VACUUM FURNACES

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Heat Treat Radio #110: Isolated Heat, the Future of Vacuum Furnaces

Heat Treat Radio host, Doug Glenn, and guest Bryan Stern from Gasbarre Thermal Processing Systems discuss the shift from single chamber batch furnaces to isolated heat vacuum furnaces. They explore the benefits and challenges of isolated heat systems, including temperature control, cycle times, and cost effectiveness for handling various parts. 

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




The following transcript has been edited for your reading enjoyment.

Introduction to Isolated Heat Vacuum Furnaces (00:01:30)

Doug Glenn: We want to talk about something that Gasbarre is calling isolated heat furnaces. In this case, these are vacuum furnaces. What’s an isolated heat vacuum furnace? And why is it called “isolated heat?”

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Bryan Stern: To start off, this isn’t something that’s Gasbarre specific. This is a generic distinction and concept with furnaces. It’s been around for a while, but the primary difference with an isolated heat furnace is that the heat chamber in that furnace stays at temperature, in between processing and throughout the process, and it’s held under vacuum during that time as well.

Doug Glenn: Gotcha. We’re going to talk primarily about vacuum furnaces — though, I know that’s also possible in an atmosphere — and the typical vacuum furnace today is the single-chamber vacuum furnace. Maybe it’s obvious already, but can you explain the differences between the isolated heat and a typical single chamber?

Bryan Stern: The single-chamber, batch processing furnace is by far and away the most prevalent technology that’s used. And the difference is that everything in that process is going to happen in a sequential order — everything from loading, evacuating the chamber, ramping everything (the chamber and the work) up to temperature, holding it, doing whatever process you have, cooling it back down, backfilling it, and then unloading it. It’s all a sequential operation. You close the door, the work sits in the same place, and you run through the entire process.

gray vacuum oil quench furnace from Gasbarre
Gasbarre’s Vacuum Oil Quench Furnace, with isolated graphite heating chamber, includes 2 BAR gas quench capabilities.
Source: Gasbarre Thermal Processing Systems

Whereas, with the isolated heat, it remains at temperature. That requires three primary additional components in addition to your single-chamber batch. It requires an extra chamber, for evacuating because you’re going to need an antechamber or a way to load that work in after having pumped it down. So, by default you need a second chamber. You need some kind of dynamic sealing door between the two chambers that you can open once your evacuation chamber is pumped down; and you need some means of moving the work between those two chambers.

These are the fundamental differences. But where it gets interesting is the impact it has on the rest of operations and efficiency.

Doug Glenn: The single chamber has dominated the market for a long time. How have those single-chamber furnaces really affected the design of vacuum furnaces? And are there some significant design differences in these isolated heat furnaces?

Bryan Stern: Yeah. It’s kind of funny, but anyone who’s familiar with single-chamber batch furnaces recognizes there are a lot of challenges to doing vacuum processing that way.A simple way to look at it is if you were trying to cook pizzas in an oven: But if you had to start with the oven cold, open the door, put the pizza in, and then you can’t touch it until the whole thing goes through its process; you heat up the oven and then wait till it cools down at the end and pull it out. It wouldn’t be an ideal approach.

A simple way to look at it is if you were trying to cook pizzas in an oven: But if you had to start with the oven cold, open the door, put the pizza in, and then you can’t touch it until the whole thing goes through its process; you heat up the oven and then wait till it cools down at the end and pull it out. It wouldn’t be an ideal approach.

Bryan Stern, Gasbarre

That’s the distinction with the vacuum portion of it specifically. For a lot of single-chamber batch equipment, you have to pump it down and wait to preheat the oven. That adds a lot of time. So, the then it makes vacuum processing more expensive, and it’s harder to scale. People know there is inconvenience around vacuum processing in general. And the answer to that has typically been to increase workload sizes because if you’re going to have dead time at the front, you’d rather distribute that cost over a thousand parts instead of a hundred parts.

You want to increase the throughput so you’re not waiting for a bunch of little batches and paying for all that dead time with a few parts.

Equipment Challenges with Single Chamber (00:06:32)

Bryan Stern: There’s been a general trend to just increase load sizes, and I am generalizing. It’s not necessary for everything. But you get into some massive single-chamber batch furnaces that are often larger than necessary for the parts. And, unfortunately, those load sizes are kind of detrimental to a lot of the objectives of heat treating.

You have a much more difficult time maintaining uniformity for both process temperature and gas for the parts while you’re heating up and cooling down. And you’re going to have a much higher deviation between the temperature at the center of the load and the surface of the load, as well as process gas concentrations.

That trend toward larger load sizes than necessary (because of the inherent challenges of the single-chamber batch method) leads to other challenges that you then have to overcome. It takes longer to soak out, and quite often (something that I’m sure a lot of people will be familiar with) you end up leaving gaps in the work zone anyway — spaces between parts to allow gas circulation to achieve quench rates enabling you to cool faster because you’re not getting enough gas to the center of the load. Since you have these massive loads, you’ve moved in a direction that’s not really helping anything that you’re trying to do. And that’s a bus that we’ve all been on.

Doug Glenn: So, you’ve got uniformity issues inside the load. And that’s an interesting perspective. The process takes so long inside that one chamber, it tends to increase the size of the load so that you’re doing more at once.

How about the efficiency of the process? If you’ve got a chamber that is designed just for isolated heat, and you’re just heating in that chamber, I would assume that chamber can be designed differently than a chamber in which you’re going to do preheat convective.

Bryan Stern: Absolutely. There are of trying to do everything in one space. I think the equipment challenges come from exactly what you’re talking about — trying to heat and cool in the same space. Anyone who’s been remotely involved in the production of single-chamber batch equipment knows that you’re doing a bunch of things that are in tension with one another. To start, if you’re trying to cool in the same space, very often you’re putting nozzle penetrations all through your insulation pack.

Right away you’ve shot your thermal efficiency in the foot because you have direct radiation out of those nozzles. And people have tried with marginal success to come up with ways of sealing off those nozzles during the heating section and opening them during cooling. Some tried more static approaches, some active changes to the furnace.

But the other issue is that you’re hurting the cooling, too, because you’re restricting your gas flow. You’re heating up the gas that you’re trying to cool with by flowing it through this hot insulation pack. Your parts are sitting inside that heat cage. They’re radiating to a hot surface. Another thing worth pointing out is that often with a single-chamber batch, because you have such a limited time to pump down and you’re trying to decrease your cycle time as much as possible, the installation’s reduced just to help with vacuum levels.

Again, if you’re holding that under vacuum and you can allow it to outgas and decay, now you can have a much thicker insulation pack. You’re not putting penetrations through it. So, it’s helping your thermal efficiency in multiple ways. For example, it’s helping your cooling. When you’re struggling to get those cooling rates, you’re going to do things like bump up gas pressure. Since you’re consuming more processed gas, you’ll put a bigger motor in it — which not only costs more upfront, but it also costs more to run.

That’s a fun fact about especially high horsepower, single-chamber batch equipment: Very often the current rating for the entire system can be driven by the gas blower alone. It’s more than all the rest of the power supply, so they’re not cheap to run.

I’m not saying that you get away with half the size motor, but intuitively you know you’re requiring more than you would need if you placed that load in a dedicated cooling space, no response to gas flow radiating to a water cool jacket. So, it’s a pretty intuitive observation about the way we’re currently approaching this.

Doug Glenn: I don’t think people have thought about it because that has not been the typical way of doing it. It’s almost all single chamber.

Bryan Stern: We’re locked in there.

