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Heat Treat Today’s Coronavirus Impact Update — Phase II

On February 27th, Heat Treat Today conducted an initial Coronavirus Impact Study. We wrote about the findings on March 4th. Click here to see that initial report. Considering the historical uniqueness of what is happening and the impact that the virus and, more importantly, the impact of the reaction that has been mandated by federal, state, and local governments, Heat Treat Today decided to conduct a slightly expanded follow up study (Phase II) on March 20th — roughly 3 weeks after the initial study. Below is an analysis of the results of Phase II and where possible a comparison between Phase I and Phase II results.

Publishers Note: The coronavirus/COVID-19 situation has been accompanied by media coverage that some describe as sensational and panic-creating. Heat Treat Today’s desire is to objectively report impacts without commentary and without increasing panic.

The Phase I (February 27th) survey netted more respondents, 113, than the Phase II (March 20) survey, 75. The decrease in responses may be attributed to the day of the week that the survey was deployed — Thursday for Phase I and Friday (late afternoon) for Phase II. The length of the survey may have also impacted the response rate — Phase II having several more questions than Phase I. Neither study has enough responses to be considered “scientific” and Heat Treat Today strongly recommends that no important decisions be made based on the results of these studies.

Additionally, the phrase “coronavirus” was used extensively in Phase I whereas “COVID-19” was used extensively and in place of “coronavirus” in Phase II. It is understood that these terms are different and stand for different things. For the non-medical professional, we assumed that these two terms will mean essentially the same thing and they were used interchangeably. Our apologies to medical professionals and other who know the difference.

Finally, this survey was sent to roughly 700 heat treat industry SUPPLIERS, not end-users. The desire was to see what impact the virus and the subsequent response of governments and businesses was having on the heat treat industry specifically, and not on the wider industrial economy as a whole.


Current Impact

Q: Has the coronavirus/COVID-19 ALREADY impacted your business?

The two studies were divided up into two broad sections: 1) what impact the virus has ALREADY had, and 2) what impact the virus is ANTICIPATED to have.

The percentage of respondents claiming that COVID-19 had already impacted their business essentially doubled from Phase I to Phase II going from roughly 40% to nearly 80%. And the number of respondents saying that there has been no impact fell from nearly half in Phase I to roughly 12% in Phase II. Below, Phase I results are shown first, then Phase II results.

Phase I (click to enlarge)
Phase II (click to enlarge)

Q: How has the coronavirus/COVID-19 ALREADY impacted your business?

The responses here were also significantly different. Please note that the charts below are not 100% comparable. While both green bars denote supply chain difficulties and both blue bars represent travel restrictions, there was a third option added to the Phase II options that was not in Phase I. Therefore, the tan or yellow bar actually represents two different answers between the studies as does the blue bar at the bottom. Please read these charts and the tables that follow them carefully to see the difference between the last two bars.

Suffice it to say, however, that while supply chain concerns did not increase significantly between the two studies, travel restrictions nearly tripled going from 30% in Phase I to nearly 90% in Phase II. Effectively, travel is banned in the North American heat treat industry … something never before experienced.

One final point. In the Phase II chart below, you’ll notice that the last option is “Other (please specify).” For the sake of relative brevity (!), these “Other” comments have not been included in this report. If you’d like to see these comments, please email htt@heattreattoday.com and request a full “Phase II Coronavirus Report.”

Phase I (click to enlarge)
Phase II (click to enlarge)

Q: What steps are you ALREADY taking to minimize the impact?

In Phase II, an additional question was asked regarding what steps have already been taken to minimize the impact of the virus. There was no equivalent question in Phase I. Below are the results. Please notice that the complete wording of the answers are shown in the table below the chart and the “Other (please specify)” answers are not shown, but may be obtained by emailing htt@heattreattoday.com.

Phase II (click to enlarge)

Anticipated Future Impact

In both studies, we then moved from the CURRENT situation to what people were ANTICIPATING for the future.

Q: In what ways to you anticipate that the coronavirus/COVID-19 will impact your business?

The top bar, the green one, represents an anticipated difficulty with a company’s supply chain — difficulty getting materials to manufacture their heat treat product or component. This number stayed at roughly 25% in both studies.

The green bar is also the same in both studies representing travel restrictions. This number, however, took a huge jump between Phase I and Phase II — 43% to 79%.

