OP-ED

Cost of Fuel Drives Change

Jim Roberts of U.S. Ignition engages readers in a Combustion Corner editorial about how rising fuel costs have driven dramatic improvements in furnace efficiency and combustion technology over the past 60 years, transforming heat treat processes from 20% to 70% fuel efficiency.

This editorial was first released in Heat Treat Today’s January 2026 Annual Technologies to Watch print edition.


A furnace guy walks into the shop and sees the cost of gasoline. “This keeps going up, what gives?”

My first car got about 10 MPG — we will not even go near to discussing when that was. Gasoline costs have since driven cars to become more efficient with 30+ MPG vehicles.

Last month’s article highlighted how there are five qualities in our heat treat processes: Quality and Accuracy, the necessary attributes; Efficiency and Performance, the variables; and Profit, which comes whenever we improve the two variables. We have discussed government regulation on emissions and technological breakthroughs that improved combustion technology in earlier articles, but now we turn to the connection of combustion and cost: how gasoline costs drove improvement of the two variable qualities of heat treat processing for combustion, Efficiency and Performance.

Gasoline Costs: A Timeline

Up until about 1960, the world of heat processing was pretty much a level playing field with Efficiency and Performance. We had tons of fuel at our disposal. Pollution was known but not yet a criterion to manage processes. So, burner efficiency and design were very low end. Nobody cared. Fuel was almost free. In doing research for this story, I found records of natural gas being less than $0.50 per million BTUs. Electricity was on par with delivered BTU costs. But then the cost of fuel started to fluctuate. The furnace guys started to notice; if nothing else changed, our friend Profit would weaken.

From 1930 to 1980, electricity pricing went up 500%. Natural gas started to bounce around in price. It was less than a $1.00/thm in the ’60s and ’70s, peaking during times of fuel shortage at $16.00/thm. Ten years later, in 2016, it hit $2.30/thm again. Some pretty wild fluctuations. In fact, it should be noted that the industry overseas had already begun to shift technologies — several years ahead of the U.S. — because they had been suffering with high fuel costs in Great Britain, Germany, Western Europe, and in Asian markets.

Furnace guy and the suppliers had to improve the efficiency and performance.

Troubleshooting and Combustion Design Changes

At first, you look at easy fixes to improve Efficiency and Performance. An example would be that insulation and refractory science really improved. If you can keep the heat in the furnace, you need less fuel to hold it at these high temperatures, right? So, improve the insulation.

Next, let’s get the burners from just being the opening in the furnace that you pour gas into, and make the burner more like a carburetor on an engine. Let’s get control of the air and gas ratios.

Next, let’s recover some of the flue gases and pre-heat the air coming into the burner. When you do that, the flame temp goes up, sometimes by as much as 400-500°F. That means higher heat transfer rates to the parts inside a now well-insulated furnace. Huge efficiency gains started happening.

Efficiency and Performance got a huge boost when the burners started to have high velocity discharge rates. In other words, we now had flames that were hotter and going into the furnace at several hundred miles an hour more than before. With that comes circulation improvement inside the furnace. And much like pudding in a blender, the faster the beaters, the smoother the mix. To give you an idea of the scope of these improvements, form 1960 to 1990, a matter of only 30 years, furnace and burner technology improvements went from 20% fuel utilization to estimated 60-70% fuel efficiencies, even higher in some instances. And there it was, super efficiency driven to occur by fuel cost and flucturation of supply.

To really hit home what that meant, let’s look at a 1,000-lb load of steel. Our process temp is 1750°F. Our furnace and combustion efficiency used to be 20%. That would require 1,370,000 BTU to heat up in an hour. Now, with 75% furnace and burner efficiency, that’s 352,000 BTU. You just saved approximately 1,000 ft3 of gas per hour! If we use the average industrial gas price today at $3.80/1,000 ft3, the difference of all this is $24,000/year, and that’s just a 1,000-lb load. Real world, the numbers are significantly higher, as all you furnace guys know. Imagine the dollar savings when fuel was at $16.00/thm?

And so, there it is. The well-known realization that in most markets, the dollar cost of the energy triggers improvement of technology.

Until next time…

About The Author:

Jim Roberts
President
US Ignition

Jim Roberts president at U.S. Ignition, began his 45-year career in the burner and heat recovery industry focused on heat treating specifically in 1979. He worked for and helped start up WB Combustion in Hales Corners, Wisconsin. In 1985 he joined Eclipse Engineering in Rockford, IL, specializing in heat treating-related combustion equipment/burners. Inducted into the American Gas Association’s Hall of Flame for service in training gas company field managers, Jim is a former president of MTI and has contributed to countless seminars on fuel reduction and combustion-related practices.

For more information: Contact Jim Roberts at jim@usignition.com.