Doug Glenn: But when you do start thinking about it, it makes a lot of sense that your efficiencies would improve — design and operational efficiencies. All those things would improve because you’ve got dedicated chambers.

Bryan Stern: Another thing with regard to efficiency is your size and your power supply to overcome all those losses, the decreased insulation. When you move to dedicated positions, you know in your position that ramping your power supply can be sized for it. And people have worked to overcome that with typical power supply sizing by doing things like adding multiple taps on the secondary side of the transformer to try to get a better power factor. But if you’re dedicating stations within your equipment, then you can right-size your power supply.

Two men (Doug Glenn, Bryan Stern) talking, HTR banner on top
Bryan Stern: “When you move to dedicated positions, you know in your position that ramping your power supply can be sized for it. And people have worked to overcome that with typical power supply sizing by doing things like adding multiple taps on the secondary side of the transformer to try to get a better power factor. But if you’re dedicating stations within your equipment, then you can right-size your power supply.”

Recent Developments (00:13:21)

Doug Glenn: That brings me to a question about the single-chamber vacuum furnaces that have typically been used. To my knowledge, there are not a lot of isolated heat furnaces or dedicated chamber vacuum furnaces out there, although, I know that one of the companies you guys acquired years ago made their name there. But have there been any developments in recent years that have led to more popularity for, or the possibility of doing, isolated heat vacuum furnaces?

Bryan Stern: Yeah, it’s a great question. It’s something that I’ve done a lot of thinking about because we tend to have a mentality with technology that if it was such a great idea, people would be doing it. So, why aren’t more people doing this?

We can learn a lot from looking at another industry. Specifically, the prevalence and immersion of some of the emissions regulations that are coming along is newer to our industry. I think we’ve been able to get away with doing things in a way that might be really inefficient for a while. But it’s not new in some other industries.

There is a great example that I love because it has so many analogies for what we’re looking at in vacuum heat treating specifically: If you look at the history of the adoption of fuel injection in the automobile industry — I’ve always assumed that fuel injection was adopted as soon as it came along because it was a better technology, and it had been around since the 1920s and 30s.

It was developed and used in some military applications, and right away it was hailed as a better technology. It was more efficient, it was cleaner, but people just didn’t want to change. That wasn’t the direction that everyone was moving in. There were some manufacturers that tried. There were some mass-produced vehicles that had fuel injection in the early 1950s, but it still wasn’t taking off.

And then in 1970 the pushed manufacturers specifically to start adapting it more. But it wasn’t welcome. Some supporting technologies needed to be developed better, especially with computers controlling those systems. As reliability increased for those throughout the ‘80s, there were some amendments to the Clean Air Act from 1970. Then it really started to hit the market and be adopted. And what finally sent it is that consumers started to experience the benefits.

Now we don’t even think twice about it. It’s the de facto standard. You’re not going to go find a car dealership in your area that has their specialty line of carbureted vehicles. There are still places they’re used, but the advantages of fuel injection are so great because you’ve got dramatically improved fuel efficiency and much longer engine life. People say cars last way longer than they used to. And it’s because this new technology that had been around for almost a century, by the early 2000s, had been sitting around, and people hadn’t experienced the advantages of it.

One of the things that I love about that analogy is that it also demonstrates this isn’t a complete switch. It’s a gradual change, and there’s still a place for the old technology. It doesn’t mean that isolated are going to completely replace single-chamber batch vacuums. But if you look at the places carbureted engines are still used, you’ll find them on a racetrack or in lawn equipment.

So, in these places where the upfront cost is really important and you’re not getting enough operating time on it, the improved efficiency is not going to pay off if you were to pay up-front since you’re not using it enough. That carries over well to some of the single-chamber batch vacuums because they will always be around, and they’re going to be more preferred for intermittent use applications where the runtime is not as long.

Doug Glenn: That’s an interesting perspective. Have any of the technologies developed recently — like transfer mechanisms, control systems, or anything of that sort? Is there anything substantially new that had to take place before you could get isolated heat furnaces, or have most of those technologies, similar to the fuel injection, been around for a long time?

Bryan Stern: I think they’ve been around like that analogous technology adoption. There’s certainly going to be a refinement of some technologies to be robust for it to work.

screenshot of smiling bearded man with 40U40 profile
Click on the link to read more about Bryan Stern in his Heat Treat Today 40Under40 profile.

There are some good solutions out there. There are some bad solutions out there. And I think the higher possibility of getting into a bad solution with a less mature product is one of those obstacles people are facing. Things don’t change when forces are in equilibrium. So, the fact that we’re not changing as an industry to adopt some of this stuff just means that the forces motivating that change have not overcome the obstacles. There are definitely some obstacles to it.

And I’m sure we’ll get into talking about those some, but we have that nudge from regulation that’s happening. We’ll see, and continue to see, this type of product mature and those dynamic sealing mechanisms and transfer systems. And I think what’s really going to send it is that there are a lot of benefits that address a lot of problems that we’re all familiar with. It’s just not the de facto standard.

There are ways that the industry is organized around the methods that we use currently. A great example of that is the pizza example where you look at the back of the box of pizza, and you’ve got a recipe that says to preheat the oven and then pop it in for 15 minutes. If you can’t do that anymore, and you have to put the pizza in while the oven is cold and let it ramp up, now you have to change the recipe. And that’s the way we’re organized right now. We’re organized with processes for material that’s starting cold. It’s actually a harder way to do things, because the way that different equipment ramps up is harder to control. So, it’s not necessarily a better recipe, but it’s what we have.

The vacuum level specifications are another big impact. In single-chamber batch equipment, you’re exposing it to atmosphere every cycle, and you’ve got to pump it down quickly. So even when you pump it to very low vacuum levels, what’s left is still often oxidizing constituents.

If you can hold it at vacuum (even though it’s not getting to the same ultra-low pressures), and if it’s allowed to absorb from the surfaces and outgassing from materials (even at a higher pressure), you can have a pure environment. And that’s really counterintuitive. It’s not built into equipment specs because people associate the vacuum level with purity, and it’s really more about dew point and the constituents of what’s in the gas. You can have just as pure an environment with much higher pressure. And again, we’re just not organized around that right now.

Continuous and Non-Continuous Systems (00:21:56)

Doug Glenn: Let me restate something you said earlier and tell me if I’m accurate on it. You were saying that because of the single-chamber vacuum furnaces, we tend to increase the load sizes. So, I’m assuming the load size of the isolated heat furnaces could be significantly smaller and, therefore, have better uniformity within the load, both in the heat up and the quench. Is that an inherent advantage of the isolated heat?

Bryan Stern: It’s not specific to all isolated heat equipment. We’d have to get into discussing the fact that you can’t have continuous and non-continuous isolated heat systems. And it’s an important distinction. The distinction being that you have your heat chamber, you’re keeping it at temperature in a multi-chamber batch system, which is still a form of isolated heat equipment. You’re going to be moving your work in and out the same direction.

So, you’ll get a lot of the advantages that we’ve talked about. You’re able to have dedicated design for heating and cooling. You’ll have your thermal efficiency. There are a couple things you’re not going to get. You’re not going to be able to increase the throughput. Whereas, if you move to a continuous furnace where you’re moving that work in, and then you’re moving it to the other side . . . We can keep working with the pizza analogy: If you need more pizzas, and it takes 15 minutes for a pizza, you can move it through three stations for five minutes per station. Now, you’re getting a pizza every five minutes instead of every 15 minutes, right? If you’re able to do that and produce loads faster, then you can decrease the load size. And then you’re going to see all the benefits of decreasing that load size — improved uniformity, faster times, and better cooling.

red lettering and green lettering to the right of a red flame with green arrows circling it
Click on the image to read “Vacuum Heat Treating in a Carbon-Conscious Market” by Bryan Stern, in Heat Treat Today’s November 2023 Sustainability issue.

