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!
A global manufacturer of aircraft parts has ordered a single-chamber vacuum furnace for brazing jet engine parts. The new equipment will replace a 30-year-old unit previously operating in its Poland-based plant.
Jędrzej Malinowski Sales Manager SECO/WARWICK Group Source: LinkedIn
The new Vector® vacuum furnace is being supplied by SECO/WARWICK, which also manufactured the retiring equipment. The upgrade is based on a standard Vector vacuum furnace with a working space of 900 x 900 x 1200 mm, with screen insulation and metal heating elements. The solution has been adapted to industry specific needs and can heat treat jet engine components, such as complex gears or main shafts.
“This unit is distinguished by the ability to carry out efficient and clean high vacuum processes thanks to the use of a molybdenum heating chamber and a very efficient pumping system. This ensures very high purity and the dynamics required for brazing processes. Another big advantage is the very good temperature uniformity in the molybdenum heating chamber and compliance with the strict requirements of industry standards such as AMS2750,” said Jędrzej Malinowski, sales manager, SECO/WARWICK Group.
The press release is available in its original form here.
“Communication is key.” As heat treating equipment and processes evolve, it becomes critical that the accompanying control systems also develop to maintain “communication.” In this Technical Tuesday installment, guest columnist Stanley Rutkowski III, senior applications engineer at RoMan Manufacturing, Inc., discusses how digital control system communications have improved to increase energy efficiency for manufacturers with in-house heat treat operations.
This informative piece was first released inHeat Treat Today’sMay 2024 Sustainability Heat Treat print edition.
Industrial furnace applications that rely on resistive heating will consume large amounts of electrical energy when processing their loads. Utilizing digital controls technologies to maximize this type of heating allows for a cleaner-and thus greener-approach to energy demands.
Typically, heat treat processes have a long duration (hours to days in length), and each load can have its own unique recipe in the amount of power required. With unique recipes, there tends to be a ramp-up phase (getting the vessel to temperature), followed by a soak phase (which demands more control over the power system), and then a cool-down phase (an even more controlled state). As the power is controlled through the furnace system, disturbances occur with different technologies. This starts with “tube technology,” then variable reactance transformer (VRT) technology, then silicon controlled rectifier (SCR) technology, and finally IGBT (insulated-gate bipolar transistor) technology. As these technologies have evolved, their ability to communicate information digitally has allowed for less disturbance in the power system and allowing both a less expensive energy bill and a cleaner energy usage for the process.
Definitions
Electrical Power
Power losses in an electrical system are defined by five aspects (Figure 1):
Resistance (R): a function of the material cross section and the length of an electrical conductor.
Reactance (XL): a function of the area in a circuit and is a vector 90 degrees offset from resistance.
Capacitance (XC): a vector 180 degrees offset from reactance. In inductive circuits, capacitance can be added for power factor correction.
Impedance (Z): the vector sum of resistance, reactance, and capacitance.
Power Factor [cos(F)]: the ratio of resistance to impedance. In industrial applications, displacement power factor (DPF), the offset of the current to voltage waveforms, is used in the billing of electrical power.
There are five unique aspects that define electrical power usage (Figure 2):
Real power (kW): the amount of power that is generated.
Reactive power (kVAR): the amount of power that is wasted.
Total power (kVA): the rate at which power is consumed. This is also referred to as apparent power.
Power factor (cos(F)): the ratio of real power to total power. In industrial applications, the displacement power factor (DPF) is the offset of the current to voltage waveforms and is used to bill for electrical power.
Peak demand: the capacity required when the power grid experiences the highest power demand in a specified period of time.
3 Most Popular Types of Control Systems
For the most part, today’s furnace manufacturers use three main types of control systems: VRT, SCR, and IGBT. Each operates with slightly different methods to control how power goes into the heat treat furnace and creates heat.
VRT Control System
One traditional resistance heating setup uses a VRT control system that incorporates a saturable reactor, which controls the power applied to the transformer in the system (Figure 3). The control transformer on the output side of the transformer feeds back to the reactor to set the limit on the input power to the transformer.
