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Heat Treat Radio #95: Heat Treat Legend John Becker

We have the honor to speak with another Heat Treat Legend in our industry, John L. Becker, president and founder of Heat Treat Equipment. Doug Glenn, publisher of Heat Treat Today and host of this podcast, has been chatting with the legends walking among us who’ve been involved with the North American heat treat to get a sense of where they’ve been, what they’re doing, and what advice they would share with the current generation. “Tenacious” is the word that comes to mind from this conversation.

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.

A Summer at Ford Motor Company (01:20)

Doug Glenn: John, you were the founder and owner of the J.L. Becker Company which was recently purchased by Gasbarre Furnace Group. You’re no longer associated with that company, since you sold it. You are associated with Heat Treat Equipment, Inc., which you also started.

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How did you get started in the heat treat industry?

John Becker: It goes back to the summer of 1964 when I had been going to a junior college, and I started dating my wife. Her father was in the steel division at Ford Motor Company, and I needed a summer job in 1964. Through his contacts, I was able to get a job there. My position was very "prestigious." I had my own tool; it was called a broom! Through sweeping up, I was a first-class janitor. Then, I was able to move up to a helper’s position.

In working there for the summer, I saw a lot about the making of steel and the production processes. I used to hang around the lab, because in the summer, the lab was air conditioned; and I could pretend that I was interested in that area. By the end of the summer, they asked if I would consider going on co-op for metallurgy. I thought, “Well, that sounds easy. I can do that,” not realizing what I was in for.

"I received a BES in 1968"
Source: Western Michigan University

I started in metallurgy, and worked for Ford and went to Western Michigan University where I received a BES (Bachelor of Engineering Science) in 1968. During that time of co-op, I worked and took classes. I used to take classes at Wayne State, Lawrence Tech, and other places where I could get some hours or get a class.

After I graduated, they put me in an area called the AADGO (Automotive Assembly Division General Office) where I was a fastener engineer. We were dealing with nuts, bolts, screws, and washers. I started visiting heat treat shops. At the same time, they put me on the MBA management program through the University of Michigan.

There were a lot of people in Rockford, IL, that made fasteners. One of the areas we were concerned with was heat treating. That thing called the Delta or appendix C, the Q101 (Quality 101 points) for Ford.  I would go around inspecting plants, and I got to know several people in heat treating. I was a bit fascinated by it.

In 1970, Ford laid me off. I was still finishing up school, and I had a child. I actually started teaching school part time and did that for a while. I was a “the permanent substitute,” so I would work a lot of different days. That was quite enjoyable!

I started working for a company that sold high temperature materials: conveyer belts, etc. and was pretty successful. I looked at what I was getting paid. At this company, some reps were getting 10%. I was getting a salary and expenses, and I understood that it was a pretty good deal. But I still looked at reps and figured I made 10% of that value.

Starting a Business in a Basement (06:18)

I decided to really go on my own, and I started the J.L. Becker Company out of my house as a rep. I had four principals, and a few others in the industry. I didn’t represent these, but I could sell their products. Two examples were the wire mesh conveyer belt of Canada and I Squared R, which provides silicon carbide heating elements. We had a line of hearth plates, thermocouples. I became the Lockheed engineering rep. Because of that, I called on a lot of OEMs like Surface Combustion and Atmosphere Furnace and others.

"My dad gave me an old phone."
Source: Unsplash.com/Nguyen Dang Hoang Nhu

We built it up. Everybody in Michigan had a basement. My dad had given me a used desk and, in those days, you had a phone that was wired to the wall. My dad had given me an old phone, so I started a company. In the basement of the house, I had a little cubby, about 4 ft by 7 ft, and that was my world headquarters.

After 6 months, I started to interview for a new job with salary and benefits, and all the things I didn’t have, because it wasn’t as great as I thought.

I had been calling on Monroe Auto Equipment in Monroe, Michigan. Monroe Auto Equipment has four plants that do powdered metallurgy; they make components for shock absorbers. I had become friends with a guy there, Fleming Pruitt. I still remember his name to this day.

He called me and asked for a particular product. I got a price for it, called him back, and he said, “I made a mistake. I didn’t want 20 pieces, I wanted 200.” I was going to make 10 bucks a piece or some number like that. All of a sudden, I was, like, “Whoa!” That started it.

Then I got another order, another order, and another order. Over time, I started thinking: “Why don’t I have some of my own products where I can control the price?” I could buy it for X and add my overhead to it.

Growing the Business (09:13)

In 1974, I moved to an office in Livonia, Michigan. It was in a multitenant-type building, and the fellow had rented two spots, and there was one empty office. I started there. I ended up hiring a gal by the name of Carol Campbell, right about then, for $90 a week and no benefits. She did an outstanding job for me.  Around 1976, I hired Dave Peterson. Dave still, as you know, works with me today. I couldn’t chase him away. I tried and failed.

"I added another piece of the puzzle."
Source: Unsplash.com/Nathalie Segato

From there, I added another piece of the puzzle. Each year we expanded. I got busy enough where I visited someone who I was selling different components to, and they had a piece of equipment they wanted to get rid of. I had visited someone else the day before who was looking for the same thing. I didn’t have to be that bright to understand that this guy wanted a dollar, and this guy was willing to pay two dollars. That worked out pretty well, and I did that a few times. But then the next time I did it, the person said, “You need to take it out.” So, I was able to; there was a group of guys and my office, at that time, was right behind Holcroft in Livonia. I got to know a lot of guys that worked there, and they would come and work for me on weekends. We would dismantle, move things, and ship them out.

Eventually, I got a little shop. I hired a fellow, whose name is Charlie Hatala, who now has Great Lakes Industrial Furnace. Charlie ran the shop, and then we started refurbishing equipment.

Then, in 1978 or 1979, BorgWarner Corporation in Michigan asked me if I could build a tempering furnace. I was doing maintenance for them installing components. I did a lot of brazing and sintering furnaces and some batch furnaces. They needed to do temper. I said yes, having never done it before.

Eventually, we figured it out.

I hired an engineer who worked for us part time for a while, and the shop became a busier situation. We started to build some equipment.