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Answers in the Atmosphere: Nitrogen — The Swiss Army Knife for Thermal Processors

In this installment of Answers in the Atmosphere, David (Dave) Wolff, an independent expert focusing on industrial atmospheres for heat treat applications, explores the versatile role of nitrogen gas in thermal processing.

This informative piece on nitrogen’s critical functions in safety, as a diluent, and as an atmosphere component — including production methods and purity requirements — was first released in Heat Treat Today’s November 2025 Annual Vacuum Heat Treating print edition.


As discussed in the introduction for this series of gas-focused columns, nitrogen gas is ubiquitous in thermal processing — by far the most-used delivered or generated gas in secondary metallurgy. This column covers many important considerations for the use and availability of nitrogen gas, featuring the insights from my recent interview with Air Products experts: John Dwyer, principal engineer; Bryan Hernandez, commercial technology sales engineer; and Emily Phipps, strategic marketing manager. Because of its key role in thermal processing, we expect to have additional columns on nitrogen gas in this series.

Nitrogen serves three important purposes in secondary metallurgy:

  1. Safety
  2. Diluent
  3. Atmosphere

Regarding safety, the Air Products experts shared important attributes of nitrogen and several applications it is most often used in. According to them, nitrogen:

  • will not react with most metals used in fabrication applications until reaching extremely high temperatures
  • will not support combustion or oxidation
  • has about the same density as air (which is 78% nitrogen)
  • is the least expensive industrial gas on a volumetric basis.

For those reasons, nitrogen is used as a purging and inerting gas in metallurgical applications, such as inerting the furnace in preparation for a flammable atmosphere to be introduced, as well as expelling flammable atmosphere at the end of a furnace cycle. They further noted that the National Fire Protection Association (NFPA) Standard 86 for Ovens and Furnaces mandates that nitrogen be always available for furnace inerting except for very specific exceptions where alternative approaches are used (burn in and burn out). Beyond the strict safety considerations, nitrogen protects furnace linings and components from high temperature oxidation.

Dwyer, Hernandez, and Phipps emphasized that when used as a diluent, nitrogen makes it possible to use relatively small volumes of a more expensive reactive gas or gas blend and ensure that the diluted active gas can provide benefits for an entire furnace load of parts. Examples include nitrogen/hydrogen atmospheres where nitrogen gas can enable a relatively small volume of very powerful reducing gas hydrogen to be mixed with a higher volume of nitrogen to fill the furnace interior. I would add that a blended atmosphere of nitrogen/hydrogen will have a higher density than hydrogen alone, and hence may distribute more widely in the furnace rather than just pooling at the ceiling level.

They further discussed how nitrogen can be used as a sole constituent in a furnace atmosphere in many cases, especially at lower temperature ranges, such as tempering and stress relief. In situations where surface finish is a secondary consideration, or where additional operations are going to be performed, they note that the part lower finish quality provided under inert nitrogen alone might be acceptable.

The team then reported that nitrogen forms the bulk of the atmosphere and cryogenic air separation is now available virtually worldwide; because of this, liquified or gaseous compressed nitrogen can also be delivered to clients virtually worldwide. Cryogenically separated nitrogen is, by the nature of the process, extremely pure, and can be assumed to be 99.999% or purer as delivered into the client’s storage vessel. Nitrogen can also be made at the client’s site, using non-cryogenic or cryogenic air separation techniques. For secondary metallurgy, non-cryogenic techniques are the most common because the volumes of nitrogen required are too low for a dedicated cryogenic air separation unit.

Continuing along this line, they explained that while both pressure swing adsorption (PSA) and hollow fiber membrane techniques can be employed to generate nitrogen for a single customer site, the PSA technology is the one primarily used to supply generated nitrogen for thermal processes. This is because the membrane technique for non-cryogenic nitrogen generation makes relatively impure nitrogen, with too much oxygen to achieve the desired surface properties sought by heat treaters. As such, membrane generated nitrogen is primarily used for chemical blanketing and similar low temperature air displacement applications.

The final discussion point I will share from the interview today is about the variability in accepted purity based on the planned usage of nitrogen. The three Air Products experts pointed out that NFPA86 mandates that the atmosphere in a furnace must be below 1.0% oxygen before any flammable gas species can be introduced. So, they continued, nitrogen used solely for safety purging can be relatively impure and still achieve the 1.0% maximum oxygen allowed. When used as the sole atmosphere component (i.e., 100% N₂), or as a carrier gas blended with an active gas like hydrogen, they explained that nitrogen purity must be much higher in order to achieve acceptable surface quality. In general, for atmosphere uses, it should be assumed as a general rule that the purer the nitrogen is, the easier it is to achieve satisfactory heat treat results. The three concluded this thought noting that in blended atmospheres it may be possible to use slightly higher levels of active gases (like hydrogen) to react with excess oxygen in the nitrogen supply, but that approach is unlikely to make sense economically since nitrogen is typically far less expensive than an active gas.

