Solar Atmospheres in Souderton, PA, has commissioned two additional 2-bar vacuum furnaces, expanding its capabilities to meet demand in the aerospace and industrial gas turbine sectors. The equipment will allow the company to specialize in hydride/de-hydride processing of titanium, tantalum and niobium.
Mike Moyer Vice President of Sales Solar Atmospheres Souderton
These vacuum furnaces, produced by the heat treater’s sister company, Solar Manufacturing, feature large working hot zones (45” x 45” x 72”) and are rated for operations up to 2400°F with a precise temperature uniformity of ±10°F.
“We’re thrilled to add these advanced furnaces to Solar Souderton’s lineup,” said Mike Moyer, vice president of sales, at Solar Atmospheres. “Equipped with Solar Manufacturing’s latest control systems, they ensure efficient, safe operation — meeting our customers’ needs for competitive pricing and fast delivery. This installation reinforces our commitment to consistently high-quality service.”
More Solar Atmospheres News…
Robert Hill, FASM President Solar Atmospheres of Western PA
Solar Atmospheres of Michigan, Inc., announced the completion of its 20,000 square-foot facility expansion, marked by the official receipt of an occupancy permit from Chesterfield Township.
“Next week, we’ll begin the process of moving our Shipping and Receiving Department, along with other essential ancillary equipment, into the newly completed adjoining building,” said Bob Hill, president of Solar Atmospheres of Michigan. “This expansion is a vital step forward, enabling us to optimize workflow, boost production capacity, and further improve the quality of our vacuum heat treating services for our valued clients.”
The expanded facility will allow Solar Atmospheres of Michigan to streamline operations and meet growing customer demands from various industries.
The press releases are available in their original forms here and here.
As Thomas Bauernhansl, professor of Production Technology & Factory Operations at the University of Stuttgart, aptly states, “We are going from more supply-oriented production to a demand-oriented one. In many cases, the customer determines which version he wants to have [of] a product — the manufacturer adapts to this and his processes accordingly.”
This shift is critical for the heat treat industry, where the need for advanced automation and robotics integration is paramount to achieve higher efficiency, consistent quality, and reduced costs.In this Technical Tuesday, Dennis Beauchesne, general manager at ECM USA, discusses the increase in use and installation of automation and robotics in manufacturing and specifically how companies within the heat treat industry have adapted to their implementation—and become innovators in their usage.
This informative piece was first released inHeat Treat Today’sJanuary 2025 Technologies To Watch in Heat Treating print edition.
Industry Automation
In the last 10–15 years, an upward trend is consistent with the increased investment value of integrated automation within a heat treatment plant. At the beginning of the 2000s, it was common to have an automatic transport car transporting batches to different stations, but, in the last five years, far more complex automation solutions are in demand. In order to meet the requirements of future industry robotics and automation, our industry must adapt to the new and improved technology offerings and standards that are being used in other industries.
Figure 1. Annual robotics installation by industry 2021-2023
According to World Robotics, there has been a significant increase in robotics usage and installations since 2020 (Figure 1). For example, the automotive industry shows installations almost doubled from 2020 to 2022 with 83,000 installations in 2020, compared to 136,000 installations in 2022. The industrial robot market was expected to grow by 7% in 2023 to more than 590,000 units worldwide. Although it exceeded 500,000 installations, robotics were down 2% (possibly due to COVID-19) compared to the prior record year. Of interest to note for the automotive industry, the industry increased its robotics demand in 2023 to surpass electronics with a 25% share (electronics was close with 23%, down by 5% due to inventory levels stabilizing after supply chain bottlenecks mostly vanished).
Table 1. North America’s robotics comparison 2022 to 2023 Source: World Robotics
Specifically for the United States and Mexico, peak robotics installation demand was documented in 2022, but demand has been consistent within +/-5% (Table 1). The future of robot installations is trending to grow and exceed 50,000 units in North America for 2024. Nearshoring of supply chains will create demand for automation technology in the years to come, according to Christopher Müller in his World Robotics 2024 – Industrial Robots presentation.
Manufacturing Concepts
The company SEW has previously published its ideas and concepts of autonomous transporters distributing the raw parts to the production cells, after the soft processing to the hardening plant, and finally the hard machining (Figure 2). All steps are configured within the component so the process steps can be well documented on a component basis.
Figure 2. SEW concept from Hiller, “The networked hardening shop,” 2019 Source: ECM GmbH
As can be seen in the SEW Figures, the original hardening plant is shown as a continuous furnace. However, this type of plant technology can be seen as contradictory to current production needs. To be compliant with this new philosophy, plant technology must be as modular, flexible, and automatable as the rest of the production layout and components. Heat treatment must also be controllable and unloadable with automatic transport units. Robots must be able to load batches and navigate the plant (according to CHD, steel, part numbers, etc.). The smaller the batch size, the larger the value of robotic component documentation. Furthermore, a reduction in batch size is advantageous for flexibility, costs, and heat treatment of many requirements for production runs.