I hired an engineer, a fellow by the name of Don LaFore, who has now passed away. Don came in and helped shepherd us along to do design work. We started to build some belt-type furnaces for sintering and brazing. There were other people in the industry who had small operations to do refractory work or do electrical. We leaned on those individuals and started to build.

By 1980, I had two guys in engineering, Dave in sales, Carol in the office, and my wife, Eileen, was our CFO, as she still is today. It just went from there!

By 1983, we moved to another larger building.

In 1989 we moved again, and then in 2000, we moved to an even larger facility.

So, we had gone from about $700k–$800k to about $25 million in my last couple of years. In fact, we have equipment we built in the Ukraine for which my son, Matt, did the startup. We just looked at it in satellite, and it’s still standing and hasn’t blown up yet. That particular system, we duplicated twice for Russia.

Becker Goes International (14:16)

We built equipment in Israel, Dubai, Saudi Arabia, Thailand, and China. Korea was the first place, out of the country, where I sold a piece of equipment. That was right at the beginning, probably in the later part of the 1970’s, maybe very early 1980’s.

"We built equipment in Israel, Dubai, Saudi Arabia, Thailand, and China."
Source: Unsplash.com/Lucas George Wendt

At Ford Motor Company, there was a research scientist; he was a Korean doctor. He  had gone back to Korea to head a thing called KIMM (Korea Institute of Machinery and Materials) and he called me and ordered a furnace. We built the furnace, a research-type sintering furnace and endo generator, and I actually went to Korea and did the startup. That was one of the first international ones. We’ve shipped equipment to Canada, to Mexico, and to quite a few different places.

At 68 years old, in 2011, I sold the company to Gasbarre.

 Becker’s Network in the Heat Treating Industry (16:02)

Doug Glenn: Give us a recap of some of the people with whom you’ve interacted.

John Becker: There was a startup company in around 1970/71 called Custom Electric Furnace, where Tim Mousseau worked as an engineer. Charlie Hatala was basically the president and shop manager. They had all come from a company called Alexander Engineering which goes way, way back.

I started repping them, and I sold a few furnaces for them.

Another guy that was repping around there was Jeff Smith; he worked for the which represented a company out of New York that made heat exchangers. Jeff came up with the idea of making his own heat exchangers, and that’s when they started SBS Corp.

During that same time period, I became friends with John Young. John’s father had Perfection Heat Treating Company, and his father, unexpectedly, died just before Christmas around 1976, I believe. John and I became friends. His wife’s name was Eileen, and my wife’s name was Eileen. We both had degrees in metallurgy; our backgrounds were very parallel to one another.

John and I ended up buying the heat treating company called Steel Improvement Company, and John ran that company successfully for about 10 years. Also, John and I got in on a few other companies too.

1984 and 1985 hurt the heat treat industry in Detroit, so we ended up liquidating both those companies.

Just like Jeff Smith, people from, refractory people, we interfaced with so many people here. In the metropolitan Detroit area, you have everything you can think of: Electrical supplies, wire, refractory, engineering help, machining, fabricating, steel suppliers. Everything is right at our fingertips. You have a real cornucopia of support-type people from lawyers to accountants to medical to whatever. It was a good place to nurture a company.

Like I said, we built the company up, and I was really motivated to sell.

In 2009, my oldest boy died. That hurt me personally, obviously. Then, in 2010, my younger son, Matt, who’s kind of a Mensa kid, announced he was going to leave to open a brewery. He has been extremely successful.

Then, Gasbarre approached me. My thoughts of passing the business on to my sons were trash, so I sold the company. After I sold it I consulted with them for a couple years; it was all part of the contract. I realized I really didn’t want to get out of it; I had pulled the trigger a little too quickly.

I’m 79, and I still work almost every day. I love the business, and I’ve come to know so many people in the business that I interface with. I’ve had some very, very strong supporters over the years for the equipment that we’ve built.

One guy that was probably the nicest guy — you couldn’t have asked for a better friend — was Jim Hendershot who had Carolina Commercial Heat Treat. Jim sold it to Gibraltar and on and on. Now, most of their plants are part of Bodycote.

John’s Supporters (22:32)

Doug Glenn: Are there two or three people who had a significant impact, people that encouraged you to carry on?

John Becker: You know, I really can’t point to anybody individually. Obviously, my wife was a supporter. She was burdened with the accounting side of the business.

"It was more people believing in me..."
Source: Unsplash.com/Brett Jordan

I had a lot of different people. There was a buyer at Ford who was very supportive. Another guy at AC Spark Plug up in Flint; I did a lot of work for them and built several pieces of equipment. So, it was more people believing in me and believing that I could do the job and giving me the opportunity to do it.

My best friend just passed away a week ago (he was a Ford dealer). He would listen to me all the time and give me advice. He had built up a company where he was the number one Ford dealer for 1921 and 1922 in volume, worldwide, in the small little town of Livonia. It was very prestigious. He was a very well-liked individual. He gave me a lot of advice about not trying to micromanage, about giving up control and giving control to other people, hiring people and trusting them to let them do their job, and how to treat individuals. I think I learned a lot from that.

John’s Significant Accomplishments (25:20)

Doug Glenn: What are one or two your significant accomplishments?

John Becker: Dave Peterson worked with a company (and I won’t mention their name), and I joined him. This company had bought a used piece of equipment and did some converting on it to do a process. They had built one, and then we built their next one and “upgraded” it to the next phase.

We worked on the design and built and built and built it to where they had about 50 of these units. I think, between myself and Gasbarre, there may be 55 of them built. If you look at it, it’s roughly a million dollars apiece; they were very successful. They were using my son, Matt, who developed the software and automated all the controls to mass flow sensors, etc. This was early on before a lot of things that we have today. If you look back, this was all new technology at the time.

That was a “feather in our cap,” and that was a whole team. The engineering department did the engineering, the shop and the people in fabricating all had ideas and those were incorporated into it, and Matt redeveloped the software and the controls and developed all the programming. Before they had a lot of mechanical and timing issues where a bell would ring and an operator would have to do something, this was all automated. It took the operator out of what was a 30, 40, 50-hour process.

