FEATURED NEWS

Heat Treat Radio #111: Heat Treat NextGen Brynna Keelin Kelly-McGrath

/ FEATURED NEWS, HEAT TREAT RADIO, MANUFACTURING HEAT TREAT TECH

If curiosity were a person, Brynna Keelin Kelly-McGrath would be her name. Having risen at Moog, Inc. to the position of materials and process engineer, Brynna shares her early STEM interests and how she stays up-to-date on industry trends and ideas. In this highly engaging NextGen profile on Heat Treat Radio — with host and Heat Treat Today’s publisher, Doug Glenn — get to know this talented metallurgist.  

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

The following transcript has been edited for your reading enjoyment.

Meet Brynna Keelin Kelly-McGrath (01:00)

Doug Glenn: Let’s jump into today’s Heat Treat Radio episode with Brynna Keelin Kelly-McGrath from Moog, Inc. It’s a great pleasure to be here today with Brynna, who is one of our 40 Under 40 Class of 2023 award recipients. First off, congratulations on that award, and welcome to Heat Treat Radio.

Brynna Keelin Kelly-McGrath: Thank you so much. That was an honor.

Doug Glenn: Brynna lives just south of Buffalo, New York. As you know, this interview is to get to know you a little bit more — how you got into metallurgy, heat treating, and all that good stuff. Let’s start way back. Give us a little bit about yourself as a younger person, maybe high school age and moving on up through, and then how you got involved with heat treating and metallurgy.

Check out Brynna’s 40 Under 40 profile. Click the logo.

Brynna Keelin Kelly-McGrath: Sure. I grew up in a little town called West Falls, south of Buffalo, New York, and about 20 minutes from Moog. While I was in high school, I took AP chemistry and physics and fell in love with those topics. I knew from a younger age that I was going to wind up being an engineer eventually; I just didn’t know what kind. But I was pretty sure I wanted to be a chemical engineer, so I toured a couple of colleges.

At one of them, I met with a materials science professor to talk about the differences between chemical and materials science engineering. I was sold. I was all set and ready to go be a polymers engineer. I picked Purdue University, started going there, and was absolutely loving it.

The summer after my freshman year, I got an internship with Moog, which was right around the corner from my hometown. The internship was primarily metallurgical, due to the nature of Moog’s products, and I absolutely loved it. I was not expecting to like it, and it was just so great. So, I transitioned all of my coursework over to metallurgy, and I kept coming back to Moog for internships, and that was fantastic.

Learning from Industry Experts (03:32)

When I started off at Moog, it was right around the time when two of our subject matter experts in heat treatment were transitioning to retirement. I started learning as much as I could as fast as I could about heat treatment. There was obviously a lot to learn there, but it was a great time.

After working at Moog for a couple of years, I decided I wanted to go back and pursue my other passion, which was manufacturing engineering. So, right now I’m working on a master’s degree after work to combine metallurgy and manufacturing.

“When I started off at Moog, it was right around the time when two of our subject matter experts in heat treatment were transitioning to retirement. I started learning as much as I could as fast as I could about heat treatment.”

Brynna Keelin Kelly-McGrath, Moog

Doug Glenn: Wow. You’re a classic overachiever. That’s pretty good. And you said Purdue, correct?

Brynna Keelin Kelly-McGrath: Yeah.

Doug Glenn: Okay. And you did your undergrad there. Did you actually end up graduating with a materials engineering degree or a metallurgy degree?

Brynna Keelin Kelly-McGrath: Materials science and engineering.

Brynna shares how she got started in the industry.
Source: Heat Treat Today

Doug Glenn: All right. Good. You spent the summers back at Moog and enjoyed that. You know, we see a lot of the older generation retiring, so you’re filling the brain drain, as we say, which is great. Are there are many other young people at Moog?

Brynna Keelin Kelly-McGrath: Yeah, their internship co-op program has been fantastic in bringing in a lot of students right out of college and getting them hooked on our product line and the sort of manufacturing we do. And we’re definitely getting more recent college graduates. But, you know, with people retiring, those are some awfully big shoes to fill.

Doug Glenn: For sure. What exactly does Moog make at your facility? They’re a large corporation; I know they usually make a lot of automotive, maybe aerospace, components but are you able to say specifically what Moog does there?

Brynna Keelin Kelly-McGrath: We specialize in high precision motion actuation systems. From a metallurgical side, we’re working with a ton of really cool materials. So it’s not just steels or aluminum, it is a lot of aerospace applications, defense. The materials and process engineering group is physically orchestrated on our headquarters campus as well as the space and defense building, so we do get to see quite a bit of that. From the metallurgical perspective, there is a lot to see and work on.

Doug Glenn: You mentioned you were thinking about being a chemical engineer, but then you saw the materials. Do you remember what it was about that and metallurgy that attracted you? Anything specific?

Brynna Keelin Kelly-McGrath: I remember sitting through that talk with a materials professor at Purdue, and he was talking about what the day to day of a chemical engineer versus materials engineer looks like. I will not pretend that he wasn’t biased, because he was a materials professor. But the work he described for materials engineering was so diverse, and there were options for different settings and what you could end up working on — from being in a steel mill to working in a lab like I do. There are a lot of options, a lot of cool things. The slogan at Purdue was something along the lines of: you can’t make it without materials.

