the other white metal - sholehsanat.irsholehsanat.ir/magazine/february 2015 - · used as an...

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The International Journal of Thermal Processing FEBRUARY 2015

INSIDE

6 IH Connect34 Combustion Resources44 Firebricks Save Energy48 Cutting-Edge StainlessA Publication • Vol. LXXXIII • No. 2www.industrialheating.com

The Other White Metal 38

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6 FEBRUARY 2015 ■ IndustrialHeating.com

IH CONNECT

Welcome to IH Connect. Here’s a quick and convenient way to connect with leading industry

suppliers through social media, website or e-mail. Below is a list of advertisersin this month’s issue. Surf, follow, friend or connect with them to stay abreast of the latest technologies in the industry.

Across Internationalwww.facebook.com/AcrossIntltwitter.com/acrossintlinfo@acrossinternational.comwww.acrossinternational.com

Ajax TOCCO Magnethermicwww.linkedin.com/company/

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Can-Eng Furnaces Internationalwww.linkedin.com/company/

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Custom Electric [email protected]

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G-M [email protected]

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INEX [email protected]

J.L. Becker, a Gasbarre Furnace Group [email protected]

Kureha America [email protected]

Protection Controls [email protected]

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Saint-Gobain Ceramicswww.facebook.com/saintgobaingroupwww.linkedin.com/company/saint-gobaintwitter.com/saintgobainwww.youtube.com/user/[email protected]

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Tinius Olsenwww.facebook.com/TiniusOlsentwitter.com/[email protected]

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IndustrialHeating.com ■ FEBRUARY 2015 9

FEATURESIndustrial Gases/Combustion

Combustion ResourcesReed Miller – Editor, Industrial HeatingIn this article, we strive to make you aware of resources that exist to help you make better sense of combustion-related issues and answer your combustion-related questions.Read it online at www.industrialheating.com/combust

Nonferrous Heat Treating

Aluminum:The Other White MetalPeter Hushek – Phoenix Heat Treating, Inc.; Phoenix, Ariz.While many heat-treating companies have moved from general processing to selective processes, the trend has been mainly to one of specialization. The thinking is that specializing will simplify focus on process improvement, enhance productivity and increase profitability. Read it online at www.industrialheating.com/whitemetal

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Ceramics & Refractories/Insulation

Using Insulating Firebricks to Maximize Energy SavingsSteve Chernack – Morgan Thermal Ceramics; Augusta, Ga.Selecting products made with the right manufacturing process makes the difference. This article demonstrates the energy savings related to using cast versus other forms of IFB.Read it online at www.industrialheating.com/IFB

Nonferrous Melting/Forming/Joining

Producing the Highest Quality Stainless Steel CutleryRichard F. Speaker – Air Liquide Industrial U.S. LP; Houston, TexasDick Desaulnier – Dexter-Russell Inc.; Southbridge, Mass.Troubleshooting furnace heat-treatment quality issues, such as oxidation and discoloration, can sometimes be challenging. At times, normal, conventional troubleshooting steps and techniques may not always work. This article discusses the experiences of a knife manufacturer, and our sidebar covers a melting discussion.Read it online at www.industrialheating.com/cutting

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CONTENTS FEBRUARY 2015



CONTENTS FEBRUARY 2015

COLUMNS Editor's Page Nonferrous is Big and Getting BiggerThere seems to be a lot of nonferrous news lately, and we’ll do our best to pass it along. Check out this column for information from Alcoa’s annual meeting as well as news about GM’s increasing use of aluminum.

Federal Triangle Time to Fix our National DilemmaBarry Ashby asks, then tries to answer, a very important question: What does America do about public disenchantment with federal government? As the author describes, this problem has a profound impact on U.S. industry.

The Heat Treat Doctor® Lightweight Metals for the Transportation IndustryWe will learn more about the battle being waged between aluminum and alternative materials in the transportation industry. To understand who will win and why, one must look at the drivers this industry faces to stay technologically relevant as well as the lightweight material options, properties and costs.

International China's Way to Professionalization and CatenationThere are more than 1,000 heat-treat facilities in China. Most of the 300 largest are in the Yangtze River Delta and Pearl River Delta. Over time , their developing trend is professionalization and catenation.

MTI Profi le Zion Industries

IHEA Profi le Educational Opportunities in 2015

DEPARTMENTS28 Industry News

32 Industry Events

33 Economic Indicators

52 Products

54 Literature Showcase

55 The Aftermarket

56 Classified Marketplace

62 Advertiser Index

On the Cover:

Workers at Phoenix Heat Treating relocate a liquid-nitrogen tank from under a drop-bottom solution heat-treat furnace to where the aluminum parts can be removed.

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INDUSTRIAL HEATING (ISSN: Print 0019-8374 and Digital 2328-7403) is published 12 times annually, monthly, by BNP Media, Inc., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualifi ed individuals. Annual

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GAME CHANGING INNOVATIONFOR THE AUTOMOTIVE INDUSTRY

WITH CAN-ENG’SLIGHTWEIGHTINGTECHNOLOGY...

LESS IS MORE

CAN-ENG FURNACES INTERNATIONAL LIMITED is the industry leader in the development of automated heat treating systems for the processing of light-weight aluminum automotive structural components. For an innovative response to your design challenges, email Tim Donofrio at: [email protected] to learn about CAN-ENG’s latest advances in energy saving technology, material handling and automation.

The latest advancements in the processing of aluminum automotive structural components: Batch, Modular and Continuous Heat Treatment System ConceptsOverhead Conveyor and Roller Hearth Conveying Systems for the Solution and Aging Treatment • Hybrid Water and Precision Air Quench (PAQ) Systems Required for Thin Walled Components • Rapid Heating – Short Cycle Hot Air Impingement DesignsInfrared Heating • Rapid Quench Transfer Designs • T-4, T-5, T-6 & T-7 Processing Systems

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Manor Oak One, Suite 450, 1910 Cochran Rd., Pittsburgh, PA 15220412-531-3370; Fax: 412-531-3375; Online: www.industrialheating.com

MANAGING DIRECTOR John Schrei [email protected]; 248-786-1637

GROUP PUBLISHER Darrell Dal Pozzo [email protected]; 847-405-4044

EDITORIAL/PRODUCTION STAFFReed Miller Associate Publisher/Editor – M.S. Met. Eng., [email protected]; 412-306-4360 Bill Mayer Associate Editor, [email protected]; 412-306-4350Linda Becker Contributing Editor, [email protected]; 262-564-0074 R. Barry Ashby Washington Editor, [email protected]; 202-255-0197Dan Herring Contributing Technical Editor, 630-834-3017; [email protected] Peters Contributing Editor, [email protected]; 216-570-4537Karen Talan Production Manager, [email protected]; 248-244-6246Brent Miller Art Director, [email protected]; 412-306-4356

AUDIENCE DEVELOPMENTJillian Chiudioni Audience Marketing Coordinator Alison Illes Multimedia SpecialistAnna C. Silvestri Audience Audit ManagerFor subscription information or service, please contact Customer Service at: [email protected]; 847-763-9534 or Fax: 847-763-9538

LIST RENTALPostal & Email ContactsKevin Collopy Sr. Account Manager; 402-836-6265,Email: [email protected]; Toll Free: 800-223-2194, ext. 684Michael Costantino Senior Account Manager, [email protected]; 402-836-6266

ADVERTISING SALES REPRESENTATIVESKathy Pisano Advertising Director and Online Advertising Manager, [email protected]; 412-306-4357, Fax: 412-531-3375Becky McClelland Classifi ed Advertising Mgr.,[email protected]; 412-306-4355Rick Groves Eastern Sales Manager, [email protected]; 248-244-6444; Fax: 248-502-2109Steve Roth West Coast Sales Mgr., [email protected];520-742-0175, Fax: 847-620-2525Hamilton Pearman European Sales Representative, +33 (1) 45 93 0858,[email protected]. V. Shivkumar India Sales Representative, [email protected]. Arlen LUO Newsteel Media, China; [email protected];Tel: 0086-10-8857-9899, Fax: 0086-10-8216-0061Becky McClelland Reprint Quotes; [email protected]; 412-306-4355

SINGLE COPY SALESAnn Kalb [email protected]; 248-244-6499; Fax: 248-244-2925

CORPORATE DIRECTORSJohn R. Schrei PublishingRita M. Foumia Corporate StrategyMichelle Hucal Content DeploymentMichael T. Powell CreativeScott Wolters EventsLisa L. Paulus FinanceScott Krywko Information TechnologyMarlene J. Witthoft Human ResourcesVincent M. Miconi Production

Product of the Month: Hydraulic TesterTinius Olsen’s SL series represents the highest standard in hydraulically powered universal testing machines. It features a patented dual-pressure hydraulic loading system and a rugged four-column construction for exceptional load frame rigidity.

Web Exclusive2014 Feature Article BibliographyThis is a complete list of all the feature articles that appeared in Industrial Heating in 2014. All articles are listed by topic and include month and page number. This is a great resource for those that like to keep tabs on what appears in our pages throughout the year.

Atmosphere Heat TreatmentVolume I: Principles, Applications, EquipmentThis book, written by Dan Herring, will make a comprehensive resource on atmosphere heat treatment and provide readers with a wide range of useful information, both from a practical and technical standpoint. Readers will be able to make better and more-informed decisions about their equipment, process and service needs. What makes this book unique is that it is written specifically for the heat treater, engineer and metallurgist by one of their own.www.industrialheating.com/aht

Heat-Treat WheelLooking for great resources to provide an overview of metallurgy and the heat-treatment industry? Industrial Heating has created a “wheel” that contains editorial content for many high-temperature thermal processes in one place. Each spoke of the wheel is clickable to some of our most popular articles. http://www.industrialheating.com/htwheel

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February is our focus on nonferrousmaterials and processing. There seems to be a lot of nonferrous news lately, and we’ll do our best to pass it along.

On Monday, Jan. 12, Alcoa held a public meeting to discuss 2014 and look forward to this year. Through the marvels of technology, we “sat in” on this meeting. It was a good year for Alcoa and other aluminum manufacturers after several not-as-good years. The growing usage of aluminum (more on that later) has resulted in an increase in aluminum prices of 27% since February 2014. For Alcoa, this resulted in a 14% increase in revenues last year. In the fourth quarter, their cash from operations was the highest in Alcoa’s history. Adjusted earnings in 2014 was the highest experienced since 2008. Alcoa CEO Klaus Kleinfeld predicted 7% global growth in 2015. Kleinfeld highlighted six different industry segments, predicting some growth in each. Aerospace is expected to be the largest at 9-10%. Keep an eye on their Micromill™ process for the next generation of aluminum sheet.

Aluminum NewsAutomotive is certainly a large reason for thegrowth in aluminum demand. Ford introduced its all-aluminum F-150 this fall, and as I write, the F-150 was taking the truck-of-the-year prize at

the 2015 North American International Auto Show in Detroit. How much higher is the price of the truck due to aluminum? We have seen different numbers from $395 to $3,000. General Motors plans to introduce a largely aluminum-bodied truck by 2018, and they have signed contracts with both Alcoa and Novelis to meet these sheet demands. Around 70% of this material will need to be 6xxx heat-treatable aluminum sheet, which will require a tremendous increase in heat-treating capacity in the aluminum industry to meet this growth. GM’s 2014 Corvette Stingray and 2015 Z06 convertible are using an all-aluminum frame with cutting-edge joining technology. GM has patented

a process for resistance spot welding, which is incorporated along with laser welds, structural adhesives and machined fasteners. Incorporating aluminum in such a demanding application would not be possible without recent advancements in computer-aided engineering software. More than 17,000 frame iterations involving 186,000 computational hours were required to develop the aluminum frame. The surge in aluminum demand is due in part to aluminum-lithium alloys. These are described in this month’s Heat Treat Doctor® column. As Dan Herring mentions, the alloy is being used on NASA’s Orion crew module. Increased demand for Al-Li will continue to be a boon for Alcoa. Kleinfeld mentioned that the FAA recently certified Al-Li for Pratt & Whitney’s PurePower® engine. A recent report indicates that the global alumi-num alloys market is expected to grow at an annual rate of 4.8% from 2014 to 2020. The need for recycled aluminum alloys is also expected to expe-rience a rise. Globally, the key players driving the aluminum market are Aluminum Corp. of China Ltd., United Company RUSAL Plc, Norsk Hydro ASA, Alcoa Inc. and Dubai Aluminum Co. Ltd.

RegulationsAs 2015 unfolds, we encourage you to payattention to new regulations and executive orders that may affect your business. We warned everyone in this column last year that the current administration may begin to move with a new sense of urgency in their last days. In the first seven days of 2015, 300 new rules were unveiled, according to federal data (www.regulations.gov). Included are proposed EPA air-quality standards for lead and National Ambient Air Quality Standards for Ozone. A major, not-yet-finalized rule is the EPA’s carbon dioxide emissions limits for new power plants. The rule would limit the amount of CO2that can be emitted by newly built facilities. The limit is so low that it could only be met by coal plants if they use carbon capture and storage (CCS) technology, which has yet to be used on a commer-cial scale without government subsidies. What will this do to energy costs, and how will that affect our energy-intensive industry? Stay tuned.

Nonferrous is Big and Getting Bigger

REED MILLERAssociate Publisher/Editor

[email protected]

EDITOR'S PAGE

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Public disenchantment with all threebranches of federal government (numerous polls show this regularly by a two-to-one margin) raises an important

question: What does America do about this problem? America has prospered mightily with our Constitution as supreme law. There is no clause or implied power in the national or various state constitutions that enable a state to veto federal laws unilaterally. Further, the Constitution authorizes Congress to exercise only those powers enumerated in Section 8, Article I, and nowhere does it authorize the Executive branch to make any law. Our marvelous Constitution, defined by our founders, cites but five ways our citizenry can change real and perceived problems.

1. Change political leadership via elections2. Defund implementation of laws by vote of

Congress3. Change or repeal laws by legislative action4. Challenge objectionable law and regulation

in court(s) to gain resolution5. Amend the Constitution.

As a practical matter, these remedies are cumbersome and time-consuming (purposefully in my view) to inhibit misuse, and they are not always applicable. As one observer put it, “How does government defund Executive-ordered amnesty?” In addition, federal courts have already ruled multiple times that the approach of claiming state sovereignty over enforceable law is unconstitutional (no kidding). All of this is becoming important as several states are initiating “nullification” laws whereby a state exempts itself from federal laws (and successive outgrowths of regulation) or judicial action not to its liking. A recent such action is Texas House Bill 98, which proposes a bicameral committee charged with reviewing all federal actions to determine if it is unconstitutional or incompatible with state law. This is not a new approach. Historically, nullification has not proven effective. Efforts to enact nullification have been a failure primarily due to politicians in those states, where attempts and results are still dithering with no resolution.

