Consider the numerous systems in your heat treat operations. What makes up the anatomy of each furnace? In this “Anatomy of a . . .” series, industry experts indicate the main features of a specific heat treat system. In this feature, the full-page spread identifies main features in a roller hearth furnace.
The mark-ups for these reference images are provided by Premier Furnace Specialists.
Download the full graphics by clicking the image below.
Search www.heattreatbuyersguide.com for a list of roller hearth furnace providers to the North American market. If you are a roller hearth furnace supplier and are not listed here, please let us know at editor@heattreattoday.com.
This series will continue in subsequent editions of Heat Treat Today’sprint publications. Stay tuned!
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HAMR titanium furnace for Virginia facility (Source: IperionX)
IperionX announced their HAMR (Hydrogen Assisted Metallothermic Reduction) furnace has completed its final mechanical assembly and passed factory acceptance tests. The furnace will be delivered to the company’s Virginia Titanium Production Facility as a foundational asset to the low-cost titanium supply chain.
The HAMR furnace is a large-scale titanium furnace with IperionX-patented technologies. HAMR is a powder metallurgy process technology that allows for the production of titanium powders.
Installation is expected during 2024’s second quarter, with production of titanium beginning mid-2024. To ramp up low-cost titanium production, IperionX has received $2.4 million from the DoD as part of a $12.7 million grant fund.
To learn more about IperionX’s Viriginia Titanium Production Facility, visit this link.
This press release is available in its original form here.
How long until heat treat operations use hydrogen for combustion? Considerations like cost and pipeline infrastructure are key in answering this question. For these industry experts, the consensus is clear: It is uncertain when, but hydrogen is coming. Doug Glenn, publisher of Heat Treat Today, moderated a panel of four industry experts in 2023 during which they addressed topics about advancements and challenges surrounding hydrogen combustion. Read an excerpt of their answers below. For the full interview go to www.heattreattoday.com/hydrogen2023.
What’s New for Hydrogen?
Dr.-Ing. Joachim G. Wuenning President/Owner WS Wärmeprozesstechnik GmbH
Joe Wuenning: In Europe, several steel companies are getting large funds to really go in on the hydrogen road to make green steel. If you have green steel, you will also convert the downstream processes. These places are large locations where the steel plants are running.
Automotive companies will ask for green steel. How long will it take until the heat treat shop will get to the point of using hydrogen for combustion is uncertain, but I’m sure it will be, in the end, coming also there.
Brian Kelly Applications Engineering Manager Honeywell Thermal Solutions
Brian Kelly: We have seen projects secured that have come to fruition firing on hydrogen. They’ve fired on hydrogen to prove it works and then moved back to natural gas since the H2 supply is not readily available.
What we’ve seen in the U.S. is a slowdown in some of the inquiries and questions about hydrogen. There may be a slowdown in the fervor of the talk about hydrogen, but it is certainly in the background and maybe a little bit more towards how do we be more green until hydrogen gets here?
Robert Sanderson Director of Business Development Rockford Combustion
Bob Sanderson: We’ve seen more inquiries, specifically from a lot of laboratory users who are trying to develop new engines, processes, and combustion products and looking for all the support and the technology to safely handle transport and bring that hydrogen into the lab under various test conditions.
A few users, too, want to understand: If they make the change to hydrogen, what’s going to happen with the rest of their systems?
Mark Hannum Manager of Innovation and Combustion Laboratory Fives North American Combustion
We have seen some early hydrogen requests going on which have tapered off a bit. I think it goes hand in hand with users becoming more familiar with the systems and having more of their questions answered. But I think some of it also depends a bit on the market pressures and the demands. The cost of natural gas has gone down dramatically. It’s going down faster than the cost of hydrogen is coming down. Hydrogen is going to keep coming down and keep becoming more and more affordable. Then it will reenter into the marketplace.
Mark Hannum: Probably the biggest thing is some of the regulatory and law changes that have happened. The Inflation Reduction Act certainly puts in place a lot of supports for hydrogen production and hydrogen-based systems for decarbonization.
Burgeoning Users of Hydrogen
Kelly: New inquiries have come from a lot of different places for us. We’ve had food and beverage, some heat treating, and plastics. Some of the inquiries have been waste to energy, sequestering CO2, and capturing the hydrogen. That’s how we’re going to produce it.
Wuenning: Our business is in the steel and heat treating industry. I’m not so much in touch with the other industries, but I think it would come from everywhere — everywhere the people are willing to pay for it. Of course, we have never beat natural gas on price, so far. Hydrogen is never going to come free out of the ground. But we all know the reasons why we want to get rid of the fossils.
In heat treat, we see another tendency, and that is the use of ammonia. We try to check out whether we can use ammonia because with hydrogen you need pipeline connections, and it will take quite some time until the pipelines will carry hydrogen to the last little heat treater somewhere in the countryside.
Hannum: One of the nice things about hydrogen is if you have a clean source of water and electricity, you might be able to make hydrogen in a remote location. You might not need to pipeline it; you could make the gas and use it on site.
The need for pipeline infrastructure is a key issue in the use of hydrogen.
In the steel industry in Europe, these major investments are being played out and committed to, but we’re years away from being adopted, for day-in and day-out use.
There are a lot of segments that are performing really meaningful tests at the industrial scale because they’re all trying to de-risk the switch from natural gas to hydrogen. Are there any process-side impacts that they need to understand that would impact product quality or product suitability or any of those things? All that stuff is going on now, and I think it’s going to take a couple of years for everyone to sort of work through and have a good understanding of whether there’s anything they need to be worried about beyond just the fuel switch itself, if there’s any process.
Sanderson: A lot of the push I’ve seen has come out of the aerospace and the automotive industries, not so much on the products that they make but more on the manufacturing side of it.
Advancements and Challenges with Hydrogen
Sanderson: We’re doing a lot more work now with stainless materials. There is quite a bit of involvement using stainless and other materials that have higher nickel contents and other materials to help work into the grain boundaries.
Working with hydrogen has some unique challenges compared to other fuels. It’s the smallest atomic molecule out there and it just wants to permeate into everything. With a lot of the higher, high-end pressures, there is a lot of chance of steel embrittlement, but if you can get away from those higher ends and try and get down to more usable, friendly working pressures, you don’t stand as much risk on the hydrogen embrittlement and dealing with leaks and permeability. So, just helping people understand that those are some of the changes that need to come into play for a safe, long-term solution in their applications.
Hannum: We have installed some hydrogen-firing capability in our lab; it was about a $400,000 investment. So, at this point, we can fire a substantial amount of input for longer durations than we could before. So, that’s really helpful when we’re looking at what the impacts are across our entire burner product range, when we look at a conversion from natural gas to hydrogen.
It also lets us perform some process-based studies where we can really simulate industrial processes and have a longer duration hydrogen firing. So, we’ve been able to support some customers by simulating some of their processes here and actually firing the materials that they would normally fire at their plant to look at hydrogen impact on those materials.
We’ve also gone to a couple of our customer sites and participated in studies with them. One of those earlier this year, right after THERMPROCESS, was Hydro Aluminum in Spain; we melted aluminum with hydrogen without any natural gas. That was, I think, the first industrial scale melting of aluminum with hydrogen.
Wuenning: We have now put into place an electrolyzer for making our own hydrogen, and not relying on the bottles coming in or on ammonia supply. We installed a big ammonia tank so that we can run the ammonia tests on site, develop the crackers and account for them. And, of course, we are involved in several research projects together with universities and some sites that do all these things to try it out.
