Heat TreatToday publishes twelve print magazines a year and included in each is a letter from the publisher, Doug Glenn. This letter first appeared in March 2025 Aerospace Heat Treatingprint edition.
The world is a better place when people know what their job is and then stick to that job. When the carpenter knows that their job is working with wood and then works with wood, things go well. When the pipefitter doesn’t try to be an electrician but sticks to pipefitting, things go well. It’s only when we forget (or never knew) who we are or why we’re here that things begin to go terribly wrong.
This is just as true in the C-suite as it is on the shop floor when it comes to running a business. CEO, CFO, COO, presidents, and VPs all benefit the business by sticking to their huckleberry bush just as the welder, the electrician, and the plant operations guys prosper the business when they do what they’re called to do.
In the C-suites, however, there seems to be more confusion about what it is they are there to do and company leaders more frequently get distracted from their huckleberry bush than do the guys in the shop. Here are some good, yet ultimately unhelpful things that have kept company leadership from focusing on profits — which ought to be their huckleberry bush.
Environmental Concerns
If ever there was a worthy cause, caring for the planet should be toward the top of the list, coming in second only behind caring for people. Business leaders proceed at their own risk if they completely ignore environmental issues. But elevating “saving the planet” over profits is a common mistake made by well-meaning leaders. The driving question that should underlie all business questions is whether or not profits will increase, not only what impact the decision will have on the environment. The EV craze, which has petered out significantly since this time last year, is a great example of company leaders losing sight of profits in favor of the environment. The number of car manufacturers who boldly announced electric-only or significantly enhanced EV fleets in 2024 only to have the two-by-four of company profits hit them squarely upside the head is astounding. Most of them have backtracked or are in financial hardship for not backtracking.
Well-meaning environmentalism should never come at the expense of profits.
Diversity, Equity, Inclusion (DEI)
Another distraction from focusing on profits has been, while to a lesser degree now as compared to this time last year, the DEI movement. DEI, to its credit, is people-focused and, undoubtedly, was well-motivated by many. Nonetheless, kowtowing to externally imposed social norms in order to avoid becoming a corporate pariah carries with it the seeds of failure, because profits and overall corporate health will suffer. Such was the case for countless large and small companies, including McDonalds and Harley Davidson, that elevated DEI above profits. The primary (though not the only) factor that should drive hiring and promotional concerns within a company should be competency and effectiveness. Will the individual help enhance company profits or not?
“Profit” Is NOT a Four-Letter Word
In her classic work, Atlas Shrugged, Ayn Rand makes this very point. When we vilify “profits,” we do not do ourselves or our fellow man any good. One might say, “It is not profitable to vilify the word ‘profit.’” Profit is good, and it is enormously comforting to see company leaders of all stripes returning to a good, healthy embrace of the profit motive.
Obviously, the ill-founded desire for profits at all costs regardless of the impact on the freedoms and liberties of others is not good and is the exact reason why we have courts of law. Profit cannot and ought not be at the expense of others’ freedoms. Further, the profit motive should not go right up to the line of violating personal freedoms. A true and good profit motive is not devoid of compassion and long-term thinking. It values human life and liberty and tempers its decisions based on what is good in the long run for human flourishing. Sound, profit-motivated decisions are often not easy black and white decisions. There are countless intricacies and complexities. Nonetheless, our default position ought not to be the disparaging of profits. Quite the opposite.
Company leader, stand strong as you do all that you can to build your company profits and don’t be ashamed to say so.
In each installment of Combustion Corner, Jim Roberts, president of U.S. Ignition, reinforces the goal of the series: providing informative content to “furnace guys” about the world of combustion. The previous column examined the air supply inlet — the inhale, and this month, Jim is examining the exhaust system — the exhale, and how to inspect it, maintain it, and manage it.
This informative piece was first released in Heat Treat Today’sMarch 2025 Aerospace print edition.