Figure 3. VRT Control and Transformer Schematic (CT=control transformer); Source: RoMan Manufacturing, Inc.
SCR Control System
Figure 4. SCR Control and Transformer Schematic; Source: RoMan Manufacturing, Inc.
Another traditional resistance heating setup uses an SCR control system that includes dual thyristors (gated diodes) to control the amount of power applied to the primary of a transformer.
The SCR control delays the start of the waveform, and the control point is reset when the waveform crosses the zero line.
Figure 5. Comparison of Sine Waves; Source: RoMan Manufacturing, Inc.
IGBT Control System
Finally, an IGBT control system uses a diode bridge, capacitor, and switching transistors to control the amount of power applied to the primary (i.e., main power input of a transformer). The input frequency to the transformer is controlled by the switching transistors. Since the IGBT control system utilizes all three phases of the power system, the IGBT control can be set to a particular phase for the zero cross (for phase orientation in the application, synchronous mode) or left floating (non-synchronous mode), as is demonstrated in Figure 6. The input voltage to the transformer is increased by the operation of the IGBT control. As such, potential energy savings may be had with these types of controls as compared to tradition controls (such as on-off contractors, time proportioning controls, or other types of current proportioning control systems).
Figure 6. IGBT Control and Transformer Schematic; Source: RoMan Manufacturing, Inc.
Synchronization with the IGBT can be to the incoming lines (A, B, or C phase) and can be offset from each of the phases. The ability to offset from a phase allows for traditional arrangements (Single Phase, Scott-T, Delta and Wye) as well as unique offsets allowing for additional vector heating in the application with AC outputs. The unique arrangements beyond the traditional systems could allow for more uniform heating of the part and less energy being consumed during the process.
Advantages of Utilizing Communications
As technology for controlling heating systems has evolved, and with an emphasis on clean energy sources, the ability to communicate with the control system has increased as well. This communication allows for more precise control of the run for the load, improved power usage (better power factors and less peak power usage as well as less total power usage), and inputs into a preventive maintenance program.
Table A. Analog vs. Digital IGBT Systems
With an IGBT system, both analogue and digital control communications are available today. See Table A for a comparison on how each control option works.
In addition to the EIP defined pieces, there is the ability to access the FPGA system for graphical outputs that can be downloaded into another system in your process for storage, comparisons, or general record keeping for a part run. The FPGA is an internal processor in the control that allows for more data, charting, and diagnostics to be captured and used by the system for both energy consumption and possible preventative maintenance purposes.
Why does this matter? Let’s turn to some possible ways of using the data generated from digital controls systems:
Evaluate average, minimum, and maximum DC bus voltages to plan for the best time and day to run heat treat jobs. For high power draw jobs, planning ahead can minimize power costs; similarly, knowing power trends can be helpful to plan jobs requiring sensitive control of the heating.
Evaluate transformer output voltage to allow the system to detect any shorts in the process. If the controller output and transformer output diverge from the known turns ratio, a change has occurred in the system. This could be corroborated if controller on time and output power do not trend.
Track furnace run records with EIP communications and FPGA data. This will be most helpful in processing lots of data, as is the case for Milspec records.
Evaluate changes in power factor to monitor any loose cables, and so avoid reactive power losses.
Evaluate the current versus the voltage to monitor the resistance of the system. If there is an increase in the resistance, you could project the trends in wear of the heating elements, therefore predicting future required maintenance.
Evaluate the critical control temperatures of the system to know if it is being run close to, or above, its ratings or if there is a disturbance in the cooling systems.
Use knowledge of power usages and power stability to update recipes for load runs so they use less power over the total run; this allows for a less costly power-savings solution. With less power usage, more output of the total facility can be had as each station contributes less to energy consumption
Even more benefits can be realized when users and builders of furnace systems and component manufacturers collaborate in the design of the total system. Such dialogues lead to the creation of more interactive and intuitive solutions that minimize power consumption, minimize downtime, and maximize outputs. These practical benefits are the foundation of a greener system.
About the Author:
Stanley F. Rutkowski III Senior Applications Engineer RoMan Manufacturing, Inc.