There was an additional answer added to the Phase II study so the tan/yellow bar represents two different things in the charts below. In Phase I, the yellow bar represented “Other” responses. In Phase II, it represents an anticipated drop off in business levels and it was this answer that gleaned the highest number of responses — just over 8 of 10 respondents anticipated a drop in business levels due to the virus.

Phase II (click to enlarge)
Phase II (click to enlarge)

Q: What steps do you anticipate taking to minimize the impact of the coronavirus/COVID-19?

There was another additional question added to the Phase II study asking what actions the company anticipated taking to reduce the impact of the virus. Below are the responses.

Phase II (click to enlarge)

Q: What impact will the coronavirus/COVID-19 have on your company’s bottom line?

On this question, it is safe to say that the answers were significantly less optimistic in Phase II than they were in Phase I. In Phase I, over 50% felt that the virus would impact their bottom line 5% or less. In Phase II, the “5% or less” answer was given less than 10% of the time, meaning that over 90% of the respondents anticipate that the virus will have a greater than 5% impact on their bottom line. In fact, the highest number of respondents chose “11-20%,” and the second largest group was the group anticipating “Over 20%”.

Phase I (click to enlarge)
Phase II (click to enlarge)

Q: How long do you anticipate the coronavirus/COVID-19 will impact your business?

This is another question where the answers were significantly different between the two studies. The “3 to 6 month” answer came in nearly identical on both studies sitting at roughly 60% in both cases. Marked changes occurred, however, on both sides of the “3 to 6 month” answer. Those anticipating an impact of “0-2 months” fell by nearly half from roughly 30% in Phase I to just over 17% in Phase II. The big gainer was in the “7 months or more” category where the numbers over doubled from only 10% in Phase I to 25% in Phase II. Obviously, the heat treat industry is bracing for a much longer impact than initially anticipated in Phase I.

Phase I (click to enlarge)
Phase II (click to enlarge)

 


Actual Sickness

The above question was the LAST question asked in the Phase I study. Phase II respondents were given the optional opportunity to answer one more personal question. The reason for asking this question was to get at the actual health impact of the coronavirus/COVID-19 verses the impact caused by the reaction of governments, media, and others who might be unduly heightening anxiety levels whether purposefully or unwittingly. As you can see from the chart and table below, nearly 80% of the respondents chose to proceed with the optional question.

Phase II (click to enlarge)

The question itself is rather long and can be read in the chart below. As you can see, of those proceeding to this more personal question, over 80% chose to actually answer the question. Of those answering the question, nearly 95% knew of no one in the heat treat industry (as defined by the question) currently infected with the coronavirus/COVID-19 and a full 97% knew of zero or one person infected. (Please note that the percentages above are based on a base of 38 people who chose to give a numeric answer.)

Phase II (click to enlarge)

A Complete Copy of the Report with “Other” Comments

If you’d like to see a complete copy of the Phase II results (with all personally-identifiable or company-identifiable information removed), please email htt@heattreattoday.com and request a copy of “Phase II Coronavirus Report.”

(source: Unsplash.com)

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High-Temp Differential-Expansion Problem and How to Solve It

 

 

Source: Vac Aero International Inc.

 

 

 

 

If you’ve ever tried to braze together materials that have widely different Coefficients of Thermal Expansion (COE’s), you know that the material with the higher expansion rate will grow faster than the other when heated and contract faster when cooled down. You also know that once the two different materials have been brazed together and cooling begins, the shrinkage-rate differences between those two materials can produce significant shear stresses at the brazed interface between them and be so strong that the thin brazed joint may be torn apart at either interface. Other similar weaknesses and damage can result as well.

In this HTT Best of the Web Technical Tuesday feature, Dan Kay of Kay and Associates, a vacuum and atmosphere brazing consultant, explains the details of this problem and the solution.

Dan Kay
Brazing Engineer
Kay and Associates

An excerpt: “Today’s brazing technology is based on a strong foundation of the brazing experiences of many people around the world over a period of many decades (even centuries). I’ve now been very active in the brazing world for almost 50 years and, like my predecessors in the world of brazing, I’ve learned a lot about this fascinating joining process (and I’m still learning). In the article, I’d like to share with you one of my brazing experiences from many years back, one that involved high-temperature differential-expansion between an 18″ (45 cm) diameter tool steel die and a thin carbide plate (round disc) that needed to be brazed to the die’s front surface for wear-protection.”