A guy walks into a room full of furnace guys and says, “Is it just me, or is it a tad stuffy in here?”
We have all been able to imagine that it is hard to focus and do your job in an environment where it seems like it’s hard to breathe. Well, our hard workin’ buddy, the furnace, is continually stuck in a cycle of trying to breathe in, breathe out — and then somewhere in between, the magic of combustion and heat happens! We talked last month about the “breathe in” part of the combustion process. This month, we are going to remind you that if you take a really good, productive, inhaled, life giving breath, you are probably going to want to exhale at some point, too!
Tip 2: Ensure Exhaust Systems Are Properly Functioning and Clean
Inhale, exhale. It makes sense that if we were earlier having issues with the air supply inlet, the exhaust should also be checked. Today’s combustion equipment is sophisticated and sensitive to pressure fluctuations. If the exhaust is restricted, the burners will struggle to get the proper input to the process. I used to use the example of trying to spit into a soda bottle. Try it. It’s tough to do and invariably will not leave you happy. Clean exhaust also minimizes any chance of fire. Read on for three examples.
A. Check the Flues and Exhausts for Soot
If you are responsible for burners that are delivering indirect heat (in other words, radiant tubes), you have a relatively easy task ahead to check the flues/exhausts. Each burner usually has its own exhaust, and one can see if the burners are running with fuel-rich condition (soot/carbon). Soot is not a sign of properly running burners and will signal trouble ahead. Soot can degrade the alloys at a chemical level. Soot can catch fire and create a hot spot in the tubes. Soot obviously signals you are using more fuel than needed (or your combustion blower is blocked, see the first column in this series).
As a furnace operator or floor person, it should be normal operating procedure to look for leakage around door seals.
Here’s a sub tip: If you cannot see the exhaust outlets directly, look around the floor and on the roof of the furnace up by the exhaust outlets. Light chunks of black stuff is what is being ejected into the room when it breaks free from the burner guts (if it can). That will tell you it’s time to tune those burners. If you do not have a good oxygen/flue gas analyzer, get one. It can be pricey, but it will pay for itself in a matter of months in both maintenance and fuel savings.
B. Seriously … Check the Flues and Leakage Around Door Seals
If you are running direct-fired furnace equipment, or furnaces that have the flue gases mixed from multiple burners, it gets a little trickier. All the same rules apply for not wanting soot. Only now, it can actually get exposure to your product, it can saturate your refractory, and it can clog a flue to the point that furnace pressure is affected. An increase in furnace pressure can test the integrity of your door seals. It can back up into the burners and put undue and untimely wear and tear on burner nozzles, ignitors, flame safety equipment, etc. As a furnace operator or floor person, it should be normal operating procedure to look for leakage around door seals.
C. Utilize Combustion Service Companies
Ask the wizards. Combustion service companies can usually help you diagnose and verify flue issues if you suspect they exist. It’s always a great idea to set a baseline for your combustion settings. Service companies can help you establish the optimum running conditions. Again, money well spent to optimize the performance of your furnaces. I’m sure you already have a combustion service team; some are listed in this publication. Otherwise, consult the trade groups like MTI and IHEA for recommended suppliers of that valuable service.
Check flues monthly. It should be a regular walk around maintenance check.
Don’t let the next headline be your plant. See you next issue.
About The Author:
Jim Roberts President US Ignition
Jim Roberts, president at US Ignition, began his 45-year career in the burner and heat recovery industry directed for 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.
The Cybersecurity Maturity Model Certification (CMMC) 2.0 compliance process is detailed and complicated, and businesses in the defense industrial base (DIB) may be tempted to delay this regulatory hurdle. In this Cybersecurity Desk column, which was first released inHeat Treat Today’sMarch 2025 Aerospace print editionJoe Coleman, cybersecurity officer at Bluestreak Compliance, a division of Bluestreak | Bright AM™, explains why companies putting off CMMC 2.0 compliance may end up scrambling to meet deadlines, incurring costly delays, and even facing potential disqualification from future DoD contracts.
