Over $9 million FedDev Ontario investment is helping Cyclone Manufacturing Incorporated (Cyclone) to add a heat treatment oven at its Milton facility, commercialize 1,500 parts, and support 110 jobs at Milton and Mississauga locations.
This investment through the Aerospace Regional Recovery Initiative, will help Cyclone expand its facilities in all its four locations. The expansions will also include commercialization of 1,500 parts, a temperature-controlled production area at one of its Mississauga facilities, increase the company’s ability to create new and larger aircraft metal parts, and continue to perform sub-assemblies for major OEMs like Bombardier, Boeing, Airbus and Embraer.
MP Adam van Koeverden and MP Rechie Valdez visited Cyclone Manufacturing Incorporated’s (Cyclone) Milton location Source: Cyclone Manufacturing Inc.
Adam van Koeverden, the Member of Parliament for Milton, along with Rechie Valdez, the Member of Parliament for Mississauga–Streetsville, visited Cyclone at its Milton facility. “This project will help Cyclone expand in a green way," commented van Koeverden, "supporting 110 local jobs while contributing to the growth of the aerospace sector here in southern Ontario.”
“Today’s investment will help the company emerge from the pandemic as a key player within the global aerospace supply chain," added Valdez.
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Vacuum furnaces are widely used in the aerospace and automotive industries. These furnaces are used for multiple processes including brazing, aging, and solution heat treating for countless materials. Typically, vacuum furnaces are utilized to ensure a lack of oxidation/contamination during heat treatment. This article will talk about the origins, theory, and main parts of vacuum technology and how it is used in both aerospace and automotive industries.
This Technical Tuesday feature was written by Jason Schulze, director of technical services at Conrad Kacsik Instrument Systems, Inc., and was first published in Heat Treat Today's December 2022 print edition.
A Brief History
Vacuum furnaces began to be used in the 1930s for annealing and melting titanium sponge materials. Early vacuum furnaces were hot wall vacuum furnaces, not cold wall vacuum furnaces like we use today. Additionally, most early vacuum furnaces did not utilize diffusion pumps.
Vacuum Heat Treat Theory
Vacuum technology includes vacuum pumping systems which enable the vessel to be pulled down to different stages through the process. Degrees of vacuum level are expressed opposite of pressure levels: high vacuum means low pressure. In common usage, the levels shown below in Figure 1 correspond to the recommendations of the American Vacuum Society Standards Committee.
Vacuum level will modify vapor pressure in a given material. The vapor pressure of a material is that pressure exerted at a given temperature when a material is in equilibrium with its own vapor. Vapor pressure is a function of both the material and the temperature. Chromium, at 760 torr, has a vapor pressure of ~4,031°F. At 10¯5, the vapor pressure is ~2,201°F. This may cause potential process challenges when processing certain materials in the furnace. As an example, consider a 4-point temperature uniformity survey processed at 1000°F, 1500°F, 1800°F, and 2250°F. This type of TUS will typically take 6-8 hours and, as the furnace heats up through the test temperatures, vacuum readings will most likely increase to a greater vacuum level. If expendable Type K thermocouples are used, there is a fair chance that, at high readings, you may begin to have test thermocouple failure due to vapor pressure.
Figure 1. Vacuum levels corresponding to the recommendations of the American Vacuum Society Standards Committee
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
Vacuum Furnace Pumping System
Vacuum heat treating is designed to eliminate contact between the product being heat treated and oxidizing elements. This is achieved through the elimination of an atmosphere as the vacuum pumps engage and pulls a vacuum on the vessel. Vacuum furnaces have several stages to the pumping system that must work in sequence to achieve the desired vacuum level. In this section we will examine those states as well as potential troubleshooting methods to identify when one or more of those stages contributes to failure in the system.
Vacuum furnaces have several stages to the pumping system that must work in sequence to achieve the desired vacuum level. Each pump within the system has the capability to pull different vacuum levels. These pumps work in conjunction with each other (see Figure 2).