It’s very successful. That shows how the whole group pulled together and did it.

"I'm tenacious like a bulldog..."
Source: Unsplash.com/MattODell

My success has been talking. Sales. I’ve been able to connect with people. I’m tenacious like a bulldog on an ankle; it’s hard to get me off. My middle initial is “L” and I tell everybody it’s for “Lucky.” I’ve been very fortunate to have a very loyal group of individuals. Like, we’re here now at Heat Treat Equipment. Bill Richardson started me in 1980 and was chief engineer and is with me now. Dave Peterson was my sales manager since 1976/77 and is with me now. The people in our shop, I did not solicit them. They came to me. When I had J.L. Becker, they were the ones that made the clock work.

I would go out, do the sales, contribute to them, and try to close the deal. I had more people — we had four or five gals, plus the CPA, plus my wife in the office, for insurance, employee benefits, payroll, paying the bills, etc. That worked very well, but that wasn’t my department. I looked at it macro work, but the micro work was done by all of them. They were very organized. The same was true for the shop and in engineering.

I really have to say they’re the ones that made the business keep moving. I would come in and say, “I’ve sold another standard piece of equipment except everything is different.”

Lessons Learned (30:43)

Doug Glenn: Over your work career, were there any disciplines that you developed? Were there any disciplines you developed you felt were beneficial for you and for your company?

John Becker: I can’t think of anything specifically. They always say, “Never quit. Never take ‘no’ for an answer.” So, I never quit. I used to tease some of the other guys because they would call on a customer for years, literally 4–10 years, and nothing would happen. Then, there was that lucky change in personnel. All of sudden, everything started to happen. We became “their guys.”

I was tenacious, and I listened. I do a lot of talking, but people don’t realize I do listen. Understanding, in sales, what does your customer want, what’s the expectation? I’m not going to pick on any other company, but some, more or less, “fell from the catalog.”

I always thought we were willing to change to try to modify or make our equipment fit our customer’s needs, not our customer needs fitting our equipment. We always went in and would change things. As I said, “Another standard piece except everything is different!”

I know when I sold the company, Gasbarre enjoyed quite a bit of repeat business from our customer base. I think our customer base was loyal; the loyalty came back from being loyal to them. We, like everyone else, had problems. My point was: We need to fix the problem, not fix blame. We didn’t worry about the cost. When it was done and resolved, then we could go back and look at it to find out if the problem arose from something we did, was it improper usage, etc.?

We never walked away from a problem and trust me, I had them over the years.

Doug Glenn: Did you ever lose any big money on them?

John Becker: Yes. More than once, and we lived to tell about it! The problem was sometimes I was quick on the draw. A guy that draws fast can shoot his foot off. The gun goes off a little too quick. Every time I would try to jam a square peg into a round hole — like I said, I was tenacious. I would fight and fight and fight for an order and get it and get creamed.

Work-Life Balance (34:55)

Doug Glenn: How did you handle work-life balance?

John Becker: It was never a struggle. I worked 6 days a week; when the kids were growing up, I coached baseball. I had a soccer team I coached in Northville for both my boys. We loved Florida because my grandparents were down there. My mother’s parents were down there, and my parents moved there. I had a brother and sister that lived there, etc.

We started going down to Florida very early in our lives in the 1970’s. We took vacations with the boys. There are plays and things they did at school; we did all that. We had a pretty good life.

Over the years, I’ve developed a lack of memory. When I walk out the door of work, my memory just falls off somewhere. I’m driving home and when I get home, I can’ remember things. Even though Eileen was involved in the business, I didn’t go home and talk about the business. I left it at work.

[blockquote author="" style="1"]One thing I’ve learned is that the work you didn’t do today will be there tomorrow. The work will be there.[/blockquote]One thing I’ve learned is that the work you didn’t do today will be there tomorrow. The work will be there. Early on, I did a few things. I missed a funeral for a friend that I still look back at, 30 years later, and say, “I could’ve cancelled or rescheduled those appointments, and I could’ve gone there.” I still think I should have gone to the funeral, and I didn’t and I’m sorry, today. The appointments that I went to never turned out to be anything.

I’ve always carried that around, that I should have been there for that person even though they had passed. You make decisions, and I think you’ve got to remember that a lot of these things will be there tomorrow that you don’t get to today.

Advice to Young Leaders in the Industry (37:48)

Doug Glenn: Were there one or two lessons you learned along the way, words of wisdom you would give?

John Becker: Send your resumes out somewhere else? Find a different career! I don’t mean that; the industry has been good to me.

I think that one of the things for younger people, especially in sales, is this: I would go work on a sale and I would think, “Boy, I’ve got this thing,” and find out I lost to a competitor, not realizing the purchasing guy’s brother-in-law was my competitor. So, understanding the politics of situations, the relationships. I’ve had people that I’ve been very, very close to and they would go out for bids, but I knew I was getting the work. Get to understand the relationship, who they’ve worked with in the past.

The other thing I think is important is technical society. I belong to ASM (ASM International, formerly known as the American Society for Metals). I used to belong to MPIF (Metal Powder Industries Foundation), the APMI (American Powder Metallurgy Institute).

I was one of the original associate members of  MTI (Metal Treating Institute), but actually I was an MTI member back in the 70’s because we (John Young and I) owned the heat treat shop. John was the member, and I was the alternate. They were very, very down on a salesperson, like me, coming to those types of meetings. I did go to a couple. In fact, the very first or second meeting that Lance ever had, I met a guy who was from out in Oklahoma, by the name of John Hubbard. That was back in, probably, 1980, roughly, ’81 maybe; it was in that time.

Doug Glenn: So, for those who are listening that might not know, Lance Miller was the executive director of the Metal Treating Institute (not anymore, Tom Morrison is currently in that position). John Hubbard ended up being the CEO of Bodycote for years and years.

John Becker: I think in establishing relationships, try to be as honest as you can with your customers. There is a certain point that, I think, to maybe be a little guarded in your answers. Be as honest as you can without giving away your company secrets or whatever. Say you’ve had something in the background in your company that’s gone on and it’s affecting something. You don’t need to broadcast that, but you should maybe tell your customers you’ve had some issues that are going to delay or change things. That’s the best thing.