Introduction
The Cybersecurity Maturity Model Certification (CMMC) 2.0 is not only a regulatory hurdle, it represents a fundamental shift in the cybersecurity landscape for the Defense Industrial Base (DIB). Ignoring this critical initiative can have severe and potentially irreversible consequences for your company’s future.
Many companies mistakenly believe they can afford to delay their CMMC 2.0 compliance efforts, assuming they have plenty of time to prepare. This is a dangerous assumption. Achieving CMMC 2.0 compliance is a detailed and complicated process that typically takes 12–18 months. Delaying implementation can leave your company scrambling to meet deadlines and increase the risk of costly delays, missed opportunities, and even potential disqualification from future DoD contracts.
The High Cost of Inaction
The consequences of failing to prioritize CMMC 2.0 compliance are significant:
Loss of revenue and market share: Non-compliance directly impacts your ability to bid on and win DoD contracts. This translates to lost revenue, limiting growth and a significant competitive disadvantage against companies that have already achieved compliance
Erosion of trust and reputation: Failing to meet cybersecurity standards can damage your company’s reputation within the DIB. This loss of trust can impact not only your relationship with the DoD, but also with other key stakeholders, including clients, contractors, partners and investors. Some of your clients may have already asked if you are compliant.
Increased vulnerability to cyberattacks: A weak cybersecurity posture leaves your company highly susceptible to cyberattacks. These attacks can have devastating consequences, including data breaches, system disruptions, and significant financial losses. The key cybersecurity component of CMMC is NIST Special Publication 800-171.
Significant financial penalties: Non-compliance can result in substantial financial penalties, including fines and contract termination. These penalties can severely impact your company’s bottom line and long-term growth.
Operational disruption: The process of implementing and maintaining CMMC 2.0 controls can require significant amounts of time and resources. Delaying these efforts can disrupt your company’s operations, impacting productivity and potentially hindering critical projects.
The Benefits of Proactive Action
By proactively addressing CMMC 2.0 compliance, your company can gain a significant competitive advantage to win more business:
Competitive head start: Companies that prioritize CMMC 2.0 compliance gain a significant first-mover advantage. They can demonstrate their commitment to enhanced cybersecurity to the DoD, build stronger relationships with government agencies, and position themselves as preferred partners for future contracts.
Reduced stress and increased efficiency: Starting early allows for a more gradual and less stressful implementation process. This reduces the risk of last-minute scrambling and allows for a more efficient and effective integration of cybersecurity measures into your existing workflows.
Enhanced cybersecurity posture: The CMMC 2.0 framework provides a structured approach to enhancing your overall cybersecurity posture. By implementing these controls, you not only improve your compliance but also strengthen your defenses against a wide range of cyber threats.
Improved operational resilience: A robust cybersecurity program enhances your company’s operational resilience. By minimizing the risk of cyberattacks and their potential disruptions, you can ensure business continuity and maintain a competitive edge in the market.
Building a culture of security: CMMC 2.0 implementation encourages a shift towards a culture of security within your company. This includes raising awareness among employees about cybersecurity risks, fostering a sense of shared responsibility, and promoting best practices at all levels.
Conclusion
Click image to download a list of cybersecurity acronyms and definitions.
CMMC 2.0 is not an option; it is a critical requirement for any company seeking to do business with the DoD, its prime contractors, and/or downstream service providers. Procrastination is not an option. By taking proactive steps to understand and address CMMC 2.0 requirements, your company can mitigate risks, enhance its cybersecurity posture, and gain a significant competitive advantage in the evolving defense landscape.
For an up-to-date resource list of common cybersecurity acronyms, click the image to the right.