Kelly: The latest this year is an investment for one of our factories to have an electrolyzer-type system, so a full-blown, cradle-to-grave type of system to be able to produce the hydrogen. Muncie is investing in that whole substructure with the capability of increasing to tube tankers before the electrolyzer comes so there is significant investment on that end. And from the product end, we’ve just kept testing and looking at the whole product line, not just burners, but all the controls and things to be associated with hydrogen firing.
In addition to the controls behind the system, we must also think about the development of simpler and/or more complicated systems. These updated systems are necessary because of changes in air/fuel rations and all the concerns that pop up when using different fuels.
These systems need to take into account what the process is requiring, namely holding tighter air/fuel ratios and also being less dependent on low temperature air-heating applications, but also being able to use higher temperatures and higher oxygen rates with some excess air. We’ve been working on those types of systems and looking at that when the clients are in a situation where they can fire on either fuel. How critical it is to hold capacity and air/fuel ratio and things of that nature, and how can we make that as easy as possible for the client?
But, yes, a lot of activity on that basis. And even in product development looking at the future — lower NOx and lower emissions burners that go in conjunction with hydrogen. In the lower and high temperature range, we’ve got to look at a burner that can fi re via flex-fuel type burner. Maybe not just hydrogen and natural gas but something in biofuels or renewable-type fuels.
Automating Brinell hardness testing could mean saving on expensive laboratories, as was the case for one oil tool industry manufacturer. Learn the basics of Brinell hardness testing, its strengths and weaknesses, and options for automation.
This Technical Tuesday article, written by Alex Austin, managing director of Foundrax Engineering Products Ltd., was originally published in Heat Treat Today’sDecember 2023 Medical and Energy Heat Treat print edition, both in English and in Spanish.
Brinell Hardness Testing: Strengths and Weaknesses
Alex Austin, Managing Director, Foundrax Engineering Products Ltd.
In many steelworks producing large forgings and billets, in numerous heat treatment companies, and near many factory lines producing components for safety-critical applications, you’ll find a Brinell hardness tester. These machines have been used all over the world for more than a century (the test was first demonstrated by its inventor, the Swedish metallurgist August Brinell, in 1900), determining metal hardness by means of a tungsten carbide indenter ball that leaves a dish-shaped indentation in the surface of the test material.
In the test, the material sample is placed on a rigid anvil, and the indenter descends onto it under loads ranging from 1 kg up to 3,000 kg, depending on the material. Indenters vary in diameter from 1 mm to 10 mm. Most tests use a 3,000 kg load and a 10 mm ball, and the standards always refer to this as “HBW 10/3000.” HBW stands for Hardness Brinell Wolfram, Wolfram being another name for the tungsten carbide the indenter ball is made from. After the (approximately) fifteen second indenting cycle, the indentation is measured across both its x and y axes, as a minimum, by a special calibrated microscope. The mean of the diameter readings is then fed into the Brinell equation.
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Naturally, most technicians would rather not use that equation, so they look the indentation diameter up on a chart and “read across” to the derived hardness.
The great advantage of the Brinell test, when considered alongside other metal hardness testing methods, is that the large indentation diameter (typically between 2.4 mm and 6 mm) means the test result is generally unaffected by the grain structure of the metal. It also means that the surface of the test sample can be adequately prepared in just a few seconds with an angle grinder. For these reasons, the test is regarded by many as the “default” one for rough-surfaced and/or coarse-grained samples.
On the block in image (Figure 4), the distortion around the indentations can be seen very clearly.
That seems pretty simple, but there are inherent weaknesses in the Brinell test: measuring the indentation. In our previous article (read it in Heat Treat Today’s August 2023 Automotive Heat Treat print edition), we used this image (Figure 2) to illustrate how difficult it could be to work out exactly where an indentation edge begins and ends.
You might look at Figure 2 and think, “I’m pretty confident about where that indentation edge is,” but it’s trickier than it looks, because the process of indenting doesn’t just push material downwards; it also spreads it sideways, and you get a “pile up” around the rim of the indentation. The pile up may be difficult to see on hard material, or there may be a subtle “lip” inside the pile up that represents the true edge, but considered in cross-section, indentations look roughly like this simple sketch above (Figure 3).
Figure 2. Measurement of Brinell hardness test indentation (Source: Foundrax Engineering Products Ltd.)Figure 3. Sketch of cross-section of indentation (Source: Foundrax Engineering Products Ltd.)
The overhead light illuminates the “pile up” rim very clearly on some of those indentations as a highlight around the edge. Where, exactly, does the pile up end and the true edge of the indentation begin? Bear in mind that 0.2 mm can equal 20 hardness points. You could show an indentation to three experienced workshop technicians and receive three different answers to the diameter question, and this problem has been a challenge of the Brinell test from its inception. Special blocks are available for training technicians in measurement, but the problem of operator interpretation was such that, in some quarters, the Brinell test was regarded as a bit “rough and ready.” “Ok for the workshop but not for the lab,” was perhaps how it was once seen.
Why Automate the Brinell?
The first question to consider when looking at the automation of the Brinell test is the measurement system because this is the inherent weakness. There are, of course, applications where only narrow tolerances are acceptable, and disagreements can arise between customers and suppliers.
Over the years, certain manufacturers, who mill heat treated materials for the oil tool industry, confided to us that they were regularly using expensive testing laboratories because of clients disputing the hardness figures of their products. They had previously been using manual microscopes. Obviously, this has reputational, as well as financial, consequences. If a manual microscope is employed on raw materials at the goods-in-process stage and there’s an error reading the hardness, you could find at final machining that you have put a lot of time and effort into a part that, in the end, is too hard or soft for the intended application.
Manually manipulating the microscope may not be worth the effort, especially when even a diligent operator may read the result incorrectly. With an automatic Brinell microscope, however, there is the possibility of major time and cost savings.
4 Levels of Automation
#1 Beginnings of Brinell Automation
The first step in automating Brinell hardness testing began 40 years ago when the world’s first automatic measurement microscope hit the market. The system, still being regularly refined, was able to measure the diameter of the indentation across over 100 axes, calculate the mean, and determine the hardness in a split second. It can handle most surface irregularity, operate in poor lighting, and warns operators of unacceptable surface preparation. Additionally, its precision adjusts for spatial error when lining up with a graticule. Within a few years of launch, a major oil tool manufacturer’s quality chief recommended its use to his suppliers, and user uptake was rapid.
#2 Integrated Microscope Model
A further step in automation is to dispense with operator handling of the microscope entirely by the acquisition of a tester with an integrated microscope. The microscope mentioned above, for example, is a feature on several hardness testing machines. The heavy-duty indenter holder pivots away from its normal line of thrust at the end of the indenting cycle, allowing a supra-mounted camera to view the indentation. This is hugely advantageous: no separate apparatus near the test machine, reduced handling time, and thus, much faster testing overall. Results from such machines are displayed next to the control panel and quickly uploadable to company quality systems.
Figure 4. Block with distortion around indentations (Source: Foundrax Engineering Products Ltd.)
#3 Dispensing of Manual Operations
Another automation option is to dispense with a hand-cranked anvil capstan and purchase a tester with a fixed anvil and movable test head. The technician is not required to manually raise and lower the anvil to allow for variations in the size of sample. Instead, the test head automatically “takes up” the space and also clamps the test piece very securely in place during the test cycle.
#4 Incorporate Custom Hardness Tester in Production Line
The fourth, and obviously most dramatic, automation step to consider is incorporating a custom-designed hardness tester into the production line. In some industries, this is essential. Large billets and forgings can’t be lifted into the jaws of a benchtop or floor-standing Brinell tester; so, for highly accurate testing of such items, a larger machine is required (Figure 5).
Figure 5. A custom-designed production line hardness tester. This machine is now in Texas. (Source: Foundrax Engineering Products Ltd.)