But you only get that if you go to continuous. With that specific type of isolated heat equipment, versus just any isolated heat equipment, you’ll get much better thermal efficiencies because in the multi-chamber batch setup you’re not heating and cooling the furnace every time and throwing that energy away. But because you’re loading and unloading on the same size, you’re still going to leave that heat chamber unoccupied, sitting and holding its temperature, consuming energy in between loads. With continuous furnaces, you’re not going to do that. You’re never going to throw all that energy away. There’s minimal holding power required. So, there is a distinction between the continuous and non-continuous isolated.

Doug Glenn: How would it work with a non-continuous isolated heat furnace? If the process required you to preheat, heat, and quench, what is it you’re going to use? Transfer cars? How does that work?

Bryan Stern: If you have multiple heating levels, you can still control the heat. But often you’d introduce it at an intermediate temperature and then ramp it up the rest of the way. So again, all the advantages that you get as far as quenching, typically with a two-chamber piece of equipment like that, your quench chamber is going to serve double duty as your evacuation chamber. You’re putting it into the quench chamber first, evacuating it again, and bringing it back and quenching it.

Challenges with Isolated Heat Systems (00:26:39)

Doug Glenn: These systems sound good, but I’m sure there are some challenges. Are there some drawbacks? I can hear some people saying, these sound like great pieces of equipment — especially the continuous version. I can understand the efficiencies, but what about the complexity? Is the design complexity of these units an issue?

Bryan Stern: It’s definitely one that I face a lot on the application side. It’s a much more complicated process — especially because the process itself is going to impact each of those positions. And you would care if I sold you an oven for your kitchen, and the only thing I cared about was that it can go to this temperature, and it can operate at this pressure, but I didn’t care what you did with it, I didn’t care how much work you get through it. I just had these maximum parameters.

As soon as you move to talking about continuous, you’re right away much more involved in throughput — going to drive and often the number of positions to get the index rate you need for the load size. Now you care how long each step of the process takes, and you’re trying to balance that among positions so that you’re not letting anything sit longer than it needs to because you’re over this particular soak time.

Trying to get continuous equipment sized for an application is more of a process than some people are expecting. And again, we’re just not wired that way. So, you can throw out a spec for a single-chamber batch furnace and say you need this operating temperature, this ultimate vacuum level, and this uniformity . . . and more! But when you come and want to get into a piece of equipment like this, we’re going to have a couple conversations — we’re going to talk about some things no one else is asking. And that’s what can be a hurdle up front, though we’re able to overcome it.

Two men (Doug Glenn, Bryan Stern) talking in split screen, no hands seen
Bryan Stern, Gasbarre, discusses furnace cost effectiveness and flexibility. “It’s just going to be a lot more expensive if you’re doing a process that doesn’t require the way that that furnace was built. So, it’s not that you locked yourself in. It’s just that if you’re constantly changing processes or you have much shorter processes or the throughput isn’t a benefit, then that’s where a single-chamber batch might be a better solution.”

Doug Glenn: But it also may limit flexibility, I assume, of the different processes you could run in that equipment, too. In a batch system, you can put the load in there and do whatever you want, it’s going to potentially take longer to get it done. But maybe in an isolated heat system, where the heat chamer is only designed to do X, maybe you can’t do X times two. Does that make sense?

Bryan Stern: Yeah. It’s not as much true for a two-chamber or multi-chamber isolated heat batch style furnace because you have the same flexibility of dedicated design. On a continuous furnace, but if you’re going to be doing that a lot, is it worth paying for something that can be optimized one way if you’re going to be using it in a flexible way. They have a lot of flexibility — I would argue just as much as batch. It’s just going to be a lot more expensive if you’re doing a process that doesn’t require the way that that furnace was built. So, it’s not that you locked yourself in. It’s just that if you’re constantly changing processes or you have much shorter processes or the throughput isn’t a benefit, then that’s where a single-chamber batch might be a better solution.

Cost Effectiveness (00:30:23)

Doug Glenn: And then the other objection that jumps to my mind is capital equipment outlay. Can we address that, compared to single chamber?

Bryan Stern: This is this is another one that’s near and dear to my heart because I think there’s a lot of misconception here since it’s very application specific and hard to answer generally. But like we talked about, you’re going to have another chamber.

So, if you’re looking at a smaller system, it may not immediately be more cost effective. If you’re looking at a continuous system that’s replacing several furnaces, now you’re not paying for that oversized power supply on each piece of equipment; you’re not paying for a pumping system for each piece of equipment; you’re just buying it for the one evacuation chamber. Or maybe you have a backup, but now you’re starting to distribute and be much more selective about your material cost, and there’s definitely a break-even point in there.

It’s really a question of whether or not the process improvements are enough of a benefit on the smaller size. But very quickly the upfront cost starts to lean in favor of the continuous, especially if you’re looking at multiple pieces of equipment.

But the bigger thing here, the thing that I feel more passionate about, is that we tend to get really hung up on the upfront cost. And I think that’s something that can be very detrimental to missing out on value. It’s very easy to say: I’m going to have this amount of revenue, I’m going to pay this for equipment, and I’m not going to dive into maintenance and operating costs — and that’s a difficult question to answer but is a huge piece of the puzzle. Yet we often don’t put in the legwork because the information is not readily available. And it takes a more sophisticated accounting approach to look at project value over the life of the equipment.

Intuitively, we know that you could pay more for something that would improve efficiency or throughput or performance because in the long run that would pay off. And going back to the car analogy, when is the last time you bought a car and didn’t pay any attention to the fuel economy on it? It’s hard to do that without a little bit more accounting elegance.

Intuitively, we know that you could pay more for something that would improve efficiency or throughput or performance because in the long run that would pay off. And going back to the car analogy, when is the last time you bought a car and didn’t pay any attention to the fuel economy on it? It’s hard to do that without a little bit more accounting elegance.

Bryan Stern, Gasbarre

So, you have to look at the cash flow problem, do something like a net present value approach. And when you start looking at the operating cost savings, the efficiency improvements, and then a huge one that people miss is in the single-chamber batch furnaces we’re heating it up and down. That’s aggressive thermal shock and cycling. A lot of design goes into trying to get components to last because there’s thermal ratcheting and things wear out super quickly. For these continuous systems that are just sitting at temperature, that goes away for the most part.

They’re still consumable products, but the maintenance costs are dramatically improved, and you can talk to people who are using the systems. But again, that’s not something a lot of people have experienced, and it’s hard to quantify. So, if you just look at the upfront costs then it’s easy to miss out. You’re looking for an aggressive payback because you’re just hoping it’s going to cover the operating and maintenance expenses versus actually factoring those in and saying that those overall for the project life are going to increase value.

Limitations and Benefits of Isolated Heat (00:34:09)

Doug Glenn: That makes sense. Two final questions for you here: Are there any types of companies out there where it doesn’t make sense to use an isolated heat type system, whether it be a double chamber or continuous or whatever? And are you seeing, from the activity of , any industries that really should be looking at them?

Bryan Stern: Answering your first question with regards to the limitations, there are a couple situations where you’re not going to want to be looking at isolated heat.