In this article, Dan, who is also a HTT consultant, helps readers understand the high-temp differential-expansion problem, explore what steps can be taken to prevent it, and ties it all together so that readers can clearly understand what to do.

Read the entire article from Vac Aero International,  An Old High-Temp Differential-Expansion Problem

Image source: Vac Aero International Inc.

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Simulation Software and 3D Printers Improve Copper Coils

This informative feature was contributed by CENOS, a simulation software developer. Read on to learn about how 3D printing is revolutionizing the heat treat world, particularly in the production of copper coils.

3D printing, also known as “additive manufacturing,” is a hot topic now as it broadens possibilities for on-demand and customized products, even with complex geometries. It eliminates the need for welding, soldering, bending, and similar steps in coil design as 3D printers build the object in one piece and in the exact shape as drawn in CAD.

(source: PROTIQ)

“3D printing unleashes design opportunities for induction coils, while 3D simulation software allows validating design performance. . . . We believe that 3D printing of copper will grow even more in significance for coil production, and possibly even become a part of the conventional manufacturing process,” said Max Wissing, Development Engineer at PROTIQ.

Currently additive manufacturing is widely used for steel parts, and for a long time printing machines were not able to print pure copper items. But now the technology has developed, and since the second half of 2019, it’s possible to print on demand 100% pure copper coils. Some companies with notable success offering this innovation are PROTIQ and GH Induction.

Main Benefits Simulations Enable Together with 3D Printing:

  • freedom of design
  • optimized geometry
  • more homogeneous heating
  • lower lead time
  • less material waste
  • cost reduction

3D Printed Copper Comparison:

RS-cooper Pure copper
Electrical conductivity: 50 MS/m Electrical conductivity 58 MS/m
Elongation at break: 25% 100% IACS
Improved strength for high loads Elongation at break: 50%
Tensile strength: 230 Mpa Tensile strength: 220 Mpa
Yield strength: 180 Mpa Yield strength: 125 Mpa
Density: 98% Density: 99.8%

Fewer Man-Hours, Faster Processes

Coils are a critical part of induction heat treatments as they must be replaced from time to time due to deterioration. This interrupts production and requires several man-hours for recalibration. In comparison to conventional manufacturing, 3D printing induction coils offer great benefits.

First, additive manufacturing provides better reproducibility and higher accuracy compared to the manual bending, which reduces necessary recalibration times. Second, it allows lower cost and faster production of inductors. Finally, using numerical simulation methods, the coil’s heat pattern is precisely predicted and visualized, helping optimize inductor geometry. This allows for creating a perfect coil with the first prototype.

Simulation and 3D Printing Process Illustration:

(source: PROTIQ)

Simulations as the Enabling Factor for Coil Durability

Simulations allow full freedom of design and point out places for improvement in producing a more efficient coil production process. 3D printers build objects layer upon layer, allowing them to make even complex geometries in one piece without soldering. Simulation of the design process allows predicting coil heating, which altogether results in a longer coil lifetime. Because there is no need to bend or join parts together with heat treatment, this also allows for eliminating some intermediate steps of the supply chain. Another notable benefit is that the lifetime of 3D printed coils can exceed conventionally manufactured copper coils up to two times, as reported by PROTIQ’s automotive industry clients.

Currently there are only a few copper coil printing companies because the material is not easily processed in additive manufacturing.

Comparison of maximum copper coil dimension as a single piece:

PROTIQ GH Induction
Length: 250mm Length: 200mm
Width: 250mm Width: 200mm
Height: 300mm Height: 100mm

The possible size of the printed coils varies between really small ones, measuring only a few millimeters, and bigger shapes that are used in the automobile industry. Coils that exceed the maximum printable dimensions can be joined together afterward via welding or brazing without problems.

Regarding the time, copper coils can be printed within a few days. Compared to the conventional way, which takes up to several weeks, this method enables fast-paced product tests and generates flexibility for the customer due to shorter delivery times.

3D Printing Future Forecast

GlobeNewswire market research shows that the global 3D printing metals market is estimated at USD $774 million in 2019 and is projected to reach USD $3,159 million in revenue by 2024. This suggests we will see even more and bigger 3D printed metal parts.

In a greater perspective, Boeing is demonstrating an impressive point that additive manufacturing currently has no limits. Boeing’s GE9X engines are now fully 3D printed, combining more than 300 engine parts into just seven 3D printed components.