In the December 2025 installment of Answers in the Atmosphere, I’ll share further insights that my interview uncovered. Until then, consider your unique nitrogen needs and therefore whether having direct access to this gas for the benefit of your heat treat operations is essential.

About The Author:

David (Dave) Wolff
Independent expert focusing on industrial atmospheres for heat treat applications

Dave Wolff has over 40 years of project engineering, industrial gas generation and application engineering, marketing, and sales experience. Dave holds a degree in engineering science from Dartmouth College. Currently, he consults in the areas of industrial gas and chemical new product development and commercial introduction, as well as market development and selling practices.

For more information: Contact Dave Wolff at Wolff-eng@icloud.com.

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Refine Your Process, Get Profits

Jim Roberts of U.S. Ignition engages readers in a Combustion Corner editorial about how focusing on the right priorities in the right order naturally leads to profitability in heat treating.

This editorial was first released in Heat Treat Today’s December 2025 Annual Medical & Energy Heat Treat print edition.


It’s a crisp winter day, and a furnace guy walks into the heat treat plant and says, “Something has changed here, it feels…more modern.” The rest of the furnace guys shrug and continue with the tasks at hand. But the furnace guy is right — something has been changing all along and will continue to do so in the foreseeable future, I’ll wager.

We’ve talked about how certain trends and needs have driven the growth in the industry. My ramblings have included bed posts and pipelines and the flavors of different fuels, and what it all boils down to is change. These changes are attempts to get the following qualities into our processes in the heat treating world:

  1. Quality
  2. Accuracy
  3. Efficiency
  4. Performance
  5. Profit

“But Jim, you listed profit as the last measuring stick! What is wrong with you?” It would be pretty easy to invert this list; turn these guideposts upside down and the world you are in would still work. But if we add longevity in business as an additional goal, then it will not be too long before you begin to realize that the order is listed correctly here. For the most part, in my experience, the heat treating industry has kept the order intact. It is an honorable path, I think.

Quality and Accuracy are the new givens. We do not have to spend time on this. As long as we have been wielding control over metal, those properties are the constant. From hammering out the very first horseshoes, if they did not fit the horse or cracked and broke after a couple of steps, you were not in the horseshoe business very long. These days, standards clearly map out the goal: a client tells us what is demanded, maps it out for us in a specification, and we meet it.

Items 3 and 4 are where we focus today. If we can improve Efficiency and Performance after meeting the Quality and Accuracy targets, then good old item 5 happens — Profit. It just happens. What a concept! Now you may think this is a re-run of every BUS-101 class or seminar you have seen. Maybe you are right, but this is where I veer off as a furnace guy and get back to the business of combustion as it applies to our industry.

We talked earlier about how the natural gas industry expanded and built this fantastic infrastructure to provide fuel to all of us. Electric providers did and are still doing the same thing.

At the end of the transmission line, whether gas pipe or electrical cable, sit the furnaces and ovens that heat treating needs. The buck stops here. Speaking of bucks, in order to get to profit, what must we do? If we really only have Efficiency and Performance in our control (Quality and Accuracy are presumed to be met), then let’s look at how that changed, in furnace guy world…next year [in 2026].

All the best to everyone in the Holiday seasons. May you be blessed with good health and happiness.

About The Author:

Jim Roberts
President
US Ignition

Jim Roberts president at U.S. Ignition, began his 45-year career in the burner and heat recovery industry focused on heat treating specifically in 1979. He worked for and helped start up WB Combustion in Hales Corners, Wisconsin. In 1985 he joined Eclipse Engineering in Rockford, IL, specializing in heat treating-related combustion equipment/burners. Inducted into the American Gas Association’s Hall of Flame for service in training gas company field managers, Jim is a former president of MTI and has contributed to countless seminars on fuel reduction and combustion-related practices.

For more information: Contact Jim Roberts at jim@usignition.com.

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Endings… People We Lost

Beginnings and endings often come together. As we begin the new year, we want to pause to remember a few lives that came to an end in 2025. Although the following individuals are by no means the only important endings, Heat Treat Today would like to honor the memory of these individuals who left their mark in the heat treating world.

This tribute was first released in Heat Treat Today’s December 2025 Annual Medical & Energy Heat Treat print edition.


Waldron “Wally” L. Bamford (1932-2025)

Source: CAN-ENG Furnaces International

Wally Bamford, co-founder of CAN-ENG Furnaces International, passed away in Ottawa, Ontario, at 93. After serving as a Royal Canadian Navy officer, Wally entered the heat treating and furnace-building industry and helped establish CAN-ENG in 1964. Under his leadership, the company became a global name in industrial furnace design and manufacturing. He also served as the first Canadian president of the Metal Treating Institute (MTI) and was a generous supporter of its scholarship program. Wally is remembered for his integrity, optimism, and lifelong commitment to advancing the heat treating profession.