Brynna’s Family Background (07:30)

Doug Glenn: That’s really neat. So, I haven’t asked you about your family at all. What did they think when you told them, hey, I’m thinking about being a materials engineer or a metallurgist?

Brynna Keelin Kelly-McGrath: My father is an industrial engineer, and my mother is a pharmacometrician, so they’re both in the stem field already. I think it was no surprise that I was going to pursue engineering and then, metallurgical engineering specifically. I think they were happy to encourage me to pursue any of my passions. And my father knew a couple of materials engineers and thought that it would work out for me. They were excited.

Undergraduate Research (08:16)

Doug Glenn: They were very supportive. That’s great. When you did your undergrad at Purdue, did you have to work on a final paper or any specific projects that were of interest to you?

Brynna Keelin Kelly-McGrath: I did some undergraduate research in the metallurgy realm. But my senior project for graduation was along the lines of characterizing shot for shot peening and the degradation of shot and the residual stress that it imparts. It was like a cool mix of FEA modeling with actually characterizing the material. It was a neat project.

Doug Glenn: Have you had to do any of that at Moog?

Brynna Keelin Kelly-McGrath: There’s a fair deal of materials characterization. We have shot peening, but I’m not super involved with it.

Current Work at Moog (09:35)

Doug Glenn: Gotcha. That’s interesting. Can you describe what your typical day at Moog looks like now and what you’re working on?

Brynna Keelin Kelly-McGrath: Sure. My typical day is a good deal of talking with all types of engineers, explaining metallurgical concepts. Because we work on a lot of different materials, there’s a lot to understand there. A good portion of my role is talking with other engineers about how a heat treatment procedure works or what’s metallurgically happening, how to modify a manufacturing sequence, how to design so that the product’s going to work.

But then I also specifically work in a failure analysis lab. This could be anything from something’s coming off the manufacturing line a little bit wrong or something failed in the field. We’ve got a beautiful characterization lab full of all the toys that you could think of, including two SEMs and a chemical lab. There’s a good deal of analysis there, too.

Doug Glenn: You seem like a person who enjoys your work. Is there any specific story or instance of something happening, either in school or at work, that really made you happy that you were in metallurgy and heat treat?

Brynna Keelin Kelly-McGrath: Oh, goodness. That’s a good question.

I would have to say I’ve had a couple projects at work, without getting into too many specifics, where we discovered something new metallurgically that we didn’t know was happening before. And then working through that, how did we not know it before? What do we know about it now? And what are we going to do to utilize this new thing that we discovered and take advantage of it? From a heat treat perspective, sometimes that means modifying our procedures, modifying our fixturing, creating something new.

It’s neat to see the modifications happen and come up with the new parts on the other end. It’s been very exciting to work on interdisciplinary teams like that.

“My typical day is a good deal of talking with all types of engineers, explaining metallurgical concepts. Because we work on a lot of different materials, there’s a lot to understand there. A good portion of my role is talking with other engineers about how a heat treatment procedure works or what’s metallurgically happening, how to modify a manufacturing sequence, how to design so that the product’s going to work.”
Source: Heat Treat Today

Doug Glenn: Yeah. I’m curious about this. You’ve been out in the work world for how many years?

Brynna Keelin Kelly-McGrath: Three and a half.

Doug Glenn: Okay. So, you’ve been out of school and working four years, and the amount you know about metallurgy and heat treating now is four years’ worth. Does it kind of amaze you the amount of stuff we don’t know?

Brynna Keelin Kelly-McGrath: Absolutely. Metallurgy is an old science, but you know we’re still [developing] the tools and technology and it’s great to find out new things.

Doug Glenn: Right. A lot of people get involved and say, “Well, I don’t want to go into metallurgy and heat treat because it’s a mature industry,” but I was curious if you felt the same way.

It’s really quite fascinating because there is a lot that happens. Like you were saying at Moog when you discovered things, a lot of stuff that’s happening and we really don’t know why. The more we can discover about it, the better.

Brynna Keelin Kelly-McGrath: Absolutely.

Top Industry Resources (12:58)

Doug Glenn: Let me ask you this. You obviously come from a smart family; you’ve got parents who are well educated, and you are as well. What are some of the metallurgical/heat treat resources that you use to stay current?

Brynna Keelin Kelly-McGrath: I think the best resource that’s out there is people. The network that I’ve been growing comes from a variety of different sources. I’m part of a few industrial committees, and it’s just a great way to meet people from all ends of the spectrum of metallurgy — from those producing the material to those making something out of it to the people who are going to use it all the way down the line.

Finding other metallurgists in those realms, and also through venues like ASM and our local Buffalo chapter — meeting people who have more experience than I do and have seen it before. If I’m seeing something for the first time, there’s definitely someone who spent their whole career on that. It’s really great to tap into those resources. That’s my number one.

And then my second choice would be the ASM handbooks. I’ve always got at least two open on my desk.

“I think the best resource that’s out there is people.”

Brynna Keelin Kelly-McGrath, Moog

Doug Glenn: Those are great resources. ASM over the years has pumped out some very, very good stuff. Is there anything else about your work or your schooling that is of interest or excited you that you’d like to share?