Taking into consideration all of the benefits listed above, one has to wonder whether additive manufacturing will become the norm in the coming decades in many of the traditional manufacturing processes.

(source: PROTIQ)

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Boeing Attack Aircraft Design Revealed in FARA Competition

Boeing Defense, Space, and Security recently revealed the single-engine, single-rotor helicopter it is proposing to the U.S. Army as part of the Future Attack Reconnaissance Aircraft (FARA) prototype competition, initiated in 2018. The goal of the contest, part of the Army’s broader Future Vertical Lift program, is to develop a successor to the Bell OH-58 Kiowa scout helicopters used for observation, utility, and direct fire support.

Mark Cherry, Vice President and General Manager of Boeing’s Phantom Works (source: Boeing)

“We’re offering more than a helicopter,” stated Mark Cherry, vice president and general manager of Boeing’s Phantom Works. “We’re offering an affordable and fully integrated system for the Army, the mission and the future. We’ve blended innovation, ingenuity and proven rotorcraft experience with extensive testing and advanced analysis to offer a very compelling solution.”

Boeing emphasized that its FARA design meets the Army’s current mission needs “while evolving as technologies and missions change.”

The FARA competition awarded design in April 2019 to AVX Aircraft, Bell Helicopter, Boeing, Karem Aircraft, and Sikorsky Aircraft. Two manufacturers will be selected to proceed with their designs this year, and the prototypes will be delivered in 2023.

(source: Boeing)

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Three Batch Steam Treaters Shipped to Medical, Automotive Industries

(source: Gasbarre Products, Inc.)

Three batch steam treaters were recently shipped to the medical and automotive industries. Gasbarre Thermal Processing Systems recently received three separate orders for batch steam treating equipment. The batch steam treaters produce an oxide layer that promotes corrosion and wear resistance properties and provides an attractive surface finish. The three unique orders range in size from 18” to 30” in diameter and 12” to 48” deep. The gross load weight capacity ranges from 300lbs to 1800lbs with Gasbarre supplying the production tooling. The equipment is electrically heated and has a maximum operating temperature rating of 1400℉.

Steam treating processes are used in many different industries. As such, these orders will be shipped to companies that provide products to the medical, additive manufacturing, automotive and consumer products industries.

Stryker Hero JR Hip Replacement
Source: Stryker.com

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GKN Aerospace to Collaborate with GE and Saab for Swedish Air Force

The Swedish Air Force has selected GKN Aerospace for technical product support and maintenance, repair, and overhaul (MRO). GKN Aerospace will provide these services as well as spare parts supply for the Gripen E RM16 aircraft engines of the Swedish Air Force. The RM16 is the Swedish name for the engine based on the General Electric F414 that powers the F-18 Super Hornet. GKN Aerospace’s continued support to the platform was confirmed by the Swedish Defense Material Administration (FMV) in January. GKN Aerospace will closely collaborate with Saab and GE to build up the necessary infrastructure and competence for the new engine type.

Joakim Andersson, President of Engines at GKN Aerospace

President of Engines for GKN Aerospace Joakim Andersson said, “GKN Aerospace is proud to further expand our relationship with FMV, GE, and Saab to the new RM16 aero-engine support. Our unique and efficient engine maintenance and support capabilities have served the Air Force operations since 1930.”

GKN Aerospace is also the original equipment manufacturer (OEM) and type certificate holder of the Gripen C/D RM12 aero-engine and has been supporting the RM12 aero-engines since the first Gripen aircraft went into service in 1997.

(source: GKN Aerospace)

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Heat Treat Brain Trust on Industry Innovations That Have Enhanced Automotive Heat Treating in Recent Years

This week’s Technical Tuesday installment is a Heat Treat Today original that was first published in the Heat Treat Today Automotive magazine in June 2019.

This industry is richly endowed with a heritage of experienced metallurgists and skilled professionals. This era is one of innovation and trends – especially in automotive manufacturing. How does the heritage of the industry and the vision of the future come together? We’ve compiled input from a selection of Heat Treat Today’s own industry experts on a question about new stuff going on in both the labs and the shops. (To see what other fields and specialties our Heat Treat Consultants work in, go to: www.heattreattoday.com/consultants)

Question: “Thinking about the automotive heat treating industry, what is one of the more interesting, innovative or helpful technologies, processes, materials, or products that you’ve seen recently?”

The Heat Treat Brain Trust Responds:

Sandra Midea

Sandra Midea is a consulting metallurgist and founder of Midea Group Inc.