It seems that in the real world the only possible hope for successful use of nullification can derive from a majority of states using the process collectively. We might otherwise call this a Constitutional amendment process. And it is important to remember that our founders did not specifically address the concept of what is now termed nullification, but they did uniformly state that the power to declare laws unconstitutional is delegated to federal courts. The essence of the concept of nullification has plagued us repeatedly, and the to-and-fro on these matters is certainly one of the biggest points of dispute between federal and state governments and the interests of the people. It is important to understand three things. State officials are not bound to enforce federal law that the state determines to be unconstitutional, and Congress cannot mandate that states enact such laws. Secondly, states may not block federal authorities that attempt to enforce a federal law unless a court with proper jurisdiction has determined that the law is unconstitutional. And, last but not least, individuals are not exempt from prosecution by federal government when their state of residence has legalized an activity or pronounced that a federal law is unconstitutional. The impact these matters have on U.S. industry are as obscure and convoluted as you can imagine. Laws and regulations at issue recently included implementation of the Affordable Care Act; the increased cost of gas and electric energy due to EPA emission regulation on suppliers; the costs of emission-control regulations (gas, liquid and solid) on manufacturers; and increased taxes on corporate earnings. A study appearing in Journal of Economic Growth (see March 21, 2013; J.W. Dawson and J.J. Seater) cites “total factor productivity” as composed of traditional governmental inf luences of spending, taxation, deficit and monetary policy, to which they add regulation. The study indicates a 28% reduction in American GDP as a result of federal intervention since 1949, the inception of our regulatory onslaught. What can or will be done about these matters? We don’t yet know, but my prediction is that this topic will be at the core of a coming U.S. crisis.

Time to Fix our National Dilemma

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Several newsworthy items crossedThe Doctor’s desk late last year: the announcement that Alcoa officially opened the world’s largest aluminum-lithium plant

in Lafayette, Ind., (IHDaily NewsBrief, Oct. 15); the release of The Aluminum Quick Reference App (ASM International, Oct. 16); and word that Alcoa has signed a $1 billion contract with Boeing to supply multiple aluminum components over the next several years (Oct. 20). These announcements peaked The Doctor’s interest in learning more about the battle being waged between aluminum and alternative materi-als in the transportation industry. To understand who will win and why, one must look at the drivers this industry faces to stay technologically relevant as well as the lightweight material options, proper-ties and costs. Let’s learn more.

Automotive Fuel consumption, greenhouse gas (GHG) emissions and global dimming/warming are the principle drivers for change in the automotive industry. For every 100 kg of weight reduction in an automobile, a fuel savings of 0.3-0.5 L per 100 kilometers is possible with a reduction in CO2emissions of 0.8-1.1 kg per 100 kilometers. The interest in moving to aluminum and other lightweight alloys in automobiles is fueled in large part by government regulations/mandates, cost (performance versus cost in dollars saved

per kilogram), safety (i.e., How light should we go?) and performance (acceleration, braking, handling, noise, vibration and harshness). Other options are conventional low-carbon steel, with a cost advantage while targeting weight reduction; and HSLA steels and AHSS (advanced high-strength steels, or so-called “lightweight steel”), where weight reduction is achieved by thinner/lighter material made possible by higher strength. Aluminum advantages are in the total amount of aluminum used per vehicle, life-cycle/recycling advantages, space frame versus monocoque (i.e., skin or “egg shell”), loading and forming/joining (e.g., the absence of spot welds, use of rivets, etc.). An example is the Corvette Z06 (Fig. 1), which is ranked as Car & Drivers’ number-one performance-ranked coupe and convertible. It can achieve 650 horsepower in a choice of two transmissions: a 7-speed manual or an 8-speed paddle-shift automatic. The driver-centric Z06

Lightweight Materials for the Transportation Industry

THE HEAT TREAT DOCTOR®

DANIEL H. HERRINGThe HERRING GROUP, Inc.

[email protected]

Table 1. Aerospace aluminum alloys

Alloy series Alloy Properties Applications

1xxx Pure Low strength, excellent thermal/electrical conductivity and corrosion resistance, high refl ectivity

Fuel fi lters, electrical conductors, radiator tubing, lighting refl ectors, decorative components

2xxx Cu High strength, relatively low corrosion resistance, good elevated-temperature strength

Aircraft skin, fi ttings, wheels, ballistic armor, forged and machined components

3xxx Mn Medium strength, good formability, good corrosion resistance Storage tanks, heat exchangers, pressure vessels

4xxx Si High castability, high machinability, high fl uidity, low ductility Large housing castings

5xxx Mg Medium strength, good formability, excellent marine corrosion resistance Interior trim, pressure vessels, armor plate, marine and cryogenic components

6xxx Mg, Si Medium-to-high strength, good corrosion resistance, easily extruded Piping, marine screw stock, door and window frames, exterior trim

7xxx Zn Very high strength, prone to stress corrosion, poor corrosion resistance Aircraft construction, armor plate

8xxx Li Very high strength, low density Aircraft and aerospace structures, foil, heat-exchanger fi n stock

Fig. 1. Corvette Z06 showcasing the use of lightweight alloys

Courtesy of Chevrolet



includes technologies like a Driver Mode Selector, which allows for customization of vehicle performance dynamics with the turn of a knob. On or off the track it is available with an industry-exclusive Performance Data Recorder, which records high-definition video with telemetry overlays on playback.

Another example is the number-one selling truck in the U.S., the Ford F150, which has undergone a dramatic redesign taking advantage of the best of steel and lightweight alloys. Aluminum alloy 6463 is used in the body and bed to reduce the total vehicle weight by 320 kg (705 pounds).

BMW has introduced an Al-Mg die-cast engine block, which is 15% lighter than a comparable all-Al alloy engine. Both BMW and GM have an all Mg block (Fig. 2) under development that is 25% lighter than an all-Al engine.

AerospaceAluminum has a long history in aviation (Table 1). Fuel consumption, GHG emissions sustainability and global dimming/warming are also the principle change drivers in the aerospace industry. Aluminum’s dominance is being challenged today by GFRPs (graphite-fiber reinforced plastics), carbon/carbon composites and aluminum-lithium alloys.

For example, the Orion spacecraft (Fig. 3) has olive-green aluminum-lithium metal panels designed to be covered by an ad-vanced version of the thermal protection tiles that were earlier used on the space shuttle. Design challenges such as pressure testing cracks during weld strength testing have yet to be fully addressed.

Alloying with lithium reduces structural mass by three effects:• Displacement: A lithium atom is lighter than an aluminum

atom. Each lithium atom then displaces one aluminum atom from the crystal lattice while maintaining the lattice structure. For every 1% (by weight) of lithium added, the density of the resulting alloy is reduced by 3% and increases in stiffness by 5%. This effect works up to the solubility limit of lithium in aluminum, which is 4.2%.

• Strain hardening: Introducing another type of atom into the crystal strains the lattice, which helps block dislocations. The resulting material is stronger, which allows less of it to be used.

• Precipitation hardening: When properly aged, lithium forms a metastable Al3Li phase (δ’) with a coherent crystal structure. Precipitates strengthen the metal by impeding dislocation motion during deformation.

Finally, all-aluminum combat ships have been introduced and are designed to be fast, maneuverable and modular – or, as they like to say in the Navy, lethal, f lexible, survivable and affordable. Aluminum in the 5xxx series (e.g., 5086, 5083, 5456, 5454) and 6xxx series alloys (e.g., 6005, 6061, 6082) are in use. The properties and attributes of aluminum that make it an attractive choice are its high strength-to-weight ratio; density (one third of steel); corrosion resistance (although pitting and crevice-corrosion problems have arisen); weldability; ease of forming, bending and machining; availability and diversity of semi-finished products; high thermal and electrical conductivity; nonmagnetic properties; and recyclability. ConclusionWhat stands out in this discussion is that the materials are changing and with them our role as heat treaters. Moving forward, changes in the alloys, product form, function and specifications will influence (and perhaps dictate) the way in which we will perform heat treatment.

References1. Herring, Daniel H., Aluminium Battles Alternative Lightweight

Materials in the Transportation Race, Presentation at the SECO/WARWICK Aluminum Seminar, October 2014

2. Professor Joseph Benedyk, Illinois Institute of Technology/Ther-mal Processing Technology Center and Editor Light Metal Agemagazine, technical contributions and private correspondence

3. DOE briefing on Automotive Magnesium R&D for Lightweighting, 2014.

4. Chicago Auto Show, 20145. Aluminium Exposition, Dusseldorf GmbH, 20146. Aeromat 20157. Commander Fred Latrash, U.S. Navy (retired), Dr. Brett Conner,

Alcoa Defense and Derek Novak, ABS Americas, Webinar on “Advantages of Aluminum in Marine Applications,” 2014

Fig. 2. All-magnesium, six-cylinder engine block developed by the DOE with GM’s R&D team

Fig. 3. Astronaut compartment on the Orion spacecraft

Cour

tesy

of N

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ince the 1980s, the automotive,mechanical equipment, aerospace and aviation, rail transit, wind power and nuclear power industries in China

have developed at a rapid pace. The necessary assemblies and basic parts are also developing quickly. As a result, the demand for heat treating is growing to keep pace. Meanwhile, the existing heat-treat equipment in China is comparatively backward and badly in need of transformation and upgrade. Motivated by energy conservation, consumption reduction, environmental protection and cost reduction, the way forward for heat treatment in China is to focus on commercial heat treating with professionalization and catenation. The market share of in-house heat treating will reduce, and commercial heat treating will increase. There are three key problems in manufacturing basic parts in China: short life, bad reliability and heavy structure. Heat treatment and surface technology are suitable solutions to these problems. In total, there are more than 10,000 heat-treat facilities in China. About 3,000 of these are commercial heat-treat facilities, most of which are private enterprises. Most of the 300 largest are in the Yangtze River Delta (e.g., Shanghai, Zhejiang province, Jiangsu province) and Pearl River Delta (e.g., Guangdong province). The market and services of these facilities are regionalization. That is to say, their customers are also in the same area or same province. In the long run, the developing trend is professionalization and catenation. A good example is Bodycote, a very famous global heat-treat company. Many countries and regions have Bodycote facilities. Many good and large customers of heat treating

are already professionalized and catenated (e.g., automotive and aerospace). These customers have factories in South China, East China, Central China, Southwest and Northwest China. If their heat treaters can offer them standard service with high quality and consistent productivity, it will be a win-win situation. More professional commercial heat-treat companies will also need more advanced equipment and materials. During China’s 12th Five-Year Plan (from 2011-2015), the demand for controlled atmosphere continuous furnaces will be 150 sets each year. For sealed multipurpose furnaces as well as vacuum heat-treatment furnaces, 300 sets of each will be needed each year. The demand for ceramic fiber will be 30,000 tons each year, and quench-oil demand will be 50,000 tons each year. Additionally, the development of advanced processes – step isothermal quenching, intensive quenching, gas nitrocarburzing, ion nitriding, sealed multipurpose furnaces, high-pressure gas-quenching (HPGQ ) vacuum furnaces, etc. – will be given priority. I believe that there will be more and more professionalized and catenated heat treaters and well-known companies in China in the coming years. I look forward to, and welcome, that future.

China’s Way to Professionalization and Catenation

INTERNATIONAL

ARLEN LUO Editor,

Industrial Heating [email protected]

S


Introducing the new CamProTM, stationary camshaft heat treating system. Building on Inductoheat’s patented SHarP-C

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for Crankshafts/Camshafts), this machine can produce a higher quality part with almost undetectable distortion, shorter cycle times and longer inductor life compared to conventional heat treating. The CamProTM offers superior results while using less energy compared to conventional induction camshaft hardening.

Call or click today to learn more about our induction systems!Inductoheat, Inc. 32251 North Avis Drive

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MTI PROFILE

ob and Dorothy Puls took a chance wayback in 1977. It was then that Bob decided to leave his job as a production manager for a growing screw machine business in

northeast Ohio and start his own company. He saw a need in the Cleveland area for an induction heat-treating facility that focused on high-volume work. The answer was Zion Industries.

Today, 38 years later, Zion Industries hasapproximately 100 employees at three locations (all of which are ISO/TS 16949 certified): Valley City, Ohio; Grand Ledge, Mich.; and Hildebran, N.C. Bob Puls Jr., Bob and Dorothy’s son, opened Zion Industries’ North Carolina facility in 2000. He returned to Ohio in 2003 to take over the role of president. The Michigan plant started production in January 2005. The company provides induction services – including heat treating, annealing, tempering and brazing – to primarily the automotive, lawn and garden and hand-tool industries. One thing that sets the company apart from the competition is that it is fully self-sufficient. As Puls Sr. did 38 years ago, Zion Industries still designs and engineers its induction equipment and systems. It also makes its own tooling and induction coils in-house, most of which are dedicated specifically to a particular customer’s production program. This all means that it does not have to rely or wait on third-party sources to meet demanding deadlines. Zion Industries is able to operate this way because of its employees’ wealth of industry knowledge and depth of professional experience. Zion Industries typically works with parts that are able to be picked up by hand, usually 40 pounds or less. The company is capable, however, of processing shafts up to 60 inches in length. It

is currently in production on a 12 million piece-per-year project, where it processes one piece every second. As for equipment, Zion Industries has a system that is used to process more than 2,000 fasteners per hour. Throughout the entire organization, the company has more than 30 induction machines ranging in power from 5-300 kw and frequencies from 3-450 khz. It can handle volumes from single-piece process f low to fully automated systems. The company isn’t dedicated only to induction services. Zion Industries offers magnetic particle inspection services, prototype development and consulting services. It also, from time to time, receives requests to build induction material-handling equipment. Having three separate locations has proven to be extremely beneficial. If a catastrophic event were to occur at one plant, Zion Industries can switch production to another plant until repairs are made. This minimizes the potential for any downtime. The company’s induction machines are designed to be portable, so it can transport equipment around within buildings or from plant to plant. Each facility operates on the exact same system, so any company employee can walk into any site any day of the week and immediately be productive. Zion Industries operates three shifts a day at each plant. It’s impressive how far Zion Industries has come in a relatively short time frame. The company recently doubled the size of its North Carolina plant and kicked off production with dual automated induction systems. It also recently put a specially designed system into service at its Michigan facility. Visit www.zioninduction.com for more information on Zion Industries.

Zion Industries Induction Heating Specialists

MTI Metal Treating Institute

904-249-0448www.HeatTreat.net

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IHEA PROFILE

he Industrial Heating EquipmentAssociation (IHEA) is offering several excellent educational events in 2015. IHEA’s mission is to provide services

to member companies that will enhance their capabilities to serve end users and improve their business performance. The following events and resources help IHEA achieve that mission. Visit www.ihea.org for additional details on the events listed below. You can also contact Kelly LeCount at 859-356-1575 if you have any questions.

Safety Standards SeminarExplosions and fires in industrial heating systems can result in injury, loss of life, loss of property and loss of production. Understanding the required use of the American National Standards governing the compliant design and operation of ovens and furnaces is essential for everyone involved with this type of equipment. IHEA’s two-day seminar will be held April 21-22 at the Hilton Garden Inn O’Hare outside of Chicago. It is designed for individuals involved in the design, manufacture, service or operation of ovens, furnaces, kilns, dryers, thermal oxidizers for a wide range of industrial applications. It is intended to help the attendee become better acquainted with the new NFPA 86 – Standard for Ovens & Furnaces, 2015 Edition. Speakers will discuss changes in the NFPA 86 standard that was released in September 2014. Learn about these important standard changes and how they affect operations.

The Ins and Outs of IR: Ecient Curing with Infrared Webinar IHEA’s Infrared Equipment Division (IRED) is once again partnering with Products Finishing

magazine to present a free educational webinar on Tuesday, April 7 at 2:00 p.m. (EST). It will focus on infrared curing for industrial finishing applications and provide an in-depth look at infrared technology. It will also review all equipment sources of infrared followed by a discussion of a wide variety of IR applications for industrial finishing.

