclassified Information (CUI).
  • Level 2: Advanced: For companies that store, process, or transmit CUI.
  • Level 3: Expert: For companies implementing highly advanced cybersecurity practices.

It will be referred to as DFARS 242.204-7021 when integrated into government-awarded contracts.

Source: Department of Defense

What Is NIST SP 800-171?

NIST SP 800-171 is the National Institute of Standards and Technology Special Publication 800-171 Rev. 2. It outlines security standards for non-federal organizations that handle CUI, ensuring they maintain strong cybersecurity practices. Compliance is mandatory for DoD primes, contractors, and supply chain service providers.

NIST 800-171 specifies five core cybersecurity areas: identify, protect, detect, respond, and recover. These areas serve as a framework to protect CUI and mitigate cyber risks. The standard comprises 110 security controls within 14 control families, leading to 320 control or assessment objectives. Compliance is measured on a 110-point scale, with a possible range from -203 to 110. An initial negative score is not uncommon.

Even for organizations with some cyber/IT security measures, retaining a qualified DFARS/NIST 800-171 consultant or a CMMC Registered Practitioner (RP) or CMMC Registered Practitioner Advanced (RPA) is highly recommended to guide you through the process.

Similarities Between NIST SP 800-171 and CMMC

Both CMMC and NIST SP 800-171 aim to strengthen information security and protect sensitive data, ensuring the confidentiality, integrity, and availability of organizational information assets. Here are some of the key similarities:

  • Control Alignment: CMMC 2.0 Level 2 aligns with NIST SP 800-171 Rev. 2’s 110 controls.
  • Focus: Both frameworks emphasize protecting data confidentiality, integrity, and availability.
  • Role Definitions: They describe roles within an organization’s cybersecurity program and interactions among those roles.
  • Asset Identification: Both require identifying assets and vulnerabilities and creating a risk management plan.
  • Cybersecurity Program Development: Organizations must develop a program with policies, procedures, and standards.
  • Risk Management: Both require identifying, assessing, prioritizing, and responding to risks, though CMMC is more comprehensive.

Differences Between NIST SP 800-171 and CMMC

While both frameworks enhance cybersecurity, they have distinct features:

  • Compliance Requirement: DFARS 252.204-7012 mandates NIST SP 800-171 compliance; DFARS 252.204-7021 mandates CMMC certification for handling CUI.
  • Assessment: NIST SP 800-171 compliance is self-assessed, while CMMC requires an independent third-party assessment.
  • Levels: CMMC has three certification levels, each more stringent than NIST SP 800-171 alone.
  • Scope: CMMC integrates additional NIST SP 800-172 practices and industry standards beyond NIST SP 800-171.

Conclusion

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

Understanding the differences between CMMC 2.0 and NIST SP 800-171 Rev. 2 is crucial for organizations enhancing their cybersecurity posture. Both frameworks are essential for assessing maturity in governance, risk management, incident response, data protection, and technology assurance. Adopting these frameworks ensures proactive adaptation to evolving threats and compliance with regulatory standards.

About the Author:

Joe Coleman
Cyber Security Officer
Bluestreak Consulting
Source: Bluestreak Consulting

Joe Coleman is the cybersecurity officer at Bluestreak Compliance, which is a division of Bluestreak | Bright AM™. Joe has over 35 years of diverse manufacturing and engineering experience. His background includes extensive training in cybersecurity, a career as a machinist, machining manager, and an early additive manufacturing (AM) pioneer. Joe presented at the Furnaces North America (FNA 2024) convention on DFARS, NIST 800-171, and CMMC 2.0.

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

Find heat treating products and services when you search on Heat Treat Buyers Guide.Com

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US DOE Strategy: Why the Heat Treating Industry?

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES, MANUFACTURING HEAT TREAT NEWS, OP-ED

The heat treating industry is under pressure to reduce its greenhouse gas emissions (GHGE), and the response has been a noble effort to attain sustainability. In two previous articles in this continuing series, guest columnist Michael Mouilleseaux, general manager at Erie Steel, Ltd., discussed the U.S. Department of Energy’s initiative related to the decarbonization of industry and its potential impact on the heat treating industry.