I’ve had the opportunity to work first hand with an induction company in North Royalton, Ohio, (Induction Tooling Inc.) to create an in-house facility that develops and validates induction heat treating processes. The objective was to create a space with the right equipment and personnel where induction processes and tooling could be tested—to innovate, to provide proof of concept, to troubleshoot, and/or to validate processing parameters, in the most streamlined process available. For the automotive industry,
the lab has been used to reduce the time required to get products/processes ready for the PPAP. Bill Stuehr, the company’s president and CEO, had the vision that induction process development could occur rapidly by condensing the design, manufacturing, development, testing, and characterization and metallurgical validation processes all into one facility. With seven power supplies from different manufacturers and three material handling systems available for induction process development, an automotive supplier’s production induction heat treating department can be mimicked for power, frequency, quench & quench method, and material handling methodology. This allows incremental process and tooling development to occur in a laboratory environment without the cost of breaking into production.

This development facility is backed up with an ISO 17025 commercial metallurgical testing laboratory. Sample parts are checked for appropriate microstructure, grain size and hardness requirements and reported to the customers. Initial lots of evaluation parts can also be produced. This allows the inductor and process to be developed and validated before the tooling ships to the heat treating customer. While some process tweaks may need to occur at the final facility, the time required for a company to be ready to begin the PPAP process can be significantly reduced.

 

Max Hoetzl

Max Hoetzl previously served as president of IHEA and vice president of technology with Surface Combustion, Inc.

One of the most interesting things I’ve seen in the automotive heat treat industry is the use of robots to load and unload furnaces. The use of robots has significantly improved the operation in many ways.

Following are some of the examples:

  • Remove humans from hazardous environment,
  • Increase throughput,
  • Provide part loading for uniform thermal treatment.

 

 

 

 

 

 

Joe Benedyk

Joseph Benedyk is a research professor at Illinois Institute of Technology and a mining & metals consultant. (Image source: Light Metal Age)

Reducing Heat Treatment Time in the Precipitation Hardening of Aluminum Alloys

Strengthening aluminum alloys through the precipitation hardening process by solution heat treatment and aging is considered a fundamental step in the manufacturing of high strength-to-weight products that meet performance requirements in both the aerospace and automotive industries. The automotive industry is focusing on 7xxx alloys because of their high strength. Among the high strength 7xxx (Al-Mg-Zn) alloys is the mainstay alloy 7075, which can achieve a tensile strength of as high as 80 ksi when age hardened to a -T6 temper. However, to achieve these high strength levels in 7075 alloy at conventional aging temperatures requires aging for 24-48 hours, a stumbling block to its application in automotive products.

Figure 1. Comparison of age hardening curves for 7075 alloy solutionized at 914°F (490°C) and water quenched: A1 and A2 aged in a single step

Research at the Illinois Institute of Technology Thermal Processing Technology Center has shown that by selectively double aging 7075 alloy, the aging time to achieve maximum hardness and strength can be reduced to as low as two hours under laboratory conditions (see Figure 1) or demonstrably much shorter aging times in an extrusion plant trial. The obvious advantages of significantly shorter aging time for 7075 and other heat treatable aluminum alloys are not only energy savings but also increased plant productivity through much reduced processing time. The begged question of applying the double aging process to other heat treatable wrought aluminum alloy systems is under review.

 

Jim Senne

Jim Senne is the owner and president of MetalPro Resources, LLC.

PSA generated nitrogen has become increasingly popular for use in heat treating applications, and at a fraction of the cost, due to advances in PSA technology. Typical cost per standard unit volume are 15% to 25% of the cost of bulk liquid nitrogen. Purity can range from 95% to 99.999%, however many processes demand less than full purity. PSA technology can dial into the specific requirement, making it even more economical. The equipment has excellent reliability and requires only general maintenance on the associated air compressor and periodic filter changes. As well, the CMS (Carbon Molecular Sieve) material can last 20+ years. Processes that require a nitrogen cover gas are particularly well suited, such as induction hardening, tempering, and stress relieving. Other suitable applications include nitrogen/methanol atmosphere, FNC, N2+scavenger gas mixes, and purging.

 

 

Matt Orfe

Matt Orfe, an expert in lean manufacturing, is the head of sales and VAB product management for AeroSPC, Inc.