Just be yourself; don’t try to be somebody else. And you know what, if you don’t come home laughing and having a good time and enjoying yourself, you’re in the wrong business.

 

 


About the expert:

John Becker, president at Heat Treat Equipment: Founder and president of Heat Treat Equipment (est. 2011), has a long and distinguished career in the heat treat industry as the founder and long-time president of J. L. Becker Company, a manufacturer of new furnaces and heat treat equipment.

Contact:

Website: www.heattreatequip.com

Email: john@heattreatequip.com


 

To find other Heat Treat Radio episodes, go to www.heattreattoday.com/radio.

 


Search heat treat equipment and service providers on Heat Treat Buyers Guide.com


 

 

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Vacuum Furnace Revitalized and Upgraded

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A Terre Haute, IN, company has completed the commissioning of a vacuum furnace system for a Mid-Atlantic manufacturer. The furnace was upgraded with an oversized vacuum pumping system, updated piping, all metallic hot zone, and control system.

Mercer Vacuum Components and Services Inc took the existing SS vessel and stripped it to the base. All of the vacuum piping was upgraded from .625" copper piping to 2.000" KF style SS piping. The hot zone utilized graphite board with moly elements that MVCS upgraded to a multiple layer metallic lined hot zone utilizing the OEM designed molybdenum elements. New inlet and outlet water headers were also supplied. The control panel was upgraded to include a new PLC and HMI. Instrument upgrade was performed by Mercer Technologies. The entire furnace system was taken apart and painted before reassembling.


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Anatomy of a Furnace: Tip-Up Furnace

OC

Consider the numerous systems in your heat treat operations. What makes up the anatomy of each furnace? In this "Anatomy of a Furnace" series, industry experts indicate the main features of a specific heat treatment system. For this inaugural feature, note how the schematics demonstrate how the tip-up furnace is able to process massive loads in an atmospheric sealed environment at highly controlled temperatures.

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Annotations for this furnace corpus were provided by Dan Herring, The Heat Treat Doctor®, The HERRING GROUP, Inc. A front view of a tip-up furnace as well as a back view of a different tip-up are provided along with the labels.

Download the full graphics by clicking the images below.

Click to download now!

 

This Technical Tuesday article is drawn from Heat Treat Today's February's Air & Atmosphere Furnace Systems print edition.

Search www.heattreatbuyersguide.com for a list of tip-up furnace providers to the North American market. If you are a tip-up furnace supplier and not listed here, please let us know at editor@heattreattoday.com

This series will continue in subsequent editions of Heat Treat Today's print publications. Stay tuned!


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News from Abroad: A New Technique, Equipment, and Celebrations

Heat Treat Today is partnering with two international publications: heat processing, a Vulkan-Verlag GmbH publication that serves mostly the European and Asian heat treat markets, and Furnaces International, a Quartz Business Media publication that primarily serves the English-speaking globe. Through these partnerships, we are sharing the latest news, tech tips, and cutting-edge articles that will serve our audience — manufacturers with in-house heat treat.

In this article, originally published in Heat Treat Today's March 2023 Aerospace Heat Treating print edition, we look at new tech in Japan, a low emission material in Germany, an alliance of specialists in Mexico, and an executive move in a global industrial gas company.


ArcelorMittal Low Carbon Emission Wire Rod for C.D. Wälzholz GmbH & Co. KG

Delivery of the first low-carbon emissions wire rod coils at Wälzholz in Hagen, Germany
Source: ArcelorMittal

"As part of their business partnership, ArcelorMittal will supply C.D. Wälzholz GmbH & Co. KG with low carbon emissions wire rod from the Hamburg plant in the future. These steels are produced on the basis of scrap and renewable electricity (100 percent). The low carbon footprint of 504 kg CO2/t of steel is confirmed with an official Environmental Product Declaration (EPD). The delivery of the first 20 tons took place . . . at the cold rolling company’s site in Hagen, Germany. uses the material to manufacture heat treated profiles for industrial applications."

Read More: "Waelzholz purchases low carbon emissions wire rod from ArcelorMittal" at heat-processing.com

Hugh Grant, New Director for Linde

Hugh Grant, Director, Linde
Source: gasworld.com

"Linde plc announced that its Board of Directors has elected Hugh Grant as a new director of Linde plc, effective January 23, 2023. Grant will serve on the Nomination and Governance and the Human Capital committees. Grant, a Scottish national, is a highly regarded former executive and director who brings substantial global experience to the Linde plc Board of Directors. He served as Chairman, President, and Chief Executive Officer of Monsanto Company, a global provider of technology-based solutions and agricultural products that improve farm productivity and food quality, from 2003 until 2018, when he led the sale of Monsanto to Bayer AG. "

Read More: "Linde Board Elects Hugh Grant as New Director"at  heat-processing.com

 

New Tech for Shinkansai Steel Co., Ltd.'s -ton Electric Arc Furnace

New tech for Shinkansai Steel Co., Ltd. plant
Source: Furnaces International

"Designed by Danieli Automation, Q-One uses the latest digital power electronics technology to maintain the EAF power-factor values close to unity. The power-feeding system that will be installed at Sakai will have a five-unit configuration with a total maximum power of 54,6 MVA."

Read More: "Danieli to supply patented tech to Japanese EAF" at furnaces-international.com


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This Week in Heat Treat Social Media


Welcome to Heat Treat Today's This Week in Heat Treat Social Media. You know and we know that there is too much content available on the web, so it’s next to impossible to sift through all of the articles and posts that flood our inboxes and notifications on a daily basis. Today, Heat Treat Today brings you another hot take of the latest compelling, inspiring, and entertaining heat treat chatter from the world of social media.

We're looking at microscopic images, some in-depth heat treat content, a recap of networking opportunities, plus much more!

If you have content that everyone has to see, please send the link to editor@heattreattoday.com.


1. Art or Science?

Through heat treatment, austempered ductile iron (ADI) becomes incredibly strong. For ADI, the material has been austempered such that the matrix is transformed into ausferrite, or a mixture of acicular ferrite and austenite. The image below has been elevated to art-gallery quality with the use of selective color etching.