Michael “Mike” A. Shay, Hauck Manufacturing (1953-2024)

Kevin Walters
Research & Development Manager
OMG Inc.

Mike Shay of Lebanon, Pennsylvania, passed away at 71. Mike dedicated much of his career to Hauck Manufacturing working in field services and sales; his last position held was president of Hauck. Known for his strong leadership and community involvement, he served on local boards and was active in his church and the Boy Scouts. Mike is remembered for his dedication to both his work and his community, as well as his warmth and generosity toward colleagues and friends. Surviving in addition to his wife are his children, Daniel Shay (Julia) of Wilmington, DE, Erin Koch (Dan) of Lebanon, grandchildren, Lydia and Bennett Shay, and a brother, Patrick Shay.


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Navigating Heat Treaters’ Most Defining Moments

We like to celebrate the wins for good reason: they inspire us when times get tough. Regardless of where you find yourself in the North American heat treat community, you will face challenges that may redirect your life and prompt you to question your goals or values. Given this universal experience, we asked respected individuals from across the industry to share the hardest decisions of their professional lives. Just as successes inspire resilience, these challenges offer lessons in navigating the toughest moments of your career.

This inspiring piece was first released in Heat Treat Today’s September 2025 Annual People of Heat Treat print edition.


“No Jerks” Rule, with Sarah Jordan

Sarah Jordan
Founder & CEO
Skuld, LLC

For Sarah Jordan, president and CEO of the cutting-edge casting startup Skuld LLC, hard decisions have paved the path of her career. An earnest visionary — and as down-to-earth as they come — Sarah has made a habit of launching startups for the metal processing industry. Today, she leads a team that has developed a toolless, net-shape casting process and the equipment to perform it, advancing the way parts are formed while minimizing post-processing needs.

It comes to no surprise that her hardest decision came while forging this path. In 2009, Sarah’s first startup, Aesir Metals, faced fall-out from the 2008 economic recession. The impact was most acute when their largest customer informed them that they were unable to pay.

Faced with this reality, Sarah had to make the painful choice to close the company. Just after Christmas that year, every employee was let go. “And that’s awful when everybody’s…you know, they’re counting on you, their families are counting on you.” It was her first time navigating such a challenge, and while it was difficult, it became a formative experience.

Leading her current company, Sarah operates with a “‘no jerks’ rule.” She says culture and people are critical, and the postmortem of Aesir Metals revealed other opportunities for improvement. While mistakes are inevitable — learning requires that — she moves forward, determined not to repeat the same ones.

Upgrade Your Skillset, with Kevin Walters

Kevin Walters
Research & Development Manager
OMG Inc.

Kevin Walters‘s official title is R&D manager at OMG Inc. out in Massachusetts — however, his nickname “Father of Interns” is extremely fitting. With decades of engineering experience, Kevin has dedicated 25 of them (and counting) to mentoring interns, first at Spalding Sports Worldwide and now at OMG. Using his own career for reference, he tells them this story.

Approaching his forties with four boys near or in their teenage years, Kevin began thinking seriously about his career trajectory. He knew that to stay relevant in engineering, he needed to expand his skillset. In this field, the rule is simple: upgrade your abilities or risk becoming obsolete. The question was how.

“I’m a guy who likes to fix stuff — work with my hands,” Kevin told me. The typical career-advancement routes didn’t seem like the right fit: waiting for an opportunity to open up in the company could take too long, a doctorate might pigeonhole him into academia, and an MBA didn’t align with his engineering focus. It took five years of consideration, conversation, and research to find the right path.

That opportunity appeared when he learned about a management degree specifically tailored for engineers. With Spalding’s full “blessing” and tuition reimbursement program, Kevin enrolled at Western New England University, taking two courses per year while balancing his job and his sons’ baseball games. In five years, he had earned his Master’s of Science in Engineering Management.

These kinds of programs have become more widely available, and Kevin encourages his interns to pursue them. “Engineers, if they don’t upgrade their skillset, become obsolete,” he says. “I see too many engineers who graduated with their four-year degree — did great things at the beginning of their career — but because technology is advancing and they’re not learning with it, they are not as useful as they used to be.”

Each summer, Kevin continues mentoring one or two interns, urging them to think strategically about building their résumés and preparing for an industry that never stops moving.

It’s the People, with Dan Bender

Dan Bender
Director of Sales
Control Concepts

As Dan Bender reflects on his 47 years in industry, many as director of sales at Control Concepts, one priority has guided him: bring in business so the people in manufacturing have a job, can feed their families, and keep a roof over their heads.

In the late ’80s and early ’90s, there were a lot of mergers and acquisitions of companies by holding firms. A general attitude that “work is work” within industry started to emerge. He observed that people were being treated as just another factor of direct manufacturing costs.

This inhumane approach was augmented by a larger lack of pride in the business by the leadership. He also perceived that businesses were treated as financial investments; leadership seemed to be just concerned with flipping the company for a profit. Eventually, these factors reached Dan’s workplace.