One of the most impressive pieces of equipment that I’ve seen in use in VAB (vacuum aluminum braze) furnaces in the automotive industry would be the in-furnace data loggers for monitoring the temperature of the parts being brazed.  The instrument is loaded into the VAB furnace with the parts to be brazed and wirelessly transmits the temperature data through the furnace chamber wall to the receiver/monitor.

This eliminates the need to plug in thermocouples with the furnace door opened, as the load sensors can be attached to the unit prior to insertion into the chamber.

Multiple thermocouples can be used with the system and multiple data logger units can be used for high volume applications. Very accurate, very easy-to-use, and very impressive!

 

 

 

Debbie Aliya

Debbie Aliya is founder and president of Aliya Analytical, Inc.

My instant response is always that the most innovative, interesting, and helpful technologies are educational in nature— the knowledge that allows people to make the best use of the common materials that still form the foundation of our industry. How many products would be more reliable if people properly selected, specified, and inspected the heat-treated materials that they use? How many products would be more reliable if the purchasing and specifying functions had a realistic idea of how much variation they should expect in a given part, lot, from lot to lot, and over an extended period of time? For example, how many people in engineering and purchasing know what a furnace uniformity survey is?

Purchasing often does not want to use an alloy steel, but if they need uniformity of strength, and there are different section thicknesses, they may save money and headaches if they pay the extra up-front to get the hardenability into a range that will provide consistency.

How many companies have minimum hardness or case depth specifications, without an upper limit? If the parts are to be electroplated, they increase the risk of hydrogen embrittlement, an issue that seems to come around in the industry every 10 years or so.

It wasn’t an automotive company, but I have had at least one client specify a quench and temper heat treatment for an HSLA (high strength low alloy) steel, which completely defeats the purpose of the HSLA grade system.

There are still a lot of people doing design work who think that calling out a composition requirement gives a certain strength level. For many of the European and Asian steel specifications, this is true, but the American specifications are often for composition only.

How many companies still do not require lot traceability? In the automotive world, if it’s a critical part, traceability is generally required, but there are still a lot of parts that fall through the cracks.

 

Doug Shuler

Doug Shuler is the owner of Pyro Consulting LLC.

The most interesting thing I have seen in the automotive heat treating industry is a new pyrometry technology software system known as C3 Data.

This solution enables those in the heat treatment industry to comply with specific industry quality requirements of pyrometry, saving enormous amounts of time in the process.

While C3 Data is currently better known in the Nadcap world for their solution for AMS2750, their new CQI-9 version should be something that heat treaters in the automotive world consider.

This fits with my motto of working smarter—not harder!

 

 

Irwin Brown

Irwin Brown is Managing Principal & Co-founder of Cosmos Consulting Group.

Nowadays, the heat treating industry, especially automotive, enjoys an abundance of riches. We are witnessing increased business volume coupled at the same time with efficient new equipment and technologies, such as additive manufacturing, AI, supply chain improvements, and amazing software. So, why are so many thermal processors unable to raise EBITDA? We are also witnessing critical worker shortages as well as many current employees voluntarily resigning in record numbers. What is the secret to improved quality and increased profits? In our work with industry clients, we found a way to lead employees to better serve customers, thus unlocking vast potential. This strategy, based upon a little deployed thirty-year old method, provides a rapid turnaround that makes productivity soar.

This “secret sauce” is Servant Leadership, which remains the best and most useful technique for transforming difficult relationships among modern multi-cultural employees. Old style command-and-control employers hesitate to recognize and acknowledge how decades-old management behavior is unsustainable with today’s workforce. More enlightened owners, in their own self-interest, value a more dedicated workforce. Employees do not leave companies; employees leave their managers.

Servant Leadership permits owners to run their business rather than having the business run them. Building strong, working relationships creates positive results and is not soft leadership. As Ken Blanchard likes to say, “the power of love beats the hell out of the love of power.” Servant Leadership costs nothing and has proven it can spearhead a rapid turnaround.

 

Dan Herring

Dan Herring is The Heat Treat Doctor® at The HERRING GROUP, Inc.

Intriguing question. In my mind, it is the emergence of the electric car and the innovations it will spawn. The motivation is there: a new generation that demands to be green, countries such as China passing laws on vehicle energy reduction (a so-called energy vehicle score), and technological improvements. Battery performance is rising (distance per charge), battery costs are falling (potentially lowering vehicle cost), battery life is up, and weight reduction is a reality. Another reason is the simplicity it brings to the vehicle (the absence of a multi-speed transmission, for example) and a reportedly lower cost for common repairs (this might be a bit misleading as one has only internal combustion engine vehicles to compare with).

