OP-ED

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

Click to share your Reader Feedback!

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.

Find Heat Treating Products and Services When You Search on Heat Treat Buyers Guide.com

US DOE Strategy Affects Heat Treaters Read More »

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.

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

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

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.

Click to share your Reader Feedback

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

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

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

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

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

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

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:

Click to share your Reader Feedback
  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

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

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

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

Cybersecurity Desk: Artificial Intelligence and Heat Treating Read More »

Merry Christmas from Heat Treat Today

/ FEATURED NEWS, HEAT TREAT NEWS, OP-ED / Leave a Comment

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!

 

 

Merry Christmas from Heat Treat Today Read More »

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

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

Sustainability Insights: Vacuum Heat Treating in a Carbon-Conscious Market

/ FEATURED NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT TECH, OP-ED, VACUUM FURNACES TECHNICAL CONTENT

Reducing the industrial carbon footprint has been at the forefront of much discussion, heat treat industry-specific or otherwise. How can heat treaters dealing with vacuum operations consider sustainability in a carbon-conscious market? 

This Technical Tuesday Sustainability Insight article was written by Bryan Stern, the product development manager at Gasbarre Thermal Processing Systems, for Heat Treat Today's November 2023 Vacuum Heat Treating print edition.

Bryan Stern
Product development manager
Gasbarre Thermal Processing System
Source: Gasbarre

There is a growing understanding that changes in environmental policy and corporate initiatives will have an increasing impact on the landscape of domestic processing and manufacturing industries in the near future. This is of particular interest to the heat treating industry as thermal processing intrinsically consumes large amounts of energy.

Contact us with your Reader Feedback!

Energy has always been a financial reality for heat treaters, but the impact of transitioning environmental reform will reach beyond monthly utility bills. This is because large players in primary heat treat markets will seek to integrate low-carbon service and equipment suppliers into their direct and indirect supply chains to meet decarbonization objectives.

As a result of this impending trajectory, there has been more attention on furnace design and energy sources within the thermal processing industry. One topic that has received a great deal of focus is the potential benefit of vacuum furnaces as a less emissions-intensive approach to heat treating. Although fundamentally based on electrification, it would be difficult to argue that at least some of the interest in vacuum does not stem from a reactionary desire to distance thermal processing from the image of fire-breathing fossil fuel furnaces given the current political environment.

But beyond the undeniably more marketable aesthetic, the legitimate question remains: Does vacuum heat treating provide tangible environmental advantages over combustion-fired atmosphere alternatives?

Atmosphere integral quench furnace

The soundness of the argument for electrification and vacuum is not as obvious as it might first appear. To start, eliminating on-site combustion does not eliminate CO2 emissions. Electrical utilities still have emissions factors (reported in CO2 equivalent emissions per kWh) that must be accounted for as part of Scope 2 supply emissions. Counterintuitively, the national average emissions factor for electric power is 2.2 times that of natural gas to produce an equivalent amount of thermal energy.1,2 This is primarily due to the inefficiencies associated with generating and transporting electricity versus converting fossil fuels directly to thermal energy on site.

In addition to having higher emissions, electricity is 3.6 times the cost of natural gas for an equivalent amount of energy based on national averages for 2022.3,4

The cost effectiveness of gas fired atmosphere furnaces historically has been the motivator behind their use, unless the process benefitted in some other way from vacuum processing.

If electricity has a greater carbon footprint and is more expensive per unit of energy than fossil fuels, why is the industry transitioning to electrification and increasingly favoring vacuum processing? The answer lies with several factors both internal and external to the equipment itself.

Within the scope of the equipment, gas fired furnaces are intrinsically inefficient. Burners exhaust hot gas which continuously siphons energy away from the process. Although less significant for direct fired burners, this effect is amplified for indirect burners, which are commonly used. Recuperators and regenerators can dramatically improve efficiencies by recycling exhaust to pre-heat combustion air, but additional energy is always required for burner systems beyond what is needed to heat the work and overcome losses through insulation. Electric furnaces, on the other hand, have no such additional demand, and the energy they consume is more directly applied to the process. Although the type of energy used is more financially and environmentally costly per unit, electric vacuum equipment uses that energy more efficiently.

In addition to the demands from the burner exhaust, gas fired furnaces usually depend on a blanketing atmosphere to protect the work from oxidation. Endothermic gas is commonly used for this purpose, and in addition to the heat input required for endothermic gas generation, CO and CO2 are products of the reaction. Although it is an objective of endothermic gas generation to minimize the amount of CO2 present in the furnace, the CO exhausted to the atmosphere eventually reacts to form CO2, leading to a higher effective emissions rate. The use of a vacuum as a protective atmosphere is less carbon-intensive as it relies primarily on the power required to operate the vacuum pumps. This leads to much lower emissions to create the processing atmosphere.