Figure 2. Vacuum pumps work in conjunction with one another
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
The mechanical pump is the initial stage of vacuum. This pump may pull from 105 to 10. At pressures below 20 torr the efficiency of a mechanical pump begins to decline. This is when the booster pump is initiated.
The booster pump has two double-lobe impellers mounted on parallel shafts which rotate in opposite directions (see Figure 3).
Figure 3. Booster pump positions
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
The diffusion pump (Figure 4) is activated into the pumping system between 10 and 1 microns. The diffusion pump allows the system to pump down to high vacuum and lower. The diffusion pump has no moving parts.
Figure 4. Diffusion Pump
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
The pump works based on the vaporization of the oil, condensation as it falls, and the trapping and extraction of gas molecules through the pumping system.
Image 1. Holding Pump
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
The holding pump (Image 1) creates greater pressure within the fore-line to ensure that, when the crossover valve between the mechanical and diffusion pump is activated, the oil within the diffusion pump will not escape into the vessel.
Vacuum Furnace Hot Zone Design
Image 2. Insulated
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.Image 3. Radiation
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
The hot zone within a vacuum furnace is where the heating takes place. The hot zone is simply an insulated chamber that is suspended away from the inner cold wall. Vacuum itself is a good insulator so the space between the cold wall and hot zone ensures the flow of heat from the inside to the outside of the furnace can be reduced. There are two types of vacuum furnace hot zones used: insulated (Image 2) and radiation style (Image 3).
The two most common heat shielding materials are molybdenum and graphite. Both have advantages and disadvantages. Below is a comparison (Tables 1 and 2).
Table 1
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.Table 2
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
Vacuum Furnace Quenching System
Quenching is defined as the rapid cooling of a metal to obtain desired properties. Different alloys may require different quenching rates to achieve the properties required. Vacuum furnaces use inert gas to quench when quenching is required. As the gas passes over the load, it absorbs the heat which then exits the chamber and travels through quenching piping which cools the gas. The cooled gas is then drawn back into the chamber to repeat the process (see Figure 5).
Figure 5.Diagram of gas quenching
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
Vacuum Furnace Trouble Shooting
In Table 3 are some helpful suggestions with regard to problems processors may have.
Table 3
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
Summary
Vacuum furnaces are an essential piece of equipment when materials need to be kept free of contamination. However, there are times when this equipment may not be necessary, and is therefore considered cost prohibitive, although this is something each processor must research. This article is meant to merely touch on vacuum technology and its uses. For additional and more in-depth information regarding vacuum furnaces, I recommend a technical book called Steel Heat Treatment, edited by George E. Totten.
About the Author: Jason Schulze is the director of technical services at Conrad Kacsik Instrument Systems, Inc. As a metallurgical engineer with over 20 years in aerospace, he assists potential and existing Nadcap suppliers in conformance as well as metallurgical consulting. He is contracted by eQuaLearn to teach multiple PRI courses, including pyrometry, RCCA, and Checklists Review for heat treat.
The Government of Canada announced it is to receive Lockheed Martin’s 5th Generation F-35 Lightning II aircrafts as a result of the Future Fighter Capability Project competition.
The Royal Canadian Air Force will add 88 of the F-35A multirole stealth fighters. The aerospace and defense industries will benefit with high value jobs in the production of these aircraft.
“Canada is our friend and a close ally. Their decision to procure almost 90 jets underscores the value of the incredible F-35 Lightning II,” said Lt. Gen. Mike Schmidt, program executive officer at F-35 Joint Program Office United States Air Force. The F-35 strengthens Canada’s operational capability with its allies as a cornerstone for interoperability with NORAD and NATO.
“Together with our Canadian industry partners, we are honored by this selection and the sustainment of critical jobs that will continue to equip Canadian workforces with advanced skills,” said Lorraine Ben, chief executive at Lockheed Martin Canada. “The F-35 program yields tremendous economic benefits for Canada’s aerospace and defense industry."
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Beginnings and endings often come together. As we begin a new year this month, we want to pause to remember a few lives that came to an end. Although the following are by no means the only important endings, Heat Treat Today would like to honor the memory of the following individuals who left their mark in the heat treating world.