While the transition has begun, I feel there are two major hurdles to overcome. First is infrastructure. A massive investment is required to make recharging as available to the public as stopping now to get gas. Every gas station in any country in the world must be mandated to have multiple charging stations. The hidden issue here, both domestically and around the world, is that it will require changes in the law – and the fossil fuel lobbyists are powerful, well established, and entrenched in the government sector. Also, the cost of electricity (in some regions of the world) is not price competitive. Second is public perception. Yes, everyone wants one, but who wants to be first? The phrase I like to use is that John Q. Public doesn’t mind being on the cutting edge, he just doesn’t want to be on the bleeding edge.

 

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Homocarb Pit Furnace Dispatched to Power Industry

An electrically heated homocarb pit furnace was recently shipped to a manufacturer in the power industry. It is designed to work with a protective carbonaceous atmosphere. The top loading furnace, from Lindberg/MPH, is ideal for case carburizing, hardening, annealing, and carbon restoration at temperatures up to 1750°F. Gross workload is 1600 pounds, with temperature uniformity of +/-25°F at 1650°F.

The furnace can accommodate a work basket with a 25-inch diameter that is 48 inches deep, providing a clear work volume of 13.64 cubic feet. A retort minimizes atmosphere consumption and furnace-conditioning time between loads. The cover lid utilizes an electrically operated boom lift, which provides ease of loading and unloading.

(source: Lindberg/MPH)

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Heat Treat Fringe Friday: Voice Activated Wheel Nuts Withstand Car Theft

Heat Treat Fringe Friday

Sometimes our editors find items that are not exactly “heat treat” but do deal with interesting developments in one of our four key markets: aerospace, automotive, medical, or energy. As we approach the weekend, today’s Heat Treat Fringe Friday, Best of the Web post focuses on an interesting development in the automotive industry.


Raphael Koch, research engineer, Advanced Materials and Processes, Ford of Europe (source: LinkedIn.com)

It’s one of the worst experiences a proud car owner can experience–walking out to their beloved vehicle to discover all four wheels are gone. As alloy wheels and vehicle customization have grown in popularity, component theft has unfortunately become a lucrative side business. “Some alloy wheels can cost thousands to replace, but these unique rim nuts will stop thieves in their tracks. Making wheels more secure and offering more product personalization are further proof that 3D printing is a game-changer for car production,” says Raphael Koch, research engineer, Advanced Materials and Processes, Ford of Europe.

Michael Jan Galba, Head of Global Consulting & Manufacturing Engineering at EOS (source: LinkedIn.com)

Ford engineers wanted to help customers find a solution, hence the advent of a theft resistant lug nut. The project was the result of a brainstorming session focused on finding applications for additive manufacturing within the company. In collaboration with additive manufacturing solutions provider EOS and software developer Trinckle, engineers at Ford have now developed unique locking wheel nuts using 3D printing technology. “We thought about using fingerprinting, or an iris scan or something that could actually modify the groove or curve of the lug nut,” says Michael Jan Galba, Head of Global Consulting & Manufacturing Engineering at EOS. “Trinckle proposed adapting an application they used in a completely different industry that utilized a voice wave curve.”

To read more about this story, click here.

Image: Ford Company

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North American Automotive Steel Producer Expands Mexican Operations

A North American steel supplier announced today that it has begun operating its continuous galvanizing line, which will produce hot-dip galvanized sheet steel for the automotive market. Nucor-JFE Steel Mexico, located in Silao, Guanajuato in central Mexico, has begun trial production and will move towards full-scale sales and production once customer approvals have been obtained.

Leon J. Topalian, president and CEO, Nucor Corporation

“We are excited to expand our presence in Mexico and to use our local sales network to increase our sales into this important automotive market,” said Leon Topalian, President and CEO of Nucor. “We are proud to partner with JFE Steel Corporation of Japan and to benefit from their experience as a premier supplier of high-quality products to the automotive industry.”

The hot-dip galvanized sheet steel production facility has a production capacity of 400,000 tons annually. It can produce sheet thickness from 0.4 mm to 2.6 mm and widths of 800 mm to 1,850 mm. Nucor and JFE will each supply an equal amount of substrate to be processed at the new facility.

(Source: ASM International)

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