Stanley F. Rutkowski III is the senior applications engineer at RoMan Manufacturing, Inc., working on electrical energy savings in resistance heating applications. Stanley has worked at the company for 33 years with experience in welding, glass and furnace industries from R&D, design, and application standpoints. For more than 15 years, his focus has been on energy savings applications in industrial heating applications.
David Burritt president and CEO U.S. Steel Source: U.S. Steel
Access to technology and expertise in integrated mills are among the advantages that will accompany the U. S. Steel–Nippon Steel merger, according to David Burritt, U. S. Steel’s CEO. Heat treatment processes are an element in integrated mill operations within both companies’ profiles.
On December 18, 2023, it was announced that Japanese steelmaker Nippon Steel (NSC) would acquire Pittsburgh–based U. S. Steel. Under the deal, Nippon Steel would acquire the company for $14.1 billion, which totals to $14.9 billion when including the assumption of U.S. Steel’s debt. As part of the deal, Nippon Steel will invest $1.4 billion in U. S. Steel’s assets and will share technical knowledge, stated Burritt during his keynote address to the 2024 Global Steel Dynamics Forum.
“They’re experts in integrated mills, and they want to invest here,” he said.
In April, Nippon Steel released a statement that the merger will include U. S. Steel having access to Nippon’s technologies and R&D advancements, “help[ing] U. S. Steel produce more advanced and environmentally sustainable steel for domestic customers.”
Heat TreatToday offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry. Enjoy these 21 news items.
Equipment
Tata Steel Meramandali, based in Odisha, India, placed an order with SMS group for the implementation of Paul Wurth coke oven gas injection technology at their Blast Furnace (BF) #1. This order is the first of its kind in India, setting a precedent for the industry’s move towards sustainable steel production. The project is expected to be commissioned by Q1 2026 and will be completed within 25 months.
Sousa Corp., based in Newington, CT, installed its second Ipsen Turbo²Treater vacuum furnace to its production line, expanding its capacity to meet demand for heat treating services to the aerospace, automotive, medical, and general manufacturing industries.
A Chinese partner has purchased a two-chamber VIM 50 kg induction furnace from SECO/WARWICK for casting gas turbine blades. The furnace will produce gas turbine blade castings in an equiaxed structure and has already obtained an export license.
The modernization of a blast furnace at Salzgitter Flachstahl AG has been completed by SMS group. The new Paul Wurth parallel hopper Bell Less Top® (BLT) installed offers enhanced efficiency with less maintenance.
Edwards AFB in California received delivery of a composition oven from DELTA H®/Phillips Federal. The equipment will be used for advanced materials applications R&D. The heat treat furnace supplier initially designed and engineered the walk-in oven using SolidWorks 3D modeling and developed the project as a “kit oven” for easy field assembly. After preassembly of key subsystems at their Carroll, OH facility, the system was shipped to Edwards AFB. The entire field assembly project required two weeks including commissioning and extensive training of USAF personnel.
Tata Steel Nederland selected Tenova to develop a new state-of-the-art steel production line in IJmuiden, the Netherlands. The overall contract will include engineering, supply, and advisory services for a three million tons electric arc furnace to meet current operational specifications (high-quality steel for the automotive sector).
Cavendish Hydrogen ASA, a subsidiary of Nel ASA,has received a purchase order from Alperia Greenpower SRL for hydrogen fueling equipment to be used for light- and heavy-duty fuel cell electric vehicles in Bruneck, South Tyrol, Italy. This will be Nel’s first H2Station™ installation in Italy, built for the 2026 Winter Olympics to fuel vehicles for the transfer between the Olympic sports facilities.
Newly installed material hoppers at Salzgitter Flachstahl AGCoke oven gas compressing station previously installed at HKM, GermanyDELTA H®/Phillips Federal providing composite oven for Edwards AFBLeft to right: Paolo Stagnoli (Tenova), Hans van den Berg (CEO Tata Steel Nederland), Jeroen Klumper (Tata Steel Nederland), and Nico Bleijendaal (Danieli)
Company & Personnel
StandardAero has appointed Kim Ernzen to serve as chief operating officer. In this role, Ernzen reports directly to Russell Ford, StandardAero chairman and CEO, and is responsible for global operational performance, efficiency, and excellence, as well as engineering and supply chain management for StandardAero. Additionally, StandardAero’s Engine Services and Component Repair Services division presidents will report directly to Ernzen, who will maintain close oversight of the company’s overall business performance. She replaces Kerry O’Sullivan, who is retiring from StandardAero, and will be located at the company’s Scottsdale, Arizona, headquarters office.