Images of weld metal, microstructure of coarse-grain zone, microstructure of fine-grain zone, and base material. See how the crystal orientation changes in different zones.


2. All That Chatter

Check out some of the chatter that everyone has been posting on heat treat topics over the last few months.

 

May the 4th

 

Congratulation on the New Role!

Time Will Tell
________________________________________________________
You Will Be Missed!

3.  Bumping Shoulders with Heat Treaters

It's great to connect with other folks in the industry. This past week has been an amazing opportunity to forge new relationships and strengthen old ones at trade shows and expos.

 

Rapid + TCT

 

Ceramics Expo

 

ACT Expo

 

SAMPE 2023


4. The Reading (and Podcast) Corner

Time to take your afternoon coffee and read a few technical articles from around the industry. Got too many things to do? Put on an episode of Heat Treat Radio to enjoy on your commute. Maybe you'll find some "continuing education" time this weekend!

Is there room for creativity in the heat treat shop?

Listen to an interview with Gary Sharp about ion nitriding. Topics include the history of and applications for this particular kind of nitriding.
Dig in a little deeper. Read more about ion nitriding. Hone in on TMS 80 micro alloyed steel with Dr. Rolinski.

Review of quench basics. Click to watch the video below!


5. Sleep Deprived

The excitement of nitriding keeping you awake at night?!

 

Have a great weekend!


.

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EB and VAR Furnaces for American Company

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Earl Good
Managing Director at Retech Systems, LLC
Source: Retech

A furnace manufacturer located in Buffalo, NY will provide both an Electron Beam (EB) and Vacuum Arc Remelt (VAR) furnace to an American company. This combination should allow them to expand their production.

Retech, a SECO/WARWICK Group division, will provide these two furnaces to a longstanding repeat business partner. VAR technology operates similarly to the far older metallurgical process of stick welding, except with a much larger welding rod of several tons, and it is shielded from oxidation by a vacuum chamber instead of a flux. EB technology operates similarly to the cathode ray tube in old television sets, except instead of energizing a phosphorescent screen in a sealed vacuum tube, the electron beam heats a melt pool in a large vacuum chamber.

“[This partner] has purchased Retech furnaces previously," comments Earl Good, managing director at Retech. "The VAR furnace is a follow-up to other similar systems we sold them before, as is the EB."


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Record Setting Titanium Load Processing Achieved

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Source: Solar
Robert (Bob) Hill,
President at
Solar Atmospheres of Western PA
Source: Solar Atmospheres

A western PA heat treater recently degassed 175,000 pounds of 6AI-4V titanium in their 48-foot-long vacuum furnace. This is the largest and heaviest single load of titanium ever processed in the company's history.

Solar Atmospheres of Western PA vacuum degassed the load consisting of 154 sheets of titanium 40” x 240”. Their president, Bob Hill, states, “The future of the global aerospace titanium market is very promising with the many opportunities in the commercial and military aircraft markets!”


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CFC Fixture Advantages and Challenges, Part 2

OCWhat are the factors that lead to carburization and carbon transmission? How can heat treater avoid these unwanted reactions? Discover the challenges of CFC fixtures and the steps heat treaters can take to mitigate these challenges.

This Technical Tuesday article, written by Dr. Jorg Demmel, founder, 0wner, and president, High Temperature Concept, was first published in Heat Treat Today's March 2023 Aerospace Heat Treating print edition.


Introduction

Dr. Jorg Demmel
Founder, Owner, President
High Temperature Concept

The main advantages of CFC fixtures were introduced in “CFC Fixture Advantages and Challenges in Vacuum Heat Treatment, Part 1,” which was released in Heat Treat Today’s November 2022 publication. This included a discussion of the limits of CFC in vacuum and protective atmosphere heat treatment. Successful applications of CFC workpiece carriers in heat treatment were presented along with field test results that included a brief discussion of undesired contact reactions (i.e., carburization and melting of parts). In Part 2 of this paper, the mechanisms involved with carburization and carbon transmission due to direct contact of parts with CFC fixtures will be further explained.

Mass Transfer from CFC Fixtures

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The mass transport of carbon from CFC fixtures into steel parts at high temperatures will be examined in the following areas:

  1. Reactions in oxygen (i.e., the reaction medium)
  2. Transport of carbon in CFC during exposure to oxygen
  3. Transfer mechanism into the steel parts
  4. Diffusion of carbon into the steel parts
  5. Part reactions (melting, carbide formation)

Figure 1: 1.6582 steel samples and GDEOS depth profile analysis
Source: Dr. Jorg Demmel, High Temperature Concept

CFC samples were tested in contact with steel samples under laboratory conditions in a vacuum of 7.5 x 10-7 Torr (1 x 10-6mbar). Results of the contact with CFC for steel samples at different temperatures are presented to the left (Figure 1). It is important to note that:

  • Sample (0) is the reference sample and had no exposure to the contact test.
  • Sample (0’) is the back side of Sample (0).
  • Sample (1) is the contact side at 1922°F (1050°C).

All three samples are visually identical, therefore only one is shown. Sample (2) at 1967°F (1075°C) and Sample (3) at 2012°F (1100°C) exhibited a distinct visual surface pattern after CFC contact. This was analyzed by Glow Discharge Optical Emission Spectroscopy (GDOES) and the test location (gray spot) clearly observed on Samples (2) and (3). For Sample (4) run at 2057°F (1125°C), the CFC was found to have adhered to the steel surface.

The carbon content in 10mm depth measured with GDOES (see the profiles in Figure 1) increased from initially 0.29 weight-% for the 1922°F (1050°C) test, although nothing was visible on metal surfaces. For carbon contents, see Table 1.

Table 1. Carburizing of 1.6582-samples in 10 µm depth after CX-27C1-contact (GDOES)
Source: Dr. Jorg Demmel, High Temperature Concept

CFC Reactions with Oxygen

The chemical reactions of CFC with various gases are essential in Step 1 (referenced in Part 1 of this article) and an indicator of chemical thermal suitability.