Heat Treatment & Robotics
A heat treatment plant can implement recommendations for the future of industry automation by acquiring technology for:
Automatic loading/unloading
Component recognition systems
Automatically loaded/read recipe systems
Smaller batch sizes with a wide variety of variants
Heat treatment of different applications or steels in small quantities
Maintenance/repair detection
Benefits of automating part or all production line steps include:
Shorter process times
High CHD (Case Hardening Depth) uniformity and lower distortion
Lower operating costs and labor reduction
These technologies have existed and are being implemented in heat treat operations for a few years now. The results are clear and the benefits are proven through higher quality parts, highly efficient heat treat operations, and overall more efficient production facilities.
As many machining operations have been robotized, this allows the downstream heat treat operations to easily take advantage of part placement in dunnage and plant transport systems, whether manual or automated.
Figure 3. ECM Vision System Source: ECM Robotics
Batch Loading with Robotics
Bulk goods-loading (such as clips, links, and other small parts via weight detection) as well as loading and unloading of truck shafts in fixtures and in straightening machines are just a few examples of production areas that can benefit from robotics/automation. Visual recognition systems can identify gears/parts based on the diameter or by the number of teeth on the gear and can then sort them by these features (Figure 3).
Like the visual locating of the parts by cameras, they can also be used for tracking parts and loads within a heat treatment cell. A good amount of work has been done in this area for heat treating. This work covers part marking, tray/fixture encoding, and part weighing scenarios, and allows the heat treat system to accurately process all the different parts coming through the heat treat system with the correct process recipe.
Some of the work being done has been implemented with a QR code marking system for each part before heat treatment. To ensure the correct recipe or heat treatment is performed on the proper part, this scanned code works with the heat treatment system controls to upload the correct recipe to the proper cell. This information can be further analyzed to indicate precise placement in the heat treat tray through virtual tracking.
Figure 4. QR code heat treat test picture Source: ECM USA Synergy Center
In Figure 4, you can see in the details that this client has reviewed and tested to assure the code is visible before and after heat treating with a carburizing and hardening process.
These parts are tracked when entering the system and also noted as to which heat treat tray they are on by using a binary code with holes in a tray or on a strategically placed bar code plate on the tray. With this system, they can be scanned by a camera before entry and upon exit of the furnace (Figure 5). This tray scanning can also indicate how many cycles the trays have on them to ensure the trays stay in good condition and can be cycled efficiently.
Let’s look at the SEW production concept again and re-imagine it with a more efficient vacuum furnace technology with robotic integration. In this concept, the vacuum furnace system forms the “spatially distributed production reserve” which helps autonomous transport units as “situationally self-controlling” material is delivered.
The QR code on the component represents the “knowledge-based” running card. The robots recognize the components by means of the QR code and are loaded onto the appropriate heat treat trays. The heat treatment can then be carried out on a component-related, flexible, and documented basis. Traceability of production can also be ensured (Figure 6).
Loading of the parts can be done efficiently through a series of dunnage that hold the part in specific locations which assist the robot to locate, lift, and place the parts in the heat treat tray. This method doesn’t always need to be a perfect location for the incoming work as we now have 2D and 3D cameras that can work in tandem to locate parts, even in odd stacking or randomly loaded bins.
In a recent installation, a heat treater automated their gear cutting operation to prepare the dunnage before heat treat. Therefore, the heat treat robotics phase was simplified by storing each part in a specification location for the robot to “see” with its vision system. These parts are then scanned and automatically connected to the part’s recipe as stored in the system. In a modular system using low pressure carburizing, individual cells are utilized, and production is recipe driven. These recipes are pre-developed and stored to allow each cell to utilize the recipes for many different parts. In this case, after a part is scanned, the recipe is uploaded into the next available cell and the scanned parts and heat treat fixture is moved to the cell (Figure 7).
Figure 7. Modular vacuum furnace for low pressure carburizing Source: ECM USA
Figure 8 was designed to use over 175 different parts with nine different heat treat processes which included carburizing and slow cooling, hardening, tempering, cooling after tempering and cryogenic treatment.
With further considerations for additional benefits of the automated system, fixtures were optimized by using CFC (carbon fiber composite) base trays. These trays are not only extremely stable and have non-existent growth/warpage, but they also help with robotic placement before and after heat treatment. CFC trays are flat, or can be machined to conform to part geometry, which helps to reduce or minimize distortion related to fixture warpage or creep.