Brynna Keelin Kelly-McGrath: I really liked working at Moog because it’s a cool application where I can use my metallurgical knowledge along with this new manufacturing knowledge that I’m building up. That was my favorite intersection with my undergrad degree. And now I get to actually try that out in a working sense. That’s been great.

Doug Glenn: And you’re doing a master’s in industrial engineering?

Brynna Keelin Kelly-McGrath: Manufacturing engineering.

Doug Glenn: Where are you doing that?

Brynna Keelin Kelly-McGrath: The University of Michigan.

Doug Glenn: Remotely, I’m assuming?

Brynna Keelin Kelly-McGrath: Yes.

Doug Glenn: Very nice. And how far along are you, and how much longer do you have to go there?

Brynna Keelin Kelly-McGrath: I’m hoping to graduate in December, so I’m coming closer to the finish line.

Doug Glenn: Congratulations. That’s really good.

Rapid-Fire Round (15:44)

Doug Glenn: I want to move off of metallurgy and heat treat just to learn a little bit more about Brynna. All right, so these quick questions are what I call the rapid-fire round. Brace yourself. Are you a Mac or a PC person?

Digital vs. print?: “I prefer digital. I like to have all of my work life very organized by topic, and it’s way easier for me to organize everything if I have a digital copy of it.”

Brynna Keelin Kelly-McGrath: I am a Mac person through and through. I love my Mac.

Doug Glenn: Do you use a Mac at work?

Brynna Keelin Kelly-McGrath: I wish, but no.

Doug Glenn: We have an ongoing debate here. We had a couple people that came into the organization with Macs, and I’ve always been a PC guy. So, anytime there’s a computer problem, we tease each other, “Well, that’s because you’re working on a Mac/you’re working on a PC.” Well, that’s good to know. And for your phone: Are you an Apple phone person?

Brynna Keelin Kelly-McGrath: Yeah, I’ve got an iPad. And I just got a new MacBook Air the other day.

Doug Glenn: You’re hardcore. Very good.

So, we’re a publishing company here at Heat Treat Today. And I like to ask this question: When you consume media, do you prefer hard copy or digital?

Brynna Keelin Kelly-McGrath: I prefer digital. I like to have all of my work life very organized by topic, and it’s way easier for me to organize everything if I have a digital copy of it. So even if it’s a print copy, I’ve been known to scan and file it the way that I file everything else.

Doug Glenn: Okay. Now what do you value more in work — a flexible work schedule or high pay?

Brynna Keelin Kelly-McGrath: I’m going to go with flexible work schedule. I’ve had some people close to me who have the high pay but no flexibility. And they’re the ones more jealous, so I’m going to go with that. I’ll take the flexibility.

Doug Glenn: That’s a great answer. Here’s one: Would you rather work remotely or in an office?

Brynna Keelin Kelly-McGrath: In an office 100%, I am definitely of the variety that likes to be around people. I would rather have people to talk to face to face than doing it over Teams.

Doug Glenn: I kind of assumed you were like that. How did you handle all the isolation that came with the recent pandemic?

Brynna Keelin Kelly-McGrath: I was still in college at that time for most of Covid. Purdue was only remote for half of one semester. It was a reasonably short time. And then the rest of the time we had limited capacity in classrooms and things. But when I was coming back for my internships, our department was classified as essential. We were coming into the office every day, and that was good, I enjoyed that.

Doug Glenn: So, you didn’t necessarily really have a lot of the isolation or as much as you might have had.

Brynna Keelin Kelly-McGrath: Yep.

Doug Glenn: That’s good. Okay, I won’t keep going down that road. I think that whole time period has been very impactful on our society. And I’m curious how people feel it has affected them.

I know you love working at Moog, but if you had a dream job, what would it be?

Brynna Keelin Kelly-McGrath: I don’t know. I think someday down the line, it would be cool to have my own manufacturing business. I don’t have a product in mind at the moment, but in my thoughts it has to do with metallic components and heat treatment, because that’s my passion. That would be great.

Doug Glenn: Very interesting, owning your own company and manufacturing something metal. You know what? That’s where it starts. You’re three and a half years out, and you’ve got time to develop more specificity over time. But that’s good to even know that you’re moving in that direction.

I assume you don’t work all the time. What do you do? What do you do in your free time? What do you like? What are your passions outside of work?

Brynna Keelin Kelly-McGrath: The number one time consumer at the moment is that master’s degree. But then, you know, on a pure fun basis, my husband and I are avid golfers. And all of the very short Buffalo summer we’re trying to be out there on the golf course.

“But then, you know, on a pure fun basis, my husband and I are avid golfers. And all of the very short Buffalo summer we’re trying to be out there on the golf course.”
Source: Richard-7 / Getty Images Signature

Brynna Keelin Kelly-McGrath: I’m also a bluegrass fiddler. I play in a couple bands. And that’s pretty fun, too. It’s almost Saint Patrick’s Day.

Doug Glenn: You’re a musician? You know, I’ve heard that there are some engineering schools who don’t ask you if you play an instrument, they ask you what instrument you play because there is a correlation somehow or other between music and engineering. Maybe it’s the methodical-ness, the orderliness, and all that stuff.

Brynna Keelin Kelly-McGrath: Neat, I didn’t know that.

Doug Glenn: If you’re playing bluegrass fiddle, I assume you play some by ear. I mean, I assume you’ve got some sort of natural talent there. Is that safe to say?

