Mary Glenn

Heat Treatment and Wicked Problems

BOTW-50w  Source:  Linked In – Peter Sherwin

“I am wide awake on a late night flight from Kolkata to Delhi (India) so I pick up my phone to continue reading “Design to Grow – How Coca Cola learned to combine scale and agility.” I happened on the chapter discussing wicked problems – with sustainability of water use being one of Coke’s wicked problem (basically a wicked problem is one that is ill-defined, has many uncontrollable variables and has no so-called right or optimal solutions).

Having spent the week traveling around India and visiting customers with typical heat treat problems and seeing and hearing about and presenting the latest technology solutions in Heat Treat – I have come to the conclusion Heat Treatment is itself a wicked problem.”

Read More:  Peter Sherwin – Eurotherm – Linked IN

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Vacuum Heat Treatment’s Role in Additive Manufacturing (AM) 3D Printing

BOTW-50w  Source:  Global Heat Treatment Network

“Vacuum heat treatment tasks for AM manufactured parts is the same process as  traditional subtractive manufacturing and its purpose is to assure AM parts has the correct physical and metallurgical properties for specific applications.  In some cases, when a bidder is involved, the purpose of the heat treatment process is to deciding and sinter parts. Most vacuum furnaces use up to 800°C degrees to relieve stress and a higher temperature of up to 1800°C for other processes.

Vacuum furnaces with high vacuum levels are preferred to heat treatment equipment to process AM parts. AM parts made from Titanium, Cobalt, Aluminum require vacuum levels of up to 10-6 mbar with 99.9995 Argon purity.  Argon is the preferred gas because of its neutrality and that it has no adverse reaction with the above alloy components.  Creating an Alfa surface layer on titanium parts is not desirable and should be avoided.

The small parts and small production volume influences vacuum furnaces of small to medium size. The next challenge for the heat treatment industry is to integrate heat treatment process into the AM equipment in one continuous process.”

Read More:  Amazing Vacuum Furnaces:  Vacuum Heat Treatment’s Role in Additive Manufacturing 3D Printing by Janusz Kowalewski

Vacuum Heat Treatment’s Role in Additive Manufacturing (AM) 3D Printing Read More »

Laser -Induced Breakdown Spectroscopy: A New Tool for Real Time Metal Quality Measurement

BOTW-50w  Source:  Die Casting Engineer

“Laser-induced breakdown spectroscopy (LIBS) has shown great potential for use in metal processing and can be performed directly in the molten metal, allowing for quick and representative measurements.”

Read More:  Laser-Induced Breakdown Spectroscopy:  A New Tool for Real Time Metal Quality Measurement by Shaymus Hudson, Joseph Craparo, Robert De Saro, Diran Apelian

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Quality Counts: Gas Nitriding

BOTW-50w  Source:  Thermal Processing for Gear Solutions

In general, nitriding of parts involves a thermal process that provides a tough, corrosion-resistant, and wear-resistant surface with less distortion compared to other case hardening processes due to processing temperature and no need for quenching. There are different methods of nitriding, including gas nitriding, plasma/ion nitriding, and salt-bath nitriding. This article focuses on gas nitriding.

Read More:  Quality Counts:  Gas Nitriding by Jim Oakes

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Coupling CFD and Oil Quench Hardening Analysis of a Gear Component

BOTW-50w  Source:  Thermal Processing for Gear Solutions

“The coupling of CFD and heat treatment analyses provides a more robust application of computer modeling to predict the latent heat release, distortion, and residual stresses during the quench hardening process.”

Read More:  Coupling CFD and Oil Quench Hardening Analysis of a Gear Component by B. Lynn Ferguson, Zhichao (Charlie) Li, David Greif, Zlatko Kovacic, Simon Urbas, Rok Kopun

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Bodycote Greenville Open for Business

Bodycote, the world’s largest thermal processing services provider, is pleased to announce that its new plant in Greenville, South Carolina is open for business. The facility is now ready to process metal and alloy parts that require brazing or vacuum heat treating services.

The new Greenville facility primarily serves the Southeast region’s manufacturers and their supply chains in the aerospace, defence, energy and medical industries. The plant is expected to receive Nadcap accreditation by the end of 2016, offering quality assurance based on stringent auditing standards for the aerospace and defence industries. Bodycote intends to offer additional services from the facility in the future in response to customer demand.

This investment is part of Bodycote’s further expansion in the Southeast USA. Bodycote is committed to offering world-class heat treating and specialist technology services and is investing in improvements as part of an ongoing strategy to provide the best possible capabilities, mix and geographical network to better serve customers.