Steelhead Technologies launched Steelhead University, an online learning platform designed to expedite user training and streamline software implementation. The comprehensive curriculum of eight core administrative courses equips users with fundamental knowledge essential for navigating the intricacies of the company’s software.
Solar Atmospheres’ newest acquisition, Solar Atmospheres of San Diego, has announced the addition of Chris Constable as their new vice president of operations. Chris has nearly 25 years of heat treating experience that includes quality, operations, management, plant safety, business development, and sales.
Ipsen USA welcomes Max Stormo as the new Ipsen customer service (ICS) operations manager as the company streamlines its aftermarket services in Souderton, PA. Stormo comes to Ipsen after an extensive career working as a manufacturing operations leader in Texas, and a recent role as vice president of operations at a manufacturer in the Philadelphia region.
Solar Manufacturing, Inc., announced the hiring of Nicholas Max, BSME Drexel University, as its chief mechanical engineer to head up its vacuum furnace mechanical design group. Nick is also pursuing an MBA at Lehigh University in Bethlehem, PA. He will be tasked to lead the further development of energy efficient hot zones, vacuum vessels, high pressure gas quenching systems, and vacuum pumping systems.
Ipsen USA has confirmed its commitment to the growth of the Ipsen Customer Service (ICS) Parts Department by expanding staff and implementing strategic initiatives. Christina Connelly, parts manager for Ipsen in Cherry Valley, joined the team in 2022, and has since hired six additional employees. Connelly and her veteran team members and new hires are focused on reducing turnaround time and increasing customer responsiveness.
Swiss Steel Group announced its participation in a renewable energy consortium, the “Initiative EE-Industrie.” This initiative, consisting of 19 small and medium-sized enterprises (SMEs) in Germany, aims to build, operate and utilize wind and photovoltaic plants for self-supply with green electricity.
Kanthal and Danieli have announced a partnership to jointly scale up Kanthal’s demonstrated electric process gas direct-heating solution, Prothal® DH, to full industrial scale. With the installation in Energiron hydrogen-ready DRI plants, fully green DRI production will be achieved. Additionally, the introduction of Prothal® DH technology in blast furnace operation will reduce CO2 emissions in ironmaking.
Kim Ernzen, Chief Operating Officer at StandardAero Screenshot of Steelhead University knowledge check on adjusting powder coat recipesChris Constable, Vice President of Operations, Solar Atmospheres of San DiegoMax Stormo, Customer Service Operations Manager, Ipsen USANicholas Max, Chief Mechanical Engineer, Solar Manufacturing, Inc.Dilip Chandrasekaran, Global Business Development Manager at Kanthal (L) and Marco Lapasin, Vice President Danieli Engineering Centro Metallics
Kudos
Ipsen Global has received the German Innovation Award for the Atlas Green furnace platform, presented by The German Design Council. The award ceremony was held in Frankfurt, Germany, on May 14, celebrating the innovators that emerged from a field of 520 submissions from across 23 countries.
Industrial Steel Treating Co. was named the Manufacturer of the Year by the Jackson Area (MI) Manufacturers Association. Accepting on behalf of IST was Tim Levy, current President of IST. Members of the Levy family in attendance included current VP, Tom Levy, and former IST President, Bernard Levy. Bernard was the 2nd generation Levy family owner and spent his entire 50-year career at IST before retiring and passing the reins to his three sons in 1998.
Bluestreak Compliance™, a division of Bluestreak | Bright AM™, received approval as a Registered Practitioner Organization (RPO) by the Cybersecurity Maturity Model Certification (CMMC) Accreditation Body (Cyber-AB). This significant achievement enables Bluestreak Compliance™ to offer expert consulting services to defense contractors and suppliers aiming to comply with CMMC cybersecurity standards and prepare for their Cybersecurity Maturity Model Certification (CMMC) audits.