Brynna Keelin Kelly-McGrath: Yeah, I started that at a decently young age. And now my husband and I are learning piano as well, so it’s been fun.

Doug Glenn: What does your husband do by chance?

Brynna Keelin Kelly-McGrath: He’s a software engineer.

Doug Glenn: Two engineers in one house. That’s got to be interesting dinner time talk. That’s wonderful.

Okay. Last question for you. I give people an option here. You can answer any one of these three. What would be your favorite app, movie, or magazine?

Brynna Keelin Kelly-McGrath: The first thing that came to my mind when you asked that question was Audible. At the moment, I’m hooked on reading, or listening, to a lot of books. I consider it reading in the little bits of downtime here and there grocery shopping and driving in the car and things like that. It’s nice to spend that time a little bit more productively.

Doug Glenn: I’m with you. I think that’s great. I assume maybe you can even do some of your school reading on Audible?

Brynna Keelin Kelly-McGrath: I haven’t tried that yet. Honestly.

Doug Glenn: Sometimes people learn better by actually reading. But other people learn better by listening, so that’s fine.

If you were to encourage young people to really look into metallurgy materials, what would you tell them? What would be your encouragement to them?

Brynna Keelin Kelly-McGrath: I think the most impactful thing for me at that age was actually getting to see what they do. At Moog, I act as a tour guide for a lot of high school students. I try to show them as closely as possible what we do and what a day looks like. Because it’s great to think about the theory, but at the end of the day when you graduate with that degree, you’ve got to go work. I encourage high school students to get out there and see as many jobs as possible. Shadow people — I guess that would be my advice.

Doug Glenn: That’s good. Well, Brynna, thanks so much. Congratulations again on being awarded 40 Under 40 this last year. And thanks for taking some time to chat with us.

Brynna Keelin Kelly-McGrath: Thank you so much.

About The Guest

Brynna Keelin Kelly-McGrath
Materials and Process Engineer
Moog, Inc.
Source: Brynna Keelin Kelly-McGrath

Brynna Keelin Kelly-McGrath received her bachelor’s degree in Materials Science and Engineering from the Purdue University Honors College. She is currently working on a master’s degree in Manufacturing Engineering from the University of Michigan Ann Arbor. Brynna conducts metallurgical support for day-to-day heat tree issues and non-conformances across several divisions within Moog, Inc. She was recognized in Heat Treat Today’s 40 Under 40 Class of 2023.

Contact Brynna by visiting Moog, Inc.’s website: www.moog.com.

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EV Chassis Production Expands With Retort Furnace

/ ATMOSPHERE AIR FURNACES NEWS, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS, NITRIDING NEWS

ev chassis production expands with retort furnace

An international manufacturer of electric vehicles (EVs) is adding an advanced retort pit furnace for the production of EV chassis. The equipment’s larger working space will allow for the nitriding of very large die elements needed to produce this automotive equipment.

Maciej Korecki
Vice President of Vacuum Business Segment
SECO/WARWICK
Source: SECO/WARWICK.com

“This is the fourth SECO/WARWICK furnace for this global manufacturer of electric vehicles. Our product solves the challenge of nitriding dies for the production of large-sized chassis, using a working space with a diameter of 1,600 mm and a height of 2,800 mm. We delivered a similar solution to this partner last year,” said Maciej Korecki, vice-president of the SECO/WARWICK Vacuum Segment. 

The equipment provided to the company has a compact design with vacuum purging, electric heating supported by an internal circulation fan, and an external cooling system. The retort and heating system’s special design as well as the gas installation ensures long and reliable operation in industrial conditions. The solution is based on a standard vertical VR retort furnace with an enlarged working space (Ø 1600 mm/63 in and 2800 mm/110.2 in effective height), which will allow the manufacturer to nitride the huge dies used for electric car chassis. 

The press release is available in its original form here.

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Basic Definitions: Power Pathways in Vacuum Furnaces

/ CONTROLS TECHNICAL CONTENT, FEATURED NEWS, Manufacturing Heat Treat Technical Content, OP-ED, VACUUM FURNACES TECHNICAL CONTENT

Ever wish you had a map to follow when navigating your power source? In the following Technical Tuesday article, Brian Turner, sales applications engineer at RoMan Manufacturing, Inc., charts the route that power takes from the source to the load and back again in a vacuum furnace.

This informative piece was first released in Heat Treat Today’s June 2024 Buyers’ Guide print edition.

In a vacuum furnace, the journey from the load (the material being heat treated) to the incoming power involves a complex arrangement of components that deliver, control, and monitor electrical energy. Here’s a breakdown of the path from the source to the load and back to the source of incoming power of a vacuum furnace:

Load

The material — either an item or batch of items — that is undergoing heat treatment; can be metals, ceramics, or composites.

Heating Elements

Common materials for heating elements include graphite, molybdenum, or tungsten, depending on the temperature range and application.

Electrical Feedthrough

These are used to transmit electrical power or signals through the vacuum chamber wall. They often contain insulated conductors and connectors to ensure safe transmission without leaking air into the vacuum environment.

Conductors

The most common methods to connect power from a vacuum power source to the furnace’s feedthrough include air-cooled cables, water-cooled cables, and copper bus bar. Power efficiency can be improved when selecting the length, size, and area between conductors. This can be achieved by close coupling the power system to the electrical feedthroughs, reducing resistance and inductive reactance, and improving the power factor.