Desiring more from his employer and wanting to be useful and productive in a place where people mattered, he parted ways. He reflects, “I left a pretty good job and went out to try some other things, realizing I still had a family to support.”

Over the next few years, he explored different roles, leaning on the counsel of friends and mentors from outside the heat treat industry, many of them from his church. Then, in 2008, the recession hit. Dan was working for a European company when it eliminated nearly all North American positions, and for the first time in his career, he was out of a job.

“That was tough,” he commented. “That was a hard, a hard thing…I did some interviews, I had some possibilities, I had some decent things, but I wanted to find somewhere where…people are important.”

His faith was central to that search, and in time, he found the right fit at Control Concepts. While it was not the best offer at the time, it was “what made me feel good, and it [did turn] out to be very financially rewarding for me.”

Choosing to stick with his principles also meant staying in an industry where he had built decades-long relationships. Dan says he looks forward to seeing those connections at tradeshows like Heat Treat 2025 this fall and Furnaces North America next year. “It’s to me, you know…that’s a blessing that I can have conversations with those people and feel a real sense of knowing they are very interested in what you’re doing as well as you being interested in what they’re doing at this stage in their career and your life.” Serving the heat treat industry, and the people in it, is why Dan has no plans to retire anytime soon.

Never Stand Still, with Bill Stuehr

William (Bill) Stuehr
President & CEO
Induction Tooling Inc.

What do you do when an unforeseen market collapse changes the fabric of your business? William (Bill) Stuehr, engineer, founder, and CEO of Induction Tooling Inc., has a clear answer: make a plan and move forward. “I’m a pragmatist,” he says. “I look at things the way they are, then I make decisions and proceed with what has to be done. That’s all.”

In 2005, Bill built a brand-new facility to expand his operations from 14,000 to 30,000 square feet. Business had been picking up for induction heating since the 1980s and ’90s, and manufacturers of driveline components were interested in induction. Induction was becoming more accepted on two fronts: first, as a green energy source; second, as an integrated manufacturing step in cell production, allowing automotive components such as wheel bearings and axle shafts to come out finished at the end of the line. With the expectation to expand to 50 employees by 2015, the city even granted Induction Tooling a tax abatement to encourage expansion and boost the local economy.

The critical moment happened in 2009, beginning on the heels of the 2008 financial crisis. With the housing collapse, people stopped purchasing automobiles, and the automotive industry went reeling. In April and June, General Motors and Chrysler appeared before U.S. Congress after filing for bankruptcy. Bill’s tier 1 automotive manufacturing customers began shutting down operations. “I had never seen it in my career, ever.”

Work was running out. Bill made the hardest decision of his career: “I had to lay off half of my workforce. I went from 28 people to 14 in less than a year.” Some of them had been with him since he started in the late 1970s. “It was out of my control. I tried to keep them on as long as possible without suffering the financial hardship of my own.” Even in hard times, the company covered all employee medical insurance, a practice Bill maintains to this day.

By 2012, the market showed signs of recovery. Bill pivoted the business to focus almost exclusively on CNC automation for rebuilding tooling — a move that met the needs of their tier 1 customers with high production rates and sidestepped the challenges of rehiring or retraining a large workforce.

Commenting on today’s market, Bill revealed it had never truly recovered. “The buyers of the automotive companies had the time to seek outsourcing worldwide.” He continued, explaining that over the course of the four years that followed the crash, there was enough offshoring of driveline components to an enthusiastic, energetic workforce with new facilities and abilities. Reshoring to the U.S. has not gained back the momentum that it had, though perhaps that will change with the priorities of the current U.S. administration.

From those years came a few lasting lessons. First, embrace automation to keep the business profitable, especially when attracting young talent is a struggle. Second, when hard times come, make a plan and commit — but remember that you can’t control time, the weather, or other people. Bill sums it up with gritty simplicity: “You never stand still; you just keep going. ‘What do I have to do and how can I get it done?’ That’s it.”


Bethany Leone
Managing Editor
Heat Treat Today
Contact: Bethany Leone at bethany@heattreattoday.com

Navigating Heat Treaters’ Most Defining Moments Read More »

Merry Christmas from Heat Treat Today

As we wrap up 2025, our hearts are full. This year brought meaningful growth across the heat treat community — from stronger in-house innovation to new digital tools, expanded training resources, and stories that reminded us why this industry matters. We’re grateful for every reader, partner, and friend who walked with us through another year of learning and connection.

During this season of hope, we celebrate the joy and peace that Christ brings. May that light fill your homes, your work, and your days ahead.

Our offices will be closed for the Christmas holiday, but we look forward to returning in the new year with more news, insights, and encouragement for heat treaters everywhere.