This article first appeared in Heat Treat Today's December 2022 Medical and Energy print edition. Feel free to contact Bethany Leone at bethany@heattreattoday.com if you have a question, comment, or any editorial contribution you’d like to submit.
William “Bill” Cleary Surface Combustion (1960–2022)
Bill Cleary joined Surface Combustion directly after graduating college and remained with the company through the next 36 years. Working as a mechanical engineer and later as senior sales engineer, Bill was a constant presence at Surface Combustion — always the first person to help and listen.
Roger Joseph Fabian Lindberg & Bodycote (1940–2022)
Roger Fabian received his B.S. in metallurgical engineering in 1962 and his MBA in 1980 from Rensselaer Polytechnic Institute. He began his career with Lindberg Corporation in 1962 as a plant manager at Lindberg’s Boston Division, and in 1964 transferred to the Berlin Division, where he was named chief metallurgist and quality control manager. He was promoted to division manager at Berlin in 1979 and named vice president of Lindberg Heat Treating Company in 1992. When Lindberg was purchased by Bodycote Thermal Processing in 2001, Roger was named Eastern Region sales manager and finally retired in 2010 after 48 years. Roger had many professional accomplishments, including president of ASM International, president of the ASM Heat Treating Society (an affi liate society of ASM International), and was a long-time member of both societies. He also served as a president for the Metal Treating Institute (MTI), and as chairman of the ASM Technical Programming Board. He was instrumental in the development of the Center for Heat Treating Excellence (CHTE) at Worcester Polytechnical Institute and served as director-at-large and industrial liaison. He was known to be always a gentleman and a friend.
Klaus Hemsath Surface Combustion (1935–2022)
Klaus Hemsath and his family emigrated from Germany in 1967 to begin work at Surface Combustion. To this day, Klaus has over 60 patents to his name in the United States. Among his many accomplishments in the heat treating industry, Klaus founded Indugas, Inc. and wrote several books on climate change. Klaus will be greatly missed by his son, Mark Hemsath (Nitrex), as well as all others in the heat treating industry who knew him.
David Soderberg County Heat Treat (1951–2022)
With over 45 years of experience in metallurgy, Dave Soderberg had a vast knowledge of nitriding, aluminum solution aging, stress relieving, and other heat treating processes. His expertise especially honed in on aerospace heat treating, where he was appointed the designated supplier quality representative by GE Aerospace Engineering Group. Dave was a skilled metallurgist, able to develop heat treatments according to custom specifications.
Jon K. Tabor Allied Mineral Products (1933–2022)
After a 65-year career in refractories, Jon Tabor joined Allied Mineral Products in 1970 and helped to build it to the multi-national corporation it is today. Some of John’s accomplishments at Allied were transforming it into an employee-owned company and establishing a manufacturing presence in several countries, including China, South Africa, the Netherlands, and Brazil.
Keep that furnace running! Obviously, a furnace leak can be quite counterproductive and make it troublesome or even impossible to keep it going. What can be done? Thankfully, there are several solutions. This best of the web article gives helpful measures in defining leaks, detecting leaks, solutions for effectively stopping a leak, and much more.
As you move through the post, you'll encounter a tutorial that starts with the basics. A furnace leak if defined with differences described between a normal leak and something such as an outgassing problem. Then, other information is presented with descriptions on the rate of the leak and possible locations for said leak. The article continues with methods for leak checking and wraps up with a check list of sorts for vacuum furnace users.
An excerpt:
Some operators or leak checking personnel will often use a stethoscope when checking for leaks, as its ability to transmit low-volume sounds and eliminate external noise is exceptional. Often in gross leaks or some smaller leaks, a standard paint brush and soapy wash solution is helpful. Brush the solution around suspected leak areas. Big leaks will blow big bubbles at the leak while smaller leaks will form very fine foam.