One of those is really large parts. If an individual part is going to take up your whole work zone, then you’re not going to be able to decrease the load size and go to continuous and match the throughput. So, very large batch applications are going to be an obstacle; large parts are one area that it’s not going to shine. We’re seeing the 36” x 36” x 48” work zone is the practical cutoff. Another is the ability to use work TCs to monitor internal temperatures of the parts. That’s possible with continuous equipment. You can do a data pack and record temperatures, but it’s certainly not as convenient. So, when it comes to R&D, validating internal temperatures, and processes that require that, that’s another hurdle and limitation of this type of system.

The footprint is another one due to a second chamber for a batch style process is probably going to be larger in the space that it occupies because you’re not getting smaller in the work zone. So, it’s a question of whether you have the floor space, and do the other benefits of that system make up for the space it’s going to take up?

gasbarre logo

Doug Glenn: Those are good caveats. How about industries that you’re seeing who really should be adopting these things that either are or ought to be?

Bryan Stern: I don’t think it’s super industry specific, but there are some processes that benefit. And just a couple would be anything with a really short cycle time, because the dead time is going to consume more of the process.

If you can eliminate that and you only need to be at temperature for a little piece of time, then getting the rest of that dead time to be in parallel with the process to increase your throughput makes you a great candidate. But on the other hand, long processes are also a good candidate. If you’re holding it at temperature for a long period of time, boosting that efficiency while you’re in temperature, and better matching a power supply to what you’re doing.

So, good candidates could have short or long cycle times, involve any processes that require tight control, or benefit from isolating them from the space. Censoring can be a good candidate for rising carbon trading, where you can now actually have a dedicated space that maybe even operates at a higher vacuum level for whatever you’re trying to do, or you’re not worried about contaminating the parts with whatever process we’re running, or you need a tight time control. So, gas processes like that.

Oil quenching is an obvious candidate because you already have two chambers most of the time and isolating it, maintaining it at temperature, and keeping it clean from any oil vapors makes it a great example.

For anything with expensive parts, you can minimize the risk by decreasing the load size instead of having a many thousand-pound load where if something goes wrong, you’ve lost it. And especially for applications where that can be a really expensive thing if something goes wrong, you’d rather have it go wrong with much less material at risk.

Doug Glenn: I would think traceability is also probably easier in one sense. With this isolated heat system; you don’t have a huge batch in there. You’re processing potentially smaller batches, and you’re able to isolate which batches are at what temperature or what kind of quench they go through. Those may be some advantages.

Bryan Stern: You had a very specific application for a client who was concerned with a lot of small parts and traceability down to each part, and we’re looking at that system. Anytime you have a high volume of work, if you’re looking at multiple batch, single-chamber batch furnaces to meet throughput, that’s one of the biggest indicators you really should probably be looking, or at least considering, these other systems. And any time you have a lot of small parts in baskets, a large single-chamber batch furnace with stacked baskets of tiny parts, you’ll probably have a lot of benefit.

Doug Glenn: I assume that if somebody is looking at purchasing multiple single-chamber furnaces, you guys would have some sort of a calculator to help them assess if it makes sense financially and process-wise to go with six batch furnaces or one continuous. Is that a safe assumption?

HTR logo, gasbarre 110, image of smiling man with slight beard, text about isolated heat

 

Bryan Stern: Yeah, that’s one of my favorite parts of the process is to take a specific application, go through and break it down, and put together that full project ROI where you’re actually starting to assemble what are we looking at for maintenance costs? What is it going to cost to operate? And now you’re starting to see at a project level, not just the upfront cost, which option is going to be best. And it is so application specific. It’s kind of neat to walk through that with a client and see what comes out the other end. Because at the end of the day, you want what the best solution is. It could be this or that. But when you can actually put that picture together for a process and assist someone with picking the best equipment for what they need for their process, that’s fun.

Doug Glenn: And just for the listener’s benefit, because we haven’t done a lot of talking about your company Gasbarre Thermal Processing Systems. You guys can provide either the isolated heat systems or, if you do the calculations on your handy dandy spreadsheet and it turns out they’re better doing the standard single chamber, you guys can do those, too. So, it’s not like you’re going to push one over the other but whatever makes sense. Right?

Bryan Stern: I see that as a huge advantage. You’re not going to get a bias of us at Gasbarre trying to push you into this because it is what we’re selling. We are able to wade through that decision with the client and help pick the equipment that’s best for them.

Doug Glenn: Helping them make a better choice, super, Bryan. Thank you.

About the Expert

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 8 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 recognized in Heat Treat Today’s 40 Under 40 Class of 2020.

Contact Bryan at bstern@gasbarre.com or go to gasbarre.com.


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Sintering Considerations: Vacuum vs. HIP

Source: TAV Vacuum Furnaces

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

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

An Excerpt:

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

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


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Sintering Considerations: Vacuum vs. HIP Read More »

Solar Atmospheres Acquires Certified Metal Craft Inc.

Solar Atmospheres, Inc. announced their most recent acquisition, Certified Metal Craft (CMC) located in El Cajon (an East County suburb of San Diego). With nearly 55 years of serving the Southern California region, CMC and the Wiederkehr Family have established themselves as a source for heat treating and brazing services. With the addition of CMC to the Solar Family of Companies, CMC establishes Solar’s 6th nationwide location and bolsters their West Coast presence.

Derek Dennis
President
Solar Atmospheres California

CMC has extensive capabilities to include vacuum, aluminum, atmospheric, endothermic, salt bath and cryogenic processing and currently employs 25 dedicated employees. Servicing the aerospace, medical, and commercial markets, CMC is Nadcap-accredited and holds a long list of customer and prime approvals. Tim Wiederkehr will immediately assume the role of V.P. of Operations and report to Derek Dennis, president of Solar Atmospheres of California, Inc.

Derek Dennis states “Solar is excited to welcome the dedicated CMC team into the growing nation of Solar companies.” He adds, “Together, we will continue to grow our west coast footprint while solidifying our industry leading approach of being the ‘go-to’ choice for all heat treating & brazing needs with an unwavering commitment to honesty and integrity in all relationships.”

This press release is available in its original form here.


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Solar Atmospheres Acquires Certified Metal Craft Inc. Read More »

The Melting Point: Lesson on Eutectic Reactions

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

Contact us with your Reader Feedback!

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

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

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


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Heat Treater Completes Michigan Move

Source: Solar
Robert (Bob) Hill, FASM
President
Solar Atmospheres of Western PA
Source: Solar Atmospheres

Solar Atmospheres of Michigan has successfully relocated from the old Fraser and Warren facilities to a new location in Chesterfield, Michigan. All ten furnaces (both new and existing) are fully operational at the Chesterfield plant, heralding a new era of efficiency and productivity.

This spring, construction will begin on a 15,000 square foot expansion on an adjacent lot. The expansion will allow for the investment in cutting-edge vacuum furnaces from Solar Manufacturing.

Bob Hill, president of Solar Atmospheres of Michigan, states, “Our future is very bright in Michigan. The consolidation and expansion will allow us to elevate our service standards and meet the evolving demands of our clientele across Michigan and the surrounding states. Solar of Michigan remains steadfast in its dedication to innovation, service excellence, and customer satisfaction as it ventures into this new chapter of growth and expansion.”

This press release is available in its original form here.


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Heat Treater Completes Michigan Move Read More »

Car Bottom Furnace Increases Large Component Heat Treat for Solar Atmospheres

Solar Atmospheres of Western PA recently commissioned their third car bottom air furnace. This Class 2 air furnace has a maximum operating temperature of 1350°F measures 60” wide x 38” high x 168” deep.

