OP-ED

Streamline Essential Nadcap Certifications

/ AEROSPACE HEAT TREAT TECHNICAL CONTENT, MANUFACTURING HEAT TREAT, OP-ED

Nadcap certifications are integral to aerospace heat treating. Maintaining compliance, however, can be a headache. Learn how a new technology is streamlining Nadcap certifications.

This article by Chantel Soumis was originally published in Heat Treat Today’s March 2024 Aerospace Heat Treat print edition.

Challenges to Capture Nadcap Certifications

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The Nadcap certification (National Aerospace and Defense Contractors Accreditation Program) plays a critical role in maintaining the integrity of heat treating processes, especially in the aerospace and defense industries. Recognized globally, the certification sets rigorous standards for heat treatment facilities, ensuring that heat treating processes produce parts and materials with the necessary strength, durability, and reliability.

The certification addresses the data that needs to be documented concerning all aspects of the heat treat processing, such as temperature control, process documentation, and quality management. A survey from the Performance Review Institute (PRI) indicates that 80% of aerospace and defense companies consider Nadcap accreditation as a requirement when selecting suppliers, and 90% of aerospace and defense prime contractors would disqualify a supplier without Nadcap accreditation. And when such a strict standard is implemented and then subject to regular audits, a 40% reduction in nonconformance costs are likely, as was reported by companies in the aerospace and defense sector in a study by the National Center for Manufacturing Sciences (NCMS).

While compliance with Nadcap and other heat treat certifications demonstrates a commitment to quality and opens doors to lucrative contracts with aerospace, defense, and other precision industries, actually capturing the data can be tedious. The effort and cost of employing disconnected systems — capturing measured data from system A, making the certification documents in system B, and then emailing the certification results to clients from system C — can be cut by synthesizing these actions into one system.

Digitizing Certification Management for Complete Compliance Control

Many organizations facilitate the certification process via digital means. This may be through the use of digital quality management systems (QMS) or enterprise resource planning (ERP) software that includes modules designed for certification management. These tools help automate record keeping, provide alerts for upcoming certification renewals, and streamline the overall certification tracking process, ensuring that heat treating operations remain compliant and efficient.

Nadcap Scanner tracking a process via QR code

But more should be done.

Veterans Metal, a metal finishing plant in Clearwater, Florida, was driving manual processes: everything was written down and data was being entered into spreadsheets for tracking purposes. Like many heat treaters, each step the company took to process a part required manual intervention to write down 20+ line items of information and then incorporate the associated data entry into spreadsheets.

The company was looking to modernize their plant.

After careful evaluation of Veterans Metal’s processes and needs, Steelhead Technologies developed and deployed the Steelhead Certification Scanner (or Nadcap Scanner) line that includes a handheld scanner and a system of QR codes to facilitate an easier user experience, including an interface that allows for swift operator proficiency, typically within minutes. This digital interface allows users to measure data, create certifications, and email this from the one system.

Smart Scanning in Action

The metal processing company received a 15-minute walk-through of the Nadcap Scanner, how to process parts, and where to find the data within the system. Using the handheld device, operators scanned QR codes (specifically created by Steelhead Technologies) that were placed on processing stations. As parts were moved from one process station to the next manually, a user would scan the accompanying QR code on the next current station, locking in data from the previous process and automatically reflecting that the next step was in process.

When operators scanned a process station, the device showed the remaining time in the process and displayed all parts being processed, custom instructions, and key data collection, such as oven temperature. This timer automatically starts when a process station QR code is scanned, gives a one minute warning when the process is nearing completion, and stops automatically when the next process station QR code is scanned.

Chet Halonen, a plant optimization expert for Steelhead Technologies, presented the “Powered by Steelhead” certification to the Veterans Metal team.

With the intuitive layout and guided steps, operators were easily able to navigate the accreditation process, significantly reducing time spent on extensive training. More importantly, the Nadcap Scanner line eliminated handwritten data entry, margin of error, and additional time needed to develop certifications since the scanner automatically generates them from the data and sends them to clients. The scanner has since been adopted by many other Nadcap-compliant operations across the United States.

Take Nadcap Digital

Achieving Nadcap accreditation is crucial for showcasing a commitment to quality, aligning with industry benchmarks, and accessing lucrative business opportunities. With the advent of digitized solutions like the Nadcap Scanner implemented within a comprehensive manufacturing ERP, companies will streamline the accreditation process, enhance operational efficiency, and bolster compliance with a system that’s “literally just button clicking,” as one manufacturer observed.