The first installment, “US DOE Strategy Affects Heat Treaters“, appeared on April 10, 2024, in Heat Treat Today, as well as in Heat Treat Today’s March 2024 Aerospace print edition. The second in the series, “U.S. DOE Strategy: Ramifications for Heat Treaters“, appeared on June 18, 2024, and in the May 2024 Sustainability print edition. This informative conclusion to the series was first released in Heat Treat Today’s June 2024 Buyer’s Guide print edition.

The endeavor to reduce greenhouse gas emissions (GHGE), albeit noble in intent, begs the question: Why is the heat treating industry being asked to reduce its greenhouse gas emissions?

Some background:

  • The United States’ GHGE account for approximately 14% of the total worldwide emissions.
  • According to the U.S. DOE, U.S. industry accounts for approximately 23% of the total U.S. GHGE.
  • According to the U.S. DOE, “process heating” accounts for approximately 43% of the total GHGE generated by U.S. industry.
  • According to the U.S. DOE, heat treating accounts for approximately 2.8% of the GHGE they have attributed to process heating.
  • In sum, heat treating accounts for 0.3% of the total U.S. GHGE (23% x 43% x 2.8%), and 0.04% of the worldwide GHGE (14% x 23% x 43% x 2.8%).

Why is the Department of Energy imposing natural gas restrictions on an industry that they have calculated to be responsible for 0.3% of the country’s total emissions?

The answer has two parts. First, natural gas has been deemed “unacceptable” due to its generation of CO2 as byproducts of combustion, and our industry has been swept up in an uninformed effort to stem global warming (or as it is now known, climate change). Remember: Heat treating accounts for just 0.04% of global GHGE!

Second, this administration has spent something between several hundred billion and a trillion U.S. dollars to incentivize power, transportation, and industrial sectors in their effort to stem global warming. Years from now, we will look back at this as one of the greatest capital reallocations in our history. If we can accept that the “past is a prologue,” we have a storied history of government failures to determine the future of the agricultural, aircraft, and financial sectors. This is already happening in Western Europe: Power is substantially more expensive, and industrial output has dropped nearly 6% for the past two years — the European Investment bank attributes the reduction in industrial output to “elevated energy costs.”

Perhaps it’s time for us to take notice and slow down this effort until such a time that we have the technology in place to accomplish decarbonization without eviscerating our industrial, transportation, and power industries. A greatly overused term today is “existential threat” — but our livelihood, our national security, and our way of life are, in fact, on the line.

Attend the SUMMIT to find out more about the DOE’s actions for the heat treat industry.

On www.heattreattoday.com/factsheetDOE, you can utilize the one-page resource to let governmental officials know what our industry is, who we are, who we employ, and the effect this effort has in regulating us out of business.

I want to thank Heat Treat Today for providing me with this forum to speak on this issue, as I believe this needs to be said.

I want to thank Surface Combustion, Gasbarre, and Super Systems Inc. for the guidance they provided me with in navigating the technology of this subject matter.

Any errors contained herein are mine and mine alone.

About the Author:

Michael Mouilleseaux
General Manager at Erie Steel, Ltd.
Sourced from the author

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.

For more information: Contact Michael at mmouilleseaux@erie.com.  

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Dual Chamber Vacuum Furnaces vs. Single Chamber Vacuum Furnaces — An Energy Perspective

/ FEATURED NEWS, GUEST COLUMN, Manufacturing Heat Treat Technical Content, OP-ED, VACUUM FURNACES TECHNICAL CONTENT

The need to understand how certain furnace designs operate comes at a time when heat treaters are weighing each energy cost and benefit of their systems and processes. Read on for a quick summary on how dual chamber furnaces preserve energy.

On April 17-19, 2024, TAV VACUUM FURNACES provided a speaker at the 4th MCHTSE (Mediterranean Conference on Heat Treatment and Surface Engineering). The speech focused on the energy aspects of vacuum heat treatment, a subject towards which all of us within the industry need to pay attention for reducing the carbon emissions aiming at a zero net emissions future.

We have already analyzed the essential role that vacuum furnaces will play in this transition, with a focus on the optimization of energy consumption in our previous article. With this new presentation, we wanted to emphasize how selecting the right vacuum furnace configuration for specific processes may impact the energy required to perform such process. For doing so, we compared two different furnace designs — single chamber vs. dual chamber vacuum furnaces — detailing all of the components’ energy consumption for a specific process.

TAV DC4, dual chamber vacuum furnace for low pressure carburizing and gas quenching
Source: TAV VACUUM FURNACES

As a sneak peek into our presentation, we will summarize below how the main features of the two vacuum furnaces design are affecting their energy performance.

