Heat treater ALP Aviation is increasing its production capacity and expanding process capability with a vacuum furnace. The furnace is dedicated to low pressure carburizing of transmission components for helicopters and other aircraft.
Sławomir Woźniak CEO SECO/WARWICK Source: secowarwick.com
The new vacuum furnace is configured with horizontal charge loading, a maximum cooling gas pressure of 15 bar of argon and nitrogen, and a 900mm x 900mm x 1200mm (W x H x L) charge area.
This Vector vacuum furnace is the heat treater's 4th installation in a 13-year cooperation with SECO/WARWICK, the parent company of North American-based SECO/VACUUM. "Our 13-year relationship with ALP AVIATION continues to be of mutual benefit on all technical and managerial levels," says Sławomir Woźniak, CEO of SECO/WARWICK Group. "[We provide] the technology, equipment and process knowledge which has enabled our client to grow their business. Our Group values working close to the customer."
Heat treaters across North America in Georgia, North Carolina, and Ontario have requested that heat treat furnaces be used in the production of powertrain, suspension, and steering/linkage components for the automotive sector. The demand for new furnace equipment has been driven by both light weighting initiatives and a shortage of in-house heat treatment capacity.
Cast Link Belt Press source: CAN-ENG Furnaces Ltd.
CAN-ENG Furnaces International Ltd., a global furnace systems group based in Canada, has been contracted by multiple unique customers in the United States and Canada to deliver these different furnaces for the heating and heat treatment of both aluminum and steel closed die forgings. The furnace configurations -- either under construction in the company shops or in the early stages of commissioning -- include rotary hearth, chain conveyor, roller hearth, mesh belt and cast link belt.
All contracts will be in production by late Q1 2021.
A captive heat treater in New England will receive a 10-bar gas quenching vacuum furnace. The model features high pressure gas quenching and vacuum carburizing. With temperature uniformity of ±10°F, it is consistent with AMS2750F requirements.
Jason Davidson Northeast Regional Sales Manager Solar Source: solarmfg.com
"The research and development done with our sister company, Solar Atmospheres, on the alloy selection, carburizing, and recipe process development, was instrumental to the sale of the furnace," states Jason Davidson, Northeast regional sales manager at Solar. He adds that the customer valued the additional resource that the sister company had to offer.
The furnace has a graphite insulated hot zone with a work area measuring 24” wide x 24” high x 36” deep and a load weight capacity up to 2,000 pounds. Its maximum operating temperature of 2400°F.
You can see these dimensions in the video below that the supplier, Solar Manufacturing, shared on Twitter.
Solar Manufacturing recently shipped a 10-bar gas quenching vacuum furnace to a captive heat treater in New England.
Global commercial heat treater HTA Group (HTA) ordered a vacuum aluminum brazing furnace. It will operate within a tight temperature tolerance of +/- 3° C, as dictated by AMS2750F, allowing HTA to continue to provide accredited heat treatment processing services to the global aerospace industry.
With three locations in Australia and one in the United States, HTA will be using this furnace to braze aluminum parts for applications where the use of brazing flux is not permitted due to corrosion. This is the seventh furnace -- and the 3rd vacuum brazing furnace -- that SECO/WARWICK will be providing to HTA.
"Our team of experienced heat treatment professionals appreciate working with SECO/WARWICK experts and technologies," said Norm Tucker, director at HTA Group. "We demand high quality, precision solutions due to the stringent requirements of the aerospace applications that we work with."
The vacuum aluminum brazing system has been designed with 6 temperature control zones in order to meet the temperature requirements of +/- 3° C as specified by the AMS2750F pyrometry specification. Additionally, the furnace provides the deep vacuum and perfect temperature uniformity to meet the Class 1 requirements of the pyrometry specification. The powerful high vacuum system will be equipped with a large diffusion pump and built to accommodate loads up to 800 x 800 x 1600mm (W x H x D). The furnace will be equipped with an external gas cooling system, which will both accelerate the process and improve the part quality after brazing.
Edward Rolinski Senior Scientist Advanced Heat Treat Corp.
Mike Woods President Advanced Heat Treat Corp.
Why do forging dies fail? How can heat treating prevent failure? And what specific role does gas- or plasma-assisted nitriding treatment play in enhancing metal structure?
Heat Treat Todaybrings you this Best of the Web feature article this Technical Tuesday to answer these questions. Written by Dr. Edward Rolinski and Mike Woods of Advanced Heat Treat Corp., this article explains the impact of forging process, material and press type; heat treatment for forging dies; and nitriding forging and stamping dies.
An excerpt: "Surface properties critical for die performance can be further elevated by a surface-treatment process employing a multi-gradient design strategy, a novel plasma, multi-step treatment with formation of the nanostructured layer/coating developed by Advanced Heat Treat Corp."