Infrared Hands-On SeminarIHEA’s IRED Division returns to Alabama Power’s Technical Applications Center to present its Infrared Hands-On Seminar on Oct. 9. The interactive seminar allows attendees to get hands-on experience in a laboratory setting in addition to traditional classroom instruction. This one-day event will highlight the benefits of using infrared technologies and review all equipment sources of infrared, followed by a discussion of a wide variety of IR applications for the industrial heat-processing industry. Attendees receive top-notch training from experts in infrared technology, applied demonstrations in the lab and a copy of the Infrared Process Heating Handbook.

IHEA Learning AcademyThe IHEA Learning Academy offers online video training in the industrial process-heating industry. There are a variety of educational presentations that run from 20-40 minutes long. They are designed to educate, inform and provide an understanding of many industrial process-heating technologies. Videos are added to the IHEA Learning Academy periodically. Check our website often for updates.

Educational Opportunities in 2015

IHEAIndustrial Heating Equipment Assoc.

859-356-1575www.ihea.org

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Vacuum FurnaceSolar Atmospheres, in an effort to accommodate increasing vacuum-processing requirements, placed an order with affiliate Solar Manufacturing to supply a large-capacity horizontal vacuum heat-treating and brazing furnace for its facility in Fontana, Calif. The furnace has a work zone measuring 54 inches high x 54 inches wide x 144 inches deep and is capable of

processing a workload of 30,000 pounds at 2200°F (1204°C). The entire hot zone utilizes high-efficiency Rayon graphite felt insulation and a hot face of CFC. The furnace is expected to increase plant processing capacity by more than 25%.www.solarmfg.com

Vacuum FurnaceVAC AERO sold a high-pressure quench vacuum furnace to a Southeast Asian manufacturer and integrator of high-performance aerospace systems and components. The furnace is designed to have rapid heating rates while maintaining tight uniformity at high vacuum levels. It is equipped with a gas-quench system capable of quench pressures up to 6 bar. The furnace features a carbon hot zone measuring 36 inches wide x 30 inches high x 48 inches long with a heavy-duty hearth designed to support a uniformly distributed load of 2,500 pounds. www.vacaero.com

Continuous Mesh-Belt Atmosphere HardeningFurnace SystemCAN-ENG Furnaces International Ltd. commissioned a1,500-pounds/hour continuous mesh-belt atmosphere hardening furnace system for a large North American fastener manufacturer. The system is designed to provide atmosphere hardening and

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tempering of high-volume fasteners and includes a computerized loading system, mesh-belt controlled atmosphere hardening furnace, oil quench system, pre- and post-wash systems, and enhanced part tracking. This furnace system is fully compliant to meet the requirements of AIAG CQI-9 Heat Treatment System guidelines.www.can-eng.com

Two-Row Pusher FurnacePremier Furnace Specialists of Farmington Hills, Mich., received an order from a Texas-based manufacturer for the design, fabrication and installation of a two-row pusher furnace system. The

fully automatic furnace line features a self-positioning return tray system, PLC-based controls and a full HMI interface. The surveyed temperature uniformity profile achieved results that surpassed customer specification. www.premierfurnace.com

Temper OvensAjax TOCCO Magnethermic Corp. supplied three temper ovens to a major automotive parts manufacturer in Mexico for the tempering of CV joints. Each oven is designed for a maximum operating tempera-ture of 250°C (482°F) with uniformity of +/- 5°C. The continuous-belt, variable-speed conveyor carries more than 240 parts per hour through the oven and cooler system, which are robot loaded and manually unloaded. Each oven is controlled with a PLC and touch screen, which includes a programmed system shutdown once the proper cool-down temperature has been achieved. www.ajaxtocco.com

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Dual-Chamber FurnaceLucifer Furnaces delivered a space-saving, dual-chamber furnace to Precision Solutions of Richmond, Utah. The company, which is bringing their heat treating in-house, will use the furnace to heat a variety of tool steels. The unit has working dimensions of 12 inches high x 14 inches wide x 24 inches long in both the upper and lower chambers. The upper hardening chamber reaches 2200°F (1205°C), while the lower tempering oven heats to 1200°F (650°C). Both chambers are lined with a multilayered 4.5-inch combination of lightweight firebrick hot-face insulation and mineral-wool backup insulation. www.luciferfurnaces.com

Induction Heating SystemAmbrell sold two 10-kW, 150- to 400-kHz induction heating systems to a manufacturer of pipe grippers for the oil and gas industry. The heating application involves heating two grippers in one coil. Two grippers, which are steel faces with carbides in place, are placed into the coil. They are heated to 1400°F (760°C) within 90 seconds. The carbides are then pressed into their joints.www.ambrell.com



H.C. Starck Signs Agreement for 3D Printing TechnologyH.C. Starck and Rapid Prototype and Manufacturing (rp+m) agreed to develop advanced, innovative products using the latest 3D printing technology and metal manufacturing. The agreement will promote development synergies by combining H.C. Starck’s strengths in fabrication of technology metals with those of rp+m, a provider of additive manufacturing solutions.

Brembo to Build Foundry in MexicoBrembo will invest $39 million to build a foundry and a new production plant for aluminum calipers in Escobedo, Nuevo Leon, just outside of Monterrey, Mexico. The facility is expected to commence initial production in 2016 and be fully operational by the end of 2018. The foundry will have a melting capacity of 14,000 tons, and the machining facility will be capable of producing 2 million aluminum calipers per year.

Boeing Opening Composites Center in St. LouisBoeing started construction on a new 367,000-square-foot facility in St. Louis that will build parts for the newest member of its 777 commercial airplanes family, the 777X. The plant will create about 700 new jobs. Construction should be complete in 2016, with work on 777X wing and empennage parts starting in 2017. The facility is an expansion of Boeing’s current tooling center at the site and will contain six autoclaves.

Shiloh Industries Opening Plant in TennesseeShiloh Industries Inc. opened an aluminum die-casting plant in Montgomery County, Tenn. Shiloh, which acquired the brownfield site in August 2013, has initiated renovations, upgrades and the addition of new equipment to the facility. The company estimates it will invest over $20 million and add more than 150 new jobs to support future production needs and customer demands.

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Alcoa Acquires German Aerospace CompanyAlcoa will further expand its global aerospace business through a definitive agreement to acquire privately held Germany-based TITAL, a leader in titanium and aluminum structural castings for aircraft engines and airframes. TITAL employs advanced techniques needed to manage titanium’s reactive properties, including cold-hearth melting and centrifugal and gravity casting.

Timken Acquires Specialty Bearing CompanyThe Timken Company reached an agreement with to acquire the assets of Revolvo Ltd., a specialty bearing company based in Dudley, U.K. Revolvo makes and markets ball and roller bearings for industrial applications in process and heavy industries. The company’s split roller-bearing-housed units are widely used by metals end users.

GE Oil & Gas to Invest in Texas FoundryGE Oil & Gas announced plans to invest $60 million in expanding and modernizing its foundry operations in Lufkin, Texas. The Lufkin foundry produces industry-leading iron castings used to make beam pumping units and power transmission equipment. Construction is scheduled to be carried out in four phases commencing in 2016.


INDUSTRY EVENTSMarch 15-19TMS 2015Orlando, Fla.www.tms.org

April 21-22IHEA 2015 Safety SeminarChicago, Ill.www.ihea.org

April 21-23119th Metalcasting CongressColumbus, Ohiowww.afsinc.org

April 27-30Interwire 2015Atlanta, Ga.www.wirenet.org

May 4-7AISTech 2015Cleveland, Ohiowww.aist.org

May 17-20PowderMet 2015San Diego, Calif. www.mpif.org

June 15-19ASME Turbo Expo 2015Montreal, Canadawww.asme.org

June 16-20Thermprocess, GIFA,METEC, NEWCASTDüsseldorf, Germanywww.thermprocess-online.com



ECONOMIC INDICATORS

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Values above 50 indicate growth or increase. Values below 50indicate contraction or decrease. To participate in this survey,

please contact Bill Mayer at [email protected]

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INDUSTRIAL GASES/COMBUSTION

If combustion and its related efficiencies were not achallenging topic for most of us, we and others would not dedicate so many new resources to the topic. This article will point out some of these available resources, including

coverage from the pages of Industrial Heating. Over the years, improved efficiencies have been demanded by both users of combustion systems and agencies regulating these users. NOx and CO2 reductions are examples, and addressingefficiencies is key for newer systems.

New(er) PublicationsWe will start out by mentioning and discussing four newerpublications that address the combustion topic.

Combustion Engineering(second edition)While this 550-page book was originally released in 1998, the second edition of Combustion Engineering (2011) from CRC Press adds information on efficiency improvements, emission reductions and biomass utilization. The book provides a balance of combustion fundamentals and combustion-engineering applications of gaseous, liquid and solid fuels.

The target audience for this resource is college-level or first-year graduate students and workplace professionals desiring a “uniquely accessible introduction” to combustion. It is designed to be a textbook and could be used by engineers desiring to teach the topic to others who need to learn more about the subject of combustion. There is even a solutions manual and additional teaching resources available for those desiring to adopt combustion training programs. Eight chapters address the fundamentals of combustion, and the remaining eight chapters apply these fundamentals to furnaces, fixed-bed and fluidized-bed combustion and more. Numerous tables include practical data and formulae as well as extensive example problems, chapter-end problems and references.

The John Zink Hamworthy Combustion HandbookIn the past year or so, the John Zink Hamworthy Combustion Handbook (2001) was significantly revised. The original edition was comprised of 800 oversized, full-color pages written by 30 authors. The current edition has been expanded to three volumes. The 651-page Volume 1 (from CRC Press) covers the

Reed Miller –Editor, Industrial Heating

In this article, we strive to improve your awareness of resources that exist to help you make better sense of combustion-related issues and answer your combustion-related questions.

Combustion Resources


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INDUSTRIAL GASES/COMBUSTION

fundamentals. It provides concepts and up-to-date informationon industrial combustion science and engineering. I personally own this volume, and it contains many color illustrations and photos to help explain its contents.

The 628-page Volume 2 is entitled “Design and Operations,” and it provides a definitive “field manual” for operators, engineers and managers working in industrial combustion-oriented industries. Coverage includes testing, installation, maintenance and troubleshooting of combustion systems. It includes more than 600 color illustrations and photographs.

Finally, the third volume, entitled “Applications,” is 452 pages. The description seems to indicate that many of the applications described would be low in temperature for the readers of Industrial Heating. Suffice to say, however, the latest revision of this handbook (at 1,731 pages) has many updates from the 2001 edition and should be able to assist you with many of your combustion-related challenges.

Experimental Combustion – An IntroductionThis 2014 text from CRC Press strives to help the readers understand the basic skills of combustion in order for them to be able to design and develop energy-efficient and low-emission combustion systems that can meet heating demands while minimizing ecological impacts. Like Combustion Engineering, it is intended to be used as a

textbook, and it offers both review questions and problems at the end of each chapter. This one seems a bit too theoretical for many of our readers, but I’m sure it could be of use for a portion of our audience.

Atmosphere Heat TreatmentWhile not a combustion book, Daniel H. Herring’s latest book, Atmosphere Heat Treatment, might be all the combustion coverage some of us need. One section of chapter 4 covers “Combustion Systems,” providing fundamentals as well as practical coverage of burner tuning, types of burners, monitoring the process and sizing a combustion system. Add this

to all of the other practical advice offered in this 600-page reference book, and it’s worth obtaining a copy for yourself. You can order your own copy by going to www.industrialheating.com/AHT.

Industrial Heating ResourcesCombustion is a regular topic covered in IH. Over the course ofa year, the topic is covered in at least four different print issues. If you are looking for combustion-specific articles or other content, please search our website or find “Industrial Gases & Atmospheres” in our subject list on the left side of our homepage or “Combustion & Burners” on our top “Topics” tab. Looking at the most recent combustion articles, we find the following topics covered.

• A three-part web exclusive entitled “Achieving Efficient Combustion”

• “Utilizing Flue-Gas Analysis to Improve Combustion-System Performance”

• “In-House Heat-Treat Operation Improves Efficiency”• “Clean and Efficient Gas Heating of Industrial Furnaces”• “Fuel Use for Billet Reheating Reduced with Oxyfuel

Technology”• “Emerging Ultra-Low-NOx Burner Technology for the

Heat-Treat Industry”

Combustion ConceptsWere you aware that we ran a column series called “Combustion Concepts” authored by combustion expert Art Morris? These columns, which utilized aluminum heating as a practical application, can still be found in the drop-down list on the top “Columns” tab of our website. Each of these columns also contained an Excel workbook, which could be used to better understand your combustion system. Topics included but were

Add a heat exchanger

Dry

Moist

Increase, maintain insulation

Wall loss(conduction)

Use low thermal mass

insulation

Heat storage to walls & fixtures

Grossheat input

(HHV)

Netheat

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heat Heat to load

Maintain door seals & pressure

control

Opening loss (radiation)

Heat supply, demand and losses in a furnace system



not limited to the following:• Burner analysis• Exothermic atmospheres• Adiabatic f lame temperatures• Available combustion heat• Making a system balance• Making a heat balance

Art also wrote an article, “Improving Thermal Efficiency in Aluminum Scrap Melting,” for the February 2014 issue, which also included an Excel workbook. You can find this in our archives for that month. Another nonferrous combustion-

related article in the past year was “Save Money by Optimizing Your Furnace Burner Fire Rate” written by Cindy Belt. It can be found in the April 2014 archives.

Combustion Tool KitBack in 2008, we produced a 28-page resource that was inserted in our February issue. The Toolkit included some general engineering

data, information on industrial gases, and fuels and f lue data. Throughout the Toolkit, useful tips were included from Eclipse’s “20 Tips for Combustion System Care” booklet. In addition to the useful graphs, tables and charts, several practical articles were incorporated that dealt with the topics of “burners, analysis and control” and “performance and efficiency.” The data included in the Toolkit is basically evergreen, so we are making the Combustion Toolkit available to you in a digital format. You can link to it at www.industrialheating.com/CTK.

SummaryOur objective in this article was to present you with some combustion-related reference resources. If you simply search our website (www.industrialheating.com) for “combustion,” you will find about 715 results. The term “burner” results in over 530 search results. Clearly, our website provides a very useful source of information on this and many other topics of interest in the field we call industrial heating.

For more information: Contact Reed Miller, editor, Industrial Heating, Manor Oak One, Suite #450, 1910 Cochran Rd., Pgh., PA 15220; tel: 412-306-4360; fax: 248-502-2099; e-mail: [email protected]; web: www.industrialheating.com



COVER FEATURENONFERROUS HEAT TREATING

The downside, however, is that plant specializationcan lead to a false sense of security based on a single market focus and tentativeness to broaden the company’s capabilities and services. While

specialty houses will separate ferrous heat treaters from those of the nonferrous variety, broadening processing services can protect the company from the loss of key clients and business that occurs in changing markets. This is most evident in the steel versus aluminum processing arena. Aluminum is a completely different animal than steel. A simple comparison is that when steel is quenched, it becomes hard and brittle, whereas aluminum becomes soft and ductile. Hopefully, this article will demystify aluminum processing to a degree and encourage you to consider adding aluminum to spread your economic risks across different industrial markets. Why is this important? As I see it, the heat-treating industry is entering a theater of change. Adapting to this change could re-quire adding new services and client types to position the com-pany as more diversified and capable to meet future demands. To know aluminum, you first must be able to decode the way different aluminum conditions are defined. There is no basic qualification statement such as “harden, quench and temper” to conform to a certain HRC. Instead there are defined conditions that are more like landing zones as opposed

to re-temper zones that steel processing so kindly affords. You will become more familiar with the various conditions as you read on. Knowing these key properties allows us to navigate the zones that are defined by process steps as well as minimum mechanical properties. I have also included a few actual case studies written in layman’s language to help clarify the processing of aluminum.