In the case of the unwanted contact carburization considered above is similar, in a sense, to carburization of steel in contact with carbon powder or granulate. However, the actual carburization mechanism, which occurs between approximately 1616°F and 1697°F (880°C and 925°C), does not take place directly via the carbon contact but is based on the fact that solid carbon reacts with atmospheric oxygen according to the Equation Table to form carbon dioxide (CO2).

Equation Table. Reaction rates and activation energies for graphite (800°C; 0.1 bar)
Source: Dr. Jorg Demmel, High Temperature Concept

Carbon monoxide (CO) is then formed from CO2 by the Boudouard reaction (Equation 3). At high temperatures and low pressures (see Figure 2), almost only CO is present.

Figure 2. Boudouard equilibrium
Source: Dr. Jorg Demmel, High Temperature Concept

Transport of Carbon

The carbon carrier must be transported to the surface of the parts.

The cases considered in Part 1 of this article were conducted in vacuum, that is in the absence of a carburizing atmosphere. The laboratory tests were even carried out in a vacuum as low as 7.5 x 10-7 Torr (1 x 10-6mbar). Nevertheless, part surface reactions were observed.

Transfer Mechanism into the Steel Parts

Theoretically, carbon from the CFC fixtures can be transferred into the steel via solid phase (as opposed to gaseous phase) reactions. Gas particles can be adsorbed by surfaces via physisorption and/or chemisorption. The author’s personal research experience has shown that metal samples usually oxidize after a short time, even in a high vacuum of 7.5 x 10-7 Torr (1 x 10-6mbar). In particular, elements such as iron, molybdenum, and chromium have a strong ability to chemically adsorb oxygen or CO.

Furthermore, there is a disproportionately large amount of adsorbed oxygen in the CFC samples. CFC has open porosities as high as 30%. CFC in industrial practice is never completely evacuated. So, there is a disproportionately large amount of oxygen present in CFC fixtures.

It can be assumed that oxygen repeatedly escapes from the CFC and is initially available in the contact area. Proof of this can be provided by the GDOES analysis. Outside the contact areas, no (gas) carburization took place (as evidenced by the non-contact side of steel samples).

The oxygen and carbon surplus combined with close contact lead to complete reaction of oxygen creating carbon dioxide as in Equation (1). Because of the carbon surplus, almost only carbon monoxide is produced as shown in Equation (2). Because of the very close contact between CFC and steel, C-adsorption by gamma iron and desorption of carbon dioxide as in Equation (5) takes place:

Equation 5
Source: Dr. Jorg Demmel, High Temperature Concept

Since carbon dioxide immediately comes in contact with carbon in the CFC again, carbon monoxide is produced according to Equation (3). In other words, carbon dioxide regenerates immediately and the reaction starts again.

Direct carbon transfer from CFC to metal via solid phase is very unlikely since carbon atoms in CFC are firmly bound in rings.

Diffusion of Carbon in the Steel Parts

In solids, the surface diffusion usually takes place at significantly higher diffusion rates than in the bulk material. The thermodynamic driving force of diffusion or carburizing reactions is the difference in carbon activity for a specific concentration in the austenite to that of the reaction medium. The carbon activity is the ratio of the vapor pressure of the carbon in state under consideration to vapor pressure of pure carbon (graphite/CFC). Alloying elements of the steel influence the activity of the carbon.

Part Reactions (Melting and Carbide Formation)

Steel can begin to melt if, at the given values for temperature and pressure, a partially liquid phase is reached, that is, the solidus line in the phase diagram is exceeded. At even higher temperatures, the liquidus temperature can be reached and steel is completely liquid.

According to metastable iron-carbon diagram phase diagram (Figure 3), a steel such as SAE/ AISI 4340 (34CrNiMo6) alloy (DIN 1.6582) with around 0.47% by weight percent carbon does not begin to melt at 1922°F (1050°C), the exposure temperature for Sample (1), or Sample (2) at 0.56% and 1967°F (1050°C) for Sample (3) with 0.67% for 2012°F (1100°C). The iron-iron carbide phase diagram applies to steels with less than 5% (by mass) of alloying elements and thermodynamic equilibrium, so it is an accurate representation for a SAE/AISI 4340 (34CrNiMo6) alloy.

Figure 3. Metastable equilibrium diagram Fe-Fe3C for steel (good fit for 1.6582)
Source: Dr. Jorg Demmel, High Temperature Concept

A calculation of the solidus temperature shown on the iron-iron carbide diagram (Figure 3), which is dependent on the carbon content and alloying elements, yields a value of 2703.2°F (1,484°C) (J’).

For an SAE/AISI 4340 (34CrNiMo6) steel (DIN 1.6582) with 0.3% C and one for 0.5% C, the calculated solidus temperature is 2640°F (1449°C). This is shown on the J’-E’ blue dotted line in Figure 3. In other words, a lower solidus line (cf. dashed blue line in Figure 3) and thus a slight reduction in austenite phase region.

The iron-carbon diagram also indicates that melting of surfaces that have absorbed carbon (e.g., Sample No. 2) will occur at 1967°F (1075°C). This value is within approximately 90°F (50°C) of the temperature used (dotted line E’-C’-F’). From this information we can conclude that the observations seen in Figure 1 are not the result of melting, but rather imprints due to surface softening.

The melting (c.f., Figure 1) observed in Test No. 4, which occurred at 2057°F (1125°C) is likely due to partial carburization of the steel surface and exceeding the solidus temperature. A micrograph confirms eutectic melting and high carbon content, which could also be indirectly confirmed by hardness measurement.

Carbide Formation

Additional reactions can occur between carbon absorbed from the CFC fixtures and the steel parts due to either separation of carbides (e.g., iron carbide in the form of secondary cementite) or carbide formation with alloying elements such as Ti, V, Mo, W, Cr, or Mn (listed in decreasing tendency to form carbides).

Table 2. Reactions between C and metal
Source: Dr. Jorg Demmel, High Temperature Concept

Table 2 lists various elements in alphabetical order that react with carbon above the specified temperatures to form reaction products mentioned, primarily carbides. It should be noted that the temperatures listed apply only to pure metals and pure carbon. As such, they provide only rough approximations of a temperature at which a reaction might begin.