The newly installed equipment, manufactured by Heat Treat Equipment Inc., joins two other HTE car bottom furnaces that are 14’ long and 20’ long respectively.

“After successfully hardening in vacuum at 1850°F +/- 10°F, the fully hardened die was transferred to the air car bottom furnace for the triple temper operation of 1025°F +/- 10°F.” – Bob Hill, President, Solar Atmospheres WPA and Michigan
Source: Solar Atmospheres
Source: Solar
Robert (Bob) Hill, FASM
President
Solar Atmospheres of Western PA
Source: Solar Atmospheres

Bob Hill, president of Solar Atmospheres of Western PA and Michigan, states, “the addition of this large air tempering/aging equipment compliments our five (5) state of the art vacuum car bottom furnaces very nicely. Instead of hardening and triple tempering this 6000 pound H13 die exclusively in a vacuum environment, Solar can save our customers and our company over 100 hours of valuable and expensive vacuum processing time.”

He continues, “After successfully hardening in vacuum at 1850°F +/- 10°F, the fully hardened die was transferred to the air car bottom furnace for the triple temper operation of 1025°F +/- 10°F. These large and uniform car bottom furnaces are a win/win for both the customer and for production — not exclusively for heavy parts, but also when treating long components.”

This press release is available in its original form here.


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Car Bottom Furnace Increases Large Component Heat Treat for Solar Atmospheres Read More »

EV Manufacturer Upgrades with New Nitriding Furnace

HTD Size-PR Logo

An international electric vehicle manufacturer has selected a heat treat furnace supplier with North American locations for a second nitriding furnace to operate in parallel with an existing one.

The car maker already purchased an identical SECO/VACUUM nitriding furnace last year. The added heat treating capacity will ensure that the nitriding step does not become a bottle-neck in the plant’s high-pressure die casting tooling production process.

The retort furnace for gas nitriding has a chamber size of 1.6m (63”) diameter and 2.8m (110”) depth, accommodating a load up to 1m x 1m x 2.6m (40” x 40” x 100”). The furnace has 350 kilowatts of heating capacity divided into 3 heating zones. The durable Inconel 600 retort will offer many years of trouble-free service.

Peter Zawistowski
Managing Director
SECO/VACUUM Technologies
Source: SECO/VACUUM

Peter Zawistowski, managing director of SECO/VACUUM, said of the project, “This heat treat partner’s dies present quite a unique heat treating challenge. At SECO/VACUUM we love a good challenge, so we have built this solution with the dimensions and thermal capacity to nitride these large, heavy parts to exceed customer’s specifications”.

The nitriding furnace is also fitted with a device called a thermal oxidizer. Although the all-electric heat-treating process does not involve any combustion, the combination of ammonia and high temperatures still creates NOx emissions. The thermal oxidizer breaks down the harmful NOx molecules in the furnace discharge.

The tool and die market serving traditional and EV automotive markets uses vacuum heat treating technology extensively to produce bright, high-quality parts.

 


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EV Manufacturer Upgrades with New Nitriding Furnace Read More »

Precision Heat Treater Expands Operations with New High-Pressure Gas Quenching Furnace

HTD Size-PR LogoA precision heat treatment company Vacu Braze recently partnered with a U.S. furnace manufacturer to procure new equipment to expand its processing capabilities.

The TM8 is the first high-pressure gas quenching furnace to be installed in Vacu Braze’s clean processing room. This high-purity furnace from TM Vacuum Products expands the heat treater’s high-pressure gas quenching capacity for large and small jobs, while offering increased processing cleanliness.

The TM8 is equipped with a molybdenum all-metal hot zone and a cryogenic pump capable of helping the furnace reach the 10-7 vacuum scale. With a qualified work zone of 12” x 12” x 24”, small batches of parts made from a wider array of materials can be processed more quickly than with traditional atmospheric methods.

The new furnace is fully compliant with AMS 2750 class 2 pyrometry and fit for processing critical parts for aerospace applications. As clean processing capabilities expand, Vacu Braze is proud to provide innovative solutions to industries requiring precision, purity, and cleanliness from their heat treatment provider.

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Heat Treat Radio #99: 365° Look at Troubleshooting Vacuum Furnace Maintenance Issues

You’ve built your vacuum furnace maintenance program, but still looking for maintenance tips for common issues?

Don Marteeny and Caleb Johnson at SECO/VACUUM Technologies lay out their expert advice to assess your vacuum furnace maintenance issues from all angles. Thanks to Doug Glenn, publisher of Heat Treat Today, for hosting this interview.

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


 


HTT · Heat Treat Radio #99: 365° Look at Troubleshooting Vacuum Furnace Maintenance Issues


Contact us with your Reader Feedback!

The following transcript has been edited for your reading enjoyment.

Doug Glenn:  With us today is Don Marteeny. Don is from SECO/VACUUM Technologies LLC and is the VP of engineering. Don has a lot of experience in this industry, so his input will be valuable.

Don Marteeny
VP of engineering
SECO/VACUUM Technologies

Also with us is Caleb Johnson who is the field service manager, also for SECO/VACUUM Technologies. Gentlemen, we appreciate you joining us.

We’re just going to jump right in. We’re talking about top vacuum furnace maintenance concerns.

Trouble Reaching Vacuum Levels (01:35)

Doug Glenn:  Probably the most dire concerns is: “Dang it, I can’t get this doggone vacuum furnace down to the vacuum levels that I want.” Where do we go? What do we do?

Caleb Johnson: Yes, that is probably one of the more critical problems on a vacuum furnace. There are a lot of issues that would stem from that.

Caleb Johnson
Field Service Manager
SECO/VACUUM Technologies
Source: LinkedIn

One of the first checks I would ask to look at is the vacuum gauge itself. Does the trending look okay? Do we think the gauge is still functioning properly? What does your scaling look like? Since those are electronic items, they do have a life on them. It’s an easy one to rule out, right off the bat.

The next place to check would be your vacuum pumps. Are they functioning okay? Has the oil been changed recently? Is the pump still working well? Just going through some of the basic checks like this can tell us how the furnace is doing.

Doug Glenn:  Is it typical that the vacuum gauge will fail slowly over time? Does it start to get off target? Maybe it immediate: “Boom. This thing is just gone.”

Caleb Johnson: I think it can be either way. On the one hand, it could just not read. On our furnaces, they usually fail high. It will just say it’s at atmosphere even though you’re under vacuum. On the other hand, the low level on the vacuum gauge won’t reach as good a vacuum. Maybe the furnace is there, but the gauge doesn’t register that. The gauge itself just starts drifting. So, yes, either way — they are both common.

Check the gauge
Source: Unsplash/Justus Menke

Doug Glenn:  Alright. So, the gauge first and then the pump. Was there anything else?

Caleb Johnson:  For the pump, I think you could look at the amp draw on it and make sure the motor is still functioning properly — that’s a big one.

Doug Glenn:  Yes, good.

Don Marteeny:  Another thing that I’ve seen commonly is that a customer is running a process that may, in some way, present some contamination to the furnace. Usually, one of the questions that I ask after that process is, “How long has it been since you have done a cleaning cycle?” By that I mean, having the furnace run a hundred degrees over the process temperature for 8 hours just to basically bake everything out of the insulation.

A further question to ask: Was the furnace open over the weekend? Did somebody accidentally leave it open, didn’t pump it back down, and there’s moisture.

I would expect the first run that there would be problems reaching vacuum. There’s an easy answer to that. Yes, you might not get through the production that day, but you’ve got to put it through a cleaning cycle first. Let it run over night then start back in the morning and see where you are.