Condition OThe full-annealed condition is the softest, most ductileand most easily workable of all aluminum conditions. This condition in age-hardenable alloys (2000, 6000 and 7000 series) is arrived at by soaking at a setpoint below the solution-treating temperature followed by a controlled slow cooling

Peter Hushek – Phoenix Heat Treating, Inc.; Phoenix, Ariz.

While many heat-treating companies have moved from general processing to selective processes, the trend has been mainly to one of specialization. The thinking is that specializing will simplify focus on process improvement, enhance productivity and increase profitability.

The Other White Metal

(above) Workers push the auxillary liquid-nitrogen tank from under a drop-bottom solution heat-treat furnace on a track to where the aluminum components can be removed. The furnace is designed for solution treating of small batches of aluminum parts to large forgings and castings. PHT operates two identical solution-treating systems, primarily to serve the aerospace industry. The systems quench with liquid nitrogen, glycol and glycol/water.



typically to 500°F (260°C). The ductility can be enhanced by reducing the descent in temperature as a function of time. Soak time at the high-temperature phase of the cycle must be carefully controlled to prevent grain growth.

Condition AQ or WThis condition is extremely unstable and will vary based on the degree with which the maximum solubility of the alloying agent has been brought to complete solid solution by the soak and quench steps (commonly called the solution-treating process). In order for this condition to maintain its maximum formability, it must be quickly stored at 0°F or lower. Many alloys will continue to naturally age at temperatures as low as 0°F (-18°C), which is why the use of dry ice for storage and transport is encouraged. The 2000- and 7000-series alloys are especially vulnerable to this low-temperature natural-aging process.

Condition T-4T-4 is the condition typically referred to as the “natural age” since it occurs at room temperature. The standard timeframe associated with the natural-aged condition is 96 hours. When the degree of complete solid solution is high, the reaction time for reaching this condition can be reduced. While the minimum hardness may be met in less time than the 96-hour standard, the material will continue to transform itself until the maximum hardness (for the combination of alloy composition), degree of solid-solution attained, rate of the quenching and room temperature of the surroundings are met.

Condition T-3T-3 condition is very similar to T-4 with one slight variation – it receives a cold working, stretching or rolling after the quench

phase and prior to the natural age hardening. The bonus of the T-3 over the T-4 is the increased yield strength. This provides the designer with a greater range of applicable uses but comes at the loss of ductility. The reduced ductility and general formability make it useful for large surface-area parts with limited bend radii. Gentle bends are OK, squared corners are not.

Condition T-6T-6 is the highest-strength condition for most alloys that have not received cold working (work strengthening) after the quench phase. It is extremely stable in its mechanical properties and can be subjected to lower-temperature stress-relief processes without degradation of these properties. This state is achieved by an artificial-age process after the solution-treat and quench steps. It is referred to as “artificial” since it requires setpoints greater than room temperature. The cycle times can range from four hours all the way to 36 hours followed by an air cool.

Condition T-7-3, T-7-4, etc.These conditions are often referred to as the “over-aged” condition. This means that the material will be lower in mechanical properties than T-6 but have unique properties based on the alloy. In some cases, it will allow for use at elevated service temperatures without loss of strength. For example, the corrosion resistance of 7075 is increased due to this over-age process, which increases its service life. T-7-3 is often used in aerospace manufacturing, where corrosion resistance on nonflying structural components is critical

TerminologyFinally, there is much confusion about the correct wording in the processing of aluminum, specifically that caused by the

Close-up image of the large Brinell testing equipment that PHT modified to test large aluminum forgings and castings.

6061 aluminum forging of a physical vapor deposition (PVD) vacuum chamber that is used in the semiconductor industry. PHT built specialized tooling to lift and move large forgings, such as this, of varying shapes and sizes. The Brinell mill bed will support components weighing up to 600 pounds.



terms annealing, solution annealing and solution treating. Annealing will result in condition O and never age harden to condition T-4. This mix-up happened decades ago, and the confusion exists to this day. Aluminum becomes soft when solution treated, so shop managers named it solution annealing instead of solution treating. Solution annealing, or more properly solution treating, will naturally age to T-4 after the quench step.

There you have it. Someone thinking that the solution-treating process was an annealing process started the chain of confusion. Hopefully, this sets the record straight.

Now that you are familiar with the crazy nomenclature that defines aluminum processing, it’s time to wade into some of the different product forms you may encounter and the hidden land mines that can happen without warning. Similar to early GPS devices, you may eventually get to your destination, but be careful when trekking into uncharted territory.

Case Study 1Wrought stock aluminum is often purchased and sold in its final mechanical property condition (e.g., T-6). Your customer has the simple task to machine a part from this thin 6061 plate (0.250 inch x 16 inches x 24 inches). It’s easy. Simply load the program into the CNC and walk away, and parts will be perfect, right?

After all of the machining is complete, the parts are released from the tooling only to find that the simple sealing groove

that you machined in and a set of counter-sunk holes have induced enough stress on one side that you can slide a pencil under the bow in the part. To compound the problem, someone suggests f lipping the way the plate is cut from a larger sheet to run cross-grain. This time you get an oilcan effect from opposing corners. The machinist says that this never, ever happens with cold-rolled steel. And if it did, he could send it to the heat treater to stress relieve it between plates to remove the stress. Alas, aluminum is no such animal, and the challenge can be a bit more complicated if you aren’t careful. But it’s not a formidable task. The aluminum comes to you in T-6, already through the entire heat-treating sequence – solution treated at 985°F (530°C) and spray, deluge or air-knife quenched to create the solid-solution condition. It then makes its way to f lattening rollers because no one will purchase a wrinkled sheet or plate of aluminum. Now the plate looks really pretty and is precipitation hardened to T-6 at a low setpoint of 350°F (177°C). But the varying amount of subtle cold finishing performed after the quench and before the precipitation harden (age) step creates a dynamic balance with the opposing sides. If one side receives more cold finishing (slight reduction) than the other, it has the potential to spring when material is selectively removed from one side. It’s like cutting a wedge from an onion and watching the opposing layers immediately start to pull away from the opening to change the shape of the onion. Now imagine that

Peter Hushek stands in a nitrogen cloud next to a mobile auxiliary liquid-nitrogen tank after a solution-anneal process has been completed. Aluminum components in the tank were processed to condition AQ prior to final forming. They will be removed from the liquid nitrogen and temporarily stored in dry ice for the customer to pick up. After forming, the customer will return the components to PHT for final aging.

Phil Kinney performs a preliminary Brinell inspection on 2014 aluminum forgings. The forgings will be machined into turbocharger components used on electromotive diesel engines. PHT modified the Brinell to include a larger mill bed and masthead that raises 32 inches high to increase capacity for testing large, bulky aluminum forgings.




hundreds of tiny wedges are selectively extracted from your f lat onion plate. In reality, the mill needs to sell you f lat plate or round straight bar, and caveat emptor rules the day.

What is the answer? Knowing the enemy is the first order of the day. The second is to not rip away the material just because it’s soft, and you are not worried about tool life. The other important task is to start a lessons-learned log. Keep track of processing results with detailed notes on differing attack strategies based on part design, material type and (most of all) the symmetry or lack thereof. Symmetry will be a reoccurring theme to keep in mind prior to starting or even bidding a project. It’s much like checking on weather conditions before you drive into a storm.

An answer may be to recook the onion before you make cuts on the rough blank. In other words, re-solution treat, quench and age to T-6. This process will most likely release some of the bound-up energy from the cold finishing at the mill. Once the energy is released, the opposing forces and dynamic balance is minimized. This allows you to remove material from either side without the potential energy induced with the cold finishing throwing the dimensions out of balance. Imagine the semi-cooked onion that you cut the wedge out of, and the layers didn’t pull against each other.

Case Study 2For those more familiar with steel processing, it comes as no surprise that materials respond to quenching differently. The same is true of aluminum alloys, and this becomes critical when 2000- and 7000-series alloy forgings are being processed. These alloys are considered more quench-rate sensitive than, say, 6061. There needs to be a heightened emphasis on agitation uniformity in order to reduce residual stresses that happen during the cold-finishing operation at the mill. When roughing in steel parts prior to processing, the stan-dard thought is to have no sharp-entrant angles. As long as the part does not crack during quench, everything will be fine on subsequent machining operations. This is another major difference in aluminum processing, especially in the 2000- and 7000-series alloys. Balancing the section size, even to the point of leaving stock in place to enhance symmetry, will allow the residual stresses induced at the quench to be in a dynamic balance. For example, a forging with cross sections of 2, 3, 4 and 5 inches were solution treated and double aged to condition T-7-3. All the properties were verified by hardness, electrical conductivity and tensile testing. But the parts were not stable during the post-process machining operations. After several




stress-relieving steps, the tight dimensional tolerances were lostin a few forgings.

Rather than waste more time and material, it was decided to run a test on a single forging that was roughed into a much narrower band of cross sections. Instead of the 3-inch range, the maximum difference was reduced to a little over 1 inch. Additionally, the material removed was designed to allow uniform quenchant f low following the solution-treating step. The double precipitation age was completed, and inspection of hardness, electrical conductivity and tensile strength again affirmed acceptance. During post-process machining operations, the movement due to residual stresses from quenching and machining induced stresses to less than 25% of the previous movement experienced.

Case Study 3Aluminum is often sold in the annealed condition (conditionO), where it is blanked, formed and then sent through solution treat, quench and precipitation aging to its final condition. These simple formed parts are again not symmetrical. The location of the formed angles, weight-reducing holes or just a general lack of symmetry in its final form can cause distortion

to rear its ugly head during the quench step. In some cases, the distortion is so bad that parts cannot be salvaged unless the sequence of events is changed to be more in line with the heat-treating processes. The drastic temperature change from the solution-treating setpoint to the quench temperature produces an extreme thermal shock. This shock, combined with the fact that the material strength at setpoint is significantly reduced, allows the force of the quenchant (water or water/glycol) to warp the part into an unusable shape. In cases such as this, it is advantageous to hang a blank of partially formed material so that it passes through the surface tension of the quenchant. At the point immediately after the quench, the part is in a metastable condition often referred to as AQ or W condition. As long as the parts are immediately placed in a freezer or on dry ice the metastable condition is maintained. The AQ or W condition is also considerably more ductile than T-4, which allows the parts to be sent back to the customer for final forming to the desired dimensional shape. The fact that the partial radii received additional cold forming creates stiffening, which allows the part to hold the final dimensions and tolerances. The following process coordination takes effort, but it beats the difficulty of attempting to work an oilcan condition out in the final aged condition.

• Preform• Solution treat and quench• Return to customer on dry ice• Final form• Final precipitation harden

This is an example of when processing aluminum to achieve a final form requires close coordination and communication with the client.

ConclusionHopefully, these examples illustrate some of the crucialdifferences that exist between steel and aluminum processing. And, even though the processes are each very unique, the characteristics of both material types and quench rates play significant roles in desired outcome. Yes, aluminum is a different animal, but it should not be ignored when you can add production volume, attract new customers and even prevent a catastrophic customer loss due to changing market dynamics.

For more information: Contact Peter Hushek, owner and president of Phoenix Heat Treating, 2405 W. Mohave, Phoenix, AZ 85009; tel: 602-258-7751; email: [email protected]. The Nadcap-certified company is currently celebrating 50 years of business in Phoenix. Its family heat-treating heritage spans four generations and 100 years, beginning in Milwaukee, Wis., in 1915.

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Microindentation Hardness TestingMarch 24, 2015 at 2 PM ET Hardness testing is generally broken into two categories: macro-load tests and micro-load tests; that is, tests that produce large indents or small indents. Micro tests utilize either the Knoop or Vickers indenters to defi ne variations in hardness, either deliberate (as for a surface hardened case), or undesirable (as in segregation or banding), or to help identify a microstructural constituent.

Surface preparation in microindentation hardness testing is very critical; otherwise the test results may be incorrectly infl uenced by remnant damage from the preparation process.

George Vander Voort discusses the importance of microindentation hardness testing, and practical application of the process to address the problems faced by today’s metallographer.

During this webinar, we will review, discuss and examine the following: wol ta noisicerpmi ot setubirtnoc ssendrah srekciV ro poonK eht rehtie etaluclac ot desu snoitauqe woH •

test forces that produce indents less than 20 µm in length

eht ni noitairav mµ 5.0 ± a ,gnol mµ 02 naht ssel era stnedni nehw noitairav ssendrah laitnetoP •diagonal length

stluser fo nosirapmoc sulp ,sdaol tset fo yteirav a gnisu gnitset srekciV dna poonK neewteb snosirapmoC •with etched and non-etched specimens

• Demonstrating the use of microindentation hardness tests for solving many of today’s common issues

SPEAKER:George Vander VoortConsultant, Struers, Inc.

MODERATOR:Reed MillerEditor/Associate Publisher, Industrial Heating Magazine

Presented by:

Register for FREE today at http://webinars.industrialheating.comCan’t attend live? Register to view on-demand anytime.

Free Webinar



CERAMICS &REFRACTORIES/INSULATION

Engineering design and the lining materials chosenare key factors in controlling the efficiency and energy usage of equipment used in iron and steel applications. As a result, it is critical that industrial

designers understand the advantages and disadvantages of the materials they choose. For example, it is especially important to select insulating firebricks (IFBs) that minimize energy losses. Recent studies conducted on IFBs produced using the three most common manufacturing methods – cast, slinger and extrusion – show that the cast process offers the lowest thermal conductivity and provides the greatest energy savings.

IFB Manufacturing Techniques Vary Widely inAbility to Control Energy LossesThe versatile IFB is used in numerous iron and steelapplications, including: blast furnaces, ductwork in direct-reduction processes and reheat furnaces, backup insulation in coke ovens, and in tundishes and ladles. They are also used extensively to form the sidewalls, roofs and hearths of a wide variety of heat-treatment, annealing and galvanizing lines. Figure 1 shows their use in a coke oven stack (top) and in a tunnel kiln (bottom). IFBs are manufactured using a variety of techniques, the most common of which are casting, slinger and extrusion. The cast process uses gypsum plaster as a rapid-setting medium for a high water-content clay mix containing additional burnout additives. The slinger process is a form of low-pressure extrusion of a wet clay mix containing high levels of burnout additives. It includes an additional processing step in which the semi-extruded material gets “slung” onto a continuous belt to generate additional porosity before drying and firing. The extrusion process forces a damp-clay mixture containing burnout additives through an extrusion nozzle, where the extruded material is subsequently cut into bricks, dried and fired. The brick chemistries and microstructures produced can differ widely among these methods, leading to a extensive

variety of thermal conductivities within products of the same temperature rating. This variation, in turn, has an effect on the ability of different IFB types to control energy loss.