Well, as we approach the end of November 2020 and assess the economic numbers from October, there is still no real clarity to bring a sense of understanding to our crazy year. As the Industrial Heating Equipment Association’s (IHEA)Executive Economic Summary’s October report begins, “To note that there is nothing about this year that could be considered even close to normal or predictable would be the understatement of the year, if not the decade. This was the most unanticipated and bizarre recession experienced in modern history as it was not organic in any sense. It was an imposed recession that resulted from the attempt to deal with the pandemic and all the numbers for the year have been skewed to the extreme.”
However, the reports states, “This month’s indices are far better than they were a month or so ago, but almost every one of these data points demands an explanation before we have an idea what they might be telling us about the economy.” Of the 12 indices examined, nine of them were trending positive and only three were heading downward. Interestingly, though, “that only tells part of the story.”
The rebound in demand for factory orders has been a bit more consistent than the demand for durable goods and this reflects some shifts in consumer demand. It has been pointed out that consumers have been shifting their purchasing from services to goods and that has been reflected in a variety of ways.
For example, take the data for housing starts. The summary states, “The index showed a decline, but the news has been full of very positive reports on the state of the housing sector. The index shows both the data on single family homes as well as the multi-family unit and there has been a reduction in interest in the apartment option of late.” Additionally, the demand for both single-family and existing homes has been very robust.
The auto sector has also seen interesting movement. RV sales have “never been stronger and the demand for larger vehicles has been strong as people intend to travel in them.”
“There have been several trends emerging over the last few months and the data in these indices reflect them.” The report continues, “The most obvious and expected has been the shift in consumer interest from service spending to buying goods.” Those sectors that have benefitted the most from the shift have been manufacturers, transportation companies, and importers. “The bulk of these purchases have been online and that has spurred dramatic growth in the parcel delivery sector.”
While the U.S. still doesn’t compete effectively in the production of consumer goods, “there has been an increase in demand for the sophisticated machines the US produces – especially in the realm of robotics and technology.”
Companies are turning to technology and robotics at a faster pace than ever and that boosts machine sales.
In conclusion, the reports shares, “The early indicators as far as the economy is concerned continue to be transportation and the credit environment and, in both cases, there is renewed confidence regarding the future. The unfavorable numbers (such as bankruptcy and collections and disputes) have stabilized.”
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 12-page report, contact Anne Goyer, executive director of the Industrial Heating Equipment Association (IHEA). Email Anne by clicking here.
Thanksfor extra time at home with family and friends this year.
Thanks for helping us to understand that we don’t have to be in the office for long hours to get work done.
Thanks for the business we were able to keep.
Thanks for face-to-face meeting technology (like Zoom) … and the necessity of learning how to use it.
Thanks for sheltering-at-home-induced stir craziness and the realization that people are important.
Thanks for reminding us that seeing a person’s full face is far better than seeing their eyes only.
Thanks for people who smile with their eyes.
Thanks for people-loving people who hate masks but wear them to protect their fellow man.
Thanks for freedom-loving people who don’t wear masks because they believe government has overstepped.
Thanks for those who care for our physical bodies when we get ill.
Thanks for those who take care of our spiritual bodies when we get sick, sinful, weary and/or afraid.
Thanks for all those handshakes we took for granted before COVID.
Thanks for all those less-than-six-foot encounters before COVID.
Thanks for the deeper understanding of what the word “normal” means.
Thanks for the hope of brighter days ahead.
Thanks to all of you Heat Treat Today readers and advertisers who have made 2020 such an enjoyable year. All of us pray God’s richest blessing on you and your family over the upcoming Thanksgiving and Christmas holiday season.
In everything give thanks, for this is God’s will for you in Christ Jesus. Holy Bible, 1 Thessalonians 5:18
Hot isostatic pressing (HIP) has been a player in heat treating for 50 years, but recent advances in its technology are providing cutting edge opportunities for new applications in the thermal processing industry.
Heat Treat Today asked two experts in the HIPing world about the state of hot isostatic pressing: What are the latest technologies and where are its potential growth markets in the thermal processing industry? They represent both sides of HIPing – one from a HIP equipment manufacturer and the other from a HIP process/service provider. Each gives a unique perspective on the HIP market and the industry itself.
Our expert contributors are Chad Beamer, an applications engineer in Hot Isostatic Pressing, at QuintusTechnologies, a high pressure technology company, and Derek Denlinger, a corporate lead metallurgist at Paulo, a thermal processes and metal finishing operations company. This Original Content Technical Tuesday article was taken from 2020 Q4 Heat Treat Todayprint magazine.
What is HIP?
Derek Denlinger Corporate Lead Metallurgist Paulo
Paulo’s Derek Denlinger says, “Hot isostatic pressing is fundamentally, when parts simultaneously see high temperature (in some cases as much as 2500oF) and very high pressure (up to 30,000psi) from all directions for a duration of time.”