About the Author:
Joe Coleman Cyber Security Officer Bluestreak Consulting Source: Bluestreak Consulting
Joe Coleman is the cybersecurity officer at Bluestreak Compliance, which is a division of Bluestreak | Bright AM™. Joe has over 35 years of diverse manufacturing and engineering experience. His background includes extensive training in cybersecurity, a career as a machinist, machining manager, and an early additive manufacturing (AM) pioneer. Joe presented at the Furnaces North America (FNA 2024) convention on DFARS, NIST 800-171, and CMMC 2.0.
The heat treating industry is under pressure to reduce its greenhouse gas emissions (GHGE), and the response has been a noble effort to attain sustainability. In 2024, Heat Treat Today published a series of articles by guest columnist Michael Mouilleseaux, general manager at Erie Steel, Ltd., regarding the U.S. Department of Energy’s initiative related to the decarbonization of industry and its potential impact on the heat treating industry.
This update was first published in Heat Treat Today’s February 2025 Air & Atmosphere Heat Treating Aerospace print edition in response to recent changes in the U.S. administration.To catch up on previous columns by Mike, check these out: “US DOE Strategy Affects Heat Treaters“ appeared in the March 2024 Aerospace print edition; “U.S. DOE Strategy: Ramifications for Heat Treaters” appeared in the May 2024 Sustainability print edition; and “US DOE Strategy: Why the Heat Treating Industry?” appeared in the June 2024 Buyer’s Guide print edition.
As described in previous articles, President Joe Biden issued an executive order in 2021 that committed the federal government through the Department of Energy (DOE) and the Environmental Protection Agency (EPA) to reduce GHGE attributable to “process heating” by 85% by 2035 and attain net zero CO2 emissions by 2050.
These goals were to be achieved by implementing four largely unproven technologies:
Energy efficiency
Industrial electrification (using green electricity)
Adoption of low-carbon fuels (e.g., hydrogen), feedstocks, and energy sources (LCFFES)
Carbon capture, utilization and storage at the generated source (CCUS)
On www.heattreattoday.com/factsheetDOE, you can utilize the one-page resource to let governmental officials know what our industry is, who we are, who we employ, and the effect this effort has in regulating us out of business.
We further described the negative effect the implementation of these efforts would have on the heat treating industry — specifically, an increase in energy costs from 4x to 15x, with a companion reduction in energy reliability. This is not the combination that portends success in business.
In November of 2024, the people of the United States made a statement. They decided the direction of the country for the past four years was not what they wanted and chose another path, a path they chose based on what they had experienced from 2017 through 2020. As it pertains to industrial policy, they knew that reduced regulation and policies favorable to business growth were the guiding principles.
What may we reasonably expect from a Trump administration relative to this Industrial Decarbonization Effort?
At a minimum, we should expect a sober understanding of the issues and agreement that any low-carbon replacement energy technologies will come with the assurance they are cost competitive with current sources, and that they will be reliable and secure.
Is this to say that all efforts toward the achievement of a reduction in greenhouse gas emissions (GHGE) should be abandoned? Absolutely not, however, they should not be implemented with a religious zeal that places implementation above practicality. We need to recognize that if our way of life is to be maintained, these changes will be evolutionary — not revolutionary.
Should we anticipate this effort to revise the “timing” of GHGE reductions will be easy to achieve? It will not; the Biden administration has made every effort to obligate a maximum amount of the funding from the IRA earmarked for “clean energy,” understanding any funds not so obligated can be rescinded. Additionally, a concerted effort to place these funds in Republican states was made to make any recission as politically painful as possible for the incoming administration.
The incoming administration has made it clear they will scrutinize all existing funding sources that support those clean energy initiatives that distort and undermine energy independence and reliability. They have stated they intend on immediately pausing all regulatory activities until they have the opportunity to review them. They intend on rescinding all executive orders that further the clean energy agenda.
Do we have a part in this? Yes, our industry, although crucial to the manufacturing community and national security, has very little visibility. Now is the time to act and to let our representatives and senators know how important it is to pause, if not reconfigure, this Industrial Decarbonization Initiative to assure our businesses remain vibrant and vigorous.