Comparing Manufacturing MethodsTo understand the effect of the three main IFB manufacturingmethods on thermal conductivity and energy-loss behavior, researchers conducted a study to quantify the differences in energy usage that can be achieved within Class 23 and Class 26 IFBs. Figure 2 shows the thermal conductivity of the IFBs tested, a critical property since IFBs are primarily used for their insulating abilities. In each class of IFB, cast brick has the lowest thermal conductivity, followed by the slinger-produced brick, with the extruded brick displaying the highest conductivity. Researchers designed two identical electrically heated laboratory muffle kilns (Fig. 3) and conducted energy-usage studies comparing the IFB bricks. They lined the first kiln with Class-23 cast IFBs, and this formed the benchmark since they had the lowest thermal conductivity in the class. Test results are

Using Insulating Firebricks to

Maximize Energy Savings

Steve Chernack – Morgan Thermal Ceramics; Augusta, Ga.Selecting products made with the right manufacturing process makes the di� erence.

Fig. 1. IFBs are widely used in iron and steel applications.



shown in Table 1.Figure 4 is a thermograph of the kilns

during the 1000°C (1832°F) firing test. The cast-IFB-lined kiln is on the left. It shows how much heat is wasted through the body of the kiln lined with the higher thermal conductivity IFB and how the surface temperature of the kiln becomes overheated. This shows both the effect of wasting energy costs and health and safety issues caused by hazardous working temperatures.

Significantly less energy was needed to run the test kiln through a 1000°C firing cycle with the cast IFB compared to the extruded IFB (37% less for Class 23 and 38.5% less for Class 26). These energy-usage differences are due to the differing thermal conductivities of the IFBs. In materials of similar chemistry, thermal conductivity is controlled by the structure of the material. The different manufacturing methods of the IFBs studied produce materials with inherently different macrostructures and microstructures, and it is these that control the thermal behavior of the products. For example, Figure 5 illustrates the differing macrostructures of the Class-23 IFBs studied. The texture of the IFBs is finest for the cast product and coarsest for the extruded product.

Energy-Saving CalculationsAfter conducting laboratory testsdemonstrating the potential to minimize energy usage through appropriate selection of IFB for an installation

lining, researchers then ran heat-f low calculations to understand the effect on actual industrial installations. Calculations were done to assess energy running costs in strategic locations of two annealing applications that use IFBs as the lining material: a catenary strip-annealing furnace and a cast-iron part-annealing furnace.

The modeling was performed using

the most common real-life IFB lining arrangements, where walls are normally built up using standard brick sizes, while roofs are constructed from special pre-assembled roof blocks. Figure 6 shows the results. The top graphs show heat-f low calculations for the catenary strip-annealing furnace wall using cast IFB (left) and extrusion IFB (right). The bottom shows heat-f low calculations for

Fig. 2. Thermal conductivity by manufacturing technique

Fig. 3. Laboratory kilns built for energy-use study

0.35

0.3

0.25

0.2

0.15

0.1

0.05

0 0 200 400 600 800 1000 1200 0 200 400 600 800 1000 1200 1400

0.6

0.5

0.4

0.3

0.2

0.1

0

Ther

mal

con

duct

ivity

(Wm

-1K-1

)

Temperature, ˚C

Class 23 Class 26

Temperature, ˚C

Ther

mal

con

duct

ivity

(Wm

-1K-1

)

Table 1. Results of energy-usage tests

IFB Type kW used @ 800°C

% ∆ to cast

% Energy saved with cast

kW used @ 1000°C

% ∆ to Cast

% Energy saved with cast

Class 23

Cast 11.2 - - 16.0 - -

Slinger 15.1 34.8 25.8 20.9 30.6 23.4

Extrusion 17.3 54.5 35.2 25.4 58.8 37.4

Class 26

Cast 17.1 - - 20.6 - -

Slinger 20.3 18.7 15.8 27.9 35.4 26.2

Extrusion 22.7 32.7 24.7 33.5 62.6 38.5

Extrusion

Extrusion

Slinger

SlingerCast

Cast



CERAMICS &REFRACTORIES/INSULATION

the cast-iron part-annealing furnace roofusing cast IFB (left) and extrusion IFB (right).

Table 2 shows the significant differences that can be achieved for casting temperatures when using different IFB types. Using cast IFB produces much lower casting temperatures than extruded IFB. The lower surface temperature obtained using the cast IFB also produces a more comfortable working environment for operators and minimizes the risk of burns due to operators coming into contact with the surface of the installation. For the catenary strip-annealing furnace wall, the heat-f low calculations show that the lining with the extrusion IFB requires 271 W/m2 more energy tomaintain the 1200°C (2192°F) operating temperature than the lining with the cast IFB due to the lower thermal conductivity of the cast compared to the extruded IFB. The difference in energy consumption between the two simulated furnace walls equates to a savings of 42,450 m3 of natural gas per year usingthe cast IFB compared to the extrusion IFB. Assuming a gas price of $0.192/m3,this equates to an annual savings of $8,150/year for this wall section only. Assuming a furnace-wall lining life of 10 years, the total savings over the life of the kiln lining would be $81,500. The savings on the complete structure would be significantly larger. A 127 m2

working area in the wall of the catenarystrip-annealing furnace would need approximately 7,200 standard-sized IFBs. Although the cast-IFB price is a little higher, the example shows an initial payback period of just over three months. There would be continuous cost savings due to the lower energy requirements for the rest of the 10-year service life.

For the cast-iron part-annealing furnace roof, the lining with the extrusion IFB requires 434 W/m2 moreenergy to maintain the 930°C (1706°F) operating temperature than the lining with the cast IFB. For the 46.5 m2

working area, the difference in energy

Fig. 4. Illustration of wasted heat

Fig. 5. Differing macrostructures of IFBs

Fig. 6. Results of heat-flow calculations

1200

1000

800

600

400

200

0

1196

1 cm

Cast Slinger Extrusion

1195 1192

1194

837 888

476347

70

72 95

87

20

20 20

20

1200

1000

800

600

400

200

0

1200

1000

800

600

400

200

0

1200

1000

800

600

400

200

0

Tem

pera

ture

, ˚C

Insi

deIn

side

Insi

deIn

side

OutsideOutside

OutsideOutside

Tem

pera

ture

, ˚C

Tem

pera

ture

, ˚C

Tem

pera

ture

, ˚C

114.3 114.3114.3 114.3279.4 mm

228.6 228.6228.6 mm 228.6 mm

279.4 mm50.8 50.8

Vermiculite blocks ins

Vermiculite blocks ins

1426 cast IFB 1426 extruded IFB1260 cast IFB

1260 cast IFB

1260 extruded IFB

1260 extruded IFB



consumption between the two simulated furnace roofs equates to a savings of 17,615 m3 of natural gas per year using the cast IFB compared to the extrusion IFB, which equates to an annual savings of $3,382 for just this small roof section. Assuming a furnace-roof lining life of

10 years, the total savings over the life of the kiln lining would be $33,820. The savings on the complete structure would be significantly higher. The 46.5 m2 roof area would need approximately 2,600 standard-sized IFBs, so the payback for using cast IFB is less than three months.

ConclusionBy monitoring energy usage in laboratory kilns lined with IFBs manufactured by different processes and by modeling the effects on heat f low of using these same IFBs in two important iron and steel applications, research has demonstrated that IFBs manufactured by the cast process offer the lowest thermal conductivity available today at application temperatures and provide the greatest energy savings.

For more information: Contact Wendy Evans, marketing communications, Morgan Advanced Materials Thermal Ceramics, 2102 Old Savannah Road, Augusta, Georgia 30906; tel: 706-796-4200; e-mail: [email protected]; web: www.morganthermalceramics.com

Table 2. Heat-flow and energy-savings calculations

Catenary strip annealing furnace wall

Cast iron partannealing furnace roof

Cast IFB Extrusion IFB Cast IFB Extrusion IFB

Heat-flow calculations

Casting temperature 70.3 87.2 71.9 94.7

Heat loss (W/m2) 598.8 869.9 713.4 1147

Heat storage (MJ/m2) 110.6 135.6 72.92 79.8

Energy-savings calculations

Annual cost savings/m2 $64 - $73

Total annual cost savings $8150 - $3382 -

Total annual cost savings $8150 - $3382

*Assuming energy content of natural gas is 38.4 MJ/m3 and natural gas price is $0.192/m



NONFERROUS MELTING/FORMING/JOINING

This article seeks to inform the reader about theproblems that can occur while heat treating in atmosphere furnaces and the analytical equipment necessary to diagnose these problems effectively

and efficiently to avoid expensive rebuilds and lost productivity.

Introduction and BackgroundAt one of the world’s leading manufacturers of fine stainlesssteel cutlery, Dexter-Russell Inc. of Southbridge, Mass., this very challenge was faced during the hardening process of stainless steel cutlery blades. The stainless steel blades were heat treated in a Lindberg® continuous belt furnace at a hot-zonetemperature of approximately 1900°F (1038°C) in a H2/N2-based atmosphere. Dexter-Russell (manufacturer) had converted their furnaces to the H2/N2-based atmosphere in the mid-1990s, switching from dissociated ammonia (NH3), primarilyfor environmental and quality reasons. The manufacturer attempted to diagnose this discoloration/oxidation issue using tried techniques that had worked in the past: leak testing all of the internal gas piping, muffle retort pressurization, copper strip test and smoke infiltration. Unfortunately, these techniques proved unsuccessful in properly identifying the root cause. The result was lost productivity and increased costs until the problem could be identified and solved. If we recall from physics and the Ellingham Free Energy oxidation/reduction diagrams, specifically the H2/H2O ratio forchromium is present in varying high percentages in all stainless steel. (Note: This equilibrium ratio needs to be about 500 to 1.)

In other words, it does not take much moisture or oxygen, which is converted to H2O in hydrogen-based atmospheres, toproduce oxidation and discoloration of parts. Depending on the temperature at which these oxides form, they can also be quite difficult to subsequently reduce and eradicate.

Diagnostic ProcedureAs a result of lost productivity and frustration with this ongoingdiscoloration issue, Dexter-Russell approached their hydrogen/nitrogen gas supplier, Air Liquide Industrial U.S. LP and their ALTEC team of specialists in heat-treatment applications. Understanding this issue might require more sophisticated atmosphere analytical equipment and expertise. The aim was to combine their own problem-solving experiences with Air Liquide’s troubleshooting and together be able to effectively diagnose the cause of the problem.

Producing the Highest Quality

Stainless Steel Cutlery

Richard F. Speaker – Air Liquide Industrial U.S. LP; Houston, TexasDick Desaulnier – Dexter-Russell Inc.; Southbridge, Mass.

Troubleshooting furnace heat-treatment quality issues, such as oxidation and discoloration, can sometimes be challenging. At times, normal, conventional troubleshooting steps and tech-niques may not always work. This is especially true when precise atmospheric-contaminant analysis is required. This can vary based on the furnace atmosphere, the type of furnace andthe metallurgical properties of the materials being heat treated.

20

10

0

-10

-20

-30

-40

-50 450 500 550 600 650 700 750 800

Dew

poi

nt, ˚

F

H2/N2 Mixture flow rate, SCFH

Fig. 1. Relationship of dew point to furnace atmosphere flow rate



The first step was choosing correctanalyzers for the job. Because the furnace was using a hydrogen-based atmosphere for bright annealing, with no hydrocarbon enrichment additives or ammonia gases, dew point and ppm trace oxygen seemed to be the logical choice for atmosphere analysis. Further, since it is important to first eliminate the incoming gases as a possible source of contamination, it would be best to use a low dew point (accurate below -100oF)and a low ppm oxygen sensor (0-5,000 ppm trace oxygen) for these “virgin” gases. Air Liquide chose a ceramic sensor

hygrometer (-148oF to +68oF) and anelectrolytic-based trace ppm (parts per million) oxygen analyzer with a non-depleting electrolytic cell for the task. The versatility of these instruments, which also provide quick response times when monitoring in-situ furnace-atmosphere contaminants, made them a good choice. Step two is to confirm whether the industrial gases (H2/N2) were or werenot a contributor to the problem by analyzing the incoming gases before they enter the furnace as a protective atmosphere. Ideally, it is best to check the incoming gases as close to the

furnace entry point as possible and work back to the gas supply source should you encounter suspiciously high readings. Since Dexter-Russell had already checked all of their house gas lines for leaks, this second step was basically done to verify that the H2/N2 sourcegases themselves were at acceptable contaminant levels. The key to any analysis, whether on incoming gas lines or sampling directly from the furnace, is to allow sufficient time for purging the analyzers and then sufficient time for the readings to stabilize. Impatience with this step can often lead to false high readings.

Utilizing Flue-Gas Composition Measurements to Diagnose 10% Combustion-Air Deficiency Aluminum Reverb Melt Furnace with Regenerative Burners

As a follow up to a prior Industrial Heating article(October 2014), one additional melt furnace example is considered. Flue-gas compositions (%CO, %CO2

and %O2) were measured from an aluminum reverb meltfurnace operating with two pairs of regenerative burners. This furnace was direct-charged with the burners firing directly into the main hearth toward the scrap pile. All scrap was charged directly into the main hearth. During f lue-gas measurements, only clean scrap was charged (no coatings or paint on the scrap). Flue-gas measurements were made continuously throughout several batch melting cycles. The f lue-gas sample probe was located before the dilution air break in the main exhaust stack so that the gas sample was representative of the combustion atmosphere inside the furnace. Measured f lue-gas compositions were 3% CO, 0% O2 and10% CO2. These values held very consistently throughout theentire melt cycle and were consistent for several heats. During melting, the burners were firing with maximum natural gas firing rate and maximum combustion air f low. The indicated air/gas ratio was in excess of 10:1 based on f low-meter readings, which would imply oxidizing conditions (excess O2, zero CO). The f lue-gas measurements indicatedsignificantly reducing conditions, however, showing that there was not enough combustion air to fully combust the fuel. Figure A is a V-curve showing calculated flue-gas concentrations for air/gas combustion, assuming CH4 fornatural gas. The measured 3% CO and 10% CO2 concentrationscorrespond to lambda = 0.90 on this V-curve. So, it was concluded that this regenerative burner system was operating at 10% reducing conditions (lambda = 0.90), meaning that there

was a 10% deficiency in combustion air supplied. For this furnace, since only 90% of total combustion-air requirements are being supplied, only 90% of combustion energy is being released inside the furnace. The remaining 10% of fuel input energy burns downstream in the f lue exhaust duct after mixing with entrained dilution air. For this particular furnace, a 10% melt rate increase is desired. O2 enrichment has been proposed to provide therequired additional combustion O2 to combust all fuel insidethe furnace (bring lambda up to 1.0). An O2-enrichment testis planned, during which the f lue-gas measurements will be repeated to accurately establish the amount of O2 required tobring the furnace atmosphere up to neutral conditions and capture 100% of input fuel energy inside the furnace.