The whole gantry moves on one axis of travel while the test head moves perpendicular to that and, of course, up and down. This provides the full x, y, z movement. Large samples are maneuvered on and off by crane. The test head assembly incorporates the automatic microscope and results are displayed on a screen beside the control panel. Test results can be instantly uploaded to factory quality systems. The head assembly can also incorporate a milling tool for surface preparation!
With any decision to purchase plant and machinery equipment, some form of cost-benefit analysis is worthwhile. Clearly, if you’re doing a significant amount of business annually with a customer who is threatening to cease contracting with you because your hardness measurements are wrong too often, then the decision to buy an automatic microscope is not a difficult one. If staff are on overtime because mandatory hardness testing is adding too much time to production schedules, then a heavy-duty production machine with automatic microscope, movable test head, and sample clamp will pay for itself easily.
One thing is certain: Every automation option in Brinell testing increases accuracy and saves time.
About the Author
Alex Austin has been the managing director of Foundrax Engineering Products Ltd. since 2002. Foundrax has supplied Brinell hardness testing equipment for 60+ years and is the only company in the world to truly specialize in this field. Alex sits on the ISE/101/05 Indentation Hardness Testing Committee at the British Standards Institution. He has been part of the British delegation to the International Standards Organization advising on the development of the standard ISO 6506 “Metallic materials – Brinell hardness test” and is the chairman and convenor for the current ISO revision of the standard.
Skuld LLC announced that they had purchased the site belonging to the former Champion Foundry in Piqua, Ohio, a gray and iron foundry that had closed in March 2017. The company will continue to be focused on innovation in the metals industry, serving their clients through a number of innovations related to novel materials and manufacturing technologies.
The four buildings with nearly 32,000 square feet of space are being refurbished to be capable of casting a wide range of ferrous metals (gray, ductile iron, steels) and nonferrous metals (aluminum, brass, bronze, copper, nickel alloys). The plant will initially have 3,000 tons of capacity but plans are in place to expand to ten times that capacity in the next few years.
Skuld will be installing machining, foam blowing, a printer farm, and heat treating, adding to their current 5 small heat treat furnaces and adding to their operations, which primarily consist of lost foam casting. The new installations will aid the company as they serve the defense, tooling, and heavy equipment industries. They are also beginning to target production of heat treat fixtures and baskets.
Sarah Jordan, CEO, Skuld LLC
Production at the new site is scheduled to begin in April 2024. Sarah Jordan, CEO of Skuld LLC, commented, "Skuld is looking forward to getting our induction melting furnaces installed so that we can produce higher temperature iron, steel, and nickel alloy castings." She continued, "many [heat treaters] have custom furnace components and fixtures that require high temperature metals. These parts can have extremely long lead times, sometimes over a year, which is a problem if they are stocked out." By using their new tooling free processes, Jordan says that they can help clients drive lead times down to less than a month, if not a day for emergency spares.
Skuld is a company founded by two metallurgical engineers, Mark DeBruin and Sarah Jordan, with ties to the heat treat industry. DeBruin is the former CTO of Thermal Process Holdings. Jordan formerly worked in heat treating at Timken and Commercial Metals and was a staff engineer for Nadcap heat treat.
The full press release from Skuld LLC is available upon request.
Metal 3D additive manufacturing has grown dramatically in the last five years. Nearly every metal printed part needs to be heat treated, but this presents some challenges. This article will address some of the challenges that a heat treater faces when working with these parts.
This Technical Tuesday article, written by Mark DeBruin, metallurgical engineer and CTO of Skuld LLC, was originally published in December 2023’sMedical and Energy magazine.
Mark DeBruin Metallurgical Engineer and CTO Skuld LLC
In my experience, on average, about 10% of all 3D metal printed parts break during heat treatment; this number varies depending on the printer and the unique facility. While materials can be printed with wire or even metal foils, I’m going to mainly focus on the approximately 85% of all metal 3D printed parts that are made from metal powder and either welded or sintered together.
Most metal printed parts normally have heat added to them after printing. In addition to the heat of the printing process and wire electrical discharge machining (EDM) process to separate the part from the build plate, heat may be added up to five times. These steps are:
Burnout and sintering (for some processes such as binder jet and bound powder extrusion)
Stress relieving
Hot isostatic pressing (HIP)
Austenitizing (and quenching)
Tempering
3D printing can create a non-uniform microstructure, but it will also give properties the client does not normally desire. Heat treating makes the microstructure more uniform and can improve the properties. Please note that heat treating 3D printed parts will never cause the microstructure to match a heat treated wrought or cast microstructure. The microstructure after heat treating depends on the starting point, which is fundamentally different.
If the part is not properly sintered, there is a high chance it will break during heat treatment. It may also exhaust gases, which can damage the heat treat furnace. The off gases will recondense on the furnace walls causing the furnace to malfunction and to need repair. This can potentially cost hundreds of thousands of dollars.
During powder 3D printing, there is a wide variety of defects that can occur. These include oxide inclusions, voids, unbonded powder, or even cracks that occur due to the high stresses during printing. Even if there are not actual defects, the printing process tends to leave a highly stressed structure. All of these factors contribute to causing a print to break as the inconsistent material may have erratic properties.
In a vacuum furnace, voids can be internal and have entrapped gas. Under a vacuum, these can break. Even if something was HIP processed, the pores can open up and break. Even if they do not break and heat is applied, the metal will heat at different rates due to the entrapped gas.
Figure 1. Macroscopic view of a 3D printed surface (left) compared to machined surface (right) (Source: Skuld LLC)
There are also issues during quenching due to the differences in the surface finish. In machining, the surface is removed so there are not stress concentrators. In 3D printing, there are sharp, internal crevices that can be inherent to the process that act as natural stress risers (see Figure 1). These can also cause cracking.
When 3D printed parts break, they may just crack. This can result in oil leaking into the parts, leading to problems in subsequent steps.
Figure 2. Example wire mesh basket (Source: Skuld LLC)
However, some parts will violently shatter. This can happen when pulling a vacuum, during ramping, or during quenching. This can also cause massive damage to the furnace or heating elements. It can potentially also injure heat treat operators.
A lot of heat treaters protect their equipment by putting the parts into a wire mesh backet (Figure 2). This protects the equipment if a piece breaks apart in the furnace, and if a piece breaks in the oil, it can be found.
Print defects in metal 3D printed parts can be a challenge to a heat treater. Clients often place blame on the heat treater when parts are damaged, even though cracking or shattering is due to problems already present in the materials as they had arrived at the heat treater. As a final piece of advice, heat treaters should use contract terms that limit their risks in these situations as well as to proactively protect their equipment and personnel.
About The Author
Mark DeBruin is a metallurgical engineer currently working as the chief technical officer at Skuld LLC. Mark has started five foundries and has worked at numerous heat treat locations in multiple countries, including being the prior CTO of Thermal Process Holdings, plant manager at Delta H Technologies, and general manager at SST Foundry Vietnam.
Sludge, scale, and dirt are all undesirables in quench oils that can cause detrimental effects during quenching. Bag filtration and centrifuge filtration are put to the test in this investigation. Compare the results before you make your next purchase.
This Technical Tuesday article, written by Greg Steiger, senior account manager, and Michelle Bennett, quality assurance specialist, at Idemitsu Lubricants America, was originally published in November 2023’s Vacuum Heat Treatmagazine.
Introduction
The primary role of a quench oil is to dissipate the heat from a quenched load safely, quickly, and uniformly. Both sludge and heat scale have a higher heat transfer coefficient than quench oil and dissipate heat more than this quench medium. This can affect the performance of a quench oil.