Machined Copper Bar
Source: RoMan Manufacturing, Inc.

Controlled Power Distribution Systems

The furnace market today generally relies on three primary types of control power distribution systems: VRT, SCR, and IGBT. Each of these technologies employs different methods to regulate the power input to the furnace, which in turn generates the required heat.

VRT (Variable Reactance Transformer)

  • The VRT controls AC voltage to the load, this is accomplished by a DC power controller that injects DC current into the reactor within the transformer.

SCR (Silicon Controlled Rectifier)

IGBT (Insulated-Gate Bipolar Transistor)

  • Balanced three-phase voltage is rectified through a bridge circuit to charge a capacitor in the DC bus. The IGBT network switches the DC bus at 1000Hz to control the AC output voltage to a Medium Frequency Direct Current (MFDC) power supply.
  • MFDC power supply transforms the AC voltage to a practical level and rectifies the secondary voltage (DC) to the heating circuit.
  • A line reactor on the incoming three-phase line mitigates harmonic content.

Control Systems

These systems manage the furnace’s operation, including driving the setpoint of the power system, temperature control, vacuum levels, and timing. They often consist of programmable logic controllers (PLCs), human-machine interfaces (HMIs), sensors, and other automation components.

Incoming Power

This is the origin of the furnace’s electrical energy, typically from a utility grid. It provides alternating current (AC), which is distributed and transformed within the furnace system to power all necessary components. In industrial settings, power companies usually charge for electricity based on several factors that reflect both the amount of electricity used and how it’s used. Some common charges/penalties are energy consumption (kWh), demand charges (kW), power factor penalties, and time-of-use (TOU) reactive power.

Conclusion

The careful arrangement of heating elements, electrical feedthroughs, conductors, and controlled power distribution systems allows for precise temperature control, ultimately impacting the quality of the processed material. Understanding the role of various control systems, such as VRT, SCR, IGBTs, and transformers is crucial for optimizing furnace performance and managing energy costs

About the Author:

Brian Turner
Sales Applications Engineer
RoMan Manufacturing, Inc.
Source: RoMan Manufacturing, Inc.

Brian K. Turner has been with RoMan Manufacturing, Inc., for more than 12 years. Most of that time has been spent managing the R&D Lab. In recent years, he has taken on the role as applications engineer, working with customers and their applications.

For more information: Contact Brian at bturner@romanmfg.com.

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military and business personnel in aircraft hangar with inset of engines

U.S. Army Receives T901 Engines for UH-60 Black Hawk Flight Testing

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, FEATURED NEWS

U.S. Army Receives T901 Engines for UH-60 Black Hawk Flight Testing

The U.S Army recently received two T901 engines from a global aerospace propulsion, services, and systems provider. The engines have been slated for the Improved Turbine Engine Program’s UH-60 Black Hawk integration and testing.

The T901-GE-900 was developed by GE Aerospace in response to a need from the U.S. Army for increased power and reduced fuel consumption with a design that incorporates 3D-modeling, the use of ceramic matrix composites (CMCs), and 3D-printed (additive) parts. The use of CMCs and additive manufacturing enables the engine to produce more power with less weight.

Amy Gowder
President & CEO
Defense & Systems
GE Aerospace
Source: GE Aerospace

“This delivery represents the beginning of a new era and a pivotal moment in our ongoing work with the U.S. Army,” said Amy Gowder, president and CEO, Defense & Systems at GE Aerospace. “The T901 engine will ensure warfighters will have the performance, power, and reliability necessary to maintain a significant advantage on the battlefield.”

This transaction follows the first ever ground run of an aircraft powered by a T901 engine, which took place in April, when a T-901 engine powered Sikorsky’s Future Attack Reconnaissance Aircraft (FARA) prototype, Radar X, gathering data to support the engine’s integration into the service’s UH-60 Blackhawk and AH-64 Apache.

“Our team is immensely proud to announce the latest T901 deliveries to the U.S. Army,” said Tom Champion, director of GE Aerospace’s T901 program. “At every stage, these engines have demonstrated a level of performance that will undoubtedly help meet the demands of military missions for decades to come.”

Source: GE Aerospace

The next-generation rotorcraft engines were unboxed during a ceremony at Sikorsky’s facility in West Palm Beach, Florida.

Photo: GE Aerospace T901 engines unboxed during a ceremony at Sikorsky’s West Palm Beach facility. Source: GE Aerospace

The press release is available in its original form here.

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groundbreaking ceremony for Toyota Material Handling, banner in background, 4 men with shovels in the fg

Toyota Material Handling Expands, Adds 85 Manufacturing Jobs

/ AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS, HEAT TREAT NEWS, HEAT TREAT NEWS INDUSTRIES, MANUFACTURING HEAT TREAT NEWS

Toyota Material Handling is investing nearly $100M for a new 295,000-square-foot facility at its Columbus, Indiana, headquarters, adding 85 manufacturing jobs by June 2026. The project will house Toyota’s manufacturing processes, which include the production of electric forklifts and material handling products.