Furthermore, this can also apply to the gauge. Sometimes it’s not necessarily that the gauge has failed, but there is some contamination. There are ways to prevent that, like the installation of what we call “a clarifier” — basically a copper tube that allows anything that might be in the environment to condense before it reaches the vacuum gauge.

There are several remedies for these common issues, and we have to go through the list of all of them when this comes up.

Caleb Johnson: I would say, too, that cleaning cycle gives us a baseline because all our vacuum leak checks are specified in a clean, dry, empty furnace. After a burnout, you try to get rid of all that contamination. When the door hasn’t been opened yet, that’s the best time to do a leak-up check and say, “Is any air getting into the furnace?”

A lot of times, you’ll see discoloration on your load or the furnace itself — if you’re getting air or moisture in there — some blue or green colors that allude to that. Now, if the load is off-gassing, maybe that’s a common color that you’re getting, but specifically, if you’re getting air in the furnace, you may see the discoloration. The leak check would show that.

A lot of times we’re specified at 10 microns an hour, and, over time, furnaces might not meet that spec. As you get further and further from that spec, then it’s time to come back and do a helium leak check. Sometimes they’re called “using the mass spectrometer”  — we call it a leak detector — but that’s a surefire way to find out exactly where any air might be getting in the furnace.

Doug Glenn:  That was my next question on this, before we get off the topic of not being able to reach the vacuum level: Let’s say it’s not the gauge, let’s say it’s not the pump. What are the common areas? The one that jumps to my mind: Did you check the door seal? Is that valid? Are there other places that we can be checking right off if we’re failing the leak-up test? What are the most common places where we’re going to see failure to hit the vacuum levels?

Caleb Johnson:  Door seals, obviously, are the number one issue because that’s constantly opened and closed. They might dry out. The seal needs to be constantly cleaned and greased. Dirt could fall in there. That’s definitely one. Also, the furnace is going through heating cycles, so the power feedthroughs, they’ll get hot. As they expand with the heat and contract with the cold, it creates a potential for a leak because those seals are constantly shifting a little bit.

Really, any penetration that goes from outside the furnace into it is a potential for a leak. Looking at what’s going to see the heat; what’s going to move a little bit; and like the door seal — what’s been opened or even if maintenance was done and some valve was replaced or a seal was touched — that’s usually the first thing to go for.

Doug Glenn:  That was the other common sense point worth mentioning: If something was replaced in the furnace, especially anything that penetrates the shell, and you weren’t having troubles before that, obviously you want to go check that stuff out.

Don Marteeny: More to that point, we’ve come across a couple times where a valve was replaced, and that valve was, say, on the incoming gas line, maybe nitrogen or argon. All of a sudden, we have a leak, but we can’t find it. We’ve leak checked the entire furnace multiple times and still can’t find a leak.

Well, the next place to look — and it seems illogical — but the next place to look is that valve because that did change. Maybe there’s no outward appearance of any oxidation, but low and behold, there is some nitrogen or argon leaking into the furnace through a valve seep that we didn’t expect. It doesn’t happen all the time, but it does happen. That one is especially frustrating to find because it’s the last place you’ll ever look.

Waterflow alarm (08:49)

Doug Glenn:  Let’s say you’ve got a waterflow alarm. What’s the first thing we are looking for?

Don Marteeny:  I’ll jump in on that one, Doug. It’s not just a cold-wall furnace because certainly there are atmosphere-style furnaces out there that have water-cooled flanges that do require some water cooling. Many of those passages that feed those flanges or, like we talked about, power feedthroughs are very small.

All of a sudden you look down and say, “Oh, there’s an alarm on one of the power feedthroughs that’s not getting enough water; the temperature is too hot.” Okay, chances are good that there could have been some contamination that was somewhere in the system that is now blocking one of those small holes — and I’m talking a half inch or a quarter inch hole — and we just don’t have the flow that’s expected.

The natural first step is: How long has it been since you’ve cleaned the system? How long has it been since the system has been flushed? Again, it’s going to be something that you don’t typically think of, don’t do that often, but if, for some reason, there has been some exposure to air in the system (and exposure to air will develop and typically promote the growth of bacteria which can cause issues in the system) or just from natural deterioration.

A lot of those systems are steel pipe, and they develop some scale. That scale goes somewhere, and the first place you’ll see it is on the small passages because it blocks the passage.

There are a couple biodegradable descalers, at least, that I’m aware of, available on the market. If you’ve got glycol, that glycol can be pumped out of the system, screened, filtered, and put back in. At the same time, you can purchase a descaler which typically can be mixed with city water, and you basically flush the system. After maybe one or two flushes, you can be fairly confident that you’ve removed a lot of that scale and reintroduced the glycol if you need to or reintroduced the water coolant.

The important thing is that you’ve replaced the rust inhibitor or any other chemical treatments that you think are necessary or you’ve been told are necessary by the equipment manufacturer.

Doug Glenn:  On this water-cooling system, what percentage of vacuum furnaces out there have closed-loop cooling systems, as opposed to somebody just running city water through a furnace for cooling?

Caleb Johnson:  I think the majority of our customers do have closed-loop, but it also depends on how much equipment they’re cooling. If it’s a single furnace, the best scenario is usually just a closed-loop, small system. But when you have multiple furnaces in a room, then you’re on a much larger system. It takes more cooling power, and it may not be city water they’re running through. It might be an open-looped system or just multifaceted with their stations.

Doug Glenn:  It’s been quite a while, and I don’t know if it still happens that you’ve got somebody that’s running a cold-wall vacuum furnace and they’re running city water through it. Soon all you’ve got is just a bunch of sludge and stuff, and you’re not a cold-wall anymore — you’re basically just heating sludge.

Don Marteeny:  Yes. City water can be especially challenging, unlike having a glycol mixture with DI water (deionized water) or DI water that you input into the system initially. That city water can be hard, so it has a lot of dissolved solids. It can have organics that can end up causing issues if there’s a certain section of the vessel that doesn’t get the right circulation. All of a sudden you get a settlement of those sediments in the water. There are lots of different challenges that are brought on by using city water.

Caleb Johnson:  And heat is an activator, as well, right? So, as it’s trying to pull that heat off, now that’s activating some of the stuff — that’s what causes some of the scale buildup or the bacteria. Making sure that the size of the system is adequate is necessary, as well.

Doug Glenn:  On modern-day vacuum furnaces, do they have regular flow monitoring of water? Do you know if water is going through and can you tell, over time, “Hey, my flow is slowing down” — can you see it coming?

[blocktext align="right"]I would recommend if you do a routine check-out of the furnace for maintenance, maybe in the summertime, that’s the time to do it. Flushing the furnace, removing the coolant, etc., is quite an undertaking.[/blocktext]Caleb Johnson:  In our furnaces, we use digital indicators. Some furnaces actually show a flow rate, but a majority of them are just like a dial indicator with LEDs. We start with max flow and, over time, those LEDs drop out and show that you’re losing flow. Then, when it drops below the set point, that’s when you get an alarm.

Doug Glenn:  You get an alarm and then you’ve got to do all your cleaning out?

Caleb Johnson:  Those are on individual circuits, so you can tell, pretty much, which part of the equipment needs washed out.

Doug Glenn:  Before we move on to the third one, any rule of thumb on how frequently you think a vacuum furnace should be descaled or flushed out? Let’s say, even if you’re not experiencing trouble, is there a best practice time frame?