Figure 8. LPC and robotics configuration Source: ECM USA
Many system designs have been proposed to a variety of clients; however, the end goal is to design a system that is “standard.” This standard design needs to incorporate different forms of dunnage, bins, boxes, and pallets to allow a commercial heat treater to easily program the system whenever the next part comes in from their client, whatever it may be. This is a challenging task and needs to be broken out by weight category to design the robot’s reach and end tool design. In this case a robot cell offline of the heat treat furnace can be built and utilize, and ultimately use, an AMR (automated mobile robot) or AGV (automated guided vehicle) to bring the built loads to the furnaces (Figure 9).
Vacuum furnace systems have a clear advantage over traditional atmospheric systems with many features which lend themselves to integrate into the machining area with robotics and automation.
The fact that an LPC (low pressure vacuum) furnace system can process loads via a recipe input and each cell can be used to process a different case depth, or hardening cycle is highly advantageous when processing a wide variety of parts. In addition, the LPC process provides a more uniform case depth throughout the part to make a stronger part along with high quality processing. The vacuum furnace cells can be arranged in many ways to fit into existing facilities and to be able to use many methods of automation especially including robotics.
Quenching is also a key element in any hardening heat treat process. LPC furnace systems are usually associated with high pressure gas quenching (HPGQ) in a separate chamber to provide the best quenching performance. This gas quenching technique provides a clean process for each part and allows the use of CFC fixtures. There is also no requirement for post cleaning as is necessary with oil quenching.
Providing quality low pressure carburizing, clean and precise gas quenching, CFC trays for better uniformity and keeping the parts flat, and the automation benefits of robotics makes for a state-of-the-art heat treating production operation and thus completes the heat treat paradigm shift.
Figure 10. Robot loading Source: ECM USA
Conclusion
The heat treat industry wants and needs automation and robotics integration to advance production, reduce costs, and improve the overall quality of production. With traditional technology, process data evaluation and self-configured recipe values are not possible. Therefore, component analysis should be automated to meet and achieve consistent and reliable recipe values (mass flow, time). With the increase in robotics demand, vacuum furnace technology meets the variable requirements of “demand-oriented” production. Due to the flexibility of this technology, small batch size systems can be automated with robots or as bulk material.
References
Hiller, Gerald. “The networked hardening shop – the challenge to the hardening plant in the world of Industry 4.0.” ECM GmbH. Paper presentation, 2019.
Dennis Beauchesne brings experience of over 200 vacuum carburizing cells installed on high pressure gas quenching and oil quenching installations. He has worked in the thermal transfer equipment supply industry for over 30 years, 23 of which have been with ECM USA.
Retech, which provides advanced technologies for melting and refining reactive and refractory metals, has acquired ReMelt Scientific, broadening the capabilities for the vacuum and aluminum melting divisions of the SECO/WARWICK company. The two companies have been working alongside one another for decades on a less formal basis offering consulting, collaborating and subcontracting services. This acquisition formalizes that partnership.
Earl Good Managing Director Retech
ReMelt Scientific, based in Canton, Ohio, specializes in material handling and waste processing equipment for ultra-pure remelt of recycled tailings, scrap, and revert. This acquisition brings an advanced technology experience under one umbrella for clients of Retech’s innovative vacuum metallurgy solutions.
“I think ReMelt is a valuable acquisition and it seems to fit well with the Retech portfolio and the SECO/WARWICK Group business overall,” said Earl Good, managing director of Retech.
Sławomir Woźniak President & CEO SECO/WARWICK Group
The acquisition will allow the SECO subsidiary to offer more comprehensive solutions in the vacuum metallurgy segment. Vacuum metallurgy, which involves the melting and refining of metals in a controlled atmosphere, is critical for producing high-purity metals and alloys used in various high-tech applications. Aluminum melting is a complex process that requires precise control and advanced technology to ensure the production of high-quality aluminum products. ReMelt’s knowledge in aluminum waste processing and material handling will enable its new parent company to offer state-of-the-art aluminum melting solutions that meet the industry’s stringent demands.
“While ReMelt will join the Retech division, they really are an asset to the whole Group and our worldwide operations as a whole”, said Sławomir Woźniak, CEO of SECO/WARWICK Group.
The press release is available in its original form here.
Heat TreatToday offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry. Enjoy these 18 news items.
Equipment
Blue M, a global industrial and laboratory ovens manufacturer, has announced the shipment of a stacked mechanical convection oven to be used for non-hazardous curing applications between 570°F and 750°F (300°C and 400°C).
Hammerer Aluminum Industries (HAI) has implemented a Nitrex nitriding system at its facility in Romania, replacing the traditional salt bath nitriding process. The new system has a load capacity of 3,300 lbs (1,500 kg), is designed specifically for treating extrusion dies, and offers controlled nitriding and controlled ferritic nitrocarburizing.