To obtain the desired metallurgical results, the operation of a quench system must be both consistent and uniform. The presence of sludge from quench oil oxidation and scale within the quench oil, pump, and heat exchangers can lead to variability in key parameters such as grain size, hardness, case depth and surface finish. The best way to minimize the detrimental effects of sludge and scale is to remove these contaminants by filtration. This article will compare the two most popular types of commercial filtration available for oil quench systems: bag filters vs. centrifuge filtrations.
This article will compare the two most popular types of commercial filtration available for oil quench systems: bag filters vs. centrifuge filtrations.
Test Methods
To simulate a two-stage bag filter, the following lab procedure was followed.
A 300-mL sample of used quench oil was passed through a 75-micron filter paper. The filtrate from the 75-micron filter was then filtered through a 25-micron filter paper. To simulate the pressure typically found in an industrial bag filter, the filtration in both the 75-micron and 25-micron papers was aided by a vacuum pump that pulled used quench oil through the filter paper.
To simulate the effects of centrifugal separation, a benchtop centrifuge was used. A 300-mL sample of used quench oil was placed in a centrifuge tube and centrifuged for 25 minutes at a speed of 3,500 RPM. An additional 300-mL sample was placed in an identical centrifuge tube and centrifuged for 180 minutes at 3,500 RPM as well.
In addition to the lab testing of dirty quench oil samples, we monitored the particle count and pentane insolubles in samples from an in-use heat treating furnace. This study began with charging the furnace with clean quench oil that was filtered using a single stage 25-micron filter and collected after each filtration. At the conclusion of each timed centrifuge session, the filtrate and the centrifuged sample were tested across five tests, see Table 1.
Table 1. Tested parameters after simulated bag or centrifuge filtration (Source: Idemitsu Lubricants America) Note on Table 1: Pentane insolubles measure sludge and scale present in the quench oil after the filtration through the barrier filter or after the centrifuge. Millipore testing is a measure of the overall cleanliness of the quench oil after either filtration or centrifuging. Carbon residue testing measures the Conradson carbon in the filtered or centrifuged quench oil and is designed to determine if any of the quench speed improver additive in the quench oil has been removed via filtration or centrifuging. By measuring the total acid number (TAN) of the quench oil, it is possible to determine if the quench oil is becoming oxidized and beginning to create unwanted sludge. The ISO Particle Count tests for solids contamination, providing a quantitative value for the number of particles that are larger than 4 μm, 6 μm, and 14 μm.
Filtration Results
Because industrial quench oil filters are under a slight pressure, it would be very difficult to replicate this in a laboratory setting. To simulate the slight pressure found in industrial oil filters, we used a Buchner funnel connected to a vacuum pump to simulate the industrial pressure vessel. A similar setup is depicted in Figure 1.
The results post-filtration are depicted in Table 2 and Table 3.
Table 2. Tested parameters after filtering 300 mL of quench oil through 75-micron filter (Source: Idemitsu Lubricants America)Table 3. Tested parameters after filtering 300 mL of quench oil through 25-micron filter (Source: Idemitsu Lubricants America)
Another popular method of filtration in a heat treating facility is through a centrifuge. While it is impractical to use a full-size industrial centrifuge in a lab, the same results can be achieved through the use of a smaller sample size and a benchtop centrifuge. A benchtop centrifuge similar to the one seen in Figure 2 was used to produce the results in Tables 4 and 5 (below).
Understanding the Test Methods: Bag/Barrier Filtration
Figure 3. Polyethylene felt filter bag and filter canister (Source: SBS Corporation)
Bag (or barrier) filtration is the most common type of filtration used in quench oil filtration. For the heat treater, there are many different size filters available, as well as different configurations varying in the number of canisters and filters. The filter creates a barrier that particles greater than the pore size in the barrier cannot pass. The primary reasons for its popularity are economics, simple operation, and design. A typical polyethylene bag filter and filter cannister can be seen in Figure 3.
The most common filter sizes are 50-micron and 25-microns. Both 5-micron and 25-micron filters were used in this investigation because the test sample contained a high level of pentane insoluble. Additionally, since it is commonly thought that using a 50-micron filter will cause blinding and clogging, we chose a 75-micorn filter and a subsequent filtration step of using a 25-micron filter to simulate a common two-stage quench oil filter.
Understanding the Test Methods: Centrifuge Filtration
Using a centrifuge to filter out sludge and scale is also commonly used in many heat treating operations. The difference between centrifugal filtration and barrier filtration is centrifugal filtration relies on gravity, friction, and centrifugal force to separate the particles from a quench oil instead of a physical barrier (Figure 4).
Figure 4. Horizontal centrifugal filtration (Source: SBS Corporation)
In the horizontal centrifugal filtration diagram, the dirty oil enters the tangential opening (section #1) and is forced into a spinning motion. A centrifugal force (occurring in section #2) is based on the spinning pentane insolubles, scale, and any other solids contained in the dirty oil.
In section #3, the friction created by the flow of the solids, scale, and other undesirables encountering the steel body of the centrifugal separator creates a low viscosity shear layer. In section 4, the clean liquid travels through a vortex and leaves through a side discharge. The slowing velocity of the undesirables allows gravity to pull them into the debris collection area in section #5. The now cleaned oil regains its velocity and continues through the vortex created by the centrifugal forces acting on the solids to a center discharge and back to the quench tank. As the debris fills section 6, a light will illuminate, indicating the receptacle is full and needs to be emptied.
Once the undesirables fill the debris collection area, an indicator light signals the receptacle is full and a gate knife control valve (section #7), is manually closed so the debris collector can be opened via the closure (section #8).
Discussion
Table 4. Tested parameters after centrifuging 300 mL of quench oil sample @ 3,500 RPM for 25 minutes
(Source: Idemitsu Lubricants America)Table 5. Tested parameters after centrifuging 300 mL of quench oil sample @ 3,500 RPM for 3 hours
(Source: Idemitsu Lubricants America)
As seen in Tables 2 and 3, filtration does improve the overall cleanliness of the dirty quench oil. The weight percent of the pentane insolubles showed a significant improvement when filtered through the 25-micron fi lter. However, the level of pentane insolubles was still outside of the suggested limits for the quench oil.
This was not seen when the quench oil was filtered through a 75-micron filter. The 75-micron filter had little or no effect on the Millipore results. The Millipore results increased when filtered through a 75-micron filter. This leads us to believe some of the particles within the dirty oil were forced through the 75-micron filter and not through the 25-micron filter, as the 25-micron filter showed an improvement in Millipore results.
An ISO particle count was not possible on the original used samples or the filtered samples because the filter clogged on all three test samples.
The largest difference in results lies in the carbon residue testing. The level of carbon residue is essentially the same after both the 75-micron and 25-micron filter samples. Both of the carbon residue levels are within the normal suggested limits. However, the high level of sludge in the original dirty sample is likely removing some of the quench speed improver from the quench oil. The removal of the quench speed improver changes the performance of the quench oil over time.
In examining the results of the centrifuge testing in Tables 4 and 5, it is clear centrifuging for 25 minutes has better effect on the cleanliness of the oil sample than filtering through a 25-micron filter. The level of pentane insolubles after centrifuging for 25 minutes at 3,500 RPM is still outside of the suggested limit. However, running the centrifuge for three hours under the same conditions not only brings the pentane insolubles within the suggested limits, the Millipore and particle counts also see an improvement over the virgin oil sample results. The carbon residue levels behave much the same as they do in the filtration tests.
What is significant is the year-long study we conducted using actual customer data. In this study, a furnace was dumped, cleaned, and then filled with clean virgin oil. The authors then tested the ISO particle counts and pentane insolubles for one year after the furnace was charged with clean oil. These results are seen in Table 6. These data show essentially no change in the particle counts and a slight improvement in the level of pentane insolubles over the one-year period.