Don Marteeny:  Typically, Doug, this is a not a two-hour process, right? I would recommend if you do a routine check-out of the furnace for maintenance, maybe in the summertime, that’s the time to do it. Flushing the furnace, removing the coolant, etc., is quite an undertaking.

It also depends on the type of cooling system you have. If it’s truly closed-loop, and like a lot of the systems we work with today, they actually have a nitrogen blanket so there’s very little oxygen in the system. They typically don’t require flushes as frequently. But if the water that’s going through the furnace can be exposed to oxygen, then we should probably think about more frequent flushes because then you’re introducing the potential for oxidation and organic material that can cause issues.

Overtemperature Alarm (15:40)

"Too hot in here"
Source: Unsplash/siora 18

Doug Glenn:  Let’s move on to another alarm issue that’s overtemperature. It’s getting too hot here — what do we do?

Caleb Johnson:  The overtemperature is a big issue because it’s a critical part of your process, especially when it’s your control thermocouple. Thermocouples have a life, and they can fail in different ways. I think the hope would be that the reading just drops out and shuts everything down. But sometimes it shorts against the jacket, and you have a small break or it’s an erratic reading.

An erratic reading can cause bigger issues because now, maybe, the furnace is running hotter than you think or colder, and you don’t really know there’s an issue. Eventually, it will breach the max temperature and shut things down. If everything’s looking okay on the screen, you don’t really know what’s going on.

Watch your trending, make sure the temperature isn’t erratic (it should be stable), and also measure against your overtemperature controller. We usually have two thermocouples, whether it’s a dual element or two individual ones. You will have some redundancy there, but you can compare numbers to make sure they’re within a few degrees and reading accurately.

Don Marteeny:  Aerospace requires more frequent temperature uniformity surveys and system accuracy tests to be Nadcap certified. If you’re outside that realm and don’t have that audited requirement, we recommend at least an annual temperature uniformity survey and SAT.

There are two schools of thought: I can replace the thermocouple before it fails and just do it and say it’s part of doing business, or I will run it until it breaks and deal with the consequences. It’s totally up to you. Some customers do it one way, others will choose the opposite.

Both ways work, it’s just you’ve got to be, as Caleb mentioned, watching it closely. As we all know, with vacuum furnaces, we can’t see what’s going on in the furnaces, so we must rely on instrumentation. If the instrumentation is lying to you, that can cause more grief.

Doug Glenn:  Whether you’re replacing those thermocouples in advance as a precautionary step or if you’re waiting, I would assume it has a lot to do with the value of the product that you’re running in the furnace. The higher the value, I assume you’re going to say, “You know what, if I miss this and mess up the product, it’s better to replace that thermocouple.”

Don Marteeny:  Right. And how much are you running the furnace? If it’s a 24/7 operation, obviously, if you can get to the 3-month period and you’re starting to see issues, maybe you just say, “from now on, I’m just going to replace it every 3 months.”

Or, if you’re running two to three cycles a week because that’s what you need the furnace for and that satisfies your production, you might get a year out of it and it’s no big deal. But you’re right, if it’s a $1,000 thermocouple and the load in the furnace is $15,000, you really must consider that.

Caleb Johnson:  Another thing to check is just visual inspection. The control thermocouples are usually just hanging out there in the air, so if you’re running larger loads, it’s really easy to bump it. Even if you’re running a survey for aims full size of the working area, make sure that it hasn’t gotten bent or even the tip chipped off. If it does get bumped, then maybe you pay extra attention, or replace it as a precautionary measure.

Doug Glenn:  It’s safe to say: “Don’t ignore it!”

Caleb Johnson:  When it comes to alarms, yes, and don’t power through it either.

Doug Glenn: That could be catastrophic. You don’t want to open the furnace up and have a nice pool of metal!

Furnace Software (21:04)

Doug Glenn:  Let’s go on to another issue. This is probably a pretty big category because the question deals with software and software issues. Let’s say you’re having issues with the furnace software. What are some good techniques here?

Don Marteeny:  Indeed, software is quite a broad topic. The first thing that we typically look at is, is it operational, meaning is it a controller issue or is it a display issue? A lot of times, we’ll have a customer call to say, “The furnace stopped in cycle, and it won’t finish the cycle and we can’t get it to end cycle.” It turns out, usually when you start investigating, it’s not really a software issue — although it may appear to be — the software is actually doing its job. There is some underlying mechanical issue that we have to find.

As I mentioned earlier, we can’t see in the vacuum furnace when it’s running, so you have to really dig deeply sometimes to figure out what is actually happening. I think a lot of times we tend to blame the software, but that isn’t always the case.

That being said, let’s take a step back to the aforementioned display. These are Windows machines, quite frequently, and that’s a good thing because that means we can communicate with the rest of our network in any facility.

However, we all know, too, that Microsoft comes with its own set of frustrations, at times. Those obviously aren’t exempt from the display. Whether or not to update the host computer is a topic that I would highly recommend you discuss with the manufacturer. Updates can sometimes cause headaches because Microsoft is changing things in the background.

Maybe you have another manufacturer’s computer that’s not Windows-based. I would definitely talk to that manufacturer at that point. From my experience, most are typically Windows-based, and the interplay between Microsoft and the manufacturer is very important. The manufacturer of the equipment should be telling you how to handle that process.

Be careful. Most furnaces now have a LAN or local area network, so all the components are communicating via ethernet or PROFINET. Often, customers want to extract data from the equipment, which is fine, but make sure that you discuss how to do that with the equipment manufacturer. We don’t want to interfere with the addressing in that LAN. That will cause issues immediately if the equipment isn’t communicating, within that network, to each other.

Back to the beginning, it is always well-advised to look at what the equipment is telling you, what the alarms are, what the software is telling you. Then take a step back and say, “Ok, what else is going on in the furnace?”

Again, the goal, at least to the equipment manufacturer, is that we’re designing the software to help diagnose. Is it always spot-on? No. It’s still a machine. It still can have irregularities, or maybe we just didn’t think of all the scenarios. We do our best, but we don’t always catch everything.

It’s a matter of stepping back and looking at the situation. Of course, if you can’t find it, that’s when we, or any other manufacturer, can step in and say, “Hey, in this scenario, you need to go look at these items.”

Caleb Johnson:  Don was touching on software glitches, but the other thing is maybe you’re losing data. It may be a hardware issue with the computer, as well. A lot of these industrial PCs are pretty robust, and they outlive the Windows operating system. You need to check if it’s still supported by Windows, or if your hard drive is full. Because we collect trend data on our computer, there are files that will start to fill up the hard drive. Once it’s out of space, then the computer doesn’t know where to put stuff. It will start glitching and having issues. That’s another thing to check.

Doug Glenn:  Alright guys, thanks. That was the top four. What I want to do now is go into the “rapid fire round.” I’m going to give you probably four to five additional items. We don’t want to go into a lot of depth on these, and we’ll see how quickly we can run down through these.

Hot Zone Replacement (26:04)

Doug Glenn:  The first one is this: When do I know that it’s time to reline and/or replace my hot zone?

Caleb Johnson:  I think the quick answer would be a uniformity survey. Are you still uniform within your working area? Are you within the calibration, or do you have hot spots and cold spots? Another thing to check would be the energy usage for the hot zone for the heating elements. Are you pulling more power because you’re losing more heat? As the insulation erodes away, then the heat starts escaping out the hot zone area.

Doug Glenn:  Any validity just to looking at it?

Caleb Johnson:  I’d say you can see the erosion quickly. A lot of the seams where the insulation meets each other will start to become a crevice.