Let’s start by introducing the protagonist of our comparison: a single chamber, graphite insulated vacuum furnace, model TAV H4, and a dual chamber furnace TAV DC4, both having useful volume 400 x 400 x 600 mm (16” x 16” x 24”) (w x h x d).

In a single chamber vacuum furnace, like the TAV H4, the entire process is carried out with the load inside the furnace hot zone. This represents a highly flexible configuration that can perform complex heat treatment recipes with a multiple sequence of heating and cooling stages and to precisely control the temperature gradients at each stage.

Configuration of the TAV DC4 dual chamber vacuum furnace
Source: TAV VACUUM FURNACES

Alternatively, a dual chamber vacuum furnace, like the TAV DC4, is equipped with a cold chamber, separated from the hot zone, dedicated for quenching. Despite the greater complexity of this type of vacuum furnace, the dual chamber configuration allows for several benefits.

First, in dual chamber furnaces, the graphite insulated hot chamber is never exposed to ambient air during loading and unloading of the furnace; for this reason, the hot chamber may be pre-heated at the treatment temperature (or at a lower temperature, to control the heating gradient). But in single chamber vacuum furnaces, the hot zone must always be loaded and unloaded at room temperature to avoid damages due to heat exposure of graphite to oxygen.

Because dual chamber furnaces have more controlled heating, this will result in both faster heating cycles and lower energy consumption, as a substantial amount of energy is required to heat up the furnace hot zone. This advantage obviously will be more relevant in terms of energy savings the shorter the time is between subsequent heat treatments.

View of the cold chamber of the TAV DC4 dual chamber vacuum furnace
Source: TAV VACUUM FURNACES

Secondly, since the quenching phase is performed in a separated chamber, the hot zone insulation can be improved in dual chamber vacuum furnaces by increasing the thickness of the graphite board without compromising cooling performance. This translates into a significantly lower heat dissipation, to the extent that at 2012°F (1100°C) the power dissipation per surface unit (kW/m2) is reduced by 25% compared to an equivalent single chamber vacuum furnace.

Additionally, quenching in a dedicated cold chamber allows to obtain higher heat transfer coefficients and higher cooling rates compared to a single chamber vacuum furnace. Since the cold chamber is dedicated solely to the quenching phase, it can be designed for optimizing the cooling gas flow only without the need to accommodate all the components required for heating. All things considered, the heat transfer coefficient achievable in the TAV DC4 can be, all other things being equal, even 50% higher compared to a single chamber vacuum furnace. Secondly, since the cold chamber remains at room temperature throughout the whole process, only the load and loading fixtures need to be cooled down; as a result, the amount of heat that needs to be dissipated is significantly less compared to the single chamber counterpart.

CFD simulation showing a study on the cooling gas speed in a section of the cooling chamber for the TAV DC4 dual chamber vacuum furnace
Source: TAV VACUUM FURNACES

For heat treatments requiring high cooling rates, it is possible to process significantly higher loads on the dual chamber furnace compared to the single chamber model; translated into numbers, the dual chamber model can effectively quench as much as double processable in a single chamber furnace, depending on the alloy grade, load configuration and overall process. The savings in terms of energy consumption per unit load (kWh/kg) achievable in the dual chamber furnace for such processes can be as high as 50% compared to the single chamber furnace.

In the end, the aim of the speech was to highlight how the energy efficiency of vacuum furnaces is highly dependent on the machine-process combination. Choosing the right vacuum furnace configuration for a specific application, instead of relying solely on standardised solutions, will improve significantly the energy efficiency of the heat treatment process and drive the return on investment.

About the Author

Giorgio Valseccchi
R&D Manager
TAV VACUUM FURNACES

Giogio Valsecchi has been with the company TAV VACUUM FURNACES for nearly 4 years, after having studied mechanical engineering at Politecnico di Milano. 

For more information: Contact Giorgio at info@tav-vacuumfurnaces.com.

Find Heat Treating Products And Services When You Search On Heat Treat Buyers Guide.Com

 

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Sustainability Insights: Forging a Sustainable Path to Decarbonization

/ Manufacturing Heat Treat Technical Content, OP-ED

The search for sustainable solutions in the heat treat industry is at the forefront of research for industry experts. In this article, provided by IHEA Sustainability Initiatives, a path to sustainable decarbonization is suggested that cuts through the murky waters of changing terms and shifting protocol and charts instead a navigable course with updated definitions and industry resources, such as IHEA’s upcoming Decarbonization SUMMIT in Indianapolis, IN, this fall.