“We are excited about this significant strategic expansion to our Columbus campus,” said Tony Miller, senior vice president of Engineering, Operations & Strategic Planning at Toyota Material Handling, at a recent groundbreaking ceremony. “Electric products are more popular than ever, and we are committed to doing whatever it takes to keep up with increased demand.”

“Electric forklifts make up 65% of the North American market and this trend towards electrification in the material handling industry will continue to grow,” said Brett Wood, president & CEO of Toyota Material Handling North America and senior executive officer for Toyota Industries Corporation (TICO). “This investment is one of the largest in our history and signifies TICO’s commitment to the North American market, the state of Indiana, the city of Columbus, and most importantly, our dealers and our customers.”

Photo Pictured L to R: Brett Wood, Toyota Material Handling North America President & CEO; Eric Holcomb, Governor of Indiana; Bill Finerty, Toyota Material Handling President & CEO; Tony Miller, Toyota Material Handling Senior Vice President of Engineering, Operations & Strategic Planning   

 

 

The press release is available in its original form here.

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This Week in Heat Treat Social Media

/ FEATURED NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

Welcome to Heat Treat Today’s This Week in Heat Treat Social Media. We’re looking at hot summer events, hot summertime activities, and hot heat treat industry events coming soon to a social media page near you. Check out these posts, podcasts, and videos for a roundup in Heat Treat Social Media.

As you know, there is so much content available on the web that it’s next to impossible to sift through all of the articles and posts that flood our inboxes and notifications on a daily basis. So, Heat Treat Today is here to bring you the latest in compelling, inspiring, and entertaining heat treat news from the different social media venues that you’ve just got to see and read! If you have content that everyone has to see, please send the link to editor@heattreattoday.com.

1. Heat Treating Skateboards > Hot Moves

This space is usually reserved for something rich and technical, but it’s summertime in the northern hemisphere and heat treating is just as essential for the proper working of items affiliated with leisure and outdoor activities as the products that make the world go round (e.g., automotive, aerospace, etc.). “Skateboarding is not just a sport; it’s an art form, a mode of transport, and a way of life for many. But did you know that the metal trucks on a skateboard—those T-shaped pieces that mount the wheels to the deck—are a product of meticulous heat treatment?” (from Bodycote on LinkedIn, November, 2023)

Check out this recent post from Bodycote laying out how critical it is to safety and experience for skateboard trucks to be heat treated with the same level of skill that it takes to execute an ollie or a shuvit.

2. It’s a Beautiful Day in the Heat Treat Neighborhood

What’s everyone been up to on the social channels?

Summer Engineering Institute reshaping the Future of Heat Treating

Future Leaders: Report to the Dome!

Take Us Out to the Old Ballgame!

It may Be Summer but It’s Never Too Early to Think About the Fall

‘Tis also the season for Registration for 2024’s industry events and social media provides an excellent platform for getting the word out. Here are some of the events taking place just in September — don’t delay! Registration is still open for all of these!

Marking Milestones

3. Learn with Us

Sometimes, it’s the small things on social media that grab your attention or give you the “ah ha!” moment. And sometimes things affecting the industry in other places cause us to go “hmm.” Do any of these short posts make you say “eureka”?

Queueing and Sequencing (and more!)

Quiz Time

4. Open Your Ears: The Podcast Corner

You can’t read everything, we get it. Heat Treat Today is here to recommend two informative podcasts to enjoy on your daily commute!

Tune in to Listen to Heat Treat Radio #110! Isolated Heat, the Future of Vacuum Furnaces

smiling bearded man on blue background, HTR 110 logo, isolated heat text

Sharpen your hearing: Heat Treating Knives on the TTT Podcast

5. Junk Food and a Logo Extravaganza

Click through to see what Kowalski Heat Treating thinks about junk food and how that thinking gets them counting logos.

Have a great weekend!

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Heat Treat Economic Indicators: July 2024 Results

/ FEATURED NEWS, HEAT TREAT ECONOMIC NEWS

The four heat treat industry-specific economic indicators have been gathered by Heat Treat Today each month since June 2023. Through the first half of 2024, the economic indicators have shown that suppliers to the heat treat industry have expected growth across all four indicators, with numbers in June remaining in the “growth” category in three out of four heat treat industry indices. This month, suppliers are reporting that they expect indicators to reflect a midsummer calm; contractions are anticipated with some falling just below neutral.

The numbers, which were compiled in the first week of July, show that responding parties anticipate indices to reveal contraction, but the expectation for contraction is minimal for number of inquiries and value of bookings, both settling just below the “neutral” x-axis, indicated by the number “50.” Backlogs and overall health of the manufacturing economy are expected to shrink, with the backlog indicator falling below our neutral axis for the second month in a row. This is the first month that suppliers anticipate contraction across the board since data started being collected in June 2023.

The results from this month’s survey (July) are as follows; numbers above 50 indicate growth, numbers below 50 indicate contraction, and the number 50 indicates no change:

  • Anticipated change in the Number of Inquiries from June to July: 48.0
  • Anticipated change in Value of Bookings from June to July: 48.5
  • Anticipated change in Backlog Size from June to July: 44.6
  • Anticipated change in the Health of the Manufacturing Economy from June to July: 43.8

Data for July 2024

The four index numbers are reported monthly by Heat Treat Today and made available on the website. 