SECO/WARWICK recently completed three transactions: a European manufacturer of modern armament equipment and armaments supplier for NATO acquired a vacuum furnace with gas cooling and a molybdenum heat chamber; a Slovenian manufacturer ordered a vacuum furnace with 15 bar high pressure gas hardening and two nitriding furnaces; and a Turkish company purchased an induction vacuum furnace for melting and obtaining castings designed for manufacturing aviation components.
Blue M’s stacked mechanical convection oven for non-hazardous curing applicationsNitrex nitriding system to replace salt bath nitriding systemVacuum furnace and two nitriding furnaces sent to Slovenian clientSECO Vector vacuum furnace delivered to NATO member
Company & Personnel
Industry veteran Mark Stein was recently added to the Nitrex team as regional sales manager for Michigan territory. In his role, Mark will lead sales initiatives across Michigan, working directly with current and prospective clients to enhance service, optimize growth strategies, and ensure market demands are met.
To mark 175 years of innovation in specialty chemicals and distribution, Hubbard-Hall recently unveiled a new logo and a completely redesigned website. The updates reflect the company’s rich history and ongoing evolution, noting its founding year of 1849.
Bluestreak Compliance, a quality management (QMS) and manufacturing execution system (MES), has hired Rory Godsell as its new Cybersecurity Compliance Specialist to assist clients and their vendors in achieving compliance of NIST 800-171, CMMC and DFARS. He brings expertise in cybersecurity, penetration testing, ethical hacking, digital forensics, cyber operations, and project management, to the company’s mission of advancing CMMC certification services.
Steelhead Technologies, which delivers ERP, MES, and CRM solutions designed to transform job shop manufacturing, recently announced the successful completion of a $12.5M Series B funding round. This brings the company’s total funding to $23 million.
Ipsen USA announced the promotion of two team members to new roles in 2025. Matt Clinite has been promoted to Ipsen USA Sales Director, and Christina Connelly has been promoted to Director of Ipsen Customer Service (ICS) – Parts.
Mark Stein Regional Sales Manager for Michigan Territory NitrexScreenshot of Hubbard-Hall’s new websiteRory Godsell Cybersecurity Compliance Specialist Bluestreak Compliance $12.5M in funding for Steelhead Technologies Matt Clinite Sales Director Ipsen USAChristina Connelly Director of Customer Service (ICS) – Parts Ipsen USA
Kudos
Kanthal, a leader in industrial heating technology, has won the prestigious industry award “E-prize” in the category Energy Optimization for its technology that helps companies and industries transform to a fossil-free production. The award is organized by Sweden’s largest business newspaper, Dagens Industri, and the newspaper, Aktuell Hållbarhet, together with the energy group E.ON.
Aalberts surface technologies honored Olga Kovalenko, Patric Keune and Metin Önal for 25 years of commitment in Solingen. Presenting the certificates were Guido Heijnen, sales director, and plant manager Miguel Rodrigues.
TAV VACUUM FURNACES was recently awarded the title of “Best Performer Enterprise 2024 in the Province of Bergamo.” This prestigious award is reserved for the top 1000 companies in the province.
StandardAero was selected by US-Bangla Airlines, a leading Bangladeshi carrier, to provide OEM-authorized PW127M Maintenance, Repair and Overhaul Services. In addition, the company has been chosen by Brazilian Air Force to support PT6A-68C engines powering its A-29 Super Tucano Fleet, it has secured Indian DGCA Approval for its OEM-authorized PW127M Maintenance, Repair and Overhaul Services, and it has received CAAC Approval for Its LEAP-1A and LEAP-1B Engine MRO Services, enabling it to support A320neo and B737 MAX operators across China.
HeatTek, a leader in manufacturing ovens and washers, recently celebrated the company’s 25th anniversary, noting its numerous achievements since 1999, including industry accolades, editorial recognition, as well as awards identifying its positive culture as an employer. “We are incredibly proud to celebrate this milestone,” says Jason Plowman, president and 2nd generation owner of HeatTek. “The success we’ve achieved over the past 25 years is a direct result of the hard work and commitment of our employees, the trust of our customers, and the support of our partners. We look forward to continuing our journey of innovation and growth in the years to come.”
Ron Waligora, chief operating officer for AFC-Holcroft, recently announced his retirement date of May 4, 2025. Throughout his 36 years with the company, he moved through the engineering disciplines and eventually into a management role as mechanical engineering manager and later senior engineer manager in 2015. In the spring of 2023, Ron Waligora and Tracy Dougherty assumed the roles of chief operating officers. Upon the announcement of Ron’s retirement, Tracy assumed the role of president and CEO on January 1, 2025.