14

12

10

8

6

4

2

0 0.70 0.80 0.90 1.00 1.10 1.20 1.30

Dry

flue

gas

conc

entra

tion

%

Lambda

Reducing oxidizing

Measuredvalues

CO2

CO = H2

O2 = 0 CO = H2 = 0

CO2

CO or O2

CO2

O2

Fig. A. Measured and calculated flue-gas compositions from aluminum reverb melter fired with regenerative burners



NONFERROUS MELTING/FORMING/JOINING

Therefore, we allowed approximately eight hours of sample time on the incoming mixed gases to ensure stability with the final readings. Once the incoming H2/N2 mixed-gas purity was validated, step three was to take sample readings within the Lindberg muffle (retort) itself. Preferably, this is done starting at the beginning of the hot zone of the furnace, which is where the most damaging oxidation and discoloration can occur. This procedure was done using these same two analyzers, with the addition of a small sampling pump for positive displacement sample extraction at 2 SCFH flow rate. A 99.5-micron particulate filter was used to protect the analyzer cells from particulate contamination. This allowed us to effectively test the atmosphere quality for both dew point and ppm oxygen in both the beginning and middle of the hot zones (1900°F). Based on the specific type of oxidant on the surface of the stainless blades, it appeared that the oxidation was primarily originating from hot-zone oxidation.

Results Once stable readings with negligible f luctuations were achieved, the results for the incoming mixed gases were -90°F dew point and 0.5 ppm oxygen. Both gases appeared to be well within acceptable limits for industrial-grade nitrogen and hydrogen for both dew-point and oxygen content. Having eliminated the incoming gas as the potential cause of the oxidation, we then focused our efforts on the Lindberg furnace itself. Again, since Dexter-Russell had already done much of the preliminary testing of the gas lines and furnace-muffle integrity, we did not expect to encounter any mechanical defects, muff le defects or water-jacket leaks on the furnace. The only thing left was to sample the contaminant levels of moisture and oxygen within the furnace to see if there was something else going on that could not be detected by the

methods already employed (muffle pressure test/copper oxidation test). Our initial findings, without changing operating parameters such as temperature, belt speed or atmosphere (H2/N2) f low rates into the furnace, yielded telling results. The dew point in the furnace hot zone was +19°F, while the oxygen levels stabilized at about 3,500 ppm. From prior experience and database records previously established on this furnace, we immediately knew that these contaminant levels were considerably higher than typically expected. We also knew that the stainless knife parts will oxidize at 1900°F under these high-contaminant levels. With these higher-than-expected contaminant readings, the next logical step was to examine the actual furnace operating parameters. The easiest parameters to evaluate first were the overall furnace gas-f low rates. Based on the Waukee tube and f loat f low meters, the setpoints used for this test were the

same setpoints used prior to the furnace being taken down for maintenance and the hot-zone rebuild. During the rebuild, some of the gas regulators had been upgraded and replaced. This may have resulted in a slightly different delivery pressure to the f low meters, which in turn could alter the actual f low rates based on the calibration pressure established for any given f low meter. The main purposes of the H2/N2 atmosphere are first and foremost to prevent air (oxygen and moisture) ingress into the furnace muffle (retort). Typically, gas f low rates achieving a few inches water column will suffice. Second, the hydrogen in the atmosphere provides a “getter” reducing gas capability, which should reduce the oxides on the stainless surface and provide a bright finish. The intent is for hydrogen to combine and reduce oxygen levels by forming water vapor. It then becomes a matter of balancing the H2/H2O ratio to achieve “bright” parts.

Fig. 2. Before and after flow-rate changes



With this in mind, we next wantedto see the effects of increasing the total mixed-gas f low rate, not the percentages of the gases. After some initial upward f low adjustments, we found that the atmosphere contaminants in the hot zone started to rapidly decrease as we increased the mixed-gas f low. Within an hour after our final f low-meter adjustments, we achieved a dew point of -40°F and an oxygen level of 10 ppm oxygen. Given this dramatic improvement, the 314SS belt started to brighten up almost instantly. We now felt confident that we could achieve similar results on the production blades with these adjusted f low rates. Approximately two hours later, Dexter-Russell was once again producing bright, non-oxidized, annealed stainless steel blades.

Conclusions Sound engineering and experience willtypically go a long way when diagnosing and solving manufacturing issues, whether it is furnace oxidation or some other challenge. In most cases, this process experience and product expertise will allow the customer to intuitively identify the problem and resolve the issue quickly.

However, there are still those cases where an extra set of “experienced eyes” are needed along with the proper analysis equipment. In this case, fast-responding dew-point and oxygen analyzers can sometimes provide the missing piece to the diagnostic puzzle. Fortunately, after carefully eliminating many of the potential variables that can cause or contribute to furnace oxidation, we were able to effectively diagnose the problem and provide the resulting solution.

The author would also like to acknowledge the valuable contribution of Buck Raper, manager of manufacturing and engineering, who, along with Dick Desaulnier, helped bring this evaluation to a successful conclusion.

For more information: Richard F. Speaker, senior business development specialist, Automotive & Fabrication Group; Metal Heat

Treating Applications; Air Liquide Industrial U.S. LP Houston, Texas; tel: 800-820-2522; fax: 713-803-7322; e-mail: [email protected]; website: www.us.airliquide.com. Dexter-Russell, Inc. is the largest manufacturer of professional cutlery in the

U.S. The company is the proud successor to the two oldest American cutlery manufactur-ers: The Harrington Cutlery Company and the John Russell Cutlery Company. They maintain a tradition of excellence in both materials and workmanship.

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ProductsThermalProcessing

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BuehlerAbrasive CutterAbrasiMatic 450 provides four cut types with the power to get through each cut. The fully automated abrasive cutter comes equipped with three-axis motion and a full suite of advanced cutting features that save time and protect the integrity of the cut surface. Simple ergonomic controls enable programming, recall and modification of methods, while dual joysticks provide precise control of the table and wheel. www.buehler.com

Hydraulic TesterTinius OlsenSL series represents the highest standard in hydraulically powered universal testing machines. It features a patented dual-pressure hydraulic loading system and a rugged four-column construction for exceptional load frame rigidity. In addition, this hydraulic tester has a space-saving console with a smaller footprint and comfortable working height design. A range of user interface options is available (including Bluetooth and/or tethered interfaces) to enable basic tests, comprehensive tests and everything in between through Tinius Olsen’s Horizon materials testing software. SL systems are guaranteed to meet ASTM, ISO and other national and international specifications for accuracy. Accuracy is within +/-0.1% of the indicated load from 0.2-100% of frame capacity. www.TiniusOlsen.com

PRODUCT OF THE MONTH




Mesh-Belt WasherViking Blast and Wash SystemsDesigned for standard manufacturing applications, CBW6030 has a 60-inch-wide x 30-inch-tall wash zone on a chain mesh-belt conveyor. Belt flow speeds are adjustable from 2-34 feet per minute on a continuous pass-through basis. These washers include four wraparound spray bars equipped with 112 stainless nozzles for maximum coverage. The pumps do not contain bearings, seals or gaskets to replace. www.vikingcorporation.com

Gas AnalyzerCEA InstrumentsRapidox gas analyzers offer an extremely wide measurement range for oxygen and have been redesigned to allow optional sensors for specialized gases such as SF6, CO and N2O as high as 0-100% volume. These continuous, fast-responding and easy-to-use devices can be used for many applications and offer new fittings and thermocouples for temperature measurement. Each unit comes complete with data-logging software. www.ceainstr.com

Combustion SafeguardProtection Controls Inc.R-C 100 provides safety on continuous, 24-hour burner applica-tions for single burner as well as multi-burner applications. The dual/redundant self-check ultraviolet flame sensor and combustion safeguard control may be used only with 6642 Protectofiers, which have a 180-degree phase power supply. The system contains two UV tubes in one ultraviolet sensor to monitor one burner flame. Each UV tube is powered during a different time cycle to eliminate interference between the two UV tubes. It has no moving parts and displays high signal strength.www.protectioncontrolsinc.com

Multi-Function Wireless AdaptorYokogawa Corp. of AmericaA newly developed wireless adaptor enables wired devices that transmit/receive digital on/off signals or receive 4 to 20 mA analog signals to function as ISA100 Wireless field wireless devices. The multi-function adaptor is designed for use with switches, solenoid valves and other device types that utilize digital on/off signals and transmitters that utilize 4 to 20 mA analog input signals. It is ideal for industries including iron and steel, power and oil and gas. www.yokogawa.com/us

Infrared Pyrometer with Thermal Imaging CapabilitiesLumaSense TechnologiesSuited for applications where the temperature across an object is crucial, ISR 6-TI Advanced combines an infrared pyrometer with

infrared imaging capabilities. The integrated system produces a relative thermal image, which is made by combining the temperature of a center spot and an image from a video camera. It operates in a short wavelength for accurate and reliable temperature measurements between 700-1800°C (1292-3272°F).www.lumasenseinc.com

High-Temperature AdhesiveCotronics Corp.Specially formulated Resbond S5H13 has excellent high-

temperature resistance to corrosion, thermal shock and electricity. It can bond dissimilar materials in any high-temperature, high-performance adhesive application up to 500°F. Specially formulated Resbond S5H13 can bond heavy plastic to stainless steel in critical aerospace and automotive applications. It has excellent adhesion to metals, composites and ceramics, and the adhesive cures at room temperature. www.cotronics.com



LITERATURE & WEBSITE SHOWCASE

Combustion SafeguardsProtection Controls Inc.This comprehensive Service Manual covers all PROTECTOFIER combustion safeguard units. It provides important and valuable information on installation, service guides, testing and troubleshooting as well as specifications, features and application on Protection Controls’ single and multi-burner units. For a free copy, fax 847-674-7009.www.protectioncontrolsinc.com

Industrial Combustion Solutions Fives North American CombustionFives North American Combustion is com-mitted to providing innovative solutions in combustion through world-class technology, products, furnaces and services. As one of the foremost suppliers of combustion systems worldwide, we offer a comprehensive array of burners, flow control products, process con-trols, installation and engineering services along with life-cycle support.www.fivesgroup.com

Induction Heating Systems Ajax TOCCO Magnethermic CorporationAjax TOCCO Magnethermic Corporation is a world leader in the induction heating, melting and forging industries. Our proven applications include brazing, annealing, hardening, tempering, seam annealing, shrink fitting, curing, forging and melting. www.ajaxtocco.com

FurnacesCan-Eng FurnacesSince 1964, Can-Eng has been designing and manufacturing industrial heat-treating equipment for commercial and captive heat treaters, stamping and fastener companies, automotive component producers, the iron and steel industries, and aluminum foundries. Take a closer look at the systems we have to offer. For more information, call 905-356-1327. www.can-eng.com

Electric Heating ElementsCustom Electric Manufacturing Co.A new 44-page catalog describes electric heating elements for applications includ-ing die casting, heat treating and forging. Topics including element design, alloy selection, operating temperatures and power ratings are all covered. Our ele-ments, which are designed for all styles of furnaces and ovens, are used worldwide by leading manufacturers.www.custom-electric.com

Radiant TubesINEX Incorporated INEX Incorporated offers a line of silicon/silicon carbide radiant tubes capable of tem-peratures of 2450°F. These tubes have been in use in heat-treat furnaces since 1988 and have proven that their superior performance and long life can significantly reduce mainte-nance and operating costs.www.inexinc.net

Hexoloy Silicon CarbideSaint-Gobain CeramicsSaint-Gobain Ceramics' new brochure offers a comprehensive overview of its line of ceramic materials for high-performance applications, including Hexoloy® sintered silicon carbide, Norbide® hot-pressed boron carbide and Noralide® NBD-200 hot-pressed silicon nitride. Content includes technical information and fabrication processes. Call 716-278-6233 for more information. www.hexoloy.com

ZeroFlow NitridingSECO/WARWICK Corp.The ZeroFlow method is based upon performing the nitriding process with the use of a single-component atmosphere, raw ammonia (NH3). The adjustment of nitriding atmosphere chemical composition, therefore the control of Nitriding potential Np, is performed by a temporary stop and reactivation of the NH feeding into the furnace. E-mail [email protected] for more information. www.secowarwick.com

InsulationUnifrax I LLCFoamfrax™ insulation offers exceptional energy savings, installation speed and lining performance for upgrades of existing fiber linings, lining over refractory, and furnace lining patches or refits. It can be gunned directly onto metal, refractory or fiber surfaces and installed at rates in excess of 1,000 board feet/hour. www.unifrax.com

High-Temperature InsulationKurehaKureha’s high-temperature graphite and carbon insulation can be tailored to meet your specific needs. Our product line includes rigid short fiber, rigid long fiber and soft felt insulation. Being a manufacturer of all three types of insulation sets us apart and ensures that we have the product for you.www.kureha.com



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––––––– BELT FURNACES/OVENS –––––––5" × 36" × 2" BTU(Inert) Elec 1922°F30" × 5' × 16" Gruenberg Elec 450°F 36" × 18' × 6" OSI Gas 1250°F 48" × 16' × 10" Holcroft Gas 500°F 60" × 25' × 12" AFC (2000) Gas 500°F

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––––––– OVENS/BOX TEMPERING ––––––8" × 18" × 8" Lucifer Elec 1250°F12" × 16" × 18" Lindberg (3) Elec 1250°F12" × 24" × 12" Lucifer Elec 1250°F12" × 18" × 12" Lindberg Elec 1400°F14" × 14" × 14" Gruenberg (3) Elec 1200°F14" × 14" × 14" Gruenberg (solvent) Elec 450°F15" × 24" × 12" Sunbeam (N2) Elec 1200°F20" × 18" × 20" Blue-M Elec 400°F20" × 18" × 20" Despatch Elec 650°F20" × 18" × 20" Blue-M Elec 650°F20" × 18" × 20" Blue-M (2) Elec 800°F20" × 20" × 20" Grieve Elec 1250°F24" × 20" × 20" Blue-M Electric 1000°F24" × 26" × 24" Grieve Gas 500°F24" × 24" × 18" Lindberg Elec 1250°F24" × 24" × 36" New England Elec 800°F24" × 24" × 48" Blue-M Elec 600°F24" × 36" × 24" Demtec (N2) Elec 500°F24" × 36" × 24" Trent Elec 1400°F25" × 20" × 20" Blue-M Elec 650°F24" × 36" × 48" Gruenberg (2) Elec 500°F25" × 20" × 20" Blue-M (Inert) Elec 1100°F26" × 26" × 38" Grieve (2) Elec 850°F28" × 48" × 28" Wisconsin Elec 800°F30" × 30" × 30" Hevi Duty Elec 1500°F30" × 38" × 48" Gruenberg (Inert) (2) Elec 450°F30" × 48" × 30" Lindberg (Atmos.) Elec 1400°F36" × 36" × 36" Steelman Burn-off Gas 850°F36" × 36" × 60" Grieve Elec 350°F36" × 48" × 72" Gruenberg Elec 350°F36" × 60" × 36" CEC (2) Elec 650°F36" × 84" × 36" Lindberg Gas 800°F40" × 240" × 42" Moco Tunnel Oven Elec 450°F48" × 72" × 48" Grieve (Inert) Gas 1000°F48" × 48" × 60" Gasmac Burn-off (2) Gas 850°F48" × 48" × 72" Despatch Elec 500°F48" × 72" × 72" P-Quincy Gas 450°F48" × 144" × 84" Wisconsin Elec 500°F54" × 68" × 66" Despatch Gas 500°F60" × 96" × 66" P-Quincy Gas 500°F60" × 120" × 72" Wisconsin Gas 500°F60" × 96" × 84" Callahan Gas 500°F50" × 50" × 50" Grieve Elec 850°F68" × 30" × 66" Grieve Elec 350°F 96" × 360" × 60" Sauder "Tip Up" Elec 1400°F 102" × 54" × 102" Sahara Elec 350°F

Since 1936

HEAVY CARBON CO.