Countermeasures

There are several measures to avoid these unwanted reactions:

  • Ceramic oxide coatings such as aluminum oxide (Al2O3) or zirconium oxide (ZrO2) layers placed onto the CFC
  • Hybrid CFC fixtures having ceramics in key areas to avoid direct contact with metal workpieces
  • Alumina composite sheets
  • Boron nitride sprays
  • Special fixtures made of oxide ceramics

An yttrium-stabilized zirconium oxide layer (93/7) was applied to CF222 by thermal plasma spray and tested successfully (see Figure 4).

Figure 4. Yttrium-stabilized zirconium oxide layer with an average layer thickness of 110µm on CF222 material. The photograph on the right shows a hybrid CFC fixture.
Source: GTD Technologie Deutschland

Summary

It is important to consider the specific process conditions in advance so that unwanted reactions — from carburization to catastrophic melting of the workpieces — can be avoided. Effective countermeasures can be taken.

 

References

Atkins, P. W.: Physikalische Chemie. 1. vollst. durechges. u. berichtigter Nachdr.d. 1. Aufl ., Weinheim, VCHVerlag, 1988 – ISBN 3-527-25913-9.

Bürgel, R.: Handbuch Hochtemperatur-Werksto technik: Grundlagen, Werksto bean-spruchungen, Hochtemperaturlegierungen. Braunschweig, Wiesbaden: Vieweg, 1998. ISBN 3-528-03107-7.

Demmel, J.: Advanced CFC-Fixture Applications, their scientific challenges and economic benefits, In: 30th Heat Treating Society Conference & Exposition, Detroit, MI, USA, 15th Oct. 2019.

Demmel, J.: Werkstoffwissenschaftliche Aspekte der Entwicklung neuartiger Werkstückträger für Hochtemperaturprozesse aus Faserverbundkeramik C/C und weiteren Hochtemperaturwerkstoffen, Dissertation, TU Freiberg, Germany, 2003.

Demmel, J.: Why CFC-Fixtures are a Must for Modern Heat Treaters, FNA 2020 Technical Session Processes & Quality, USA, 30th Sept. 2020.

Demmel, J., et al: Applications of CMC-racks for high temperature processes. In: 4th Int. Conf. on High-Temperature Ceramic Matrix Composites, 3.10.2001, p. A-17.

Demmel, J. und J. Esch: Handhabungs-Roboter sorgt für Wettbewerbsvorsprung. Härterei: Symbiose von neuen Werkstoffen und Automatisierung. In: Produktion (1996), No. 16, p. 9.

Demmel, J. und U. Nägele: CFC revolutioniert die Wärmebehandlung. In: 53. Härterei-Kolloquium, Wiesbaden, 10.10.97. Vortrag und Tagungsbericht.

Demmel, J., Lallinger, H.: CFC-Werkstückträger revolutionieren die Wärmebehandlung. In: Härtereitechnische Mitteilungen 54, No. 5, p. 289-294, 1999.

Eckstein, H.-J., et al: Technologie der Wärmebehandlung von Stahl. 2nd Edition, VEB Deutscher Verlag für Grundstoffindustrie, Leipzig, 1987. ISBN 3-342-00220-4.

Godziemba-Maliszewski, J.; Batfalsky, P.: Herstellung von Keramik-Metall-Verbindungen mit Diffusionsschweißverfahren. In: Technische Keramik, Jahrbuch, Essen, 1 (1988), S. 162-172. ISBN 3-80272141-1.

Grosch, J.: Grundlagen-Verfahren-Anwendungen-Eigenschaften einsatzgehärteter Gefüge und Bauteile, ExpertVerlag, 1994, ISBN 3-8169-0739-3.

Hollemann, A.F.; Wiberg, E.: Lehrbuch der anorganischen Chemie / Hollemann-Wiberg. 91.-100. Aufl ., de Druyter Verlag, 1985 – ISBN 3-11-007511-3.

Kriegesmann, J.: Technische Keramische Werkstoffe. Loseblattwerk mit 6 Ergänzungslieferungen pro Jahr.

Kussmaul, K.: Werkstoffkunde II. Stuttgart, Universität, Lehrstuhl für Materialprüfung, Werkstoffkunde und Festigkeitslehre, Vorlesungsmanuskript, 1993.

Lay, L.: Corrosion Resistance of Technical Ceramics. 1. Aufl ., Teddington, Middlesex, Crown-Verlag, 1983 – ISBN 0-11-480051-0.

Marsh, H.; u.a.: Introduction to Carbon Science. 1. Aufl ., London, Butterworths-Verlag, 1989 – ISBN 0-40803837-3.

Spur, G.: Wärmebehandeln. Berlin, 1987, ISBN 3-446-14954-6.

Samsonow, G.V.: Handbook of refractory compounds. New York, 1980.

Schulten, R.: Untersuchungen zum Kohlenstofftransportmit Carbidbildung in Nickelbasis-legierungen. RWTH Aachen, Fakultät für Maschinenbau, Diss., 1988 Deutsche Keramische Gesellschaft, 1990 following. ISBN 3-87156-091-X.

 

About the Author: Dr. Jorg Demmel is the founder, owner, and president of High Temperature Concept. He received his Engineering Doctorate in the field of CFC workpiece carriers for heat treatment and served in different leading positions for Volkswagen before moving to the U.S. In this article, Demmel draws on his dissertation, “Material scientific aspects of the development of new Fixtures for high temperature processes made of fiber-composite ceramics C/C and other high temperature materials” (Technical University Mining Academy Freiberg, Germany, 2002/3), and his personal experiences. For more information, contact Jorg at jorg.demmel@high-temperature-concept.com


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New Sustainability & Decarbonization Initiatives for Heat Treat

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Searching for sustainability resources? Check out this first installment of the Sustainability Insights series, from the Industrial Heating Equipment Association (IHEA) for what’s available to in-house heat treaters across the industry.  

Discover the resources IHEA provides in their web-based Sustainability area and a new webinar series launching May 11.