The monthly Industrial Heating Equipment Association (IHEA) Executive Economic Summary released in January takes a look at the 3 common problems for the economy and provides another sector that may be surprising player. Usually, inflation, recession, and supply chain have been considered the culprits for the economic downturns in past months. There is something else edging in as cause for concern: the worker shortage. Specifically, the looming problem that the Boomer generation is retiring.
By 2030, the report projects, every worker of this generation will have reached retirement age. It is forecasted: "These people will be very hard to replace, and it will be expensive." Worker shortages have been discussed before, but now the study is showing that things are at "crises level."
"Remarkably stable" due, in part to "expansion of capital spending" Source: IHEA
The 10 economic indices have all shown a drop except two: Durable Goods and Metal Pricing. Metal prices are remaining stable even as there are signs of reducing demand. The report credits this to companies thinking there will be a slowdown this year. Global events do make copper rather volatile, but nickel and aluminum are holding steady.
"The metal markets have been stabilizing to a degree." Source: IHEA
All of these indices are slowing down: New Auto Sales, New Home Start, Steel Consumption, Industrial Capacity Utilization, Purchasing Managers Index, Capital Expenditure, Factory Orders, and Transportation Activity. It's difficult to pin just a few reasons for this, but supply and demand issues, high interest rates, and high prices overall have consumers hanging on to their money if they can.
Some supply chain resolution but "consumer demand is frequently frustrated by the lack of the desired vehicle." Source: IHEA
In the automotive arena, heat treaters can find measures of security in knowing production is still expanding.
"The estimate is that another 5 million homes are needed." Source: IHEA
Yes, the numbers are down, but overall there is a great need yet for housing. Multi-family homes see numbers still up by 12%, so that reflects well for heat treaters providing construction needs.
Some slowing in the steel sector Source: IHEA
The report on steel consumption shows decline in the three major "drivers" for the industry: commercial construction, vehicle manufacturing, and the oil and gas business.
Anne Goyer, Executive Director of IHEA
2023, it would seem, is going to see a lot of spending on labor. There is hope even while seeing numbers drop, and it is possible that the nation is moving into a better time. The claim is that the "recession threat [is fading]," and supply chain circumstances are improving with China and elsewhere.
Check out the full report to see specific index growth and analysis which is available to IHEA member companies. For membership information, and a full copy of the 11-page report, contact Anne Goyer, executive director of IHEA. Email Anne by clicking here.
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Plot your heat treat events with Heat TreatToday's Industry Calendar. This planner is located under "Resources" on www.heattreattoday.com, and it is always updating with the latest industry events. As you make your spring 2023 plans, check out three of the season's events in this original content piece!
If you have an event to add -- or want to give us a heads up on an event that you and others are going to attend -- feel free to reach out to the editors at editor@heattreattoday.com.
Jump over to the "Resource" tab on the website, and you'll find the Industry Calendar located fourth down. This calendar lets you search by month in list or calendar view format so that you can visualize your season with ease.
Preview of Spring 2023 events
AEROMAT 2023
When: March 14 - March16
"For more than 30 years, ASM International has hosted the AeroMat conference and exposition which showcases the interchange of pertinent technical information on aerospace industry material and processes."
Additive Manufacturing Users Group 2023 (AMUG)
When: March 19 - March 23
"Expert, intermediate and novice users of all commercial additive manufacturing technologies are encouraged to attend the AMUG Conference. AMUG is a global community focused on accelerating the education and advancement of additive manufacturing and 3D printing. Additive Manufacturing Users Group (AMUG) Conference brings together engineers, designers, managers, and educators from around the world to share expertise, best practices, challenges . . ."
Metalcasting Congress 2023
When: April 25 - April 27
"For more than a century, Metalcasting Congress has shaped the future of foundries. From cutting-edge research on the latest breakthroughs to professional networking and business development, Metalcasting Congress is the foundry industry’s premier gathering in North America."
There's so much more! Explore theIndustry Calendarhere.
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By this time of the year, New Year's resolutions have fallen to the wayside. Rather than feeling discouraged, treat each day as a new opportunity for learning and advancement. Heat Treat Today compiled an easy-to-access resource for you chock full of heat treat technical information.