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Heat Treating Involved in Production of Speakers

BOTW-50w  Source:  ETMM The Website

“One look at the back of the part told me it was filled with one sub-gate (see Figure 2). In the US at the time, we were trying to pack out this type of speaker grill with 12-drop systems, which resulted in poor fill and a lot of stress in the piece. In Japan, mouldmakers were using a mould material developed to enhance venting. This was a steel manufactured with interconnecting pores so the gas could pass through the seemingly solid piece of metal. To make this steel, powder metal was combined with metal fibers for added strength, cold-pressed into master blocks measuring 215 by 300 by 650 mm, sintered and heat-treated to 35 HRC. It was available with average pore diameter of either 7 or 20 microns; porosity averaged 25 percent of the mass of the block. Other materials available at the time ranged from porous ceramics to sintered porous vent buttons.”

Read More: The Potential of Enhanced Venting Materials by Tom Schade

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Enhancing Energy Efficiency of Thermochemical Vacuum-Processes and Systems

BOTW-50w  Source:  Heat Processing

“The energy optimization of thermoprocessing equipment is of great ecological and economical importance. Thermoprocessing equipment consumes up to 40 % of the energy used in industrial applications in Germany. Therefore it is necessary to increase the energy efficiency of thermoprocessing equipment in order to meet the EU’s targets to reduce greenhouse gas emissions. In order to exploit the potential for energy savings, it is essential to analyze and optimize processes and plants as well as operating methods of electrically heated vacuum plants used in large scale production. For processes, the accelerated heating of charges through convection and higher process temperatures in diffusion-controlled thermochemical processes are a possibility. Modular vacuum systems prove to be very energy-efficient because they adapt to the changing production requirements step-by-step. An optimized insulation structure considerably reduces thermal losses. Energy management systems installed in the plant-control optimally manage the energy used for start-up and shutdown of the plants while preventing energy peak loads. The use of new CFC-fixtures also contributes to reduce the energy demand.”

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AICHELIN Group Acquires AFC-Holcroft, a US Market Leader in Heat Treatment Solutions

On July 12, 2016, the Austrian AICHELIN Group acquired US-based Atmosphere Group, holding company of AFC-Holcroft. The two groups are a perfect fit: Both are leading market players with a long-standing history and state-of-the-art technologies and services in the industrial area of heat treatment solutions. AICHELIN Group – with its manufacturing companies AICHELIN, EMA Indutec, SAFED, BOSIO and Noxmat – is a leading provider of high-quality plants and systems. AFC-Holcroft is the US market leader in the production of industrial furnace equipment for ferrous and non-ferrous metals. Other main companies of Atmosphere Group are Atmosphere Heat Treating and Austemper Inc. Until now, Atmosphere Group was privately held. The parties agreed not to disclose details and the price of the transaction.

The acquisition complements the geographic presence of AICHELIN Group and strengthens the Group’s overall market position as one of the leading global heat treatment groups. The AICHELIN Group is now the largest provider of Atmosphere furnaces world-wide. With a strong presence in Europe, North America and Asia, the joint annual turnover generated by 1,100 employees amounts to over EUR 195 million (2015). The group operates a network in 32 countries.

“This is a major step in AICHELIN Group’s strategy of building a global, dynamic group of companies specializing in heat treatment solutions”, says AICHELIN Group’s CEO Peter Schobesberger. “With AFC-Holcroft as a member of our Group, we further evolve into a truly global company with strong local roots in the most important markets. We have an excellent, complementary geographical footprint and will further strengthen our leading positions.” Bill Disler, CEO of AFC-Holcroft, adds: “AFC-Holcroft celebrates its 100th anniversary this year. With AICHELIN Group as our new owner, we are sure to combine our long-standing traditions with an innovative future. AFC-Holcroft will benefit from being embedded into a family of strong global companies and brands.”

Extended product portfolio and services for customers AICHELIN Group’s business model covers all stages of the lifecycle: From design, engineering, manufacturing and installation at customer sites to comprehensive maintenance and spare part services. By combining the networks of AICHELIN Group and AFC-Holcroft, customers will get the best of two worlds: An enlarged, high quality product portfolio as well as a process innovative, world-wide service network. “Together, we have an ideal position to service our customers in the best possible way. They can benefit from our extended project capabilities and the most reliable technology of three continents. Additionally, we will continue to focus on innovation and exploit all our joint possibilities”, says Schobesberger.

As the next step, a process will start to integrate AFC-Holcroft and its sister companies into AICHELIN Group’s network in the coming months. AFC-Holcroft’s headquarters will remain in Wixom, Michigan. The current top management stays in place and most customers will keep their key account managers.

“We want to play an active role in the consolidation of the heat treatment market. We aim at joint growth and a sustainable profitability, for the benefit of our customers, stakeholders and employees”, closes CEO Schobesberger.

AICHELIN Group Acquires AFC-Holcroft, a US Market Leader in Heat Treatment Solutions Read More »

Walking Beam Furnace Energy Savings: New Skid Pipe Insulation Concept

BOTW-50w  Source:  Heat Processing On-Line

This paper discusses how energy consumption and energy loss can be reduced in reheating furnaces of hot rolling mills by using new lightweight refractory materials and a new lining concept for the skid pipe insulation.

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