This Sustainability Insights article was first published in Heat Treat Today’s May 2024 Sustainability print edition.

There is no hotter topic (no pun intended) than decarbonization. Just about everywhere you go and everything you read or listen to talks about sustainability and decarbonization. As leaders and stewards in the industrial heating industry, the Industrial Heating Equipment Association (IHEA) is committed to being at the forefront of providing valuable information and developments around the topics of sustainability and decarbonization. For the past 18 months, IHEA has been developing and delivering a highly successful Sustainability Webinar Series; continuously updating terms and definitions, frequently asked questions, and resources for the industry on the IHEA website; and, in its biggest step, is now offering a comprehensive Decarbonization SUMMIT from October 28–30, 2024 in Indianapolis, IN.

Current IHEA President and Sustainability Committee Chair Jeff Rafter states, “All IHEA members are continuously being asked about ways to decarbonize their processes. As the industry association dedicated to all things ‘heating,’ we feel it is our duty to present an unbiased view of what’s happening now, how companies can begin the process of lowering their carbon emissions on their current equipment, while beginning to look at all the alternatives that are coming and how those might fit into their operations. There is no question that change is imminent. We want to be the resource that the industry uses for information on all options to begin to decarbonize operations.”

While not much is going to happen overnight, “Legislation is going to be coming,” notes IHEA Board Member Mike Stowe, who is serving on the ISO Decarbonization Committee. “The best thing companies can do is begin preparing now. Take a look at your current operations and start making changes that improve efficiency now. Educate yourself and your staff on technologies that will help you lower carbon emissions. Be ready for what lies ahead.”

IHEA is ready to help the industry take the next step by hosting its first Industrial Heating Decarbonization SUMMIT. This event is designed to start shaping the future of manufacturing heating processes. It will include keynote addresses by industry visionaries; ways to begin your decarbonization process now; a look ahead at various technologies that can also help you decarbonize; case histories and a panel discussion on decarbonization collaboration; networking with industry leaders, and a tabletop exhibition that showcases cutting-edge technology.

Themes Running Throughout the SUMMIT Will Focus On:

  • Low Carbon Fuels in Industrial Processes
  • Carbon Capture and Storage Technologies
  • Global Benchmarking
  • Economics and Business Concerns
  • Innovations in Clean Technologies
  • DOE (Department of Energy) Programs and Tools
  • Policy Frameworks for Decarbonization

Target Audience for the SUMMIT:

  • CEOs and Executives from Industrial Companies
  • Sustainability Officers and Environmental Managers
  • Government Officials and Policymakers
  • Researchers and Academics in Clean Technology
  • Sustainability Engineers and Program Managers
  • Directors of Sustainable Manufacturing
  • Utility Representatives

“We are in a unique position,” comments IHEA President Jeff Rafter. “There has never been an issue like this that has faced our industry. Working together and bringing the industry together at a SUMMIT gives everyone a forum to learn, share ideas and best practices, review recent technologies, and begin lowering carbon emissions as an industry. No one is going to do this alone.”

IHEA’s tabletop exhibits that will accompany the SUMMIT programming will allow attendees to get a close look at a wide array of information that will help them in their decarbonization efforts. Those interested in reserving a tabletop should visit summit.ihea.org. Tabletops are expected to sell out quickly.

As IHEA works its way towards the SUMMIT in the fall, the Sustainability Webinar Series is still underway. Nearly 1,000 people have logged on over the past year since the first webinar was launched. Upcoming Webinars include:

May 16Increasing Available Heat to Lower CO2 Emissions
June 20Understanding Carbon Credits & Net Zero
July 18U.S. Codes & Standards
August 15Renewable Fuels

Additional webinars will be supplemented to this list regularly. IHEA’s webinars are free to attend. You can register by going to IHEA’s website (www.ihea.org) and clicking on the Sustainability logo on the home page. Then scroll down and click on the “Sustainability Webinar Series” to review and register for the upcoming webinars. If you have a sustainability topic you would like us to address, please email the topic to anne@goyermgt.com, and we’ll work to create a webinar.