Chad Beamer Applications Engineer – Hot and Cold Isostatic Pressing Quintus Technologies LLC
Chad Beamer of Quintus adds, “Pressure-based compaction processes can be used to establish density by applying a uniaxial pressure within rigid dies. Such mechanical or hydraulic approaches can produce non-complex parts or ‘green’ compacts. Although a cost-effective and high-throughput technique, these conventional presses exhibit geometrical limitations and compressibility constraints, yielding product that is not uniform in density and microstructure.”
“Isostatic pressing was developed with the desire to improve upon these shortcomings,” continues Beamer. “Such compaction techniques leverage Pascal’s law by using a fluid contained in a pressure vessel, either in the liquid or gas state, to transmit equal pressure in all directions on the surface of a workpiece.”
Beamer further explains, “Various isostatic pressing techniques exist today such as cold isostatic pressing (CIP), warm isostatic pressing (WIP), and hot isostatic pressing (HIP). HIP is a heat treatment process that utilizes isostatic pressure via a gas at high temperatures. It is commonly used to consolidate metal or ceramic powder and to reduce defects present in castings and additively manufactured parts. The output is a product with improved mechanical properties, workability, and reliability.”
Pore eliminated before and after HIP process
What happens in the HIPing process?
Denlinger explains, “In the HIPing process, parts are heated to a temperature high enough to weaken material strength. High pressure, usually applied through a pressurized gas medium such as argon, applies a compressive stress onto the part from every direction. Given a hold period of time, this compression effectively allows for internal voids or pores to close up due to a mixture of mechanical deformation, creep, and metallic diffusion. The part consolidation sets the stage for any other heat treatment that may follow in order to maximize material performance.”
Since the densification of the workpiece is achieved by the simultaneous application of pressure and elevated temperature during HIP, Beamer adds, “Temperatures are usually in the range of 900oF-3600oF (500o-2000oC) depending on the material being HIPed. A good rule of thumb is a temperature targeting approximately 80% of the materials solidus temperature. Pressures in the vessel can reach twice that of the pressure at the bottom of the Mariana Trench, generally in the range of 15,000-30,000 psi (100-200MPa). The combined temperature and pressure applied should be capable of exceeding the yield strength of the material.”
Latest HIP Technologies
Both Beamer and Denlinger share optimism about the new HIP advancements, especially the new high pressure heat treatment (HPHT).
Beamer states, “A recent development in HIP technology is the ability to perform rapid gas cooling and quenching in the HIP system. Originally developed to shorten cycle time, this advancement is now being leveraged to perform many of the standard heat treatments for metals in the HIP furnace. Now a single piece of equipment can be used to apply both HIP and heat treatment, all carried out in one cycle. This approach is referred to as high pressure heat treatment (HPHT). Benefits to this new treatment include:
the ability to remove an additional process step and piece(s) of equipment
more cost-effective manufacturing path
fewer times a component must be heated up
less time spent at elevated temperature
elimination of the risk of thermally induced porosity (blistering) in additively manufactured parts
“These modern systems are continuing to evolve with other promising advancements such as steered cooling. This controlled cooling approach within a HIP vessel allows cooling rates for a component to be optimized in order to achieve the desired microstructure. These advancements are quite exciting for many industries as they are expanding the design windows for material systems and creating new opportunities within a HIP system.”
“HIP has been around commercially for around 50 years,” Denlinger points out, “but more recent technology has been focused on better control of thermal aspects of the process. This is opening the doors for more fine-tuned ‘high pressure heat treatment’ processing that can offer speed and, in some cases, performance benefits that were previously not possible. These types of processes have often been coupled with the ever-growing additive manufacturing processes, though applications to more traditional manufacturing methods are gaining momentum. The influence of pressure on diffusion and transformation in materials has been identified, but not fully explored for many alloys, so new high pressure heat treatments are now being considered to compete with traditional HIP and heat treatment methods.”
What is HIP’s niche in the thermal processing industry? Who are its customers? Where do you see potential growth markets?
HIP implants
According to both men, the future is bright for HIPing.
Beamer explains why specific industries choose HIPing: “HIP is often desired where the risk of failure is not an option. Therefore, it is not surprising that HIP is commonplace in aerospace, energy, and medical industries. Applications within these industries include densification of products, consolidation of powder, diffusion bonding, as well as HPHT. For the aerospace industry, HIP is used to remove porosity from nickel-base and titanium-base castings as well as defects present in additively manufactured parts. The medical industry applies HIP to improve the quality and durability for cobalt chrome and titanium implants. HIPing of large and complex near-net-shape powder metal components to achieve fully densification is routine in the energy industry.”