Looking outside of the equipment at the overall manufacturing process, heat treating in vacuum can often eliminate post processing steps required when using other types of equipment. This may come in the form of less oxidation or scale, meaning less part cleanup, or low distortion gas quenching, allowing final machining to be moved forward in the manufacturing process or removed altogether. These potential production cost savings are not new, but the value of eliminating the emissions associated with additional manufacturing steps will only serve to further incentivize vacuum equipment moving forward.

There is one final dynamic outside the scope of the equipment that contributes to the explanation of the industry’s push toward vacuum. The emissions factors associated with electric power generation are decreasing, a trend which is expected to continue. The contribution of renewable energy to the domestic power grid is projected to more than double in the next seven years.5

Single chamber vacuum furnace

Although the contribution from renewable sources is still significantly less than fossil fuels, changes in generation are not the only factors at play. Significant efforts are being made to develop grid-scale energy storage solutions. Although most often associated as a prerequisite for intermittent production from renewables, these storage solutions serve an important function for the existing infrastructure. By storing excess power during low demand and releasing it during peak hours, grid scale energy storage would allow fossil fuel power plants to run at more optimized efficiencies without having to ramp up and down to match demand.

Beyond the process efficiencies of vacuum discussed above, investing in electric fired equipment is the only way to capture the benefits of ongoing improvements to electric supply and generation infrastructure. While the benefits of electrification may currently depend on contextual variables such as geographic location and equipment design, natural gas fired processing has a relatively fixed ceiling for future improvement. As an added advantage of electrification, the carbon accounting reductions from the improvement in emissions factors can be captured passively after the initial investment.

While the above advantages of electrification and vacuum do help explain the industry’s push in that direction, it is worth considering how vacuum equipment will continue to evolve to maximize energy efficiency and reduce emissions. Historically, the majority of vacuum furnaces have been single chamber batch style pieces of equipment. This configuration usually requires that loading and unloading occur at, or near, room temperature to avoid oxidation of sensitive materials. In addition to longer floor-to-floor times, this means that the energy required to heat the furnace is thrown away at the end of each cycle.

The competitive demand for low-carbon solutions will drive the use of multi-chamber batch and continuous style furnaces that allow stored energy to be conserved between cycles. This will be especially true as we see more high-volume manufacturing shift away from traditional continuous atmosphere heat treating. In the past, batch vacuum processing has been too restrictive to both part cost and throughput to be competitive. As emissions concerns gain prominence, vacuum furnace configurations that offer higher energy efficiencies and throughput will begin to close that gap.

The processing and energy advantages of electric vacuum furnaces have positioned them well to meet the low-carbon demands of an increasingly emissions-conscious market. It will be exciting to see how the equipment continues to develop to meet those needs in the future.

References
[1] “Data Explorer: CO₂ total output emission rate (lb/MWh),” United States Environmental Protection Agency, last modified September 26, 2023, https://www.epa.gov/egrid/data-explorer.
[2] “Carbon Dioxide Emissions Coefficients,” U.S. Energy Information Association, released September 7, 2023, https:// www.eia.gov/environment/emissions/co2_vol_mass.php.
[3] “Natural Gas Summary,” U.S. Energy Information Association, released September 29, 2023, https://www.eia.gov/ dnav/ng/ng_sum_lsum_a_EPG0_PCS_DMcf_a.htm.
[4] “Electricity Data Browser,” U.S. Energy Information Association, accessed October 3, 2023, https:// www.eia.gov/electricity/data/browser/#/topic/7?agg=0,1&- geo=g0fvvvvvvvvvo&endsec=6&freq=A&start=2001&end=2022&ctype=linechart&ltype=pin&rtype=s&pin=&rse=0&maptype=0.
[5] “Renewables,” International Energy Agency, last modified July 11, 2023, https://www.iea.org/energy-system/renewables.

About the author:

Bryan Stern is the product development manager at Gasbarre Thermal Processing Systems. He has been involved in the development of vacuum furnace systems for the past 7 years and is passionate about technical education and bringing value to the end-user. Bryan holds a B.S. in Mechanical Engineering from Georgia Institute of Technology and a B.A. in Natural Science from Covenant College. In addition to being a member of ASM, ASME, and a former committee member for NFPA, Bryan is a graduate of the MTI YES program and is proud to have been included in Heat Treat Today's 40 Under 40 Class of 2020.

For more information:
Contact Bryan at bstern@gasbarre.com or IHEA.org.

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

Sustainability Insights: Vacuum Heat Treating in a Carbon-Conscious Market Read More »

¿El paraíso perdido?

/ FEATURED NEWS, OP-ED

En los hermosos días de antaño –entiéndase, en el “paraíso”--,
las habilidades se adquirían con el paso del tiempo mediadas
por un tutor. Pero ¿qué de la actualidad?

Read the Spanish translation of this article in the version below or read the English translation when you click the flag to the right. Both the Spanish and the English versions were originally published in Heat Treat Today's September 2023 People of Heat Treat print edition.

Dan Herring
"The Heat Treat Doctor"
The HERRING GROUP, Inc.