Table 6. Particle count and pentane insolubles on a clean quench oil (Source: Idemitsu Lubricants America)
Conclusion
From the testing conducted, it is clear the filtration through a 75-micron filter has little to no effect upon the tested parameters and the performance of the quench oil. The high levels of pentane insolubles will likely clog heat exchangers, pumps, and valves within the quench system. The dirty oil will also likely cause metallurgical issues such as isolated soft spots due to the slower heat transfer of the dirty oil. The results of filtering a dirty oil through a 25-micron filter show some improvement in the pentane insoluble levels. However, the result is still outside of the recommended limits for the oil. Additionally, the ISO particle counts were not able to be tested due to the overall dirty condition of the filtered sample.
In contrast to the bag filter samples, the centrifuge samples showed a marked improvement over the dirty sample. While the pentane insoluble level was slightly out of the recommended limit for the 25-minute centrifuge sample, all results were within the recommended specifications for the three-hour centrifuge sample. In some cases, such as the particle count, the centrifuge sample had better results than the virgin sample.
While the centrifuge and filter results both show how hard it is to effectively clean a dirty quench oil, the results from the year-long study show very little difference in particle counts and a slight decrease in pentane insolubles, which can be explained through the normal addition of virgin make up oil to the quench system.
It is clear both centrifuge separation and bag filtration can improve the overall condition of a dirty quench oil. However, if your level of dirt, sludge, and scale reaches near the levels of the tested sample, a centrifuge is better at removing these than filtration. Overall, the data show the most important and efficient method is to begin filtering a clean quench oil as soon as the quench tank is charged.
About The Authors
Greg Steiger is the senior account manager at Idemitsu Lubricants America. Previous to this position, Steiger served in a variety of technical service, research and development, and sales and marketing roles for Chemtool Incorporated, Witco Chemical Company, Inc., D.A. Stuart Company, and Safety-Kleen, Inc. He obtained a BS in Chemistry from the University of Illinois at Chicago and recently earned a master’s degree in Materials Engineering at Auburn University. He is also a member of ASM International.
Michelle Bennett is the quality assurance specialist at Idemitsu Lubricants America, supervising the company’s I-LAS used oil analysis program. Over the past 12 years, she has worked in the quality control lab and the research and development department. Her bachelor’s degree is in Chemistry from Indiana University. Michelle is a recipient of Heat Treat Today’s 40 Under 40 Class of 2023 award.
Are there rapid changes in the North American aluminum industry to accommodate trending technology, or does the aluminum market have a different focus? Enjoy this Technical Tuesday article, in which six industry players responded to the following survey from Heat Treat Today’s editorial team in August 2023.
Steady and Increasing Melters’ Demand
Contact us with your Reader Feedback!
Is demand increasing or decreasing for aluminum processing/melting equipment?
AFC-Holcroft: “Yes, we continue to see opportunities for a variety of furnaces for T5, T6, and other aluminum heat treating processes. We recently signed a license agreement with Sanken Sangyo in Japan to offer their aluminum rotary furnace designs in the U.S. and Canada.”
Can-Eng Furnaces Intl., Ltd.: “Yes, particularly in finished component heat treatment systems (T4, T5, T6, and T7 processes). The processing demand is coming from new vehicle (ICE, hybrid, electric) model line-ups that are focusing heavily on lightweighting body in white (BIW), structural, and suspension components that are being converted from steel to aluminum.”
Lindberg/MPH: “We have seen an increase in aluminum scrap melting in the recent past with larger capacity melters being quoted.”
Premier Furnace Specialists: “We’re seeing a steady demand for aluminum processing equipment. Typically, our clients are requesting either aluminum solution furnaces, drop bottom furnaces, or pre-heat furnaces. There has been an increased demand for larger furnace chamber sizes and heavier load capacities as more customers are requesting furnaces that can handle a variety of materials, temperature ranges, and processes. It seems the aerospace industry is driving most of the demand at the moment.”
SECO/WARWICK: “On the molten metal side of the SECO/WARWICK business, there are a few significant projects out there which are active, and the level of inquiries is good!”
Wisconsin Oven: “We have seen an uptick in aluminum solution treat and aging equipment in recent years.”
Tracy Dougherty Chief Operating Officer AFC-Holcroft LLC Tim Donofrio Vice President of Sales Can-Eng Furnaces International, Ltd.Kelley Shreve General Manager Lindberg/MPHJacob Laird Mechanical Engineer Premier Furnace Specialists, Inc./BeaverMaticDan Peterson Product Manager Molten Metal Furnaces SECO/WARWICK Corp.Mike Grande Vice President of Sales Wisconsin Oven Corporation
AM/3D: Allusive Adoption
Has additive manufacturing/3D printing contributed to current business levels?
AFC-Holcroft: “It’s been an ongoing topic, but volumes are still low, which has kept heat treating equipment investments at a minimum.”
Lindberg/MPH: “There have been more requests than in the past few years for sintering applications which, I believe, is largely driven by the increase in 3D metal printing manufacturing.”
Premier Furnace Specialists: “The company has been receiving a number of requests for smaller batch style ovens for the processing of additive manufactured/3D printed materials. We have also fulfilled a number of requests to alter existing or used systems to meet new process requirements.”
SECO/WARWICK: “On the molten metal side, this would be what we call the powdered metals industry, we has not seen much interest in that area this year. One exception is an inquiry that our sister company Retech was fielding.”
Have international supply chain disruptions impacted demand for your company’s equipment?
AFC-Holcroft: “There are certainly disruptions, but we’re finally starting to see some improvements. Our team has worked hard to mitigate the supply chain challenges through unique forward-looking programs with our suppliers and clients. As far as demand goes, it has not had an impact at all. In fact, we are currently experiencing booking levels that we haven’t seen in more than 20 years.”
Can-Eng Furnaces Intl., Ltd.: “Clients are planning ahead to address the longer lead times.”
Lindberg/MPH: “We have noticed that supply chain issues in general, both domestic and international, have created an environment where lead times to build equipment have more than doubled. This has caused many clients to begin looking for alternative solutions to meet their needs, as they cannot wait two-thirds of a year for equipment. The largest delays are with refractory, gas burners, alloy, and many various control components.”
Premier Furnace Specialists: “Actually, we’ve seen an increase in demand for our equipment from various industries impacted by disruptions. Many companies seem to be reassessing their supply chains and expanding production capacity to avoid future disruptions.”
Dual pit furnace and water quench tank system designed and built for a client in the aluminum castings industry. It is used for aluminum solution heat treating of thick walled castings. Each furnace has a 4,000 pound gross load capacity and an operating temperature range of 300°F – 1100°F. (Source: Premier Furnace Specialists/BeaverMatic)
SECO/WARWICK: “Lately our clients are for projects that are further out, 1–2 years in some cases. Most of our end users are aware that prices are still moving up and deliveries are stretched out, however there have been some improvements of deliveries on MCC’s and PLC’s.”
Wisconsin Oven: “Not that we know of.”
The State of Sustainability in Aluminum Market
Has the sustainability push affected demand for your equipment?
Horizontal quench system used for the solution treatment of aluminum parts (Source: Wisconsin Oven)
AFC-Holcroft: “Again, no impact on demand, but our group has been offering many ‘green’ options on our equipment for years to assist our clients in the drive for a reduction in their carbon footprint.”
Can-Eng Furnaces Intl., Ltd.: “Yes, there’s more emphasis on reduced environment impact processes and equipment designs.”
Lindberg/MPH: “Not really. We have had a couple of RFQ[ET7] ’s come in related to green energy, but they are very slow-moving projects with a lot of R&D on the buyers’ end. Additionally, we have been asked to partner with these clients to develop a solution to help them meet the end goal.”