IHEA has announced Dr. Avi Shultz as keynote at the first Industrial Heating Decarbonization SUMMIT. Dr. Shultz, Director of the U.S. Department of Energy’s Industrial Efficiency and Decarbonization Office (IEDO), will provide the keynote address at its first summit, to be held October 28-20 at the Conrad Indianapolis.
Swiss Steel Group has launched a new website which focuses on customer needs, including a Product Finder that generates automated product suggestions based on customer requirements and specifications, and detailed information about green initiatives and sustainability as well as special requirements for steel grades for specific applications.
IHEA recently announced its 2024–25 Board of Directors and Executive Officers. Taking over as President is Jeff Rafter of Selas Heat Technology Co. LLC; Vice-President is Gary Berwick of Dry Coolers, Inc.; and Treasurer is Jason Safarz of Karl Dungs, Inc. Brian Kelly of Honeywell Thermal Solutions assumes the Past President position. Finalizing the lineup of IHEA’s Board of Directors for 2024-2025, the following members continue their tenure: Scott Bishop, Electric Power Research Institute (EPRI); Bob Fincken, Super Systems, Inc.; Ben Gasbarre, Gasbarre Thermal Processing Systems; Doug Glenn, Heat Treat Today; John Podach, Fostoria Infrared; John Stanley, Karl Dungs, Inc.; Michael Stowe, Advanced Energy; Helen Tuttle, WS Thermal Process Technology Inc.; and Jeff Valuck, Surface Combustion, Inc.
Dr. Bora Ozkan-Paul van Doesburg (L) and Lutz Dietzold (R) with their German Innovation AwardTim Levy (L) and Bernard Levy (R)Dr. Avi Schultz, keynote speaker at IHEA’s Industrial Heating Decarbonization SUMMITThe 2024-25 IHEA Board of Directors: Back row, left to right; John Stanley, Bob Fincken, Gary Berwick, Brian Kelly, Scott Bishop, Doug Glenn, and Jeff Rafter. Front row, left to right; Jeff Valuck, Ben Gasbarre, Helen Tuttle, IHEA Executive Vice President Anne Goyer, Jason Safarz, and John Podach. Not pictured: Michael Stowe
An aerospace company has purchased a rod overbend box furnace to heat treat parts under an inert atmosphere. The heat treating furnace has a maximum temperature rating of 2,000°F and a load capacity of 6,000 lbs.
The box furnace, which was manufactured and shipped by Michigan-based Lindberg/MPH, has an automated load transfer table and is designed to heat treat parts in a nitrogen atmosphere. A nitrogen gas flow meter controls the atmospheric conditions.
The box furnace includes an automated load transfer table. Under the table, five (5) fans with a variable-frequency drive provide accelerated cooling. The load table utilizes a pusher/puller mechanism to move parts trays in and out of the furnace.
The furnace’s radiant heating system uses heavy-gauge alloy rod over-bend heating elements mounted along the side walls and the floor. Two (2) Watlow F4T controllers control and record the furnace temperature, which allows for seven (7) zones of heating. The box furnace also meets Class 3 temperature uniformity of ±15°F at 1,000°F – 1,800°F.
The press release is available in its original form here.
EBNER Group, a global provider of heat treatment solutions, melting, and casting for the aluminum industry has increased its stake in a furnace manufacturer, including annealing furnaces. GNA alutech inc. produces aluminum melting and holding furnaces, homogenizing and annealing furnaces, and cathode sealing equipment.
Robert Ebner CEO, EBNER Group Source: EBNER Group
“We are excited to announce the full acquisition of GNA alutech inc. and would like to thank GNA’s founder, Ted Phenix, for his vision and leadership in building GNA into a successful company over 41 years. Over the last 5 years I was always impressed by the deep understanding and knowledge Ted was able to share with customers. Our strong professional developed to a strong personal friendship,” said Robert Ebner, CEO of EBNER Group.