Embracing innovative tools not only saves time and resources, but also strengthens market positioning and client relationships. By merging the prestige of Nadcap accreditation with digital advancements, heat treaters can elevate their operations to reach new heights of excellence.

About the Author

Chantel Soumis, Head of Marketing, Steelhead Technologies

Chantel Soumis is serving as the head of Marketing at Steelhead Technologies. With a robust background in manufacturing technology and strategic partnerships, she leverages over 15 years of experience to shape the company’s marketing landscape.

For more information: Contact Chantel at chantel@gosteelhead.com.

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CUI Considerations for the Heat Treating Industry

/ 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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US DOE Strategy Affects Heat Treaters

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

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

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

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

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

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

Key Benefits of Laser Heat Treating

Consistent Hardness Depth

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

Minimal to Zero Distortion

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

Precise Application of Beam Energy

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

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

No Hard Milling or Grinding Required

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

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

Applicable for a Large Variety of Materials

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

Conclusions

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

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

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

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

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

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

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

Reduce

Michael Stowe
PE, Senior Energy Engineer
Advanced Energy

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

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

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

Reuse

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

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

Refuel

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

Redesign

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

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

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

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Heat Treating AM Parts — Need To Know Difficulties and Solutions for Engineers

/ FEATURED NEWS, MANUFACTURING HEAT TREAT, OP-ED, SINTERING POWDER METAL NEWS
op-ed

Metal 3D additive manufacturing has grown dramatically in the last five years. Nearly every metal printed part needs to be heat treated, but this presents some challenges. This article will address some of the challenges that a heat treater faces when working with these parts.

This Technical Tuesday article, written by Mark DeBruin, metallurgical engineer and CTO of Skuld LLC, was originally published in December 2023’s Medical and Energy magazine.

Mark DeBruin Metallurgical Engineer and CTO Skuld LLC

In my experience, on average, about 10% of all 3D metal printed parts break during heat treatment; this number varies depending on the printer and the unique facility. While materials can be printed with wire or even metal foils, I’m going to mainly focus on the approximately 85% of all metal 3D printed parts that are made from metal powder and either welded or sintered together.

Most metal printed parts normally have heat added to them after printing. In addition to the heat of the printing process and wire electrical discharge machining (EDM) process to separate the part from the build plate, heat may be added up to five times. These steps are:

  1. Burnout and sintering (for some processes such as binder jet and bound powder extrusion)
  2. Stress relieving
  3. Hot isostatic pressing (HIP)
  4. Austenitizing (and quenching)
  5. Tempering

3D printing can create a non-uniform microstructure, but it will also give properties the client does not normally desire.
Heat treating makes the microstructure more uniform and can improve the properties. Please note that heat treating 3D printed parts will never cause the microstructure to match a heat treated wrought or cast microstructure. The microstructure after heat treating depends on the starting point, which is fundamentally different.

If the part is not properly sintered, there is a high chance it will break during heat treatment. It may also exhaust gases, which can damage the heat treat furnace. The off gases will recondense on the furnace walls causing the furnace to malfunction and to need repair. This can potentially cost hundreds of thousands of dollars.

During powder 3D printing, there is a wide variety of defects that can occur. These include oxide inclusions, voids, unbonded powder, or even cracks that occur due to the high stresses during printing. Even if there are not actual defects, the printing process tends to leave a highly stressed structure. All of these factors contribute to causing a print to break as the inconsistent material may have erratic properties.

In a vacuum furnace, voids can be internal and have entrapped gas. Under a vacuum, these can break. Even if something was HIP processed, the pores can open up and break. Even if they do not break and heat is applied, the metal will heat at different rates due to the entrapped gas.

Figure 1. Macroscopic view of a 3D printed surface (left) compared to machined surface (right) (Source: Skuld LLC)

There are also issues during quenching due to the differences in the surface finish. In machining, the surface is removed so there are not stress concentrators. In 3D printing, there are sharp, internal crevices that can be inherent to the process that act as natural stress risers (see Figure 1). These can also cause cracking.

When 3D printed parts break, they may just crack. This can result in oil leaking into the parts, leading to problems in subsequent steps.