Attend the 2025 SUMMIT to find out more about the DOE’s actions for the heat treat industry.
About the Author:
Michael Mouilleseaux General Manager Erie Steel, Ltd
Michael Mouilleseaux is general manager at Erie Steel, Ltd. He has been at Erie Steel in Toledo, OH since 2006 with previous metallurgical experience at New Process Gear in Syracuse, NY, and as the director of Technology in Marketing at FPM Heat Treating LLC in Elk Grove, IL. Michael attended the stakeholder meetings at the May 2023 symposium hosted by the U.S. DOE’s Office of Energy Efficiency & Renewable Energy.
The Heat Treat Doctor® has returned to offer sage advice to Heat Treat Today readers and to answer your questions about heat treating, brazing, sintering, and other types of thermal treatments as well as questions on metallurgy, equipment, and process-related issues.
This informative piece was first released in Heat Treat Today’sFebruary 2025 Air/Atmosphere Furnace Systems print edition.
People often ask two fundamental questions related to normalizing. First, is it necessary? Second, just what and how important is a “still air” cool to the end result? Let’s learn more.
Why Normalize?
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Normalizing is typically performed for one or more of the following reasons:
To improve machinability
To improve dimensional stability
To produce a homogeneous microstructure
To reduce banding
To improve ductility
To modify and/or refine the grain structure
To provide a more consistent response when hardening or case hardening
For example, many gear blanks are normalized prior to machining so that during subsequent hardening or case hardening dimensional changes such as growth, shrinkage, or warpage will be better controlled.
Normalizing imparts hardness and strength to both cast iron and steel components. In addition, normalizing helps reduce internal stresses induced by such operations as forging, casting, machining, forming or welding. Normalizing also improves chemical non-homogeneity, improves response to heat treatment (e.g., hardening), and enhances dimensional stability by imparting into the component part a “thermal memory” for subsequent lower temperature processes. Parts that require maximum toughness and those subjected to impact are often normalized. When large cross sections are normalized, they are also tempered to further reduce stress and more closely control mechanical properties.
Large paper roll normalized in a car bottom furnace and cooled (due to its mass) using the assistance of a floor fan.
Soak periods for normalizing are typically one hour per inch of cross-sectional area but not less than two hours at temperature. It is important to remember that the mass of the part or the workload can have a significant influence on the cooling rate and thus on the final microstructure. Thin pieces cool faster and are harder after normalizing than thicker ones. By contrast, after furnace cooling in an annealing process, the hardness of the thin and thicker sections is usually about the same.
Micrograph of medium-carbon AISI/SAE 1040 steel showing ferrite grains (white etching constituent) and pearlite (dark etching constituent). Etched in 4% picral followed by 2% nital. (Bramfitt and Benscoter, 2002, p. 4. Reprinted with permission of ASM International. All rights reserved.)
When people think of normalizing, they often relate it to a microstructure consisting primarily of pearlite and ferrite. However, normalized microstructures can vary and combinations of ferrite, pearlite, bainite, and even martensite for a given alloy grade are not uncommon. The resultant microstructure depends on a multitude of factors including, but not limited to, material composition, part geometry, part section size, part mass, and cooling rate (affected by multiple factors). It is important to remember that the microstructure achieved by any given process sequence may or may not be desirable depending on the design and function of the component part.
The microstructures produced by normalizing can be predicted using appropriate continuous cooling transformation diagrams and this will be the subject of a subsequent “Ask The Heat Treat Doctor” column.
In this writer’s eyes, industry best practice would be to specify the desired microstructure, hardness, and mechanical properties resulting from the normalizing operation. Process parameters can then be established, and testing performed (initially and over time) to confirm/verify results.
In many cases, the failure of the normalizing process to achieve the desired outcome centers around the lack of specificity (e.g., engineering drawing requirements, metallurgical and mechanical property call outs, testing/verification practices, and quality assurance measures). Failure to specify the required microstructure and mechanical properties/characteristics can lead to assumptions on the part of the heat treater, which may or may not influence the end result.