Premier Furnace Specialists: “For a minor segment of clients, the push for sustainability seems to be driving a demand for electrically heated equipment rather than natural gas. Even for those clients, however, the main deciding factors are still local utility costs, existing facility restrictions, and familiarity with existing equipment.”
SECO/WARWICK: “Environmental sustainability has definitely affected what our clients are looking for on most new inquires. Most have strict emissions requirements and are looking for combustion systems with lower NOx and higher fuel efficiency. Peripheral hooding is also commonly requested to capture emissions from around door openings and over charge wells. I would not say that sustainability has diminished the demand, however it has affected what they need with regard to emissions compliance.”
Wisconsin Oven: “Clients occasionally request energy-efficient features and designs, but not more often than in the past.”
Anticipating Growth and Novel Aluminum Applications
What plans are you making to meet future market demand?
AFC-Holcroft: “We are a global group and have recently restructured our organization to better serve our customers. We have also undergone a facility expansion to help reduce our carbon footprint and provide our clients with the best products and deliveries available in the market. This includes an expansion of our build to stock production planning to greatly reduce lead times on UBQ furnaces and EZ endothermic generators among other products.”
Can-Eng Furnaces Intl., Ltd.: “We have increased emphasis on electric battery vehicle component and materials processes and equipment design development. Additionally, we are planning further use of electric energy as an alternate heating source for system designs.”
Lindberg/MPH: “We are looking to work with vendors to create vendor managed inventory in order to reduce lead times, as well as hire additional employees to reduce labor driven lead times. We continually look for additional vendors to remain cost competitive and reducing the overall cost of manufacturing.”
Premier Furnace Specialists : “We’ve expanded vendor and supplier listings. We have also gained experience implementing existing and new alternatives for almost all of our furnace components. By reassessing our standard component choices and offering a variety to clients, we have been able to substantially reduce lead times which allows for more efficient and flexible production while reducing costs.
“We have also added new technology to aid in our manufacturing. Building parts in-house significantly cuts down on lead times and pricing. Thus, clients know that their equipment will have little or no downtime, saving them the time and stress of not running product.”
SECO/WARWICK: “We are adding engineers, field service technicians, etc. and having our “seasoned veterans” bring them up to speed! We have also moved to a larger new office location to accommodate future growth.”
Wisconsin Oven: “We have acquired additional floorspace in recent years and have been hiring aggressively in the last six months.”
What is deoxidation and how can it be useful for energy savings? In fact, can the process really save money and improve the quality of iron?
Sometimes our editors find items that are not exactly “heat treat” but do deal with interesting developments in one of our key markets: aerospace, automotive, medical, energy, or general manufacturing. To celebrate getting to the “fringe” of the weekend, Heat Treat Today presents today’s Heat Treat Fringe Friday article that answers these questions. Hint: Deoxidation is helpful, and the article points to how annealing heat treatment may not be necessary in order to meet the ferritic ductile iron elongation specification levels.
An excerpt:
Ductile iron producers typically add copper to the melt to enhance the material’s tensile strength. That becomes unnecessary when base iron is deoxidized prior to magnesium conversion treatment. The deoxidized iron’s strength rises to near 100,000 psi after deoxidation, without copper addition. Deoxidation removes the suspended MgO oxide particles that reduce strength and elongation in ductile iron.
Watlow®, a designer and manufacturer of complete industrial thermal systems, has recently completed its acquisition of Eurotherm®, a provider of controls, systems, software, and services for industrial markets around the world. How did the acquisition happen, what future technologies can we expect, and what should heat treaters know about this change?
Joining Doug Glenn, Heat Treat Today publisher and Heat Treat Radiohost, is Watlow CEO Rob Gilmore to answer all your questions.
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.
Who Is Rob Gilmore? (00:43)
Contact us with your Reader Feedback!Rob Gilmore CEO Watlow Source: Watlow
Doug Glenn: Welcome everyone. Doug Glenn here, with Heat Treat Today. I have the great privilege of talking with Rob Gilmore, CEO of Watlow. I’m excited to talk with you, Rob. We’ve got quite a bit to cover today, so let me just jump in.
First off, I want to talk about you to give our listeners a sense of you and your background. I wasn’t stalking you, but I was doing a little bit of research, and I was pretty impressed.
I’ve got a list of titles here of things you’ve done at Watlow for the last 35 years: co-op student intern — that’s where you started, which is crazy — and then R&D, product development, manufacturing, engineer, design, development manager, operations product manager, semiconductor business group manager — where you spent a good bit of time — and VP and chief. So, tell us all about your experience at Watlow.
Robert Gilmore: Yes, I’ve had an exciting journey at Watlow and was fortunate enough to get started early in my career and figure out that I wanted to be in engineering. When I first started in engineering, I wasn’t too sure that was what I wanted to do, but when I started with Watlow, it definitely validated that this was it.
I was fortunate enough to get in the R&D group and learn a lot about both thermal applications and how to apply electric heat. It just continued to draw me to it. After I got into developing a lot of products, I entered into the manufacturing side to make sure I knew how we built those products. Then I really got to spend a lot of time with customers and customers’ applications to provide good solutions and solid solutions to our customers.
Doug Glenn: We’re going to get into a little bit of the Watlow company history here. Most recently, in 2021, you became CEO of Watlow, worldwide, correct?
Robert Gilmore: That is correct. We were fortunate to get partnered with a company called to really help us really accelerate and advance our strategy in the business.
About 10–12 years ago, we really knew that the thermal loop coming together was really going to help us optimize our customers’ applications around process heating and heat treat. We’ve seen a lot of success in that arena, and we knew that we wanted to invest much more capital into the business and help our customers be successful in those applications.
Doug Glenn: I want to talk a little bit more about Tinicum in a minute, but I think I heard that you, at one point in time, worked with or for Lindberg.
Robert Gilmore: Actually, it was early in my career, right after college. Lindberg was a very important customer of ours that was dealing with heat treat and furnaces, and they challenged us with some key applications.
My boss — this is a little bit of history of how I learned a lot about heat treat — said, “They’ve (Lindberg) got some significant thermal challenges and I’m going to drop you off here and don’t come back until you figure out how to solve those thermal challenges.”
I’ve always had a passion for heat treat and heat treat applications because they are the most challenging. I learned a lot about the application and how to optimize it.
Doug Glenn: And that was Lindberg rg, the commercial heat treat company, yes?
Robert Gilmore: I think it was actually their equipment manufacturing company.
They definitely did a lot in the auto industry, and there were really some challenging applications.
Doug Glenn: You have a decent amount of heat treat experience if you’ve been working with companies like Lindberg. That’s really good.
And, by the way, I just wanted to make one other comment: I think you’re in a rare class as somebody who has worked for the company for 35 years. That’s just really unheard of.
Robert Gilmore: Yes, it’s been a great company. We’ve been fortunate enough that the family atmosphere, the opportunity to do a lot of different things in the organization, and the ability learn a lot in the organization made it attractive. And it’s not only me; we’ve got a lot of talent in the business with years of service, application knowledge, and capabilities. It’s just been a great experience.
Doug Glenn: I think it speaks to the man, somebody who sticks around that long, as well as the company culture.
Meet Watlow (06:05)
Let’s talk about Watlow for a while.
I know a lot of people in our industry know Eurotherm and a lot of people know Watlow. Watlow hasn’t been as “core,” let’s say, to the heat treat, high temperature, thermal processing market as Eurotherm might have been.
Watlow’s company logo
Robert Gilmore: The headquarters are in St. Louis, but we’ve quickly become a pretty global organization organization over the past five years. That’s why we made some of the decisions that we did; our customers are global — they’re expecting to be supported globally.
So, we’re in headquarters. But that being said, I like to tell people it used to be 75% of our employees were in the Midwest, but now, 75% are outside the U.S., looking at the growth and the acquisitions that we’ve made in business.