HeavyCarbonCompany

Use the Endocarb System for Highest Quality Deeper Case in Less Time

Each Hour Saved is $100.00 EarnedUser Friendly –Soot Free

Compare Standard to EndocarbTemp. 1750˚F – ECD

Standard System 7 hrs. = 0.059Endocarb System 5 hrs. = 0.059

Standard 140 hrs. = 0.262Endocarb 100 hrs. = 0.262

How to make money CARBURIZING!

Please ask for details:[email protected]

Booth #114 – ASM/AGMA Show • COBO Ctr., Detroit • Oct. 2015

FOR SALE

FOR SALE

To Advertise Online, contact:McClelland at 412-306-4355




Check out the latest Used Equipment Listings on Facebook and Twitter – #IHUsedEquip

Furnaces Ovens & Baths, Inc.EQUIPMENT FOR SALE

Atmosphere Generators3000 CFH Ammonia Dissociator, Electric , S & W, 4 Available2000 CFH Ammonia Dissociator, Electric, 1950°F, Rolock7500 CFH Endo, Gas Fired, 1950°F, Surface Combustion, Modular w/Endo-Injector5600 CFH Endo, Gas Fired, 1950°F, Surface Combustion5600 CFH Endo, Gas Fired, 2050°F, Williams, Air Cooled, Endo-Injector3600 CFH Endo, Gas Fired, 1950°F, Surface Combustion, 2 Available3000 CFH Endo, Gas Fired, 2000°F, Lindberg, Air Cooled3000 CFH Endo, Electric, 1950°F, Gasbarre, Water Cooled2500 CFH Endo, Gas Fired, 1950°F, AFC, Air Cooled1500 CFH Endo, Electric, 2050°F, Lindberg, Air Cooled750 CFH, Endo, Electric, 1850°F, Lindberg, Air Cooled

Box Furnaces24”W x 24”H x 48”L, Electric, 2012°F, Lindberg, Retort Furnace36”W x 40”H x 48”L, Electric, 1700°F, Beavermatic, Roof Fan, LIKE NEW18”W x 18”H x 24”L, Electric, 2192°F, Lindberg, H2 Retort, “SINTER-ALL” 18”W x 18”H x 24”L, Lindberg, “Sinter-All”, 2200°F, H2 Atmosphere15”W x 12”H x 18”L, CM, 2800°F, H2 Atmosphere166"W x 20"H top of piers to door arch, 32"H opening x 120"L, 2000°F, Gas Fired, Atmosphere, McLaughlin Services10'6"W x 6'H x 35'L, Gas Fired, 1650°F, Drever, Fiber Lined, Atmosphere, 2 Available60”W x 60”H x 60”L, Electric, 1250°F, Wisconsin, 2 Available, Rebuilt w/New Controls48"W x 48"H x 54"L, Electric, 1200°F, Sunbeam, Fiber Lined36”W x 30”H x 60”L, Electric, 1400°F, Rolock, Atmosphere/Forced Cooling,

Fiber Lined24”W x 18”H x 36”L, Electric, 2000°F, Lindberg, Atmosphere, Fiber Lined15"W x 12"H x 30"L, Electric, 2000°F, Lindberg, Atmosphere12”W x 12”H x 33”L, Electric, 2150°F, L & L Special Furnace, H2/N2

Atmosphere, RetortMANY MORE AVAILABLE PLEASE VISIT OUR WEBSITE www.fobinc.com

Belt Furnaces72"W x 9"H x 24'L, Electric, 1600°F, Holcroft, Atmosphere/Cooling16”W x 3”H x 20’L, Electric, 2400°F, Abbott Furnace, Ceramic Belt,

Atmosphere8"W x 4"H x 54"L, Electric, 2100°F, C.I Hayes, Atmosphere/Cooling12"W x 1"H x 12'L, Electric, 2012°F, Lindberg, Atmosphere/CoolingMANY MORE AVAILABLE PLEASE VISIT OUR WEBSITE www.fobinc.com

Pit Furnaces 25” Diameter x 36”Deep, Lindberg, 2000°F, Atmosphere, LIKE NEW 40” Diameter x 60”Deep, Electric, 1400°F, L & N/Lindberg, N2 Atmosphere, 2 Avail.28” Diameter x 72”Deep, Electric, 2000°F, Lindberg, CarburizerMANY MORE AVAILABLE PLEASE VISIT OUR WEBSITE www.fobinc.com

Internal Quench Furnace30”W x 30”H x 48”L, Electric, 1800°F, Lindberg, Top Cool

Roller Hearth Furnaces104"W x 24"H x 51'L, Gas Fired, 1600°F, Holcroft, Fiber Lined, Includes Trays/Baskets

Rotary Retort Furnace18" Diameter x 10'L Heat, 950 pounds per hour, 1750°F, AGF, New Retort,

Complete Line

Vacuum Furnaces 12”W x 12”H x 24”L, Centorr, 1500°C, H2 Atmosphere, Diffusion Pump, Loader48” Diameter x 60”H, Bottom Loader, Electric, 2400°F, Diffusion Pump, Abar Ipsen12”W x 12”H x 24”L, Electric, 1450°C/2642°F, The Heat Source, Moly Hot Zone, Diffusion Pump

Induction Heating335 kW, 200 kHz, 750V Output, Elphiac/Inducto-Heat, Includes Water System200 kW, 450 kHz, I.P.E./Inducto-Heat, R.F. Power Supply w/2 Heat StationsMANY MORE AVAILABLE PLEASE VISIT OUR WEBSITE www.fobinc.com

Vacuum Induction Melting 150 kW, 3 kHz, ALD, 50 to 300 pound crucibles, Pillar MK 11 Power Source,

Excellent Condition100 kW, 3 kHz, Ionex, Pillar MK 8 Power Source, Excellent Condition

Walk-In Ovens 120”W x 80”H x 168”L, Electric, 500°F, Grieve, Solvent Rated72”W x 78”H x 144”L, Despatch, 650°F, Electric81"W x 92"H x 25'L, Electric, 295°F, FECO, 350 kW, UNUSED & LIKE NEW, 2 Available72"W x 96"H x 25'L, Gas Fired, 500°F, Wisconsin Oven, Double Ended, AMS 2750D Certified, +/-10°F39"W x 58"H x 50"L, Electric, 1000°F, Despatch, Atmosphere, Cooling

Continuous Ovens60”W x 10”H x 20’L Heat, Gas Fired, 500°F, Jensen, 3 Available18”W x 6”H x 10’L Heat, Gas Fired, 500°F, Jensen, 3 Available48”W x 6”H x 26’L Heat, Gas Fired, 650°F, Wisconsin Oven52”W x 11”H x 18’L Heat, Gas Fired, 900°F, S.F.E.30”W x 11”H x 18’L Heat, Gas Fired, 900°F, S.F.E. 48”W x 12”H x 20’L, S.F.E., Gas Fired, 900°F30’W x 12”H x 20’L, S.F.E., Gas Fired, 900°F 36"W x 6"H x 25'L, Gas Fired, 600°F, Abbott Furnace Company, Cooling, 3 Available12"W x 1.5"H x 22'L, Gas Fired, 600°F, O.S.I., 4 Avail.

Cabinet Ovens48”W x 48”H x 30”L, Electric, 350°F, Precision Quincy, Roll-In Cart 20'W x 20"H x 20"L, Electric, 1250°F, Grieve, 2 Avail.36”W x 48"H x 36"L, Electric, 600°F, Blue M, TestedMANY MORE AVAILABLE PLEASE VISIT OUR WEBSITE www.fobinc.com

Miscellaneous Wheelabrator Tumblast, 7 Cubic Feet, FeMg Flights, Loader, PLC ControlsSBS Air to Oil Heat Exchangers, Various Sizes, 7 Units In StockDetroit Testing DH-2 Brinnell Hardness Tester30” Diameter Rotary Wash, Gas Fired, Stainless Steel36” Diameter Rotary Wash, Gas Fired, W/R/D 30” Diameter Rotary Drum Washer, Stainless Steel, Gas Fired, W/Blow OffAFC Charge Car, 36”W x 48”L Tray, Double Ended, PLC Controlled Pangborn Spinner Hanger Shot Blast Machine, 2 Wheels, 20 H.P. Ea., 24” Diameter x 60”H, 2 CompartmentJet Wheel Blast Multi Tumble Blast, 8 Cubic Feet, Includes Loader/Dust

Collector, PLC Controls3 Stage Dual Rotary Drum Washer, 23” Diameter Drums, 180°F Wash/Rinse,

180°F Electric Blow-Off

Contact: Jeffrey D. Hynes 248.343.1421 or [email protected] • For a complete inventory listing with photos visit www.fobinc.com





Heat Treat Equipment 42056 Michigan Ave., Canton, MI 48188 • John L. Becker, IIPh: 734-331-3939 • Fax: 734-331-3915 • Email: [email protected]

U-3611 SC Super Allcase IQ Furnace

• Manufacture: Surface Combustion• Type: IQ Furnace with top-cool heat exchanger• Serial No.: BC-43055-01• Fuel: Natural Gas• Heating: Trident tubes, Eclipse burners• Max Fuel Demand: 2940 CFH• Max Temp: 1950°F• Power: 460 V, 3-phase, 60 Hz, 110 KW• Working Dim’s: 36” wide x 48” deep x 36” high• Flow Meters: (1) air, (1) natural gas, (1) endo• General: System One rear handler, Carbon control

U-3606 Dow/Atmosphere Furnace Company IQ Furnace• Type: IQ Furnace• Serial No.: HJS11E• Model No.: DWE 30.48.24• Working Dim’s: 30” wide x 48” deep x 24” high• Load: 2,000 pounds• Fuel: Natural Gas• Heating: Radiant Tubes• Max Temp: 1850°F• Power: 460 V, 3-Phase, 60 Hz• Quench Tank: 2,000 Gallons (approximate)• Flow Meters: (1) air, (1) natural gas, (1) endo, (1) ammonia• Controls: Honeywell Controls• General: System One Rear Handler; Carbon

Control; Recirculating Fan; Shell & Tube Heat Exchanger

> Charge Car Matching Unit is also Available

2 Surface Combustion IQ Furnaces For Sale★ Available “As Is” or Refurbished ★

VACUUMFURNACES SALE• VFS 24 x 36 x 24, 2500F, 2 BARR• G-M Enterprises 14" x 20"L x 14",

2200˚F, pressure cooling• Astro 3.5" diameter x 8"H• Elatec 24"W x36"L x 18"H, 4000˚F• Abar HR50-48, 2400F, autoclave

style door, pressure quench, 36"w x 48"L x 30"H.• Ipsen 524, 24" x 36" x 24", 2400˚F• SECO 36" x 120" x 36" 2400˚F• GH Induction Atmospheres, 12" dia. x 17" H, bottom load, diff pump and mechanical

Website: www.consequip.comPhone: 810-966-1500

Email: [email protected]

EQUIPMENT COMPANY

491964 YEARS 2013

Cel

ebra

ting our 49th Year

USED EQUIPMENT FOR SALE

Mowry Enterprises, Inc.New ★ Used ★ Rebuilt ★ Solutions

★ FOR SALE ★

www.mowryenterprises.comemail: [email protected]

Phone: 978-808-8634 Fax: 508-845-4769

Abar HR 34: 24 x 24 x 36, graphite hot zone, high vacuum, external quench, 2400˚F, PLC/ touch screen controls, 6 sided heating.

TM 18 x 18 x 30, High vacuum, moly hot zone, stainless steel vessel, pressure quench

Dry Coolers self contained cooling system, 650 GPM: 12 x 8 heated pump station insulated building, process/tower system with plate-frame heat exchanger and filters. Tower mounts above self contained building

Abar HR 26 2 Bar: 2400˚F, 18” x 24” x 36” graphite hot zone, high vacuum, 2 bar pressure quench

Abar HR 46: 30” x 30” x 48”, Moly hot zone, high vac, external quench, 2400˚F

Ipsen 6 BAR, 36 x 36 x 48: graphite hot zone, high vacuum, internal quench, 2400˚F, PLC/ touch screen controls

TM 12 x 12 x 20: graphite hot zone, high vacuum, internal quench, 5 psig positive quench

Seco 48 x 48 bottom load: Moly hot zone, high vacuum, internal quench, all stainless steel vessel

For Classified Sales Contact Becky McClelland at 412-306-4355

FOR SALE FOR SALE

Moist Creamy Putty Just Apply and Let DryBonds Most Materials

Resists Chemicals, Electricity, Molten Metals

and Abrasion

High TemperatureAdhesive & Sealant

[email protected] • 718-788-5533

2300˚F

Visitwww.industrialheating.

com/employment-marketplace

to fi nd out how the Industrial Heating

CLASSIFIEDMARKETPLACE

can help you target qualifi ed job candidates!

UPDATEDDAILY




Check out the latest Used Equipment Listings on Facebook and Twitter – #IHUsedEquip

FOR SALE

Cleveland, OHPh: 440-519-3800Email: [email protected]

Ipsen Aluminum BrazingVacuum Furnace

• ID: 36"W x 48"D x 36"H• Horizontal Loading• Electric – 225KW – 1400˚F• Mechanical & Diffusion Pumps• All Digital Controls• Excellent Condition - Operational

42056 Michigan Avenue. Canton, MI 48188Phone: 734-331-3939 • Fax: 734-331-3915

E-mail: [email protected]

Batch / Box Furnaces C0007 JL Becker Box Furnace with atmosphere, 72"W x 72"H x 72"L,

1650ºF, gas-firedC0023 Wisconsin Oven Batch/Temper Furnace, 36"W x 48"D x 36"H,

1250°F, gas-firedC0029 Seco Warwick Box Furnace, 48"W x 48"H x 72"D, 1250°F, electricC0030 Seco Warwick High-Temp Box Furnace, 24"W x 24"H x 36"D,

1800°F, electricC0032 Seco Warwick Box Furnace, 75"W x 60"H x 120"D, 1250°F, electricC0033 Surface Combustion Oil Quench Furnace, 30"W x 30"H x 48"D,

1800°F, electricU3556 Pacific Industrial Box Furnace, 24”W x 18”H x 36”L, 2800ºF,

electricU3603 Atmosphere Furnace Batch Temper Furnace, 42"W x 30"H x

58"D, 1600ºF, gas-firedU3616 Degussa Durferrit Steam Tempering Furnace, 24" dia x 48"D,

1200ºFV1010 Dow Batch Furnace, 30”W x 20”H x 48”L, 1250ºF, gas-firedV1011 Dow Batch Furnace, 30”W x 20”H x 48”L, 1250ºF, gas-firedV1013 Thermolyne Furnace, Hi Temp, Front Door Loading, 10"W x 9"H

x 14"L, 2000ºF, electricV1014 Lindberg Box Cyclone Furnace, 30"W x 24"H x 72"L, 1200ºF, electricV1024 PIFCO Temper Furnace, Skid Hearth, 36”W x 48”L x 30”H,

1300ºF, electricV1026 FNC Box/Batch Tempering Furnace, 11'W x 6'H x 18'L, 2400°F,

gas-firedV1027 FNC Box/Batch Tempering Furnace, 11'W x 6'H x 18'L, 2400°F,

gas-firedV1049 Surface Combustion Temper Furnace, 87"W x 36"H x 87"L,

1350°F, gas-fired

Car Bottom Furnaces V1028 Car Bottom Furnace, 9'W x 3'H x 16'L, 2000°F, gas-firedV1029 Johnston Car Bottom Furnace, 6'W x 4'H x 18'L, 2000°F, gas-firedV1040 Despatch Car Bottom Furnace, Dual-Door, Straight-Thru, 12'W

x 5'H x 12'D, 700ºF, electric

Drop Bottom Furnaces C0031 Seco Warwick Solution Anneal Furnace System, 48"W x 48"H x