EBNER Group provides heat treatment solutions for the aluminum industry with the companies EBNER, ETS, EED, Gautschi, TPS, Hazelett, HPI, and GNA, increasing its stake in the latter to 100%. The acquisition marks the culmination of a five-year partnership between EBNER and Ted Phenix, which began with EBNER Group acquiring a majority stake in GNA in 2019.
The leadership of GNA has been placed in the hands of Kaleb Wright, president of business development, and Chantal Coupal, president of operations.
Pictured: Chantal Coupal, president of operations of GNA alutech, and Kaleb Wright, president of business development of GNA alutech
The press release is available in its original form here.
A discussion of laser heat treating begun in Heat Treat Today’s Air & Atmosphere 2024 print edition would not be complete without highlighting key sustainability advantages of this new technology. In this Technical Tuesday installment, guest columnist Aravind Jonnalagada (AJ), CTO and co-founder of Synergy Additive Manufacturing LLC, explores how sustainability and energy-efficiency are driven by precision heat application and minimal to zero distortion. The first part, “Advantages of Laser Heat Treatment: Precision, Consistency, and Cost Savings”, appeared on April 2, 2024, in Heat Treat Today, as well as in Heat Treat Today’s January/February 2024 Air & Atmosphere print edition.
This informative piece was first released inHeat Treat Today’sMay 2024 Sustainability Heat Treat print edition.
Laser heat treating is a transformative process that promises superior performance and sustainable practices. Laser heat treating epitomizes precision in surface heat treatment techniques, targeting localized heating of steel or cast-iron components. Laser radiation raises the surface temperature of the metal in the range of 1652°F to 2552°F (900°C to 1400°C), inducing a transformation from ferritic to austenitic structure on the metal surface. As the laser beam traverses the material, the bulk of the component self-quenches the heated zone. During this process, carbon particles are deposited in the high temperature lattice structure and cannot diffuse outward because of quick cool down resulting in the formation of hard martensite to a case depth up to 0.080” (2 mm), crucial for enhancing material properties.
Sustainability through Energy Efficiency
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When considering the energy consumption of a typical laser heat treating operation, it’s essential to acknowledge the continuous advancements in laser technology. Modern laser heat treating systems integrate high-power lasers, water chillers, and motion systems, such as robots or CNC machines. With a typical wall plug efficiency of around 50% for diode lasers, these systems represent a significant improvement in energy utilization compared to conventional methods. The typical energy consumption cost for running a 6 kW laser heat treating system is $20-$30/day. The calculation is based on an 8-hour shift with a duty cycle of 80% calculated at national average electric cost of 15.45 cents/kilowatt-hour.
Self-Quenching Mechanism
Laser heat treating operates on the essential principle of self-quenching, leveraging the bulk mass of the material for rapid cooling. This eliminates the dependence on quenchants required in flame and induction heat treating processes, further reducing environmental impact and operational costs.
Precision and Minimal Distortion
At the heart of laser heat treating lies its sustainable and energy-efficient attributes, driven by two fundamental features: precision heat application and minimal to zero distortion of components post-heat treatment. When compared to the conventional methods such as flame and induction hardening, laser heat treatment offers significantly localized heating. This precision allows for targeted heat treatment within millimeter precision right where the hardness is needed, optimizing energy utilization and operational efficiency. Furthermore, the high-power density of lasers enables hardening with minimal to zero distortion, eliminating or reducing the need for subsequent machining operations like hard milling or grinding.
Comparison of the die construction process before and after laser hardening Source: Autodie LLC
A Case Study of Laser Heat Treating in Automotive Stamping Dies
The image above identifies process steps typically involved in construction of automotive stamping dies. During the process of manufacturing automotive stamping dies, the cast dies are first soft milled, intentionally leaving between 0.015” and 0.020” of extra stock material on the milled surfaces. This is done to account for any distortions that will result from the subsequent conventional heat treatment processes such as flame or induction. After heat treating, the dies are then hard milled back to tolerance and assembled.
In the laser heat treating process, by contrast, dies are finish machined to final tolerance in the first step and then laser heat treated without distortion. No secondary hard milling operation is necessary. Typical cost savings for our automotive tool and die customer exceeds over 20% due to elimination of hard milling operation. Total energy reduction is significant, although not computed here. This may result in savings if carbon credits become monetized.