Aalberts surface technologies is proud to announce they have received the EcoVadis Bronze Medal. The sustainability rating reviews a company’s management of economic, environmental, and social performance, covering different industries, locations, and company sizes contributing to business sustainability on a global scale, and is based on a “best-in-class” approach, assessing whether a company reaches the best possible level for their business activity.
The Divergent team was recently granted the Nadcap12-month Accreditation for the Additive Manufacturing (AM) scope.
Solar AtmospheresGreenville, SC facility announced it has been awarded Parker Aerospace approval.
Brad Stallsmith recently marked his retirement after 43 years of dedicated service at Peters’ Heat Treating. His journey has included starting the Blade Division, mentoring new team members and ensuring high standards in processing.
Nicolai Schaaf, Sustainability Manager at Kanthal, with E-prizeMiguel Rodrigues, Metin Önal, Olga Kovalenko, Patric Keune, and Guido Heijnen, of Aalberts surface technologiesTAV board member Gerolamo Soliveri on the company’s recognition
Jason Plowman President/Owner HeatTekRon Waligora, retiring COO, AFC-HolcroftBrad Stallsmith, retiring after 43 years, Peters’ Heat Treating
Today’s News from Abroad installment highlights a new year ringing in acquisitions, partnerships and mergers resulting in increased production and expanded facilities. Read more about a heat treater developing capabilities for the advancement of vacuum heat treatment technologies, an international refractory manufacturer launching innovative operations, and a modernization project aiming to double annual production capacity.
Heat TreatTodaypartners with two international publications to deliver the latest news, tech tips, and cutting-edge articles that will serve our audience — manufacturers with in-house heat treat. Furnaces International, a Quartz Business Media publication, primarily serves the English-speaking globe, and heat-processing. a Vulkan-Verlag GmbHa publication, serves mostly the European and Asian heat treat markets.
Chinese Heat Treater Signs Agreement with ECM Technologies
M. Pelissier (left) of ECM Group & Mr. Wu (right) of Chun Yu Heat Treatment
“ECM Technologies, a subsidiary of the ECM Group, has signed a Memorandum of Understanding (MOU) with the Chinese heat treater Chun Yu, to open a Synergy Center in Shanghai. Shanghai Chun Yu Metal Heat Treatment, known as CYHT, is a customer of ECM Technologies. Geared with 3 different LPC systems from ECM Technologies, both companies agreed to cooperate on process development. CYHT is becoming the first demonstration center for ECM Technologies in China. This bilateral agreement will enable both parties to develop their activities in China around vacuum heat treatment technologies.”
RATH Mönchengladbach Opens Production Plant in Germany
International refractory manufacturer RATH opens new production plant
“The international refractory manufacturer RATH has been developing continuous oxide ceramic fibers as part of the HORIZON EUROPE project InVECOF (Innovative Value Chains for European Ceramic Oxide Fibers) for several years. A production plant for the manufacture of innovative oxide ceramic fibers has now been commissioned at the RATH Mönchengladbach site (Germany). In mid-October 2024, the company officially launched production of the ALTRA FLEX® oxide ceramic continuous fibers in K99 and M75 qualities, making it the first European supplier to offer a solution for composite material manufacturers and manufacturers and processors of heat-resistant fabrics. The new production facility will initially produce up to 10 tons of fibers per year.”
Marcegaglia Stainless Sheffield Partners with Primetals Technologies
Marcegaglia to equip all the production units of the minimill meltshop in Sheffield with automation systems from Primetals Technologies
“UK-based Marcegaglia Stainless Sheffield has partnered with Primetals Technologies to optimize production processes at its processes at its Sheffield minimill. The modernization project aims to double the plant’s annual production capacity from annual production capacity from 250,000 to 500,000 tonnes. Several intralogistics systems, process optimization solutions, technology packages and intelligent sensor systems will be installed in all production units of the in all production units of the melt shop, scrap yard and ladle tracking system.”
The ECM Group, a provider of solutions and services for industrial heat treatment companies with a subsidiary based in North America, recently acquired Vacuum Service & Maintenance (Vacuum SM), an Italian company which specializes in the maintenance of industrial furnaces for vacuum heat treatment. This acquisition will enable the company to consolidate its European presence and improve its responsiveness by being closer to its client base.
Vacuum SM anticipates the benefit of support from ECM Group while keeping its independence under the management of Roberto Bartoli, Andrea Cantarini, and Lorenzo Tirloni. The company will begin training on the products of ECM Technologies, the Grenoble-based Group’s main subsidiary.
The press release is available in its original form here.
A global supplier of equipment, systems, and digital solutions for several manufacturing sectors recently announced that it has acquired Bloom Engineering, Inc, a provider in industrial heating applications. The company will join the Freight & Industrial Components Group at Wabtec Corporation, which serves the freight and transit rail industries and is a worldwide leader in the decarbonization of freight rail.