For more information:

Connect with IHEA Sustainability & Decarbonization Initiatives https://www.ihea.org/page/Sustainability

Article provided by IHEA Sustainability Initiatives

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Basic Definitions: Power Pathways in Vacuum Furnaces

/ CONTROLS TECHNICAL CONTENT, FEATURED NEWS, Manufacturing Heat Treat Technical Content, OP-ED, VACUUM FURNACES TECHNICAL CONTENT

Ever wish you had a map to follow when navigating your power source? In the following Technical Tuesday article, Brian Turner, sales applications engineer at RoMan Manufacturing, Inc., charts the route that power takes from the source to the load and back again in a vacuum furnace.

This informative piece was first released in Heat Treat Today’s June 2024 Buyers’ Guide print edition.

In a vacuum furnace, the journey from the load (the material being heat treated) to the incoming power involves a complex arrangement of components that deliver, control, and monitor electrical energy. Here’s a breakdown of the path from the source to the load and back to the source of incoming power of a vacuum furnace:

Load

The material — either an item or batch of items — that is undergoing heat treatment; can be metals, ceramics, or composites.

Heating Elements

Common materials for heating elements include graphite, molybdenum, or tungsten, depending on the temperature range and application.

Electrical Feedthrough

These are used to transmit electrical power or signals through the vacuum chamber wall. They often contain insulated conductors and connectors to ensure safe transmission without leaking air into the vacuum environment.

Conductors

The most common methods to connect power from a vacuum power source to the furnace’s feedthrough include air-cooled cables, water-cooled cables, and copper bus bar. Power efficiency can be improved when selecting the length, size, and area between conductors. This can be achieved by close coupling the power system to the electrical feedthroughs, reducing resistance and inductive reactance, and improving the power factor.

Machined Copper Bar
Source: RoMan Manufacturing, Inc.

Controlled Power Distribution Systems

The furnace market today generally relies on three primary types of control power distribution systems: VRT, SCR, and IGBT. Each of these technologies employs different methods to regulate the power input to the furnace, which in turn generates the required heat.

VRT (Variable Reactance Transformer)

  • The VRT controls AC voltage to the load, this is accomplished by a DC power controller that injects DC current into the reactor within the transformer.

SCR (Silicon Controlled Rectifier)

IGBT (Insulated-Gate Bipolar Transistor)

  • Balanced three-phase voltage is rectified through a bridge circuit to charge a capacitor in the DC bus. The IGBT network switches the DC bus at 1000Hz to control the AC output voltage to a Medium Frequency Direct Current (MFDC) power supply.
  • MFDC power supply transforms the AC voltage to a practical level and rectifies the secondary voltage (DC) to the heating circuit.
  • A line reactor on the incoming three-phase line mitigates harmonic content.

Control Systems

These systems manage the furnace’s operation, including driving the setpoint of the power system, temperature control, vacuum levels, and timing. They often consist of programmable logic controllers (PLCs), human-machine interfaces (HMIs), sensors, and other automation components.

Incoming Power

This is the origin of the furnace’s electrical energy, typically from a utility grid. It provides alternating current (AC), which is distributed and transformed within the furnace system to power all necessary components. In industrial settings, power companies usually charge for electricity based on several factors that reflect both the amount of electricity used and how it’s used. Some common charges/penalties are energy consumption (kWh), demand charges (kW), power factor penalties, and time-of-use (TOU) reactive power.

Conclusion

The careful arrangement of heating elements, electrical feedthroughs, conductors, and controlled power distribution systems allows for precise temperature control, ultimately impacting the quality of the processed material. Understanding the role of various control systems, such as VRT, SCR, IGBTs, and transformers is crucial for optimizing furnace performance and managing energy costs

About the Author:

Brian Turner
Sales Applications Engineer
RoMan Manufacturing, Inc.
Source: RoMan Manufacturing, Inc.

Brian K. Turner has been with RoMan Manufacturing, Inc., for more than 12 years. Most of that time has been spent managing the R&D Lab. In recent years, he has taken on the role as applications engineer, working with customers and their applications.

For more information: Contact Brian at bturner@romanmfg.com.