Discolored Parts (27:02)

"Severe discoloration of stainless steel parts and fixturing discolored by a water leak."
Source: Dan Herring, "The Heat Treat Doctor"

Doug Glenn:  This is fairly typical. We mentioned it here earlier: I’m getting discolored parts. What am I looking for?

Don Marteeny:  Discolored parts are a common complaint. “Hey, I was fine last week and now, all of a sudden, it’s coming out looking like a rainbow.” It typically depends on the material being treated, but colors such as rainbow are oxidation of some sort. In a short answer — it’s a leak check. Have you done a leak test lately? What is the leak-up rate? Has it changed? That’s the first place to start.

Doug Glenn:  I have also heard: If you’re running a variety of different parts or different items/materials through your furnace, you’ve got to be careful that the previous load may have deposited some sort of material on a cold spot in the furnace. Then, when you heat it back up again, it can react with the current load. Is there validity to that one?

Caleb Johnson:  Yes, if you’re running parts that have coolant or cut-in oil or something, then that’s stuff that off-gases. If you run a high specialty metal that needs pure air, and maybe it’s a higher temperature too, then all of that is off-gassing. Normally if you’re running a special load like that, you should look at running a cleaning cycle beforehand to ensure that there is nothing in an off-gas from the previous load.

Door Seals (28:36)

Doug Glenn:  We talked about replacing the hot zone. How about replacement of door seals?

Caleb Johnson:  If it hasn’t been greased regularly or if it’s old, it will start to crack and split. Just look at the condition of the door seal and the seam, too, because a lot of times they’re glued together at a seam. If that seam starts splitting apart, that can introduce a leak. It’s time to get it replaced.

Doug Glenn:  Basically perform a mechanical inspection, unless you’re getting leak-up. Then if you can isolate that the door seal is the issue, then obviously it’s got to be replaced.

This is probably “Vacuum Furnace 101”: Every time you’re closing it, you should be wiping down the seal and the main, right? Is that a good practice?

Caleb Johnson:  Yes. And you don’t always have to clean it, clean it, but even just wiping it to make sure that the grease didn’t catch a lot of dirt in there and is still lubricating the seal.

Doug Glenn:  Two more: Let’s say you’re getting the strange black spots or black marks on the inside of the furnace, typically around heating elements and/or feedthroughs and things of that sort. What causes that?

Don Marteeny:  Back to that watching the power consumption. Some of the newer furnaces are equipped with gauges that monitor power, current, etc. If you go back and look at the trends and see a lot of current spikes, that’s a surefire indication of arcing. If you open the furnace and see black marks, what’s happening is that that carbon graphite insulation is being destroyed from an electrical arc.

The next thing to ask after that is are the insulators still in place? Have they been contaminated with something that is now preventing them from being a good electrical insulator? The other thing that comes up once in a while is what is the environment like in the furnace? Are you introducing a gas that could be creating a short, a path to ground for the electricity passing through the heating elements? Those are all some things to consider.

Doug Glenn:  If you’ve got black marks in the furnace, more than likely you’re having an arc party in there when the door is closed.

Caleb Johnson:  Yes. Make sure your heating element hardware is tight because they expand with the heat, so they will start to loosen up. You want to do periodic inspections to make sure that all the hardware is still tight.

High Velocity Fans (31:19)

"We're pushing those fan motors pretty hard during quench."
Source: LinkedIn/Daniel Dudar

Doug Glenn:  A lot of vacuum furnaces have high pressure gas quenching. There are some pretty big fans in there. Is there an A-#1 thing we need to be thinking about when we talk about high velocity fans and things of that sort? What are our concerns there?

Don Marteeny:  There are a couple different things to be aware of: Number one, when they’re in operation, most of the equipment has a failsafe to keep it from, say, drawing too much current for too long a time and overheating.

We’re pushing those fan motors pretty hard during quench, so the wear during that period is very high. Over time, of course, things like bearings are going to be a concern because they don’t always run for that long. When they are running, they’re running at 100/110%. We’ve got to keep that in mind.

The next thing to consider is how they’re cooled. It depends on the manufacturer. Some are still a fan-cooled motor inside, so they are still relying on gas cooling. It’s got to be kept clean, so that the cooling rate is correct. In our case, we’re water cooling them. We just have to maintain water flow, so we’re back to that conversation. But those, I think, would be a couple of the key things.

Maybe Caleb can expand on some of the erosion that can happen in the hot zone as a result of high velocity/high pressure quench.

Caleb Johnson:  As it erodes especially, and creates air leaks, then that air forges its path through there and makes it worse and worse. If you start to see erosion to the point where you think air is getting through, you’re going to want to try and remedy that whether by replacing the insulation or even a short-term patch until you get a new hot zone.

Doug Glenn:  You’re talking about erosion and you’re talking about where the high-pressure gas is actually eroding the, let’s say, graphite or whatever, so that now you’re exposing the shell of the furnace.

Caleb Johnson:  The rollup for the hot zone, yes.

Another thing you mentioned is high pressure. We put a lot of pressure in there, and it’s high velocity. If you have small parts, depending on the direction of flow, you want to make sure smaller parts fix nice because if they blow off your fixturing, they can cause damage within the hot zone.

Don Marteeny:  One other point to that, too, is the heat exchanger. We typically don’t think about the heat exchanger, but it’s actually doing a lot of the work in that process. Over time, typically there are rather densely packed fins in those heat exchangers to achieve the amount of heat transfer that’s required for the process, and they can get contaminated, as well. Periodically, it’s not a bad idea — certainly if you’re replacing a hot zone — to clean that heat exchanger.

Doug Glenn:  Clean and/or replace. Excellent.

Guys, thanks so much. I really appreciate your expertise. Thanks very much for being with us and sharing your expert knowledge and field experience.

Caleb Johnson:  Thank you, Doug.

Don Marteeny:  Thank you, Doug.


About the experts: 

Don Marteeny has been vice president of Engineering for SECO/VACUUM for over five years. He is a licensed professional engineer and has been a leader at the company over the last several years filling project management and engineering leadership responsibilities. Don is a member of Heat Treat Today's 40 Under 40 Class of 2021.

Caleb Johnson has worked as a field service engineer for SECO/VACUUM for several years before transitioning to field service manager. He now puts his knowledge of vacuum furnaces to good use by directing and assisting the Field Service Team, as well as by providing technical support to customers.

If you’d like to get in contact with Don or Caleb, go to www.secovacusa.com.


To find other Heat Treat Radio episodes, go to www.heattreattoday.com/radio.


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Heat Treat Radio #99: 365° Look at Troubleshooting Vacuum Furnace Maintenance Issues Read More »

Heat Treat Capabilities Grow for West Coast Aerospace Manufacturer

HTD Size-PR LogoAn eastern Pennsylvania vacuum furnace manufacturer recently shipped an external quench vacuum furnace to a West Coast aerospace manufacturer. The furnace will primarily be used for vacuum heat treating investment castings for the aerospace industry.

The Model HFL-7472-2EQ features an all-metal hot zone, a load weight capacity up to 10,000 lbs., a maximum operating temperature of 2400° F, and a 2-bar quench system optimized for argon with a 150 HP quench motor and a variable frequency drive. The furnace working zone measures 48”W x 48”H x 72”D, includes the SolarVac® Polaris control system, and is AMS2750F compliant.

 

 

 

Solar Manufacturing Vacuum Furnace

(photo source: TobiasRehbein at Pixabay)

 

 

 

 

 

 

 

Heat Treat Capabilities Grow for West Coast Aerospace Manufacturer Read More »