Mike Fetsko President Freight & Industrial Components Group Wabtec Corporation
This acquisition strengthens Wabtec’s heat transfer and energy solutions, integrating Bloom’s advanced technologies in burners, combustion systems, and overall services for industrial and process heating applications. Both companies are headquartered in Pittsburgh, PA.
“This is another exciting addition to Wabtec,” said Mike Fetsko, president of Wabtec’s Freight & Industrial Components Group. “Bloom Engineering is a great fit within our heat transfer and energy solutions business, and we already serve many of the same customers. Our shared vision toward driving customer productivity within their industrial processes will enable us to deliver a more comprehensive portfolio for our customers to operate more efficiently and sustainably.”
In addition to supplying solutions for the freight and transit rail industries, Wabtec also serves the mining, marine and industrial sectors. The acquisition is expected to provide increased value to its worldwide customer base.
The press release is available in its original form here.
If you work in a standards-driven industry, you may already feel the imperative of digitalization. In today’s Technical Tuesday, Mike Loepke, head of Nitrex Software & Digitalization, posits how, even if you aren’t necessitated to track compliance digitally, you are probably looking to synthesize and leverage the strengths of multiple advanced operations — furnace and process record-keeping, knowledge of furnace past operations, juggling different new equipment capabilities — across just one platform. In other words, you are looking to bring digitalization system management to your operations.
The Future of Heat Treatment Relies on Digitalization
The ultimate goal for heat treaters, whether commercial or captive, is to uphold the quality of their product and meet client expectations while remaining profitable. Digitalization supports these efforts as it synthesizes and presents detailed, transparent, and accessible data that allows heat treaters to better manage their equipment, processes, and product quality. In addition, the collection of detailed information can serve as a database of knowledge to be used by the next generation of heat treaters, supporting future viability and advancement in the field.
There are necessary steps to take to establish a digital solution and essential components to look for when choosing a software platform that assists heat treaters in optimizing equipment and processes, effectively creating the digitalization of the heat treat operations. Let’s explore these now.
How Digitalization Optimizes Heat Treatment Processes
Digitalization in the heat treatment industry relies on the integration of industrial internet of things (IIoT) technologies with traditional and modern heat treatment processes. Using enabling devices such as sensors, modern connectivity methods, analytics, machine learning, and IIoT software platforms, it is possible for heat treaters to collect and process data that, after analysis, drives informed decisions to optimize equipment, processes, and product quality. To put a finer point on it, digitalization occurs when a manufacturing system is digitally integrated to capture and preserve human experience and knowledge, forming a holistic virtual representation of heat treat operations.
Figure 1. QMULUS Shop Layout enables visual inspection of the current production status, the
location of goods and parts, as well as the real-time status of assets and their ongoing processes. Source: Nitrex
While digitalization varies from industry to industry and plant to plant, there are some common ways in which heat treaters can employ digital technologies to build such a system. Firstly, digitally integrated solutions can optimize process management and control. For example, when a sensor detects a temperature anomaly during a heat treatment process, the integrated software platform picks up that reading, analyzes it in real time, recognizes it as an error based on historical data or programmed parameters, and alerts the operator.
This integration also facilitates predictive, condition-based maintenance. For example, if collected data and analysis suggests that a furnace is behaving abnormally, the system can automatically generate a work order along with a list of potential failure causes, so that a technician can troubleshoot, identify, and correct small issues — such as a failing thermocouple — before they impact quality or result in equipment failure. By addressing these proactively, heat treaters can avoid extended periods of costly unplanned downtime and ensure continuous operation.
Secondly, artificial intelligence through machine learning plays a crucial role in optimizing quality control in a digitalized system. By analyzing data collected during heat treating processes, it learns to detect patterns and identify anomalies. As in the examples above, this capability enables the system to identify deviations from the desired outcomes, allowing heat treaters to quickly rectify any issues before they impact quality.
Figure 2. The heart of the IIoT data platform needs to be thoughtfully planned and designed. Illustrated are 5
steps to follow to ensure the cloud data system properly engages with the data generated from your specific
heat treat operations, ultimately delivering actionable insights. Step 1 depicts the various data sources;
Step 2 shows the data transformation, integration, and processing stages; Step 3 highlights the central
QMULUS database where data is indexed and organized; and Steps 4 and 5 demonstrate how data is further
processed, distributed, and accessed by different end-users. Source: Nitrex
Thirdly, algorithms can be programmed into a comprehensive management system to identify the most energy-efficient operating conditions for the heat treating process, helping heat treaters reduce their carbon footprint, minimize energy costs, and comply with sustainability goals.