One thing is certain, and it's that there is great deal of uncertainty about how to begin addressing issues of sustainability and decarbonization. As heat treaters begin to receive more and more questions about decarbonization, IHEA saw an opportunity to help the industry and began developing a variety of initiatives relating to sustainability and decarbonization in the industrial heating equipment industry. 

Getting Started with Sustainability 

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The first step towards decarbonization is understanding this is a topic that will not go away. While they may not see any immediate consequences, heat treaters need to at least begin preparing now for what is quickly approaching. Before long, clients are going to be demanding heat treaters show that they are lowering their carbon emissions. Thinking,This will not affect my business,” will be detrimental in the long term.  

IHEA recommends to start by considering efficiency and getting an initial assessment of carbon footprint. The fastest, easiest way to reduce carbon footprint is to burn less fuel by investing in efficiency improvements. As a side benefit, operating costs are also reduced. IHEA's current combustion courses do have content on efficiency and low carbon fuels and a webinar series specifically designed to help everyone understand how to determine their initial accounting of their carbon footprint. 

Future Plans 

The deeper driving forces that will affect our industry regarding sustainability are regulations, incentives, and energy economics. Rapidly changing environmental policy, growing technology incentives, and a shifting relative cost of fuels (and alternate fuel options like hydrogen) are opening new pathways for businesses to factor carbon footprint and sustainability into their operations. 

Because of these upcoming changes, IHEA is developing a wide array of services and tools that will help those looking to lower carbon emissions determine the best approaches for their heat treat facilities. An entirely new body of content will be developed that will be at the leading edge of this industrial revolution.  

To kick things off, IHEA has developed a Sustainability area on their website that features the foundation of information the industry needs. The Sustainability area includes the following sections: Sustainability FAQs, Sustainability Terms & Definitions, and Sustainability Resources. The Sustainability section will continue to expand by adding content and resources on a regular basis.

Additionally, IHEA is launching a series of webinars that will start the process of walking companies through the complicated issues related to decarbonization: 

  • May 11: Thermal Processing Carbon Footprint (click to register/read more)
  • June 15: Defining Greenhouse Gas (GHG) Emissions to Target NET-ZERO 
  • July 20: DOE Tools and Programs for GHG Reduction 
  • August 24: Ongoing Sustainability: Industry Best Practices for Continual Improvement 

The goal is to provide unbiased education for everyone involved in the process heating industry. The webinars are complimentary. Visit www.ihea.org and click on the "EVENTS & TRAINING" tab.  

Brian Kelly
President at Honeywell Thermal Solutions

Recently elected IHEA President Brian Kelly of Honeywell Thermal Solutions says, “IHEA is taking a leadership role because we see that this will be an ongoing and changing landscape for the industry for years to come. With the years of collective expertise of our membership we feel that we can provide information, education, and guidance to help everyone navigate what is sure to be a challenging environment.” Kelly continued by saying, “In the end, we want to be a source to count on to help our entire industry in their sustainability journey as it will be a long and winding road that will be different for everyone.” 

For more information:

Visit www.ihea.org. 


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Future Energy Flexibility

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Today's original content piece comes to us from Dr.-Ing. Joachim G. Wünning, president of WS Wärmeprozesstechnik GmbH. Thinking of how dependent countries can be on one another for energy supply, he reminds us that an energy crises in one area can have far reaching effects on the rest of the world.

What, if anything, can be done? Wünning looks to the heat treating industry to show that there are efforts to source energy from chemical carriers and to use fuel flexible furnaces. He says, "Our beautiful earth is worth preserving for future generations."

Read on to find challenges and encouragements of how to source and use energy in the years to come.


Dr.-Ing. Joachim G. Wünning, President at WS Wärmeprozesstechnik GmbH
Source: the author

Europe and especially Germany recently learned the hard way what it means to largely depend on one major energy supplier. After Russia shut off a few pipelines and destroyed two others, it was not clear if industry and households would get through the winter without major shutoffs and constraints. Now spring is here, and gas storage Is still at reasonable levels, due to a mild winter. We can temporarily relax but should be aware that the next winter is coming. Energy issues will be one of the great challenges for the next decades.

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In addition to missing energy supply from Russia, reduced availability of French nuclear power stations is another issue. This decreased availability is a result of repair, maintenance, and reduced cooling capabilities due to low river water levels. Already scarce, natural gas was used to export electricity to electric power dependent France. Last year in Germany, shares of electricity produced in coal fired power stations were up despite the clearly expressed will from a government which includes the green party.

Some of these problems do not yet apply for the United States because there are enough resources to guarantee a stable energy supply. However unforeseen things can happen like if and when certain future markets will ask for fossil free products (eg green steel).

The transition of our energy systems, to limit climate change mainly caused by the combustion of fossil fuels, will remain a major task for the coming decades. The worldwide transition to renewable energy, provided largely by solar and wind, will require a major effort.

In the heat treating industry, direct usage of electricity and chemically stored electric energy in the form of hydrogen or ammonia will be the primary sources for heating industrial furnaces.  While direct use of electricity might look like the obvious choice for the future, it might not be the case for all applications.

If you convert a furnace to electric heating, you have to rely on payable electric energy even when there is no sunshine or wind blowing. You may need to switch your furnace off when electricity is scarce. If you want a steady weather independent production, using a chemical energy carrier has advantages. In many furnaces, combustion systems are or will be available for the usage of either natural gas, hydrogen, or ammonia cracking gases.

If you invest in a fuel flexible furnace today, you can benefit from using natural gas which is far less expensive than electricity in most regions. If electricity becomes more abundant at certain times, you can generate your own hydrogen; and you will have the choice between using (natural or green) gas from the grid or your self-generated hydrogen without investing in a new furnace. This energy flexibility will present a big competitive advantage and will enable you to offer green steel when the market is asking for it.

In the future, the success of societies and industries will depend on their ability to flexibly adjust to changing conditions, energy being one of them. Our beautiful earth is worth preserving for future generations.

About the Author:

Wünning is the president, owner, and CEO of WS Thermprocess Technic Gmbh [WS Wärmeprozesstechnik GmbH] in Germany and WS Thermal Process Technology, Inc., in Elyria, Ohio.

Contact Joe at  j.g.wuenning@flox.com


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