Heat Treat Today’s Economic Indicators measure and report on four heat treat industry indices. Each month, approximately 800 individuals who classify themselves as suppliers to the North American heat treat industry receive the survey. Above are the results. Data started being collected in June 2023. If you would like to participate in the monthly survey, please click here to subscribe.

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5 digital screens and devices, one with a hand and finger touching a screen; background faded silver/gray design

Thermal Loop Solutions, Part 2: A Path to a Sustainable Future in Heat Treatment

/ CONTROLS TECHNICAL CONTENT, FEATURED NEWS, MANUFACTURING HEAT TREAT NEWS

What is the path forward for thermal loop systems, and how is “sustainability” at the forefront of this technology? The following article is co-authored by Peter Sherwin, global business development manager of Heat Treatment, and Thomas Ruecker, senior development manager, at Watlow. They examine four scopes to take into consideration when assessing thermal loop systems in the context of greenhouse gas emissions and their environmental impact.

This article is a continuation from the introduction of this topic released in Heat Treat Today’s January/February 2024 Air & Atmospheres print edition and published at Heat Treat Today on February 27, 2024, titled “Thermal Loop Solutions, Part 1: A Path to Improved Performance and Compliance in Heat Treatment”.

Sustainability

Heat treatment thermal loop solutions provide several sustainability benefits, including reduced energy consumption and waste. The power controller regulates the power output to minimize energy waste, and the possible integration with renewable energy sources and circular economy principles provides a complete power solution that spans from element design to recycling and renewables. The thermal loop solutions, in combination with insulation design and materials, provide energy-efficient solutions that contribute to sustainability and reduce the environmental impact of heat treatment processes.

When discussing these systems in the context of greenhouse gas emissions and their environmental impact, it is essential to consider Scopes 1, 2, and 3, as well as the less common Scope 4:

  • Scope 1 (Direct Emissions): Heat treatment processes often involve the combustion of fossil fuels like natural gas, propane, or oil to generate heat. These direct emissions are attributed to the equipment used in the heat treatment process, such as furnaces and ovens. Efforts to reduce Scope 1 emissions include upgrading to more efficient equipment or adopting alternative heating technologies, like induction or electric heating systems.
  • Scope 2 (Indirect Emissions from Energy): In heat treatment processes and thermal loop systems, electricity is often used to power various components, such as pumps, fans, and control systems. The emissions associated with generating this electricity are considered Scope 2 emissions. To reduce Scope 2 emissions, companies can improve energy efficiency, invest in renewable energy sources, or purchase green energy from their utility provider.
  • Scope 3 (Other Indirect Emissions): These emissions are associated with activities throughout the value chain of heat treatment applications and thermal loop systems, such as the manufacturing and transporting of raw materials, equipment, and waste management. Companies can work to reduce Scope 3 emissions by collaborating with suppliers to improve the environmental performance of their products and services, optimizing transportation and logistics, and implementing waste reduction strategies.
  • Scope 4 (Avoided Emissions): In heat treatment applications and thermal loop systems, avoided emissions may come from implementing energy-efficient technologies, waste heat recovery systems, or other innovative solutions that reduce overall energy consumption and associated emissions. By quantifying these avoided emissions, companies can showcase the positive impact of their sustainability efforts on reducing their carbon footprint. Avoided emissions can also be highlighted when subcontracting heat treatment requirements to a more energy-efficient source rather than running an in-house operation. In this approach, the heat treatment process is outsourced to an external, specialized heat treatment service provider, especially if the in-house equipment is due to be lightly utilized. These service providers operate independent heat treatment facilities and offer services to multiple clients across various industries and generally run 24/7 with high utilization.

At the component level, energy savings can be realized using current technology. Advanced SCRs provide predictive load management functions and hybrid firing algorithms and contribute to sustainability by optimizing the energy usage of heat treatment processes. These SCRs offer real-time monitoring and control of energy consumption, while predictive load management systems use specific algorithms to manage peak power loads and adjust to optimize for local conditions (load shedding or load sharing). Hybrid firing systems use a combination of firing methods to control power factors and reduce the negative impact on the electrical infrastructure.

Figure 1: Eurotherm EPowerTM Predictive Load Management / Source: Watlow

Heater design is also essential. Switching time impacts heater life with fast, modern switching modes (hybrid firing) significantly extending heater life compared to slower switching from conventional mechanical contactors.

Systems can be rapidly tested, simulated, and modeled through computational engineering. Several thermal loop systems today have improved temperature uniformity due to these methods.

Adaptive thermal system (ATS) solutions are the next frontier of thermal loop solutions. Rather than selecting the best-of-breed components — sometimes with overlapping functionality and kitting a complete solution — ATS provides a merged design between heater and control systems. ATS is already in place in several semiconductor applications, and this type of technology is looking to scale into heat treatment applications shortly.

graphic of 2 circular images (predominantly green), red arrow between; text: Watlow Introduces Adaptive Thermal Systems
Figure 2. Watlow Adaptive Thermal Systems ATSTM
Source: Watlow

Challenges and Limitations

The initial investment in heat treatment thermal loop solutions can sometimes be higher than in traditional methods. However, this investment often leads to a significantly lower total cost of ownership and improved return on investment due to the thermal loop solutions’ increased efficiency, improved quality control, and extended life.

Ensuring regulatory compliance is complex and time-consuming, requiring organizations to have the right people, processes, and equipment.