In addition to these types of operational advantages, digitalization technologies can also be used to create a database of knowledge before experienced operators and experts leave the workforce. Traditionally, a handful of experts in the plant oversee the furnaces and equipment and understand how to best control and maintain them based on experience. However, passing down this knowledge to the next generation of heat treaters can take years, which may not be possible due to a company’s workflow demands and cost pressures. Digitalization addresses this challenge by creating a streamlined and accessible database of knowledge, offering less experienced operators and technicians immediate access to detailed information about what may be happening in the equipment or process for an issue at hand. This ensures that essential insights are not lost and enables quicker problem-solving and decision-making on the shop floor.
Making the Digitalization Transformation
While digitalization presents obvious advantages, the heat treatment industry, often conservative in its approach to technology, has some initial work and investment required before realizing the full benefits.
Going “paperless” in order to unlock the full potential of the available data is an important first step. All reports, histories, drawings, and other paperwork associated with equipment, processes, maintenance activities, product quality, and other relevant information should be digitized to provide a comprehensive view of both historical and current data.
Connectivity and integration between machine and higher-level systems are essential for effective data acquisition, monitoring, and remote control. SCADA systems, Manufacturing Execution Systems (MES), and other higher-level systems are rich sources of machine and process data. Gathering and analyzing this data can provide actionable insights that operators can use to make smarter decisions about the control and maintenance of equipment and processes.
Figure 3. A comprehensive overview displays all detected control loop anomalies, indicating possible root causes as well as recommended actions. Incorporating feedback from the responsible maintenance personnel further improves accuracy and delivers more effective recommendations for future
occurrences. Source: Nitrex
Finally, just having data is not enough. The data must be accessible, transparent, and relevant to be valuable. Achieving a complete picture of all the collected data, known as data consolidation, is necessary.
To build an IIoT platform with a well-architectured data engine, heat treaters should begin by identifying and understanding the different sources of data provided by sensors and high-level systems. This involves integrating the data through interfaces adapted to the data type and source, as well as documenting the integrated data sources, data fields, and data streams. Next, a “data lake” should be created to store the collected raw data. From this foundation, a data warehouse can be established to store enriched or analyzed data, derived values, data models, and forecasts in an organized way. For heat treaters, this type of contextualized data might be grouped by parts, loads, or orders.
Once the data engine is in place, the information stored in the data warehouse must be presented in a way that makes sense to operators and technicians for them to make informed decisions for heat treatment processes. To facilitate this, a universal data interface should be considered.
Building from this well-architectured data engine, the IIoT platform can then be expanded with statistical analytics, remote monitoring, KPI tracking, machine learning, artificial intelligence, and other applications to optimize processes and increase profitability.
What Heat Treaters Need in a Digitalization Solution
Harnessing modern technologies tomake digitalization a reality presents heat treaters with the opportunity to implement a solution based on a complete and well documented data system. It also means that the solution creates a holistic solution to data analysis, interpretation, reporting, and action that supports the real-world actions of heat treaters on the plant floor and in the office.
For this reason, a digitalization solution that has cloud and on-premises allows real-time access to analysis and alert messages for operators on the floor as well as managers who are away from the plant, ensuring quick problem-solving and maximum uptime in the event of process or machine issues.
Additionally, heat treaters should look for a solution that offers the freedom to integrate all the various platforms and equipment from which data are gathered from. These may include relevant machinery and production data from the shop floor as well as third-party and custom controllers. This flexibility to synthesize information from multiple sources will ensure the digitalization efforts lead to a comprehensive solution with actionable process overviews, recipe control, batch tracking, and other customization options.
To further this intent of a holistic solution, heat treaters should consider various data capabilities with different portal views, such as a manufacturer portal, a plant portal, and a client portal. However, considering the historic value of a comprehensive software solution, it may be worthwhile to consider how each user could transfer direct feedback and add new rules into the system, creating a repository of knowledge that bridges the knowledge of outgoing generations to future heat treaters.
Finally, any platform that directs the digitalization of a plant must prioritize robust security measures. Several features to look for are:
enhanced encryption standards to keep data confidential and tamper-proof during transmission and storage;
secure protocols based on industry best practices to safeguard data integrity;
a granular access control system (ACS) to allow IT administrators to define and manage user permissions of authorized personnel, thereby minimizing the risk of data breaches and unauthorized data manipulation; and
intrusion detection and prevention systems to continuously monitor network and system activities, enabling instant identification and mitigation of suspicious behavior. This serves as an additional layer of defense against potential cyber threats.
Beyond the software setup, be sure to use best practices by conducting regular security audits to assess the platform’s vulnerabilities and ensure compliance with evolving cybersecurity standards. While digitalization of heat treat operations may seem like a task for the next generation to complete, secure software options that integrate the hard work of digitizing plant activities can make this endeavor just a step away.