These 23 ways help you set goals to access new technology, connect with industry leaders, review old and trusted practices, and so much more. We hope this original content article is helpful and would love to hear from you in the Reader Feedback button below!
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 issue, we look at updates on industry events around the globe such as electric furnaces in Finland and new technology to accommodate additive manufacturing advances.
“After the decision taken by Stahl Gerlafingen to upgrade its Electrode Regulation System as part of its secondary steelmaking process, AMI supplied the DigitARC® PX3 ERS which was delivered in May 2022, with all onsite commissioning work finished in mid-2022.”
Read More: “AMI Automation supplies steel producer with DigitARC® PX3 ERS” at furnaces-international.com
Reducing CO2 Emissions with Electric Furnace in Finland
“Iittala to receive €10 million electric furnace investment” (Source: Furnaces International)
“Fiskars Group will replace the Iittala factory’s existing, natural gas-powered furnaces with electricity-powered furnaces. The investment will reduce the factory’s CO2 emissions by approximately 10,000 tons a year (74%) and decrease nitrogen oxide and fine particle emissions.”
From right to left: Mr. Safwan Sobhan, Vice Chairman Bashundhara Group shaking hands with Mr. Burkhard Dahmen, Chairman of the Managing Board & CEO, SMS group. BMSIL & SMS Group team members during contract signing at Dhaka. (Source: SMS group)
“Bashundhara Multisteel Industries Limited, the Steel Division of Bashundhara Group, one of the largest business conglomerates in Bangladesh, signed a contract with SMS group to install an integrated facility to produce more than two million tons of hot rolled coils annually with the goal of filling the gap in demand for flat products in Bangladesh. The plant will be located at Bangabandhu Sheikh Mujib Shilpa Nagar (BSMSN), Mirsharai, Chattogram. In the future, this plant can be expanded to produce four million tons annually.”
Read More: “Bashundhara Multisteel and SMS group sign contract for integrated CSP® plant” at heat-processing.com
New Tech Accelerates Material Deposition and Alloys in AM Advancements
Dr.-Ing. Tobias Stittgen (right) and Thomas Horr, the two Managing Directors of ponticon GmbH, are standing next to a pE3D system. (Source: ponticon)
“At Formnext, ponticon GmbH will introduce its new pE3D system for Dynamic Material Deposition (DMD), a process developed for additive manufacturing, coating and repairing complex-shaped metallic workpieces. The new system combines high process speed with utmost precision and high flexibility in terms of the choice of alloying elements. With the [DMD] process developed by ponticon, alloys of any elemental compositions can be deposited on metallic and ceramic components.”
Read More: “High-precision laser cladding with short process times” at heat-processing.com
Heat Treat Todayoffers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry. Enjoy these 19 news bites that will help you stay up to date on all things heat treat.
Equipment Chatter
Global commodities group, Anglo American, and thyssenkrupp Steel have signed a memorandum of understanding to collaborate on developing new pathways for the decarbonization of steelmaking. The collaboration will focus on joint research to accelerate the development of high-quality input stock for lower carbon steel production, using both conventional blast furnace and direct reduction iron.
SECO/WARWICK delivered additional CAB lines to SUZHOU RETEK in China.
Tenova was contracted by Sinova Global to supply the basic engineering of a new silicon metal plant in Tennessee. The site will be North America’s most modern and efficient silicon metal plant, a greenfield development for Sinova Global.
Collaborative R&D between Anglo American and thyssenkrupp Steel for greener steelmaking technologies
Two CAB lines for SUZHOU RETEK
Sinova Silicon Metal Plant from Tenova
Company and Personnel Chatter
Brighton Science and Hubbard-Hall partner to provide the Infinity Surface Cleaning Intelligence Program, which is designed to aid manufacturers to prepare surfaces and prevent problems.
Thermal-Vac Technology, Inc. announced the completion of a new microgrid from Verdant Microgrid, LLC. Collaboration with the following companies ensured the completion: Eos Energy Enterprises of Edison, NJ; Stronghold Engineering, Inc. of Perris, CA; and GridSwitch Asset Management Services of Moon, PA.