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HIP: Technology that Takes Components into Space 

/ AEROSPACE HEAT TREAT NEWS, HIPING TECHNICAL CONTENT, OP-ED

Hot isostatic press (HIP) processing is a manufacturing technology used to densify metal and ceramic parts to improve a material’s mechanical properties. It is based on applying high levels of pressure (up to 2,000 bar/200Mpa) and temperature (up to 3632°F (2000°C)) through an inert atmosphere in order to densify parts and components, mostly of metallic and ceramic material, and to give them improved mechanical properties.  

HIP technology has become the decisive tool for aerospace parts and components to certify materials and parts with the strictest quality and safety controls. These developments require highly advanced, complex, and processed materials capable of withstanding the demanding work they will be subjected to.  

There are strategic materials and components in the space sector that can only be manufactured by advanced manufacturing in a specific way. Rubén García, project manager of HIP at Hiperbaric, noted that “These developments need very advanced, complex, and processed materials that are capable of withstanding the demanding work they will be subjected to. Therefore, advanced processes are needed to ensure and certify that these materials can be part of a satellite or rocket.” In addition to elements that form part of satellites and rockets and their respective engines, turbomachines, burners, and more intended for space also see benefits from HIP processing. 

Rocket engine treated by HIP Technology
Source: Hiperbaric

An X-ray inspection of each part evaluates the suitability of the component and ensures that it will not fail during the combustion process. “If we find any pores in the part, they are repaired with HIP technology, which repairs and densifies the component,” explains García. The HIP technology supplier uses Fast Cooling technology to cool materials very quickly, especially in materials whose capabilities may be impaired if they are not cooled quickly.  

Emphasizing how HIP is the key that takes components to space, García describes, “The more complex qualification components are required to go through a HIP process to ensure that the component will not fail. Materials engineering and the metallurgical process are closely tied to these innovations to ensure what some processes can’t do 100%. That is where HIP becomes our best ally.” 

Hiperbaric has devoted a HIP press for its HIP Innovation Center in Spain for companies worldwide for the purpose of investigating and developing HIP products with a particular focus on the aeronautical sector. Here, companies will find the help and knowledge required to achieve success.

About the Expert: 

Rubén García Reizábal
HIP Project Manager 
Hiperbaric

Rubén García Reizábal is an industrial engineer with a master’s degree in Material Components and Durability of Structures and has recently obtained his PhD. After his first stage in Hiperbaric, where he held the position of Quality Manager, he has been working as project manager of several R&D projects for more than 11 years. In this role, he leads all the actions of the Spanish-based company related to its hot isostatic pressing (HIP) business line, including R&D and business development efforts. 

Contact Rubén at r.garcia@hiperbaric.com. 

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Advantages of Laser Heat Treatment, Part 2: Energy Efficiency, Sustainability, and Precision

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

A discussion of laser heat treating begun in Heat Treat Today’s Air & Atmosphere 2024 print edition would not be complete without highlighting key sustainability advantages of this new technology. In this Technical Tuesday installment, guest columnist Aravind Jonnalagada (AJ), CTO and co-founder of Synergy Additive Manufacturing LLC, explores how sustainability and energy-efficiency are driven by precision heat application and minimal to zero distortion. The first part, “Advantages of Laser Heat Treatment: Precision, Consistency, and Cost Savings”, appeared on April 2, 2024, in Heat Treat Today, as well as in Heat Treat Today’s January/February 2024 Air & Atmosphere print edition.

This informative piece was first released in Heat Treat Today’s May 2024 Sustainability Heat Treat print edition.

Laser heat treating is a transformative process that promises superior performance and sustainable practices. Laser heat treating epitomizes precision in surface heat treatment techniques, targeting localized heating of steel or cast-iron components. Laser radiation raises the surface temperature of the metal in the range of 1652°F to 2552°F (900°C to 1400°C), inducing a transformation from ferritic to austenitic structure on the metal surface. As the laser beam traverses the material, the bulk of the component self-quenches the heated zone. During this process, carbon particles are deposited in the high temperature lattice structure and cannot diffuse outward because of quick cool down resulting in the formation of hard martensite to a case depth up to 0.080” (2 mm), crucial for enhancing material properties.

Sustainability through Energy Efficiency

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When considering the energy consumption of a typical laser heat treating operation, it’s essential to acknowledge the continuous advancements in laser technology. Modern laser heat treating systems integrate high-power lasers, water chillers, and motion systems, such as robots or CNC machines. With a typical wall plug efficiency of around 50% for diode lasers, these systems represent a significant improvement in energy utilization compared to conventional methods. The typical energy consumption cost for running a 6 kW laser heat treating system is $20-$30/day. The calculation is based on an 8-hour shift with a duty cycle of 80% calculated at national average electric cost of 15.45 cents/kilowatt-hour.