Doug Glenn: I saw that the company was founded in 1922. So, just last year, you guys celebrated 100 years.
Robert Gilmore: That’s correct. It’s been a great journey for the company. It’s a great, rich history of solving thermal problems over the years. It’s a fun organization, from that perspective.
Doug Glenn : It was very impressive. I know now, it’s said there are at least 14 different sites around the globe — manufacturing, development, sales, service, etc.
Robert Gilmore: At least 14 different manufacturing sites, and then probably additional sales offices and development offices across the globe.
Doug Glenn: And Watlow, the core business encapsulates heaters, temperature controls, temperature sensors. How would you describe the core business of Watlow?
Robert Gilmore: Yes, I would say we look at it as a complete electric thermal loop. So, if you look at heaters, sensors, power devices, power management devices, along with temperature controls. That is the context of that thermal loop.
Doug Glenn: Gotcha. And then we did mention earlier, it was a family-owned business up until 2021, right?
Robert Gilmore: 2021, yes, is when we partnered with Tinicum.
Doug Glenn: Which is a private equity firm.
Robert Gilmore: Tinicum is more family oriented and it’s one of the reasons we partnered with them. But many of the family stayed in the business, just in a minority, shareholder position.
As Watlow started to advance its strategy, really around 2010, the goal was to bring the thermal loop together.
So, there was an acquisition in 2013 called Semiconductor Tooling Services (STS) and then there was the acquisition of Yarbrough that happened in 2018, and then CRC Inc. happened in 2020.
Doug Glenn: And there were a lot of product introductions. I was very impressed, looking down through the Watlow history on your website, seeing the amount of new products and services and acquisitions and expansions into various countries.
The bottom line is you are a global presence.
Robert Gilmore: We pride ourselves in being able to solve complicated thermal problems. We’ve got a very rich history of having solid technical and engineering talent, so usually if somebody can’t figure it out, they call us and we help them figure it out and work with them through that.
Key Markets (11:14)
Doug Glenn: Rob, if you don’t mind, could you just hit on some of the key markets? I know, obviously, you’re not all heat treat. I know you’re doing semiconductors.
In fact, I found it very interesting, by the way, as I was looking at your history, that you started out with shoes, some sort of a shoe heater.
Robert Gilmore: Yes, if you look at the history, the founder of the business recognized there was a way to mold leather more efficiently with an electric heater, and he created the electric heater (versus steam heating) in those applications. That’s how the business took off.
Over the years, we have continued to develop new products and new solutions as electric became more of an attractive solution. We pride ourselves in bringing the together.
Doug Glenn: Let’s talk about Watlow, not Eurotherm quite yet. Are there any major initiatives that you’ve got going on now?
Robert Gilmore: Yes. As Watlow was growing up as an organization, we were very product-centric, so we sold our components into a lot industries. Ten years ago, we decided that if we brought the thermal loop together to our customers, and targeted applications that had thermal challenges in there, we could bring a better solution to their process or their equipment in those applications.
That got us started on more of a market and application focus, starting with semiconductors.
That’s been the mantra. As we find that thermal is important in these different applications, we focus on those applications and provide those solutions.
“The semiconductor has definitely been attractive.”
So, the semiconductor has definitely been attractive. When you look at refrigerated transport and some of these markets looking for a cleaner, more efficient, alternative (what I would call “the diesel engine market”), we find that in cases where we have the opportunity to use the thermal system to increase fuel efficiency or make the engine burn much cleaner, that we’re helping our customers solve such problems.
There has been a big initiative to move from fossil fuel solutions to electric solutions. We see a lot of opportunities where we can help customers come up with more advanced heat exchanger solutions to optimize and provide a more efficient thermal solution to those applications. So, we’re helping many customers solve those applications.
We’re in medical. We’re in a lot of food processing, food equipment, as you might guess.
But we try to focus on those challenging applications where thermal is critical to the process or to the equipment, and help those customers optimize those solutions.
Green Initiatives and the Electric Thermal Loop (14:36)
Doug Glenn: You hit on one thing that I was going to ask you about: the green initiative, and if that’s really played well for you guys. Would you say yes to that?
Robert Gilmore: Absolutely. When you think about emissions reductions or clean energy, thermal is critical in those applications, and that is driving a lot of our products, solutions, and technologies. We’re helping customers solve those problems day in and day out.
Doug Glenn: Could you give our listeners any sense of magnitude or size of Watlow, whether it be total number of employees, annual sales, or profit margin — just kidding on that last one.
Robert Gilmore: We have around 4,000 employees, plus or minus, at any one time, and growing fast. I probably got that number wrong. We’re probably approaching a billion dollars in revenue. I might have to think about whether I want to share that or not, but it kind of gives you a relative size of the organization. We’re invested heavily in a lot of the products and technologies and supporting our customers, right now, to try to scale the business globally.
An illustration of the electric thermal loop.
Doug Glenn: Returning to the “green” topic I asked you about, there was a term you continually mentioned. It may be a term that you’re using there at Watlow that some of our readers and I might not understand: the concept of the “electric thermal loop.” Can you address that? What do you mean by that?
Robert Gilmore: Electric has been prevailing for a number of years, but when we look at the electric thermal loop, it is descriptive of the heater engine, the sensing device, the power management system, and the control system. That’s what I call that loop.
The industry (whether OEMs or end-users) addresses thermal loop from a component mindset: somebody is providing the electric heater, somebody is providing the control system, somebody is providing the sensor.
But we really find where we specialize is optimizing for the customer’s process or for the equipment to be optimized. That’s what we focus on. That’s why I call it the thermal loop. It’s, How do I optimize process performance or application performance by focusing on ? Am I getting a real sense of management process temperature or safety limits that we have to control, because we’ve got a volatile gas or something of that nature? So, we try to optimize that thermal loop; that’s the job that we do.
Doug Glenn: That makes sense. And, also, I can see how there would be value there to your engineer-based clients in that they can come to one place and you can say, “Okay, listen, we can help create the heat, we can apply the heat, we can measure and control it.”
Robert Gilmore: That’s correct, yes.
What the Acquisition of Eurotherm Offers Heat Treaters (18:40)
Doug Glenn : Let’s jump to Eurotherm. The acquisition of Eurotherm happened in 2022, which was just last year. It seemed like a long time ago, but it wasn’t all that long ago.
Robert Gilmore: Yes, it’s gone by fast, and we’re coming up on a one-year anniversary.
Doug Glenn: So, if you can take yourself back a year or maybe even two, when you first started looking at that acquisition, at the time, Eurotherm was part of Schneider Electric, which is a huge international conglomerate. What was appealing to you guys and where did you think you were going to take this thing?
Robert Gilmore: Eurotherm had been on Watlow’s radar for a number of years. We valued them as a market leader and a competitor in the marketplace, especially when it comes to the controls and the power management space. We always viewed them as being a leader on many fronts, from the product and technology side.
As we got closer, we also acknowledged that they were in some attractive adjacent markets that we thought we could use to complement their technology and capability to help us grow in scale in the business. Then, as we got to know them a little bit better, we recognized the talent and the capability that they had.
Watlow serves a lot of OEMs. OEMs are probably the majority of our business. Eurotherm leans more towards what we would call “the end-user market.” They’re really knowledgeable about these key applications and markets. They know what customers are doing in those applications. We found that very attractive, and when we were able to acquire them, we got a wealth of talent and knowledge around markets and applications, as well as the products that we were attracted to as well.
“Eurotherm had been on Watlow’s radar for a number of years. We valued them as a market leader and a competitor in the marketplace, especially when it comes to the controls and the power management space.”