Future Trends

As Industry 4.0 and digital transformation continue to gain momentum and Industry 5.0 practices are implemented, heat treatment thermal loop solutions will become increasingly important. Integrating digital technology and machine learning algorithms will provide even greater control, traceability, and transparency, enabling organizations to make informed decisions based on real-time data and predictive analytics. In addition, as new materials and manufacturing processes are developed, adaptive and flexible heat treatment thermal loop solutions will need to evolve to meet these challenges and provide the necessary level of control and efficiency for these new applications.

Conclusion

Heat treatment thermal loop solutions provide several benefits over traditional heat treatment methods, including improved temperature control, increased efficiency, and improved sustainability outcomes. The integration with Industry 4.0 and data management systems, as well as the use of FMEA and OEE metrics, further help enhance the performance of heat treatment processes. As Industry 4.0 digital transformation and Industry 5.0 practices continue to evolve, heat treatment thermal loop solutions will play an increasingly important role in the future of heat treatment.

About the Authors:

Peter Sherwin
Global Business Development Manager of Heat Treatment
Watlow
Thomas Ruecker
Senior Business Development Manager
of Heat Treatment
Eurotherm, a Watlow company

Peter Sherwin, global business development manager of Heat Treatment at Watlow, is passionate about offering best-in-class solutions to the heat treatment industry. He is a chartered engineer and a recognized expert in heat treatment control and data solutions.

Thomas Ruecker is the business development manager of Heat Treatment at Eurotherm Germany, a Watlow company. His expertise includes concept development for the automation of heat treatment plants, with a focus on aerospace and automotive industry according to existing regulations (AMS2750, CQI-9).

For more information: Contact peter.sherwin@watlow.com or thomas.ruecker@watlow.com.

This article content is used with permission by Heat Treat Today’s media partner heat processing, which published this article in 2023.

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military helicopter against a blue, red and gold colored evening sky; logos of Spirit AeroSystems, Boeing, and Airbus in upper half

Spirit AeroSystems Announces Split Acquisitions by Boeing, Airbus

/ AEROSPACE HEAT TREAT NEWS, FEATURED NEWS

Spirit AeroSystems, a global manufacturer of aerostructures for commercial airplanes, defense platforms, and business/regional jets recently announced it has entered into a definitive merger agreement with The Boeing Company. Additionally, Spirit has agreed to a subsequent agreement in which aerospace manufacturer Airbus acquires certain Spirit assets that serve Airbus programs.

Dave Calhoun
President & CEO
The Boeing Group
Source: Linked In

The $8.3 billion Boeing transaction, expected to close mid-2025, will include all Boeing-related commercial, defense, aftermarket operations, and a commitment to ongoing partnership with the U.S. Department of Defense and Spirit defense operations. Spirit AeroSystems manufactures fuselage structures for the Boeing 737 MAX and 787 Dreamliner, among other aircraft programs.

Patrick M. Shanahan
President & CEO
Spirit AeroSystems
Source: U.S. Department of Defense

“This is an opportunity to bring back critical airplane manufacturing work on Boeing airplanes into our factories–where Boeing and Spirit world-class engineers and mechanics can work seamlessly together, focused on a common mission to build safe and quality airplanes for our customers,” said Dave Calhoun, president and CEO of Boeing, in a statement to employees on July 1, 2024.

The Airbus transaction will run concurrently with the closing of Spirit’s acquisition by Boeing and involves the potential acquisition of major activities related to Airbus, notably the production of A350 fuselage sections in Kinston, North Carolina, U.S., and St. Nazaire, France; of the A220’s wings and mid-fuselage in Belfast, Northern Ireland, and Casablanca, Morocco; as well as of the A220 pylons in Wichita, Kansas, U.S.

“Bringing Spirit and Boeing together will enable greater integration of both companies’ manufacturing and engineering capabilities, including safety and quality systems,” said Patrick M. Shanahan, president and CEO of Spirit. “We are proud of the part we have played in Airbus’ programs and believe bringing these programs under Airbus ownership will enable greater integration and alignment.”

In taking over those operations, Airbus will pay a nominal $1.00 and will be compensated with $559 million from Spirit AeroSystems.

Related press releases are available in their original form here, here, and here.

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Happy Independence Day!

/ FEATURED NEWS

Happy Independence Day from Heat Treat Today. Our team will be enjoying a long weekend of festivities, celebrating our nation’s 248th birthday with fireworks, community events, picnics, parades, and time spent with family. We have much to be thankful for; first and foremost are the freedoms we treasure articulated in that timeless Declaration of Independence and encoded in the Constitution of the United States.

We here at Heat Treat Today love to see how others in the industry honor our heritage and flag, and we thought you’d appreciate the heat treating work done by Advanced Heat Treat Corp. and shared on their LinkedIn page:

Posted to mark Flag Day, June 14, 2024, this is an ideal item for Heat Treat Today’s “This Week in Heat Treat Social Media,” but we didn’t want to wait. Here’s what the original post at LinkedIn said, “June 14th is Flag Day. We thought sharing these unique heat treated metal flags would be fun. Nitriding the flag makes it stronger and last longer outdoors.” You can see that post here.

Heat Treat Today’s offices will be closed July 4 and 5. There will be no e-newsletter either of those days. See you on Monday!

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