Bryan Stern has joined Gasbarre as the product development manager for Gasbarre Thermal Processing Systems. Bryan’s experience, knowledge, and forward-thinking will allow him to support existing clients and advance the company’s growing footprint in the vacuum furnace market.
Ipsen recently launched a new website with the goal of providing a better user experience for customers worldwide. IpsenGlobal.com now incorporates all Ipsen locations, products, and services under one domain.
Furnaces North America 2022, the premier trade show and technical conference in the North American heat treating industry, attracted over 1,200 attendees from around the world. The show produced by the Metal Treating Institute in partnership with its media partner, Heat Treat Today.
Bryan Stern Product Development Manager Gasbarre Thermal Processing Systems
New website: IpsenGlobal.com
FNA Technical Sessions, many exhibitors and attendees
Kudos Chatter
Doug Peters, CEO of Peters’ Heat Treating, received the Winslow Award, an honor that is given to an individual or business that has made valuable economic improvements.
A two chamber vacuum oil quench furnace has received Nadcap accreditation. Solar Manufacturing designed the furnace for Solar Atmospheres of Western PA.
Ayla Busch was honored with the German Leadership Award 2022. This award was presented at the annual alumni convention of the Collège des Ingénieurs and is an award for innovative corporate leadership in the German economy.
Texas Heat Treating, Inc. announces that both Round Rock and Texas Heat Treating Worth just completed ISO 17025 lab audits. The audits came back with no findings.
Representatives from TAV VACUUM gave a speech during the first day of the 27th IFHTSE Congress & European Conference on Heat Treatment 2022. The talk was about the heat treatment of titanium alloys, specifically, “Vacuum heat treatment of Ti6Al4V alloy produced via SLM additive manufacturing.”
RETECH, a SECO/WARWICK Group company, was acknowledged as “The Most Innovative Metallurgical Equipment Specialist in 2022 for the USA” by Acquisition International Magazine. Additionally, Earl Good, its managing director, has been honored by The Corporate Magazine in the “Top 20 Most Dynamic Business Leaders of 2022.″
Nitrex Metal, Inc. announced that it was selected for the “American Dream” series airing on Bloomberg and Amazon Prime. The series explores the entrepreneurial stories of men and women who founded and built incredible companies from the ground up.
Jim Oakes, president of Super Systems, has been awarded the first ever Furnaces North America (FNA) Industry Award at the trade show’s opening night kickoff reception.
At the recent 2022 MTI fall meeting held in Indianapolis, IN, the Metal Treating Institute recognized Roy Adkins, director of Corporate Quality, with the MTI Award of Industry Merit. This award is given in recognition of current and ongoing commitment to the betterment of the commercial heat treating industry with one or more significant accomplishments.
Hubbard-Hall has been awarded the Top Workplaces 2022 honor by HearstMedia Services in Connecticut. The award is based solely on employee feedback gathered through a third-party survey that is administered by employee engagement technology partner Energage LLC.
Pelican Wire Calibration Laboratory received “ISO/IEC 17025:2017” accreditation from ANSI National Accreditation Board.
Doug Peters Receives 53rd Annual Winslow Award
Lars Wagner, COO at MTU Aero Engines AG, presents Ayla Busch with the award.
Solar Atmospheres of Western PA’s Nadcap Accredited Furnace
RETECH company and managing director receive honors
Nitrex Metal, Inc. part of “American Dream” TV series
Industry Award to Jim Oakes, president of Super Systems
Roy Adkins (center) with past MTI Presidents, Jim Oakes (left) and Don Hendry (right)
Heat Treat Today is pleased to join in the announcements of growth and achievement throughout the industry by highlighting them here on our News Chatter page. Please send any information you feel may be of interest to manufacturers with in-house heat treat departments especially in the aerospace, automotive, medical, and energy sectors to sarah@heattreattoday.com.
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William “Bill” Cleary
Source: 
Heat Treat 