Also, it increases our presence in Europe and Asia. It’s a good complement from that perspective.
We’re pretty excited about having them on board. We’re finding opportunities, all the time, to help our customers solve these applications. Now that those team members have access to our heating and sensing technology, that really gives them the full thermal loop to help support their customers. It’s a great complement to the business.
Doug Glenn: Yes. That’s very interesting. Before the acquisition of Eurotherm, Watlow was doing thermal controls of some sort?
Robert Gilmore: Yes. We’ve been in the controls business and power business for quite some time. When you look at the thermal loop, the way I phrase it is “the brains” of the thermal loop are in the control and power management side of the business. I’d like to say that’s the tip of the spear of what we’re doing for our customers, and our strategy is to bring that together.
Doug Glenn: I know that Eurotherm (and I’m wondering if this is another one of the reasons why you found them attractive) has systemwide, companywide-type controls and data acquisition, data management, and that type of thing. Did that capability play into the decision?
Robert Gilmore: Absolutely. That’s probably a really solid strength that they have around the data management acquisition side of their business. As we continue to make this thermal loop much more intelligent, access to data, data/data management, and data processing really becomes a really key value driver for us in the business.
It’s really very complementary to what we would say is on our roadmap: helping people implement Industry 4.0 and having that thermal loop intelligence in the system is really critical for where we’re going and how we’re helping our customers.
Integrating Industry 4.0 Technologies for Clients (23:07)
Doug Glenn : Can you speak to 4.0, either from the Watlow side or in combination with Eurotherm, along with things that might be coming up?
Robert Gilmore: When you look at our continued advancement and our bringing more advanced thermal loop and thermal processes together, data/data management/real-time data acquisition, and allowing that thermal loop to be more intelligent, real-time, feed the process
We actually have a portfolio of what we would call I-40 technologies that are helping our customers manage their systems and process more effectively. We’re in a lot of alpha and beta testing right now, with several of our customers, to help them advance their systems and solutions, as well.
Obstacles and Initiatives (24:03)
Doug Glenn: I assume the acquisition/integration of Eurotherm has gone relatively smoothly.
Robert Gilmore: It’s gone perfectly.
Doug Glenn: Never a misstep, I know!
Robert Gilmore: It’s been a great learning experience with the team. We’re coming together and figuring out how to work together. We’re trying to focus on our customers and our opportunities and then we’ll find it easier to work together. But I’m actually very happy with how things are going, with how the teams are working and really seizing the opportunity.
Doug Glenn: Good, good. Well, you know, in the years that I’ve been in the business, I’ve developed a decent knowledge of some of the people at Eurotherm, and I will second what you’re saying — you’ve got some good people and some good talent there.
So Rob, how about market obstacles, at this point? What are the things keeping you up at night?
Robert Gilmore: I think there are always going to be some of these challenges that are in front of us, with a business that’s growing like ours. We just continue to make sure that we’re developing and bringing on new talent and developing them to support the business and our customers. I think that’s always going to be a challenge.
In terms of these initiatives and where those opportunities are and which ones to focus on, a challenge is that different parts of the world are regulating differently, which makes us support faster. Predicting how those outcomes are going to happen and seeing what we should focus on first is always a challenge. We do not lack opportunity for business and growth opportunities.
But, you know, as much as those are obstacles, I look at those as great opportunities that are in front of us, as well.
Doug Glenn: Right. We had a team meeting here the other day with our team and somebody brought up the saying that Billie Jean King used to say, “Pressure is a privilege.” So, you know, you’ve got a lot of stuff going on and it’s a nice problem to have, to be able to say, “Well, which one of these is the best one to take?” and have to make that decision.
Learn what Watlow says about making combustion more sustainable through monitoring. Click the image above to read their article contribution!
We’re coming towards the end here, Rob. How about any specific initiatives with Eurotherm into either the heat treat market specifically or Eurotherm generally, that our listeners might want to know about?
Robert Gilmore: Yes, we’re continuing to advance the strategies in these different markets. Definitely in the heat treat market, we are coming together and really having specific strategies around that, and how we can optimize the thermal loop and those applications.
But really what I’m probably most excited about is the continued investment we have in technologies and products. We see a next generation of control and power management devices along with data acquisitions that you will start to see come out in 2024 and 2025.
We continue to invest in technology platforms, in what we would call the I-40 technologies platforms. We also have some, what I would call “advanced adaptive thermal systems,” that really allow the thermal loop to be intelligent.
We’ve been launching different products over the last probably five years, and more to come from that perspective.
And I’m pretty excited about some of the heater and sensing technologies that we’re developing, which include higher temp capabilities. The temperatures are going to continue to increase in some of these applications and become more demanding, and we’ve got some interesting technologies that we will be advancing there.
I think a big thing we’re also launching in a lot of alpha and beta applications, right now, has to do with “medium voltage technology.” As you continue to see this movement from fossil fuels to electric, the low voltage solutions don’t generate enough power, and we are introducing what we will call a medium voltage technology and heater technology. So, the ability to move from 480 to 600 volts to 4200 or 7200 volts is really going to give our customers the capability to handle going to those megawatt solutions that we can help them do.
I’m pretty excited about those technologies. We’ve been introducing some of those neat technologies that are going to help our customers be successful in many of these applications. It’s some pretty exciting stuff, at least for a lonely old engineer like myself.
Doug Glenn: For electric thermal loop geeks, this is great stuff.
Robert Gilmore: Absolutely.
Doug Glenn: I will tell you, And the whole green initiative seems to be global now. We were at THERMPROCESS over in GIFA in Düsseldorf, and it was all about green initiatives.
These are interesting times and I think you guys, with your business strategy, seem to be very, very well positioned to reap the benefits.
Robert Gilmore: We are definitely excited about what we’re doing today and what we’ll be doing tomorrow. These are exciting times for Watlow.
Doug Glenn: I have one other question for you: Are you guys doing anything with AI that you’re able to talk about?
Robert Gilmore: We definitely see opportunities from that perspective. We definitely believe it’s going to help — and it is helping — support our business. I would say probably we’re in the throws of really the ability to leverage the wealth of knowledge that we have and be able to get that through our business and our team members.
Again, I can’t even imagine the number of years of talent and technology and industry leaders in our business, and I want to make sure that knowledge gets transferred on to the next generation. I think we are looking at AI, in many ways, as to how to accelerate that ability. That’s probably the only nugget I’m going to give away from that perspective.
Doug Glenn: Fair enough.
Robert Gilmore: I appreciate the time and the opportunity. I’m definitely excited that we’re going to continue to have more presence in the heat treat market; you’re going to see our name more and more.
We’re pretty excited about the future and looking forward to talking to you some more.
Doug Glenn: If people want to keep up with you guys — what’s going on, what is the latest news out on you guys — is there any direction you want to steer? Is there anything you would recommend customers or prospects do?
Robert Gilmore: We’re continuing to advance and develop our website, and that’s a good place to start, if you want to reach out. Bob, or even myself sometimes, is always interested in what customers are thinking about or what help they need, as well.
Doug Glenn: Good, very good. Rob, thank you very much.
About the expert: Rob Gilmore has been with Watlow for nearly 35 years. Throughout his career Rob has gained broad experiences in engineering, manufacturing, product management, operations and general management. As a result, he has developed a keen understanding of the application of Watlow products, services, and solutions across a broad range of industries (including industrial ovens and furnaces). Prior to becoming CEO, Rob served as COO and general manager of the semiconductor processing business unit, growing this division to Watlow’s largest market segment. Shortly after Tinicum L.P. acquired a controlling interest in Watlow in March of 2021, he was promoted to Watlow’s CEO. Most recently, Rob has led the organization through the acquisition of Eurotherm from Schneider Electric in November of 2022.