Figure 2. Example wire mesh basket (Source: Skuld LLC)

However, some parts will violently shatter. This can happen when pulling a vacuum, during ramping, or during quenching. This can also cause massive damage to the furnace or heating elements. It can potentially also injure heat treat operators.

A lot of heat treaters protect their equipment by putting the parts into a wire mesh backet (Figure 2). This protects the equipment if a piece breaks apart in the furnace, and if a piece breaks in the oil, it can be found.

Print defects in metal 3D printed parts can be a challenge to a heat treater. Clients often place blame on the heat treater when parts are damaged, even though cracking or shattering is due to problems already present in the materials as they had arrived at the heat treater. As a final piece of advice, heat treaters should use contract terms that limit their risks in these situations as well as to proactively protect their equipment and personnel.

About The Author

Mark DeBruin is a metallurgical engineer currently working as the chief technical officer at Skuld LLC. Mark has started five foundries and has worked at numerous heat treat locations in multiple countries, including being the prior CTO of Thermal Process Holdings, plant manager at Delta H
Technologies, and general manager at SST Foundry Vietnam.

For more information:
Contact Mark at mdebruin@skuldllc.com

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Sustainability Insights: How Can We Work to Get the Carbon Out of Heating? Part 1

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

The search for sustainable solutions in the heat treat industry is at the forefront of research for industry experts. Michael Stowe, PR, senior energy engineer at Advanced Energy, one such expert, offers some fuel for thought on the subject of how heat treaters can reduce their carbon emissions.

This Sustainability Insights article was first published in Heat Treat Today’s December 2023 Heat Treat Medical and Energy print magazine.

Michael Stowe
PE, Senior Energy Engineer
Advanced Energy

The question in the article title is becoming increasingly popular with industrial organizations. Understanding the carbon content of products is becoming more of a “have to” item, especially for organizations that are in the supply chain for industrial assembly plants such as in the automotive industry. Many heat treaters are key steps in the supply chain process, and their carbon footprints will be of more interest to upstream users of heat treated parts in the future. I know I am overstating the obvious here, but I am going to do it anyway for emphasis:

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  1. Heat treating requires HEAT.
  2. HEAT requires ENERGY consumption.
  3. ENERGY consumption creates a carbon footprint:
    a. Fossil fuels heating — direct carbon emissions (Scope 1)
    b. Electric heating — indirect carbon emissions (Scope 2)

Therefore, by definition and by process, if you are heat treating, then you are producing carbon emissions. Again, the question is, “How can we work to get the carbon out of heating?” Let us explore this.

Figure 1. Methane combustion (Source: Advanced Energy)

Once more, heat treating requires energy input. The energy sources for heat treating most frequently include the combustion of carbon-based fossil fuels such as natural gas (methane), propane, fuel oil, diesel, or coal. Also, most combustion processes have a component of electricity to operate combustion air supply blowers, exhaust blowers, circulation fans, conveyors, and other items.

Figure 1 shows the chemical process for the combustion of methane (i.e., natural gas). Figure 1 demonstrates that during combustion, methane (CH4) combines with oxygen (O₂) to form carbon dioxide (CO₂) and water (H₂O). This same process is true for any carbon-based fuel. If you try to imagine all the combustion in progress across the globe at any given time, and knowing that all this combustion is releasing CO₂, then it is easy to see the problem and the need for CO₂ emission reductions.

In the most basic terms, if you have a combustion-based heat treating process on your site, then you are emitting CO₂. The electricity consumed to support the combustion processes also has a carbon component, and the consumption of this electricity contributes to a site’s carbon footprint.

Figure 2. The 4 Rs of carbon footprint (Source: Advanced Energy)

So, combustion and electricity consumption on your site contributes to your carbon footprint. Knowing this, organizations may want to consider the level of their carbon footprint and explore ways to reduce it. There are many methods and resources available to help organizations understand and work to improve their carbon footprint. For this article, we will focus on the 4 Rs of carbon footprint
reduction (see Figure 2).

We will discuss each of these approaches individually in priority order in the next installment of the Sustainability Insights.

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

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Cybersecurity Desk: Artificial Intelligence and Heat Treating

/ CYBERSECURITY, FEATURED NEWS, MANUFACTURING HEAT TREAT NEWS, OP-ED / Leave a Comment
op-ed

Artificial intelligence remains a hot topic for every industry, not least heat treating. Understanding the how and why of AI’s potential impacts on the industry, however, is not so easily apparent.