Wishing you a blessed and Merry Christmas,
The Heat Treat Today Team

For housekeeping purposes: our offices will be closed from December 22, 2025 to January 2, 2026. Happy holidays!

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Answers in the Atmosphere: Successful Thermal Processing of Metals Requires Atmosphere Savvy

Heat Treat Today is pleased to welcome this regular column spot, Answers in the Atmosphere, to David (Dave) Wolff, an independent expert focusing on industrial atmospheres for heat treat applications. This column explores various atmospheres with Dave and different industry specialists.

This informative piece on the critical role of atmosphere control in metal thermal processing was first released in Heat Treat Today’s October 2025 Ferrous & NonFerrous Heat Treatments/Mill Processing print edition.


Thermal processing of metals is critical to successful production of fabricated metal parts and assembled systems. Characteristics of parts and devices, including blades, springs, wire and cable, medical implants, and electric motors, all depend on successful thermal processing to produce metallic components with specific properties to meet the requirements of the part, assembly, or device. What is sometimes overlooked, however, is that atmosphere is as critical as the heat itself. The wrong furnace atmosphere can undo the best processing recipe, while the right one ensures that parts achieve their intended properties consistently.

Tune into the news, and you will find stories about metal parts incorrectly handled during thermal processing: gears that degrade to powder, camshafts that were too soft, electric switches that fail, materials with the wrong magnetic properties, knives that cannot hold an edge, and so on. These are all problems that occur too frequently and are expensive to resolve, because metal parts are often components in a more complex and expensive assembly. (Imagine the responsibility of parts-making for military jet engines or body-implanted parts. You do not want to be the shop supplying inadequate parts!) It is imperative that heat treating and sintering processes are completed correctly the first time.

Metals thermal processing requires more than just heat. As indicated above, atmosphere is essential to the heat treating process, coming alongside temperature, time, and a specific sequence of operations in a recipe that will ensure the material yields the desired performance. Much like baking bread, thermal processing of metals requires equipment, materials, conditions, and recipes. The furnace is the main equipment (other operations may be performed in a less expensive thermal processing oven). Then there are the materials — the parts being heat treated — which may be bulk metals, alloys, or compacted powder parts with unique blends and surface morphology. The conditions of time, temperature, atmospheres, and perhaps a quenching step come together in a specified recipe. Properly done, heat treating and sintering operations will yield parts that meet the hardness, toughness, appearance, surface finish, shape, dimensions, and other specialized and specified properties.



Since cost is an important driver, metals thermal processors strive to produce compliant parts in as few steps as possible. Innovations can assist in making it possible to consolidate steps, too. But mistakes in thermal processing may result in defective parts or require expensive rework or even additional (secondary) operations to correct deficiencies.

Each issue, this column will focus on the atmospheres component of heat treating. You’ll read interviews with industry experts focused on the atmospheres used in thermal processing — from relatively inert atmospheres, such as vacuum, nitrogen, and argon, to chemically active atmospheres used for annealing, hardening, and sintering. We will assist thermal processors by explaining how various atmospheres work, what the key properties are that determine successful results, how to buy and utilize the atmospheres, and precautions and alternatives for that atmosphere.

My hope is that this column will help Heat Treat Today readers become better buyers and users of atmospheres, so that you can run a smoother, more reliable, and more profitable operation.

About The Author:

David (Dave) Wolff
Independent expert focusing on industrial atmospheres for heat treat applications

Dave Wolff has over 40 years of project engineering, industrial gas generation and application engineering, marketing, and sales experience. Dave holds a degree in engineering science from Dartmouth College. Currently, he consults in the areas of industrial gas and chemical new product development and commercial introduction, as well as market development and selling practices.

For more information: Contact Dave Wolff at Wolff-eng@icloud.com.

Answers in the Atmosphere: Successful Thermal Processing of Metals Requires Atmosphere Savvy Read More »

Flame and Fire: History of the Industrial Gas Industry

Jim Roberts of U.S. Ignition entertains readers in a Combustion Corner editorial about how the industrial gas industry evolved from its humble beginnings in the early 1900s into a precision-driven force that transformed combustion technology and modern manufacturing.

This editorial was first released in Heat Treat Today’s November 2025 Annual Vacuum Heat Treating print edition.


Let’s think about how young the industrial gas industry really is.

A Short Pipeline in Time

The first real industrial usage was way back in the 1800s somewhere. But there was no infrastructure, no supply other than bottled gas for industrial applications. The gas industry, as far as we recognize it, did not really take off until somewhere around the early 1920s when the first welded pipeline was installed. Then, as usage increased, it became apparent that safety was going to be a concern. The addition of mercaptan (rotten egg smell) was not until the late 1930s.

With the growth of commercial and residential usage, the demand for gaseous fuels grew by 50 times the original market size anticipated between 1910 and 1970! What does that demand look like? Today there are over 3 million miles of gas distribution lines connected to 300,000 miles of big transmission pipelines in the U.S. alone. All that growth in a span of 100 years, essentially. That means the transmission pipeline system in the U.S. could stretch around the planet 12 times!