Denlinger agrees, “HIP has most often been used for fatigue benefits, which is an important performance criterion in the aerospace industry. This remains in the scope, but applications in other sectors are growing due to the adoption of additive manufacturing. Oil and gas, medical, manufacturing equipment, space, firearms, and other industries are increasing their use of HIP and high-pressure heat treatment. Partnering with companies to explore additive manufacturing solutions with both HIP and traditional heat treatment in our arsenal has been very successful; challenging the status quo with the latest HIP technology and our expertise in heat treatment has been a great learning experience.
Regarding market expansion for HIP, Beamer shares, “Potential growth markets for HIP include medical, defense, space, automotive and the ongoing developments with additively manufactured applications. The medical industry is showing growth with an aging population coupled with a cultural shift to living a more active lifestyle. Another trend within the medical industry is to insource HIP versus going through a supplier, which can offer process optimization opportunities and increased quality control.”
The future of HIP technology is likely to include the automotive industry.
Beamer continues, “Growth for HIP in the defense industry can be attributed to strong government funding, such as the development work being done through America Makes. One of the most exciting growth markets here in the US is space, in which many high-profile companies are showing interest in HIP and HPHT technologies.
“Although the HIP process is not typically characterized as a high-volume process,” Beamer concludes, “the automotive industry is finding its benefits useful for cast engine blocks and emerging technology such as binder jet applications. Despite the present challenges due to the Covid-19 pandemic, specifically within the civil aerospace industry, there are many exciting growth opportunities for HIP.”
(All photos in this article provided by Quintus Technologies)
About the Authors:
Chad Beamer has a MS from the Ohio State University in Material Science and has worked as a material application engineer with GE Aviation for 7 years and as a technical services manager with Bodycote for 5 years. In February, Chad began working with Quintus Technologies as an application engineer for the Advanced Material Densification division focusing on hot isostatic pressing (HIP). As an applications engineer, he manages the HIP Application Center located in Columbus, Ohio, educates on the advancements of HIP technologies, and is involved in collaborative development efforts both within academia and industry.
Derek Denlinger is the corporate lead metallurgist at Paulo. Derek has a Bachelor of Science in Metallurgical Engineering from Missouri S&T in Rolla. He started in the foundry industry before transitioning to heat treatment at Paulo where he has been for the past 5 years. The past two years, Derek has been focused on additive manufacturing and hot isostatic pressing assisting with Paulo’s entry into the HIP market.
The energy storage company HI-POWER, a Holtec International and Eos Energy Storage joint venture, recently formed a five-year partnering agreement with a North American heat treat supplier to provide an energy efficient non-lithium, long duration energy storage solution using battery technology.
The new battery technology, a decade in the making, is an efficient non-lithium, long duration energy storage solution. One of the critical components within the battery system requires a “vacuum cathodic” heat treatment process. This newly developed surface heat treatment process enables the product to last 5,000 cycles for a 15-year calendar life with no subcooling or pumps required.
HI-POWER and Solar Atmospheres of Western PA engineers worked to develop the vacuum cathodic heat treatment needed to fulfill HI-POWER’s specifications. Today, Solar is thermally processing thousands of components to help HI-POWER deliver clean and reliable energy faster for the world’s needs.
"I came upon this opportunity at a trade show four years ago," said Mike Johnson, sales manager for Solar, "At that time, HI-POWER was perfecting their critical thermal cycle profiles in a small hot wall furnace in New Jersey. HI-POWER knew that someday they would need to employ a large vacuum furnace - and we had that capability."
HI-POWER builds one of the safest and fully integrated DC storage batteries in the world. Their “Znyth” storage batteries are especially stable when housed in extreme temperatures and are nonflammable and 100% recyclable.
(photo source: Solar Atmospheres, courtesy of EOS Energy Storage)
Keith Boeckenhauer Managing Director SECO/WARWICK USA
A Virginia manufacturer of high-quality plumbing tube recently commissioned a new heat treat furnace, expanding the plant’s capabilities to include aluminum extrusions. This is the first new aluminum processing equipment installation at the plant.
The supplier, SECO/WARWICK, noted that the vertical orientation of the work being heat treated is what differentiates this from others. The design allows the customer to maintain an efficient, semi-continuous process with little downtime between batches by staging loads in the drywells. The major benefit of this design is that it will allow the manufacturer to drop extrusions into the quench within 10 seconds after heat treating and soak.
Keith Boeckenhauer, managing director of SECO/WARWICK USA, commented that the company "has patented many standard processes related to aluminum heat treatment and controlled atmosphere brazing, [and is able. . .] to apply innovative designs to custom requirements."
The furnace was designed and built in Pennsylvania.
Heat treater ALP Aviation is increasing its production capacity and expanding process capability with a vacuum furnace. The furnace is dedicated to low pressure carburizing of transmission components for helicopters and other aircraft.
Thanks 