“Normalizing is the heat treatment that is produced by austenitizing and air cooling, to produce uniform, fine ferrite/pearlite microstructures in steel … In light sections, especially in alloy hardenable steels, air cooling may be rapid enough to form bainite or martensite instead of ferrite and pearlite.”
What Is Normalizing?
The normalizing process is often characterized in the following way: “Properly normalized parts follow several simple guidelines, which include heating uniformly to temperature and to a temperature high enough to ensure complete transformation to austenite; soaking at austenitizing temperature long enough to achieve uniform temperature throughout the part mass; and cooling in a uniform manner, typically in still air” (Herring, 2014).
It is also important to remember that normalizing is a long-established heat treatment practice. As far back as 1935, Grossmann and Bain wrote:
Normalizing is the name applied to a heat treatment in which the steel is heated above its critical range (that is, heated to make it wholly austenitic) and is then allowed to cool in air.
Since this is one specific form of heat treatment, it will be realized that the structure and mechanical properties resulting from the normalizing treatment will depend not only on the precise composition of the steel but also on the precise way in which the cooling is carried out.
The term ‘normalizing’ is generally applied to any cooling ‘in air.’ But in reality, this may cover a wide range of cooling conditions, from a single small bar cooled in air (which is fairly rapid cooling) to that of a large number of forgings piled together on a forge shop floor … which is a rather slow cool, approaching an anneal. The resulting properties in the two cases are quite different.
In plain carbon steels and in steel having a small alloy content, the air-cooled (normalized) structure is usually pearlite and ferrite or pearlite alone … More rapid cooling gives fine pearlite, which is harder; slow cooling gives coarse pearlite, which is soft. In some few alloy steels, the normalized structure in part may be bainite.
The hardness of normalized steels will usually range from about 150 to 350 Brinell (10 to 35 Rockwell C), depending on the size of the piece, its composition and hardening characteristics.
Importance of Defining Cooling Rate
In 2005, Krauss underscored the importance of defining cooling rate when he wrote: “Air cooling associated with normalizing produces a range of cooling rates depending on section size [and to some extent, load mass]. Heavier sections [and large loads] air cool at much lower cooling rates than do light sections because of the added time required for thermal conductivity to lower temperatures of central portions of the workpiece.”
Microstructures Created by Normalizing
The microstructural constituents produced by normalizing for a particular steel grade can be ferrite, pearlite, bainite, or martensite. The desired microstructure from normalizing adds an important cautionary note, as addressed by Krauss in STEELS (1990 and 2005), namely: “Normalizing is the heat treatment that is produced by austenitizing and air cooling, to produce uniform, fine ferrite/pearlite microstructures in steel … In light sections, especially in alloy hardenable steels, air cooling may be rapid enough to form bainite or martensite instead of ferrite and pearlite.”
Next time: We define a “still air” cool and look at the state of normalizing in North America.
Practical Data for Metallurgists, 17th ed. TimkenSteel.
Totten, George E., ed. Steel Heat Treatment Handbook, vol. 2, 2nd ed., CRC Press, 2007. 612-613.
About the Author
Dan Herring “The Heat Treat Doctor” The HERRING GROUP, Inc.
Dan Herring has been in the industry for over 50 years and has gained vast experience in fields that include materials science, engineering, metallurgy, new product research, and many other areas. He is the author of six books and over 700 technical articles.
The Heat Treat Doctor® has returned to offer sage advice to Heat Treat Today readers and to answer your questions about heat treating, brazing, sintering, and other types of thermal treatments as well as questions on metallurgy, equipment, and process-related issues.
This informative piece was first released in Heat Treat Today’sJanuary 2025 Technologies to Watch print edition.