USS coke gas pipeline in the foreground with the Conrail Port Perry Bridge spanning the Monongahela River, Port Perry, Allegheny County, PA (Lowe, 1994)
Source: Library of Congress Prints and Photographs Division

Most of that construction occurred during the post-war 1940s to 1960s timeline. That’s one busy industry! And it dragged all the thermally based markets and industries along with it. Now, we have come to accept the availability of natural gas as so commonplace that we cannot imagine life without it.

Responding with Precision

So, now you ask yourselves, “Why this history lesson, Jim?” Well, because we are supposed to be learning about combustion and the era of major combustion advancements — and if I would quit veering off into side topics we might actually get there. But it is all interconnected.

If you recall the story of the heat treater with the bedpost burners (October 2025 edition), he had no inspiration to improve efficiency or performance because those darn bedposts would burn gas just fine. So, what changed? Firstly, the world had been through a couple of military conflicts during this rise of the gas industry. And sadly, sometimes the best technological advances occur in times of conflict; engineering becomes more precise. All of a sudden, instead of hammering out horseshoes for the cavalry, we were heat treating gun barrels and crankshafts for airplanes. We needed to be more than precise — actually, we had to be perfect. So, we stepped away from the old heat treatment ways and developed systems that we could control to within a couple of degrees.

As a result, burners became specialized. Each process became unique and precise. Instead of pack carburizing components, a company called Surface Combustion developed a piece of equipment called an Endothermic generator. This device made carbon-based atmosphere out of natural gas or propane- and nickel-based catalysts. All of a sudden, we could do very precise non-scale covered heat treating. And the burners from companies like North American Combustion, Eclipse Combustion, Maxon, Hauck, Pyronics, Selas, W.B. Combustion, and on and on, all scrambled to develop the specific types of burners that the heat treaters and iron and steel makers needed.

Another important milestone hit around 1963: the Government got involved (gasp!). The Clean Air Act of 1963 essentially said we needed to burn our fuels cleanly and not spit smoke into the air. Those laws got reviewed again in 1970, 1977, and again in the updated Clean Air Act of 1990 with some of the biggest revisions.

With all of these changes, we had several drivers for innovation in the combustion world. Again, precision became a must. Heat treating became a very standards-driven industry. Metallurgists roamed the planet inventing both new materials and the processes to achieve them. Gas companies themselves became huge drivers of innovation and developed think tanks, like the GRI (Gas Research Institute), where people learned and laboratories hummed with development projects investigated in conjunction with burner and furnace companies. Academia became involved with industry in the form of organizations like The Center for Heat Treating Excellence (CHTE) and the Metal Treating Institute (MTI). Suddenly, the industry was more than just blacksmiths.

We’ll talk about how burner companies became design specialists and system efficiency experts and what that meant to various burner styles in next month’s offering.

References

Lowe, Jet. 1994. Panorama of Industry (Conrail Port Perry Bridge, Spanning Monongahela River, Port Perry, Allegheny County, PA). Historic American Engineering Record, HAER PA,2-POPER,1-2. Library of Congress Prints and Photographs Division.

About The Author:

Jim Roberts
President
US Ignition

Jim Roberts president at U.S. Ignition, began his 45-year career in the burner and heat recovery industry focused on heat treating specifically in 1979. He worked for and helped start up WB Combustion in Hales Corners, Wisconsin. In 1985 he joined Eclipse Engineering in Rockford, IL, specializing in heat treating-related combustion equipment/burners. Inducted into the American Gas Association’s Hall of Flame for service in training gas company field managers, Jim is a former president of MTI and has contributed to countless seminars on fuel reduction and combustion-related practices.

For more information: Contact Jim Roberts at jim@usignition.com.

Flame and Fire: History of the Industrial Gas Industry Read More »

Flame and Fire: Fuel Sources and Bedposts

In this Technical Tuesday installment, Jim Roberts of U.S. Ignition entertains readers in a Combustion Corner editorial about how fuel sources became more affordable over time and aspects of combustion burner design. Stick around for his side story on the “innovative” use of bedposts.

This editorial was first released in Heat Treat Today’s October 2025 Ferrous/Nonferrous print edition.


A furnace guy walks into a heat treat facility and sees burners everywhere. Furnace guy says to the faces in the room, “Why did you pick those types of burners?” Thinking this is a trick question, the heat treaters respond, cautiously, “To make things hot?” Of course, they are correct, because making fire and heat is the name of the game, right?

But as we have considered burner styles, designs, flame shapes, and air delivery types with our last couple of Combustion Corner columns, I suspect there was a good deal more analysis given to the selection of burners.