48"D, 1200°F, electricU3543 Despatch Drop Bottom Furnace, 4’W x 4’H x 6’L, 1200ºF, electric

Internal Quench Furnaces U3569 Surface Combustion IQ Furnace, 24”W x 18”H x 36”D, 1750ºF,

gas-firedU3570 Surface Combustion IQ Furnace, 24”W x 18”H x 36”D, 1750ºF,

gas-firedU3606 Dow/AFC IQ Furnace, 30"W x 48"L x 24"H, 1850°F, gas-firedU3611 Surface Combustion IQ Furnace, Top-Cool, 36-48-36, 1950°F,

gas-firedV1046 Surface Combustion IQ Furnace, 87"W x 36"H x 87"L, 1850°F,



gas-fired

Mesh Belt Brazing Furnaces U3310 Lindberg Mesh Belt Brazing Furnace, 18”W x 11"H x 11’L,

2100ºF, electricU3529 CI Hayes Mesh Belt Brazing Furnace, 18"W X 6"H, 2100ºF, electric

U3551 Surface Combustion Mesh Belt Furnace, 36"W x 12”H x 20’L, 750ºF, gas-fired

U3580 JL Becker Mesh Belt Brazing Furnace, 14"W x 6"H x 8'L, 2100ºF, electric

U3592 JL Becker Mesh Belt Brazing Furnace, 12"W x 6"H, 2100ºF, electric

V1035 Seco Warwick Mesh Belt Brazing Furnace, 18”W x 12”H x 8'L, 2100ºF, electric

Mesh Belt Tempering Furnaces C0010 Despatch Mesh Belt Tempering Furnace, 57"W x 14"H x 20' L,

1000ºF, gas-firedC0021 Sunbeam Mesh Belt Temper Furnace, 24”W x 8”H x 10’L,

1050°F, gas-firedC0022 AGF Mesh Belt Temper Furnace, 30"W x 20"L, 1100°F, gas-firedV1022 Surface Combustion Mesh Belt Tempering Furnace, 42”W x

12”H x 36'L, 1350ºF, gas-fired

Pit Furnaces U3547 Lindberg Pit/Carborizer Furnace, 48” dia x 60” deep, 1850ºF,

gas-firedU3548 Lindberg Pit/Carborizer Furnace, 48” dia x 60” deep, 1850ºF,

gas-firedU3549 Lindberg Pit/Temper Furnace, 48” dia x 60” deep, 1250°F,

gas-fired

Roller Hearth Furnaces C0025 Park Thermal Batch Temper Roller Hearth Furnace, 36”W x

30”H X 72”L, 1250ºF, gas-firedU3550 PIFCO Powered Roller Hearth Temper Furnace, 21"W x 16"H x

10'L, electricV1009 Ipsen Continuous Temper Furnace, 24”W x 18”H x 10’L,

1350ºF, electric

Vacuum Furnaces C0013 CI Hayes Oil Quench Vacuum Furnace, 24"W x 18"H x 36"D,

electricC0020 Ipsen 6 Bar Vacuum Furnace, 36”W x 36”H x 54”D, 2400°F,

electricU3612 AVS Vacuum Annealing Furnace, 18"W x 12"H x 24"D, 2400ºF,

electricV1004 CI Hayes Vacuum Furnace, Oil Quench, 18”W x 12”H x 30”L,

2400°F, electricV1053 Seco Warwick Horizontal Vacuum Furnace, 30" wide x 16" high

x 30" deep, 2400ºF, electricV1054 Seco Warwick Horizontal Vacuum Furnace, 30" wide x 16" high

x 30" deep, 2400ºF, electricV1055 Centorr Horizontal Vacuum Furnace, 12"W x 12"H x 12" D,

2400ºF, electricV1058 GM Enterprises VHF-701 Vacuum Furnace, 48"W x 48"H x

60"L, 2500°F, electricV1060 Abar HR26x26 Vacuum Furnace, 24"W x 18"H x 36"L, 2400°F,

electricV1061 Abar HR34 Vacuum Furnace, 24"W x 24"H x 36"L, 2400°F,

electricC0019 Surface Combustion Vacuum Temper Furnace, 36"W x 24"H x

48"L, 1350°F, electricC0027 Pacific Scientific Vacuum Temper Furnace, 24”W x 24”H x

36”D, 1450ºF, electric

Endothermic Gas Generators U3496 Surface Combustion Gas Generator - 5,600 CFH EndoU3594 Atmosphere Furnace Gas Generator, 3,000 CFH EndoV1021 Surface Combustion Gas Generator - 2,400 CFH EndoV3512 Surface Combustion Gas Generator - 5,600 CFH Endo

Exothermic Gas Generators U3581 CI Hayes Gas Generator - 4,000 CFH ExoU3593 JL Becker Exothermic Gas Generator, 2,500 CFH with gas dryerV1036 Seco Warwick Gas Generator - 3,000 CFH Exo

Material Handling - Conveyors U3565 Conveyor - Roller: 48”W x 20’L

Ovens - Cabinet U020 Blue-M Oven/Ref, 20”W x 20”H x 18”D, (-4°F/400°F)V1016 Grieve Electric Cabinet Oven, 36”W x 36”H x 36"L, 950ºF Ovens - Cart Type V1059 Wisconsin Oven Batch/Temper Furnace, 6' W x 6' H x 33' L,

800°F, gas-fired

Blowers U018 Twin City Blower - 20 HPU027 Twin City Blower - 5 HPU029 BlowerV3516 Eclipse Blower - 3/4 HP

Charge Cars U3615 JL Becker Charge CarV1043 Surface Combustion Charge Car, Double-EndedV1051 Surface Combustion Charge Car, DEDPER, 87"W x 87"L

Compressors U019 Spencer Turbo Compressor - 1.5 HPU023 Spencer Turbo Compressor

Heat Exchanger Systems U030 Graham Systems Heat Exchanger - PlateU3609 SBS Heat Exchanger

Parts - Soluble Oil Tank U3413 Conveyor & Tank - continuous soluble: 62”W x 48”H x 96”L Water Cooling Systems U3404 JL Becker Cooling Tower with Tank: Tower: 51”W x 64”H x

36”L, Tank: 72”W x 66”H x 84”LU3405 JL Becker Cooling TowerU3595 JL Becker 2-Tank Water Cooling System, 2 Dayton 1HP Motors

Washers U3564 Holcroft Batch Washer, 36”W x 72”H x 36”L, gas-firedV1052 Surface Combustion BIQ Washer, 87"W x 36"H x 87"L, 180°F,

gas-fired Transformers Extensive inventory of all types of transformers for any and all

applications Baskets & Boxes Extensive inventory of heat treat baskets and boxes

For Miscellaneous Parts Inventory and Complete Equipment Listings visit www.heattreatequip.com

SERVICES

PHOENIXINDUCTION CORPORATION

Qualified Induction Specialists with over 90 years of combined experience, providing on site:

• Troubleshooting “down” equipment• Quality preventative maintenance• Acid flushing, thermal imaging & analysis• Large inventory of OEM parts, as well as

other manufacturers, AJAX*, AIH*, Bone Frontier*, IEH*, and Robotron*

• 24/7/365 days a year emergency phone support

Call: [email protected]*Registered trademarks of their respective companies

INDUSTRIALHEATINGREPRINT PLAQUES

ARE NOW AVAILABLE

If it was printed byIndustrial Heating, it can be

reprinted by Industrial Heating.

Contact: Becky McClelland at 412-306-4355 or

[email protected]





Equipment for SaleSPECIAL OFFER

Wisconsin Oven (Mint Condition)(Quantity 2) Natural Gas Fired Walk In Series Oven, 6’ Wide x 6’ High x 33’ long, Max. Temp. 800°F, 1,000 BTU per cubic foot, vertical lift, pneumatically operated door at each end, digital Honeywell Controller, Honeywell 10” Circular Chart Recorder, digital Barber Coleman High Limit Controller, c/w Load Cart 5’4” W x 25’ long.

Harrop

Glo Bar Furnace, 18”W x 30” L x 18” H, electric, Max. Temp. 2,400°F, Barber Coleman Hi Limit & programmable Temp. Controller, L & N Strip Chart Recorder, 2 sets of Tap Switches for upper, middle & lower heaters

North American

Slot Furnace, 48” W x 6” H x 30” L, Gas, c/w with Combustion Blower and 2 North American Burners, 2 Control Panels.

Process Industrial Machinery

Typhoon Washer, 48” Dia. x 6’ H, Wash Tank capacity 420 US Gallons, Rinse Tank capacity 200 US Gallons, Turntable Capacity 1,000 lbs, Control Panel, front loading Door.

Park Thermal

Batch Oven, 48” W x 48” H x 33” L, Max. Temp 500°F, Natural Gas, 175,000 BTUH, Fuji Controller and Hi Limit

Park Thermal

Batch Oven, 48” W x 48” H, x 48” L, Max. Temp 550°F, Natural Gas, 250,000 BTU’s, Control Panel & all necessary Controls

SFE

Cyclone Pit Furnace, 28” W x 96” Deep, Max. Temp. 1400°F, 500,000 BTUH.

IMMACULATE EQUIPMENT

Surface Combustion Integral Quench Furnaces (2), 30” W x 24” H x 48”L, Max Temp 1,750° F, 1,000,000 BTUH, Trident Tubes, Endo/Natural Gas/Ammonia, SSI Atmosphere Controllers, SS1 Gold Probes, Oil Filters and SBS Coolers. System complete with a Gas Fired Temper, Washer and Charge Car.

Surface Combustion

Electric Batch/Oil Quench Furnace, 30” W x 30” H x 48”L, Max. Temp. 1,950°F, System 1 Rear Handler, 3500 Gal. Quench Tank, 2 Agitators & Controls

Seco/WarwickElectric Box Furnace, 48” W x 48” H x 72” L, Max Temp 1250°F, Powered Rollers, Load/Unload Table and Controls.

Seco/Warwick Electric Box Furnace, 75” W x 60” H x 120” L, Max Temp 1,250°F, Powered Rollers, Load/Unload Table & Controls.

Seco/Warwick Solution Anneal Quick Quench System, 48” W x 48” H x 48” L, Operating Temp. 1,200°F, 198 KW, Powered Rollers, Quench Tank, Load Table & Controls.

Seco/Warwick High Temperature Electric Furnace, 24” W x 24”H x 36” L, Max. Temp. 1,800°F, Powered Rollers, Load/Unload Table & Controls .

G-M Enterprises Horizontal Vacuum Furnace, 48” W x 48” H x 60” L, Max. Temp. 2,500°F c/w Stokes 412, Roots 615 Blower, Varian 32” Diffusion, Spencer 50 HP Blower & Heat Exchanger.

Surface Combustion(Quantity 2) Integral Quench Furnaces, 8,000 lb. payload each, 62” W x 62” L x 36” H, Max. Temp. 1,850°F, 4,600,000 BTUH, 9,500 Gallons, 2 Agitators, Eclipse Burners, 2 Rear Handler & Controls with PLC.

Surface Combustion Integral Quench furnace, 10,000 lb. payload, 87” W x 87” L x 36” H, 1,850°F, 4,600,000 BTUH, 12,500 Gallons, 6 Agitators, Eclipse Burners, 3 Rear Handlers & controls with PLC.

Surface Combustion Wash/Rinse/Dry, 87” W x 87” L x 36” H, Max. Temp. 180°F, 1,500,000 BTUH, Oil Skimmer and Controls.

Surface Combustion Atmosphere Temper Furnace, 87” W x 87” L x 36” H, Max. Temp. 1,350°F, 1,500,000 BTUH, Eclipse Burners, Combustion Blower, 2 Re-Circulation Fans & Controls with PLC.

Surface Combustion Double Ended Charge Car, 87” W x 87” L, Auto. Double Positioning, Extended Reach and A/B Controls.

Surface Combustion (Excellent Condition)(Quantity 2) Integral Quench Furnaces, 5000 lb. payload each, 36”w x 36”h x 72”l, recuperated rear handler and controls.

Park Thermal International (1996) Corp.62 Todd Road, Georgetown Ontario L7G 4R7Toll Free: 877-834-4328 • Fax: [email protected]: www.parkthermal.com



INDEX OFADVERTISERS IN THIS ISSUE

Advertiser Page Phone Website

Across International LLC 21 888-988-0899 www.acrossinternational.com

Ajax TOCCO Magnethermic Corp. 8 800-547-1527 www.ajaxtocco.com

Association for Iron & Steel Technology 41 724-814-3000 www.aist.org

Can-Eng Furnaces International LTD. 11 905-356-1327 www.can-eng.com

Custom Electric Manufacturing Co. 13 248-305-7700 www.custom-electric.com

Fives North American Combustion, Inc. 15, 27 216-271-6000 www.fivesgroup.com

G-M Enterprises Back Cover 951-340-4646 www.gmenterprises.com

Inductoheat Inc. 23 800-624-6297 www.inductoheat.com

INEX Incorporated 28, 42 716-537-2270 www.INEXinc.net

J.L. Becker, a Gasbarre Furnace Group Company 37 734-656-2000 www.jlbecker.com

Kureha America LLC 30 212-867-7040 www.kureha.com

Metal Powder Industries Federation 25 609-452-7700 www.mpif.org

Protection Controls Inc. 28, 37 847-674-7676 www.protectioncontrolsinc.com

Qual-Fab, Inc. 30 440-327-5000 www.qual-fab.net

SAFE Cronite Inc. 19 440-353-6594 www.safe-cronite.us

Saint-Gobain Ceramics, Structural Ceramics, Hexoloy 32 716-278-6233 www.hexoloy.com

SECO/WARWICK Corporation. 17, 35 814-332-8400 www.secowarwick.com

Solar Manufacturing 33 267-384-5040 www.solarmfg.com

Struers/Industrial Heating Free Webinar 43 webinars.industrialheating.com

Super Systems Inc. 29 513-772-0060 www.supersystems.com

Surface Combustion Inc. 4-5. 800-537-8980 www.surfacecombustion.com

Tinius Olsen 33 215-675-7100 www.tiniusolsen.com

T-M Vacuum Products, Inc. 3 856-829-2000 www.tmvacuum.com

Turbo Expo 47 404-847-0072 www.turboexpo.org

Unifrax, LLC Inside Front Cover 716-768-6500 www.unifrax.com

Wellman Furnaces Inc. 31 317-398-4411 www.wellmanfurnaces.com

Wire Association International Inc., The 51 203-453-2777 www.wirenet.org

Wisconsin Oven Corp. 7 262-642-3938 www.wisoven.com

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G-M Enterprises Model HVF 401-IBat California Brazing, Newark, CA

“This G-M furnace is simply outstanding, especially the pumping system and the automated data collection system. They’re the best I’ve seen.”

– Rich Penrose, President

Furnaces that work

Vacuum Furnaces - Atmosphere Furnaces - Replacement Parts - Hot ZonesLocations: East Coast, Midwest & West Coastwww.gmenterprises.com phone (951) 340-4646 fax: (951) 340-9090


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