As a very young engineer, I vividly recall our company president had a statue of a three-headed elephant in his office. One head faced forward, one faced slightly to the right, one faced slightly to the left. The moral: looking backwards is not the path forward! Let’s learn more about what the heat treatment industry will look like by the middle of this century.
The Market
A number of market studies and economic forecast models suggest that the global heat treatment market will grow to between 130–150 billion U.S. dollars by no later than 2030 and to around 200–220 billion U.S. dollars by 2040, barring another significant or sustained global economic event. These forecasts assume several minor downturns in the economy of various countries and in manufacturing segments due to economic and geopolitical factors in the coming decades.
Heat Treatment Market Shift
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The most significant and fundamental shift that is and will continue is in the makeup of the heat treatment equipment segment of the North American market. What began in the late 1990s and early 2000s as a transition from older, long-established practices and processes to equipment capable of meeting the rapidly evolving demands of technological innovation will continue. Standardization (for cost containment), changes in manufacturing methods and methodologies, and environmental considerations are also fueling this change.
A demand for higher performance products, end-of-life expectations (in some but not all products), an emphasis on systems with single-piece flow or small batch productivity are just a few examples of this change. Other factors such as equipment obsolescence, the need for even higher manufacturing efficiencies, long term operator health and safety concerns, predictive (as opposed to preventative) maintenance, and adaptation to both the speed at which the manufacturing landscape is changing and the type of flexible equipment/processes reinforce these conclusions.
From an equipment standpoint, vacuum furnaces and applied energy systems are and will continue to experience rapid growth at the expense of more traditional atmosphere furnaces. Safety, open flames and emissions of any kind (NOx, CO2, particulates) are driving this change. As such, the dramatic reduction and control of greenhouse gases and the cooling of our planet by the mid-century will be metamorphic. This trend is not only expected to continue but to accelerate (Figures 1–2).
Figure 1. North American Industry by Equipment Segment, 2012–2018 (see Herring, Atmosphere Heat Treatment, Vol. 1, 2014)
For example, the driving force behind the development, use and integration of vacuum technology into manufacturing is not only due to the fact that it is lean, green, and agile, but also that vacuum technology best addresses the identified needs of the heat treatment industry, namely:
Energy efficient equipment
Processing with minimal part distortion
Optimization of heat treatment processes (especially diffusion-related processes)
Environmentally friendly by-products and emissions
Adaptability/flexibility for new and advanced materials
Process controls incorporating intelligent sensors
Designs based on heat treat modeling and simulation
Equipment/process integration into manufacturing
Change — Its Pace and Form
A paradigm shift in the workforce has occurred, transitioning to a vastly more mobile and younger group of individuals relying on the growing role of automation and communication in manufacturing. This shift is principally responsible for accelerating the pace of change in the heat treatment industry, from what has traditionally been a slow moving and slow-to-adapt industry, to one capable of meeting the need for rapid deployment of new products and one that keeps pace with technological innovations.
Moving forward, equipment manufacturers and suppliers to the industry will continue to look at product standardization to maximize profitability, thus driving the industry to “cookie cutter” solutions or, in a diametrically opposite philosophy, looking to provide highly customized solutions, often with risk factors incorporated into the pricing as specialized solutions with high profit margins to application-specific needs.
Figure 2. North American Industry by Equipment Segment, 2024–2035 (see Herring, Atmosphere Heat Treatment, Vol. 1, 2014)
Technology/Innovation Drivers and Industry Trends
Heat treatment will always be a core manufacturing competency, and as such, decisions will continue to be made to either heat treat in-house or outsource to commercial heat treatment shops. It is significant that the percentage of manufacturers with in-house heat treat departments (80–85%) to commercial (10–15%) heat treat shops hasn’t really changed in the last six decades! The consolidation of companies is a trend that is expected to continue.
What is more prevalent today than ever is the tremendous pressure being exerted on manufacturing from senior management to increase product velocity and lower unit cost. While recalls seem to be a way of life these days, product liability and consume demands for product performance are forcing change, even in the most extreme applications.