To appreciate the history of burner design, “furnace guy” should realize why burners evolved in the first place: fuel source. When the first burners were starting to be used on box furnaces, they used oil, kerosene, and fuel that had to be pumped. Over the years, many different fuels have been used. Yet, we have a tendency to think of gaseous fuels as the only option for burner performance.

Bedpost Burners

I recall the first time I got called into a facility to try and improve the performance of the furnaces (yep, I truly am a furnace/burner guy). It was a big box furnace that could handle 3-ton quench and temper loads. At that point, I was unaware of the multiple types of burners that were out in the market.

The owner of the shop opened the furnace door for me to see the combustion system. I stared. Sticking into the walls of this big box furnace were bedposts. These “burners” were purchased at 50¢ a post from some hotel auction, and they had about 50 spare posts to boot.

Grinder slots had been cut into the top of these posts. Refractory had been mudded into the mounting blocks to protect the fuel feed, which was being forced, or should I say blown, in through the bed posts and atomized by the pressure of being squeezed through these slots in the knob at the top of the posts!

The fuel? Diesel fuel. Regular, old, out-of-the-pump diesel fuel. Or kerosene, for that matter. I was told the system could also use fire pulverized coal, sucked into the bedpost by pitot feeds of compressed air. They lit the burners with burning oily rags tossed into the chamber and quickly opened the valves controlling the fuel.

I was there to sell new modern high-efficiency gas burners.

I declared that this was antiquated, unsafe, archaic, dirty, and said about a thousand other denigrating comments.

The owner of this heat treat said, “Yep, it’s all those things, and more!” He continued, “It’s also reliable, simple, and predictable.” He mused, “I suppose that that thing hasn’t really broken down or shut off in the 25 years since we built it!”

I’m a fairly quick study and surmised that I was not going to make this sale. Duh! This furnace had everything they needed. And the gas system I was going to propose was going to be expensive.

A Burgeoning Gas Industry and Our Next Column

That furnace was still running when I made a move to another city some 10 or so years later.

Eventually, the gas industry that cropped up made fuel cheap…and I mean cheap. I thought, “I bet that guy and his accursed bedpost burners will talk to me now!” So, I went back, and that fella said, “Yeah, we got out of the business that used that old process and moved on. We’d be glad to talk about modernization.” And we did.

That same outfit that operated bedposts for burners for 50 years became a vanguard for modern efficiency and process improvement.

Natural gas as a fuel source is quite modern. Nowadays, that is essentially the truth: natural gas and sometimes other gaseous equivalents tend to be the most widely used fuels in the industrial world.

When looking at the rapid developments of burner configurations and why they developed, it is best first to understand some of the history of these developments. See you in the next installment to talk about the history of the industrial gas industry.

About The Author:

Jim Roberts
President
US Ignition

Jim Roberts president at U.S. Ignition, began his 45-year career in the burner and heat recovery industry focused on heat treating specifically in 1979. He worked for and helped start up WB Combustion in Hales Corners, Wisconsin. In 1985 he joined Eclipse Engineering in Rockford, IL, specializing in heat treating-related combustion equipment/burners. Inducted into the American Gas Association’s Hall of Flame for service in training gas company field managers, Jim is a former president of MTI and has contributed to countless seminars on fuel reduction and combustion-related practices.

For more information: Contact Jim Roberts at jim@usignition.com.

Flame and Fire: Fuel Sources and Bedposts Read More »

Heat Treat Humor: Heat Treatment For Your Funny Bone

Get your kicks out of today’s edition of Heat Treat Humor, featuring jokes from Publisher Doug Glenn, Heat Treat Today editors, and contributions from around the industry.

If you have a heat treatment joke to share please forward it along for the humor enthusiasts here at Heat Treat Today by emailing editor@heattreattoday.com. It may just end up being featured!


1. Why did the steel need therapy after quenching? It had too much unresolved stress. 

Which happens to any of us when we’re not treated right.

2. Why don’t metals gossip during annealing? They’re too busy relaxing.

Cue the shamisen music.

3. What did the furnace say to the cold titanium? You need to warm up to change.

The titanium felt it’d be hardened by the experience.

4. Why did the aluminum fail its heat treatment exam? It lost its temper under pressure.

Don’t be like aluminum.

5. What’s a heat treater’s favorite genre of music? Heavy metal.

And their favorite band? Metallica.

6. Heat treatment impacts almost every faucet of our lives.

It’s far reaching.

7. Why did Heat Treat Joe burn out in his job? He didn’t take enough time for stress-relief.

A mistake any of us can make.

8. Why did the metal fail its quenching process? Because it wasn’t all it was cracked up to be.

We and metal have that in common.

9. What kind of worship does a heat treater like? Metalliturgical.

Honey for lovers of the refiner’s fire.

10. Why did the knife adjust so easily to marriage? It had tempered expectations.

And that’s a wrap!



Heat Treat Humor: Heat Treatment For Your Funny Bone Read More »

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