Laser heat treating’s precision, efficiency, and minimal environmental footprint position it as an environmentally friendly option for heat treat operations. As industries continue to prioritize sustainability, laser heat treating may set new standards for excellence and environmental stewardship.
Aravind Jonnalagadda (AJ) is the CTO and co-founder of Synergy Additive Manufacturing LLC. With over 15 years of experience, AJ and Synergy Additive Manufacturing LLC provide high-level laser systems and laser heat treating, specializing in high power laser-based solutions for complex manufacturing challenges related to wear, corrosion, and tool life. Synergy provides laser systems and job shop services for laser heat treating, metal based additive manufacturing, and laser welding.
An aerospace, industrial gas turbine, and automotive market leader has expanded its heat treatment operations with a recently purchased air atmosphere furnace. Connecticut-based Doncaster Precision Castings will use the new furnace to support annealing, tempering, and heat treatment of steel and castings.
Doncaster Precision Castings previously received a similar model for use in its heavy-duty industrial processes within the aerospace and automotive sectors. The furnace, supplied by L&L Special Furnace, has a maximum temperature of 1850°F (1010°C) and a capacity to handle a typical load weight of 2,000 pounds.
The press release is available in its original form here.
Each year, the 40 Under 40 initiative at Heat Treat Todayrecognizes 40 rising young leaders (ages 40 and younger) in heat treat who are going above and beyond in the industry. The 40 Under 40 initiative gives names, faces, and words to the next generation of heat treat professionals.
To learn more about what makes someone a quality candidate for this honor, read below to hear from the individuals themselves — alumni of Heat Treat Today’s40 Under 40 — as they share personal updates and industry insights.
Click this link to nominate yourself, or someone you know, by June 28, 2024.
David Cunningham
At the time of David’s nomination for Heat TreatToday’s40 Under 40 Class of 2019, he was working in Process & Mechanical Design as a heat treating furnace engineer for L&L Special Furnace Co., Inc. Here he shares an exciting career (and company) update: “The biggest change since I was nominated to Heat Treat Today’s40 Under 40 is that I have taken over ownership of L&L Special Furnace Co. I became full owner of the business in January 2023.”
David Cunningham L&L Special Furnace, Co., Inc.
Something David finds most fascinating about the heat treat industry is the number of markets it serves. He says, “I am always surprised looking through our list of customers and knowing what their processes are. I never considered how many industries utilize heat treating.”
David’s advice for the incoming 40 Under 40Class of 2024 is to “Keep learning . . . there is so much more to heat treating than just making things hot. There are so many niche markets out there. One of the things that fascinated me most was learning how the glass for the Hubble was heat treated.”
An alum of the 40 Under 40Class of 2023, Kevin describes how he rose “through the ranks” in the heat treat industry starting in 2008: “[I] started out in the field on the ground as a helper and . . . worked myself up through the ranks . . . to Level 1 technician, to Level 2 technician . . . all the way up into management.” He currently works as operations manager of heat treating at ProQual Inspections.
Kevin Norton ProQual Inspections
To Kevin, the most intriguing thing about the heat treat industry is the advancements in technology, reducing manpower and improving safety. He states that, “different processes in heat treating will go far and beyond what we currently have . . . I’m looking forward to that.”
Kevin’s advice to anyone looking to do something different in their work is to “Be inquisitive; ask questions.”
Previous to Miguel’s nomination for Heat TreatToday’s40 Under 40Class of 2023, he worked as a process engineer at Nexteer. Miguel shared an exciting career update that took place soon after: “This kind of recognition gave me a plus to be considered . . . [for] the new position I have had since last year as an Advanced Manufacturing Engineer (AME)” at Nexteer.
Miguel Zempoaltecatl Nexteer
Miguel describes what he enjoys most about working in the heat treat industry, “As a good friend . . . told me, metallurgy is the oldest of the arts but the newest of the science[s], and this relationship between metallurgy and heat treatments, gives me the opportunity to learn more every day . . . I enjoy work[ing] in this area because every day [there] are new challenges.”