Today’s article, written by Joe Coleman, cybersecurity officer at Bluestreak Consulting, breaks down the pros and cons of implementing AI, to help you decide if artificial intelligence might be a beneficial addition to your heat treat operations.

This article was originally published in Heat Treat Today’s December 2023’s Medical and Energy Heat Treat magazine, and can be read in fullness here.

Introduction

Joe Coleman, cyber security officer, Bluestreak Consulting

As all of you are aware, artificial intelligence (AI) is getting more and more attention, and companies are beginning to use AI to help with many aspects of running their businesses. I’m sure you’ve heard of ChatGPT and other intelligent user interfaces (IUI). You may be one of those businesses considering the idea or experimenting with it to access its potential benefits for your business.

Like any industry, there are quite a few pros and cons associated with using AI to improve the heat treating processes. This article will outline some of these advantages and disadvantages. Always make sure you do your own research before jumping into the AI world because it’s not always what it seems.

What Is Artificial Intelligence (AI)?

Artificial Intelligence is the simulation of human intelligence in machines that are programmed to think and learn like humans. It includes a wide range of techniques and approaches, including machine learning, allowing computers to perform tasks that typically require human intelligence, such as understanding natural language, recognizing patterns, solving problems, and making decisions. AI systems are designed to learn from data, improving their performance over time without direct programming. These technologies find applications in many areas, from virtual assistants and language translation services to autonomous vehicles and industrial diagnostics, revolutionizing industries and helping to shape the future of technology

Pros of AI in Heat Treating

Quality Improvement:

  • AI systems can monitor and help control the heat treatment process in real time, ensuring you have consistent quality and to minimize defects.
  • Predictive analytics in AI can anticipate potential defects, allowing for corrective actions before they occur.

Increased Efficiency:

  • AI algorithms can optimize processing parameters and reduce bottlenecks, leading to faster and more efficient heat treating processes.
  • AI-driven automation can improve employee labor throughput and increase overall production speed.

Cost Reduction:

  • By optimizing utilities usage and resources, AI can help reduce the plethora of operational costs within heat treating facilities.
  • Predictive maintenance generated by AI can prevent costly equipment breakdowns and production downtime.

Customization and Personalization:

  • AI algorithms can analyze customer requirements and tailor heat treating processes to their specific needs.
  • Improved data analysis can lead to the development of new and specialized heat treatments for different metals and alloys.

Data Analysis and Information:

  • AI systems can process enormous amounts of data generated during heat treatment, collecting valuable information that can be used for process improvements and better-quality management.
  • Pattern recognition and statistical process control (SPC) analysis by AI can identify trends and correlations that could normally be overlooked.
Click image to download a list of cybersecurity acronyms and definitions.

Cons of AI in Heat Treating

Initial Investment:

  • Implementing an AI system requires a significant initial investment in the technology, training, and infrastructure, which may be a showstopper for smaller businesses.

Dependency on Technology:

  • Dependencies on AI systems can be a problem if there are technical glitches or breakdowns, disrupting the entire heat treating process.

Data Security and Privacy:

  • AI systems rely heavily on data. Ensuring the security and privacy of sensitive data is critical, especially when dealing with Controlled Unclassified Information (CUI), your proprietary heat treating processes, and sensitive customer information.

Ethical Concerns:

  • AI decision-making processes raise ethical questions, especially if the technology is used in critical applications, ensuring fairness, transparency, and accountability in AI decision-making is essential.

Skilled Workers Replaced:

  • Automation using AI might reduce the need for certain manual tasks, potentially leading to skilled workers losing their jobs without the necessary skills to operate or maintain AI systems.

Here’s the bottom line: You should always do your own research to see if AI is a good fit for your business. AI is not always better. There are upsides of using it, and there are definitely downsides to using it. You can’t always trust AI to give you the best information, so always make sure you confirm the information it is giving you through V&V (verification and validation).

At the Metal Treating Institute’s (MTI) national fall meeting, held October 9–11 in Tucson, AZ, Jay Owen gave an excellent presentation entitled, “Artificial Intelligence: Be Afraid or Be Excited.” Contact MTI by visiting www.heattreat.net.

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

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Merry Christmas from Heat Treat Today

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We will be celebrating the holidays with family, and our offices will be closed from December 22 to January 1. Look for your next Heat Treat Daily e-newsletter on January 2nd!