Self-Quenching Mechanism

Laser heat treating operates on the essential principle of self-quenching, leveraging the bulk mass of the material for rapid cooling. This eliminates the dependence on quenchants required in flame and induction heat treating processes, further reducing environmental impact and operational costs.

Precision and Minimal Distortion

At the heart of laser heat treating lies its sustainable and energy-efficient attributes, driven by two fundamental features: precision heat application and minimal to zero distortion of components post-heat treatment. When compared to the conventional methods such as flame and induction hardening, laser heat treatment offers significantly localized heating. This precision allows for targeted heat treatment within millimeter precision right where the hardness is needed, optimizing energy utilization and operational efficiency. Furthermore, the high-power density of lasers enables hardening with minimal to zero distortion, eliminating or reducing the need for subsequent machining operations like hard milling or grinding.

Case Study image; 16 small boxes of auto parts undergoing die machining, laser heat treat; blue inset box
Comparison of the die construction process before and after laser hardening
Source: Autodie LLC

A Case Study of Laser Heat Treating in Automotive Stamping Dies

The image above identifies process steps typically involved in construction of automotive stamping dies. During the process of manufacturing automotive stamping dies, the cast dies are first soft milled, intentionally leaving between 0.015” and 0.020” of extra stock material on the milled surfaces. This is done to account for any distortions that will result from the subsequent conventional heat treatment processes such as flame or induction. After heat treating, the dies are then hard milled back to tolerance and assembled.

In the laser heat treating process, by contrast, dies are finish machined to final tolerance in the first step and then laser heat treated without distortion. No secondary hard milling operation is necessary. Typical cost savings for our automotive tool and die customer exceeds over 20% due to elimination of hard milling operation. Total energy reduction is significant, although not computed here. This may result in savings if carbon credits become monetized.

Laser heat treating’s precision, efficiency, and minimal environmental footprint position it as an environmentally friendly option for heat treat operations. As industries continue to prioritize sustainability, laser heat treating may set new standards for excellence and environmental stewardship.

About the Author:

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

Aravind Jonnalagadda (AJ) is the CTO and co-founder of Synergy Additive Manufacturing LLC. With over 15 years of experience, AJ and Synergy Additive Manufacturing LLC provide high-level laser systems and laser heat treating, specializing in high power laser-based solutions for complex manufacturing challenges related to wear, corrosion, and tool life. Synergy provides laser systems and job shop services for laser heat treating, metal based additive manufacturing, and laser welding.

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

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Green-toned electric socket photo bg w/professional headshot in fg

US DOE Strategy: Ramifications for Heat Treaters

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES, MANUFACTURING HEAT TREAT, OP-ED

As heat treaters strive for a sustainable future, pressure mounts to make the right choices while running commercially viable operations. In this Technical Tuesday installment of a continuing series, guest columnist Michael Mouilleseaux, general manager at Erie Steel, Ltd., explores the potential ramifications of the DOE effort for industrial decarbonization in the heat treating industry. The first installment, “US DOE Strategy Affects Heat Treaters”, appeared on April 10, 2024, in Heat Treat Today, as well as in Heat TreatToday’s March 2024 Aerospace print edition.

This informative piece was first released in Heat Treat Today’s May 2024 Sustainability Heat Treat print edition.

As regulatory agencies set industrial decarbonization goals aimed at achieving net zero greenhouse gas emissions (GHGE) by 2050, heat treaters should prepare for action. But where do heat treatment technologies stand today, and what is the path going forward?  

Background

President Biden’s 2021 executive order calling for a “clean energy economy” led the U.S. Department of Energy (DOE) and the Environmental Protection Agency (EPA) to develop “The Industrial Decarbonization Roadmap,” a strategic plan for reducing industrial emissions. The plan identified five sectors — chemical, petroleum, iron and steel, cement, and food and beverage production — as targets for mitigation efforts. According to “The Roadmap,” process heating operations within these five industries represent the greatest opportunity to apply what were established as four pillar technologies:

  • Energy efficiency
  • Low carbon fuels, feedstocks, and energy sources (LCFFES)
  • Carbon capture, utilization, and storage (CCUS)
  • Industrial electrification using green electricity

In May 2023, heat treating was specifically named as a target process for reducing GHGE during the DOE’s Office of Energy Efficiency & Renewable Energy’s Low Carbon Process Heating Forum.  