About the Author:
Mike Loepke Head of Nitrex Software & Digitalization Nitrex
Drawing from a background in Mathematics and Physics, coupled with extensive R&D experience and metallurgical modeling, Mike Loepke specializes in AI and process prediction. He has led Nitrex’s initiative in developing QMULUS, a pioneering IIoT cloud-based platform. Mike’s relentless pursuit of knowledge keeps him at the forefront of evolving technology.
Heat TreatToday publishes twelve print magazines a year and included in each is a letter from the editor, Bethany Leone. In this installment, which first appeared in the December 2024 Medical & Energy Heat Treatprint edition, Bethany addresses the ongoing discussion about automation in industry, the data on how it affects labor, and the way forward for manufacturing and the government.
Feel free to contact Bethany at bethany@heattreattoday.com if you have a question or comment.
You can afford it.
Supervisors, you can afford to raise wages. Skilled laborers, you can afford to purchase a home.
Maybe you’ve heard these hopeful statements before? You can afford it, says economist Mark P. Mills, executive director of the National Center for Energy Analytics, by leaning on automation. Far from destroying jobs, tools like AI and robotics enhance productivity and require highly skilled laborers who, in turn, can and should be compensated. This editor’s page summarizes some of Mills’ main points and how these might be considered in the heat treat industry.
Labor Market Needs Automation
In a recent article released in City Journal, the economist draws attention to what he sees as a new norm for the labor market: the successful bargaining for higher wages by the Longshoremen’s Association. The result of the union’s strike means a starting salary of $80k and a mid-career salary of $150k. Mills terms this “The Great Inversion,” where we see salaries for the trades supersede 90% of salaries for college graduates.
His argument that this is the new norm rests on three points. The first is that population has been in decline; this is exacerbated in the trades by the fact that the average age for skilled tradesmen is older than the average age across U.S. manufacturing.
Secondly, though there is a trend of young workers choosing a career in the trades, not enough would fill the generational chasm that is opening as the older generation leaves the workplace. This means there is still a demand for skilled labor.
Thirdly, industrial manufacturing creates consumable goods, for which there is no end to want, unlike in food and agriculture where there is a limit of consumption. As people grow wealthier, they can afford more “wants” — even if it’s going out to eat at restaurants where iPads automate server-kitchen communications.
Even with the population decline, individuals continue to gain wealth and want to spend it, Mills explains. In this situation, particularly where we have efforts and interests in America restoring industrial productivity, the argument is that automation will allow companies to keep up with the demand for consumable goods while filling the labor gap. This result means a need for upskilling workers to work with robotics, automation software, and AI on the manufacturing floor.
Automation in Heat Treat
In the heat treat industry, I’ve heard several perspectives on this topic. Robotics and automation don’t take away jobs, some claim; they only improve labor market jobs that are there. At another’s operations, the installation of an automated piece of instrumentation didn’t result in any immediate layoff, but did result in the company not having to train an operator to fill a position since that position was no longer available.
The fact is that the pro-automation side relies on addressing situations where there is a lack in able workers in the labor market. This demonstrates that jobs are being filled by automation.
Turning to employment opportunity, it is hard to argue with Mills’ outlook that automation in jobs increases wages and profits. He supports this claim saying, “data show that, over the last half of the twentieth century, even as manufacturing productivity rose (that is, fewer labor-hours per output), the U.S. manufacturing workforce remained surprisingly unchanged and really started to shrink only when an increasing share of manufactured goods were imported — namely, when the production and labor were exported.” Interestingly, while he acknowledges the role of companies in offshoring goods in the last century, he puts focus on the difficult environment for businesses in meeting the government regulations in America. Therefore, he offers three steps forward addressed at government (in)action:
The U.S. government must look for ways to make the country more amenable to industrial expansion that go beyond subsidies with caveated use.
Policymakers must avoid intervening in the economy when a system isn’t broken. (Here, Mills addresses cost and reliability issues tied to state and federal energy policies.)
The trifecta of policymakers, unions, and manufacturers need to welcome advances in automation.
Mills points out that in order for automation to be successful, skilled laborers need to welcome it and help it, emphasizing that, like the Longshoremen’s Union strike, automation allows for wage increase.
My question to you in the heat treat industry is: What is your job function in the industry? How have you benefited from automation (AI, robotics, digitalization) initiatives in the industry? What concerns — or hopes! — do you see that have yet to be addressed? Write to me. And if any article on digitalization in this magazine strikes you, I would love to hear that, too.
References
Mills, Mark P. “The Longshoremen’s Strike and the Great Inversion.” City Journal, October 8, 2024. https://www.city-journal.org/article/the-longshoremens-strike-and-the-great-inversion.