2023 has been a year of many new things, and we are thankful to have seen many of you in-person. The heat treat community is one that is warm (pun intended) and vibrant.

We are looking to 2024 with much anticipation and hope for even 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!

 

 

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Don’t Be the Next Ransomware Victim: How To Detect, Protect, and Recover

/ CYBERSECURITY, FEATURED NEWS, MANUFACTURING HEAT TREAT, OP-ED
op-ed

Ransomware is a threat to all industries, and heat treating is no exception! This article is here to give heat treaters the "how-to" of responding to ransomware, to help keep operations safe and running smoothly. 

Today's read is a feature written by Joe Coleman, cybersecurity officer at Bluestreak Consulting™. This column was first released in Heat Treat Today's November 2023 Vacuum Heat Treat print edition.

Introduction

Joe Coleman
Cybersecurity Officer
Bluestreak Consulting™
Source: Bluestreak Consulting™

Today, the threat of being infected with ransomware is everywhere. Ransomware attacks have grown increasingly sophisticated and widespread, leading to substantial financial harm, emotional distress, and damaged reputation to those unfortunate enough to become victims.

In this article, we’ll cover ransomware — describing what it is, how it works, and most importantly, how you can protect yourself from becoming its next target. Equip yourself with the knowledge and proactive strategies required to protect your digital assets, data, and systems.

What Is Ransomware?

Ransomware is a cyber threat that wreaks havoc on businesses by encrypting computer files and extorting a ransom from victims for their release. Once your system falls victim to this malicious software, it can spread to connected devices, such as shared storage drives and other network-accessible computers. Even if you comply to the ransom demand, there’s no guarantee of full data recovery, because cybercriminals may withhold decryption keys, demand additional payments, or even delete your data. It’s important to note that the federal government strongly discourages paying ransomware demands, as it fuels criminal activity.

Click on the Image for a full list of Cybersecurity Acronyms

What Can I Do To Prevent Ransomware Attacks?

Frequent and Routine Backups: Perform regular backups of your system and essential files, and consistently verify their integrity. In the case that your computer or system is infected with ransomware, you can restore them to a previous state using these backups.

Keep Software Updated: Ensure that your applications and operating systems are up to date with the latest software/security patches. Most ransomware attacks target vulnerabilities in outdated software.

Secure Backup Storage: The best practice is to store your backups on a separate device that is not connected to the network, such  as an external hard drive. Even better, consider storing your backups offsite at a different location. After completing the backup, disconnect the external hard drive or isolate the device from the network or computer.

Exercise Caution with Links: Exercise caution when dealing with links and entering website addresses. Be especially vigilant when clicking on links in emails, even if they appear to be from familiar senders. It’s advisable to independently verify website addresses. You can do this by reaching out to your organization’s helpdesk, searching the internet for the sender’s organization website, or researching the topic mentioned in the email. Pay close attention to both directly clicking the link to and manually entering the address of a website, as malicious sites often mimic legitimate ones with slight spelling variations or different domains (e.g., .com instead of .net).

Cybersecurity Awareness Training: Businesses should prioritize providing cybersecurity awareness training to their personnel. Ideally, organizations should conduct regular, mandatory cybersecurity awareness training sessions to ensure their staff stay well informed about current cybersecurity threats and techniques employed by threat actors. These training sessions should occur at least once a year. Additionally, organizations can enhance workforce awareness by testing their personnel with phishing simulations that replicate real-world phishing emails, as well as different types of face-to-face social engineering to try to get usernames/ passwords.

Responding To a Ransomware Attack

Isolate the Infected System: Disconnect the infected system immediately from the network to prevent the spread of the infection.

Identify Affected Data: Determine what data have been affected. Sensitive data, such as customer’s electronic CUI (controlled unclassified information), may require additional reporting and mitigation measures.

Check for a Decryption Key: Explore on the internet to see if a decryption key is available. Online resources like www.nomoreransom.org can be helpful.

Restore from Backups: Restore your files from regularly maintained backups.

Report the Incident: Report ransomware incidents. Consider reporting to your local Federal Bureau of Investigation (FBI) field offices or the Internet Crime Complaint Center (IC3) at www.ic3.gov.

Do Not Pay The Ransom: Emphasize the importance of not paying the ransom as it can encourage additional criminal activity.

About the Author:

Joe Coleman is the cybersecurity officer at Bluestreak Consulting™, 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. 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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