A Closer Look at the Technology Pillars

To determine the path forward, it’s important to understand where heat treatment technology stands today regarding the four pillars.

Energy Efficiency: Among energy efficiency opportunities are furnace insulation, controls, and burner design. According to furnace and controls manufacturers that I have spoken with, advancements in insulation and heating system controls offer less than a 20% opportunity in efficiency improvement over

LCFFES: In the U.S., the primary hydrocarbon fuel for heat treating is natural gas, which has an average (commodity) cost of $2.57/MMBTU. Hydrogen has been endorsed as the preferred replacement. Hydrogen manufacturing and distribution issues aside, hydrogen has a 2023 (commodity) cost ranging from $14.00 to $40.00 per MMBTU, and a carbon footprint of 30–130% that of natural gas. “Green hydrogen” is “under development.”

CCUS: Carbon capture, utilization, and storage is currently relegated to natural gas production operations where the captured CO2 is injected into existing wells to “enhance” production. Although the DOE suggests development of advanced CO2 capture technologies are still underway, a 2023 Congressional Budget Office report states there are “fifteen CCS facilities . . . operating in the United States . . . [with] an additional 121 . . . in development.” It is fair to state there are no CCS (carbon capture and storage) facilities currently operating on the scale of a heat treating operation.

Electrification: For electrification to be impactful, electricity must be generated via green sources. Currently, 40% of the electricity generated in the U.S. comes from natural gas, 20% from coal, 19% from nuclear, 10% from wind, and 3% from solar. It is my opinion that, regardless of the incentives federal and state governments offer wind and solar energy operations, they will not reach the scale — and most certainly not the reliability — necessary to achieve the stated 2035 GHGE goals.

Cost also must be considered. The average U.S. cost for electricity was $0.086/KWH in 2023. In California, however, the cost for electricity generated with 40% renewables was $0.1819/KWH. In Germany, it was $0.289/KWH with 55% renewables. To put this into perspective, today the differential in (industrial) electricity (commodity) costs demonstrably increase as the percentage of that electricity is generated by “green” sources. To think that this trend is going to be reversed by federal mandate is paradoxical.  

A Realistic Look at the “Road Map”

While industrial decarbonization targets called for an 85% reduction in GHGE by 2023 and net zero by 2050, the goals seem unreachable using currently available technology. Replacing natural gas with hydrogen will result in significant cost increases as the commodity is 5–15 times more expensive, the equipment will require retrofitting to accommodate hydrogen, and the national infrastructure will need to be modified for hydrogen.

Electrification of existing gas-fired processes will result in a cost increase of four times, according to DOE estimates; however, based on today’s cost trends, 7–9 times higher is more likely. Additionally, the cost of converting equipment to electric operation must be considered. Mitigation efforts suggested by the DOE include improvements in efficiency that rely on yet-to-be-developed technologies and cost reductions in electricity facilitated by the wholesale use of renewable energy.

Overall, decarbonization efforts are noble. The timeframe and methodology, however, are unrealistic as they are based on the use of still-conceptual technologies.  

What Can Heat Treaters Do?

Following the lead of the automotive industry may be key. This sector reacted to the government mandates for GHGE reductions by going all in for electrification — with projections of 50% electric vehicles by 2030. A funny thing happened; these vehicles were not wholly accepted by the American public. The auto industry, led by the dealers, with the support of the UAW, and the car manufacturers petitioned their U.S. Representatives to “pause” these requirements. This political pressure caused the EPA to roll-back the implementation schedule.

Heat treaters must act now with a similar effort, but it must be aimed at preventing the promulgation of regulations that rely on still-conceptual technologies within an unachievable timeframe. Contact your local government leaders; let them know what we do means jobs and tax revenues. Contact your U.S. Representatives and Senators to let them know heat treaters are critical to our national security, the transportation system, and, in fact, the infrastructure of this country. What we do should not be outsourced, and we need to be given all the considerations of a critical industry.

The next column in this series will address the role of process heating in GHGE, analyze DOE assessments of GHGE for industry and process heating operations, and propose a fact sheet intended for use in our effort to set a realistic timeline for decarbonization 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.

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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