Camino al portal de celestial mansión,
Topé un tratador térmico en terrible
condición
Vagabundo e infeliz, bajo dura
asignación,
–¡Nunca es tarde!– animé en sencilla
afirmación.
— Dan Herring, inspirado por El paraíso perdido,
John Milton, 1667.

Los cuantiosos años trasegados en la industria del tratamiento térmico me han enseñado dos lecciones invaluables. Primero, la nuestra es verdaderamente una ciencia empírica, una ciencia cuyos secretos se dan a conocer en el hacer y (en gran medida) a través de la prueba y el error. En segundo lugar, el sentido común triunfa cuando nada más lo logra; no hay nada que pueda sustituir la experiencia práctica.

Contact us with your reader feedback!

Así las cosas, la pregunta clave a materializar es: ¿de qué manera una persona que ingresa a la fuerza de trabajo en nuestra industria logra adueñarse del conocimiento necesario para convertirse en tratador térmico de talla mundial? El tema es de particular relevancia hoy en día dadas las demandas de rendimiento que pesan sobre los productos, al igual que la naturaleza velozmente evolutiva de la tecnología. (Figura 1)

En los hermosos días de antaño – entiéndase, en el “paraíso”--, las habilidades se adquirían con el paso del tiempo mediadas por un tutor. Las personas de mayor experiencia impartían a los aprendices la sabiduría conseguida fruto del duro esfuerzo, por lo regular en dosis bien medidas según se fueran presentando situaciones que exigieran enseñar una nueva lección o ampliar algún conocimiento. En el taller de tratamiento térmico esta modalidad cae como anillo al dedo.

Figura 1. Eslabones entre pasos críticos de la manufactura de
un producto (Fuente: The HERRING GROUP, Inc.)

Pero ¿qué de la actualidad? La presión hacia la producción que se ejerce sobre la ingeniería y la industria manufacturera ha disparado la demanda de respuestas instantáneas logradas a través de las búsquedas en internet y las investigaciones superficiales. Con frecuencia no hay ni tiempo ni tolerancia para el fracaso.

Uno de mis primeros mentores se lamentaba a menudo de que “la avaricia y la codicia serán el talón de Aquiles de los jóvenes; muy pocos quieren trabajar duro, y aprender cualquier habilidad ¡es duro trabajo!”

No obstante, encontramos muchos individuos jóvenes, esforzados, ávidos de aprender y de gran inteligencia que se vienen incorporando a la actual fuerza de trabajo. Tienden a ubicarse en una de dos categorías –los de excelentes habilidades teóricas que carecen de una experiencia práctica y los de habilidades prácticas que carecen de una comprensión básica de la interrelación entre el equipo, el proceso y el resultado.

El “secreto” del tratamiento térmico radica en controlar la variabilidad relacionada con el proceso y el equipo, pero el terreno de juego nunca permanece estable. Apenas creemos tener el proceso o el equipo bajo control, algo cambia: se presenta un escape, el medio de enfriamiento se deteriora, varía la humedad en el ambiente, y corre la lista sin fin.

¿Cómo, entonces, enseñarle a la próxima generación a enfrentar estos retos? De igual importancia, ¿cómo enseñar de manera tal que logremos retenerlos en nuestra industria? Sin el debido incentivo, motivación y dirección o elegirán un camino más gratificante o se irán en busca de una industria más “glamurosa”.

La clave del éxito en el taller del tratamiento térmico hoy en día es el trabajo en equipo, y la clave para adquirir el conocimiento radica en construir redes de información. Identifica fuentes informativas confiables y enfoca en ellas tu atención. Habla con las personas paraentender no solo lo que han aprendido sino también cómo lo aprendieron. Motiva a otros a compartir lo que saben, y comparte tu propio conocimiento. Saca provecho de los recursos que tengas a la mano, de manera especial lo que te puedan brindar las personas con mayor experiencia o quienes recién sehan retirado de la industria.

No tengas miedo ni de hacer el intento, ni de fracasar. Si fracasas, levántate, sacúdete el polvo, date el espacio de decir –Eso dolió--, y sal de nuevo a fracasar una y otra vez hasta que logres tu cometido.

Por último, piensa antes de actuar y actúa solo después de haber reflexionado tanto en tus acciones como en las consecuencias de las mismas. Nunca dejes de hacerte la pregunta, –¿Por qué no hay tiempo para hacer las cosas bien, pero siempre alcanza para repetir y repetir y repetir? Aquí tienes las claves del éxito y de una carrera gratificante y duradera.

Sobre el autor:

Dan Herring, The Heat Treat Doctor®, es el fundador de The HERRING GROUP, Inc. Más de 50 años en la industria le han sumado una inmensa experiencia en campos como la ciencia de los materiales, la ingeniería, la metalurgia, la investigación de productos nuevos y muchas áreas más. De su autoría existen seis libros y más de 700 artículos técnicos.

Para mayor información:
Contactar a Dan escribiendo a
dherring@heat-treat-doctor.com

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

¿El paraíso perdido? Read More »