As a result, the most identifiable trends in today’s North American heat treatment industry are:
Growing the manufacturing portion (percentage) of GDP through mobility and adaptability, coupled with more sophisticated and higher paying jobs
Lowering product unit cost through technology adaptation
Obsoleting older equipment and technologies and replacing them with innovative new and/or high productivity heat treatment systems. Examples include:
New materials development allowing for different processing methods and/or lower temperature heat treatments while maintaining environmentally friendly equipment and processes
Transition of carburizing/ carbonitriding from atmosphere to low pressure vacuum processes with either oil or high-pressure gas quenching, or both
Use of single-piece heating and quenching of parts and/or small (versus large) batch processing to improve product velocity
Changes in product materials and/or designs to allow more low temperature atmosphere treatments (e.g., nitriding, nitrocarburizing)
Use of advanced quenching techniques and quenching technologies to better manage distortion
Implementing artificial intelligence-based modeling and simulation software capable of equipment control and process optimization
Implementing the next generation of intelligent sensors, real-time data collection methods and analytics (including cloud-based computing)
Changing the focus of companies from “generalization” toward “specialization” with respect to products, services, processes (proprietary or unique) and new or innovative technologies to capture greater market share or present opportunities to generate higher profit margins
Accelerating the implementation of lean manufacturing strategies and applying these strategies to heat treatment:
Eliminate high labor costs (via automation and controls), simplify operations (i.e., reduce the number of manufacturing steps), and adopt “build to order” strategies.
Conservation of energy, on-demand part production, shortening of process cycles, and the move toward smaller lot sizes is the order of the day.
Continuing the transition from heat treatment departments to integrated manufacturing cells
In Summary
It is, and will be for decades to come, a truly magical time in the heat treatment industry. The slow-moving, plodding, three-headed elephant has been replaced by a lean and agile animal — technology. This will not only ensure a greener workplace but an environment of innovation for future generations. And as I am fond of saying about the future, there’s “magic in the aire!”
References
ASM International, Vision 2020. 1999.
Herring, Daniel H. “Esoteric Heat Treatment Industry Critique: 2019 and Beyond.” Industrial Heating, January 2019.
Herring, Daniel H. Atmosphere Heat Treatment, Volume 1. BNP Media, 2014.
Wolowiec-Koreka, Emilia. Carburising and Nitriding of Iron Alloys. Springer, 2024.
About the Author
Dan Herring “The Heat Treat Doctor” The HERRING GROUP, Inc.
Dan Herring has been in the industry for over 50 years and has gained vast experience in fields that include materials science, engineering, metallurgy, new product research, and many other areas. He is the author of six books and over 700 technical articles.
“The Cybersecurity Maturity Model Certification (CMMC) 2.0 aims to improve cybersecurity across the defense industrial base (DIB), but many small to mid-sized businesses (SMBs) struggle to meet the standards, putting them at risk of losing crucial contracts.” In this Cybersecurity Desk column, Joe Coleman, cybersecurity officer at Bluestreak Compliance, a division of Bluestreak | Bright AM™, raises the alarm ifsmall to mid-sized heat treaters neglect compliance standards and guides companies through the minefield of cyber threats facing all SMBs.
Read more Cybersecurity Desk columns in previousHeat Treat Today’s issues here.
Despite an increasing cyber threat landscape, many small to mid-sized businesses (SMBs) in the Department of Defense (DoD) supply chain remain unprepared for compliance with NIST SP 800-171 R2 and CMMC 2.0. The Cybersecurity Maturity Model Certification (CMMC) 2.0 aims to improve cybersecurity across the defense industrial base (DIB), but many SMBs struggle to meet the standards, putting them at risk of losing crucial contracts. Surveys suggest that nearly 70% of SMBs are unready for the new requirements, and the real figure could be even higher due to some businesses inaccurately reporting compliance by inflating their assessment scores.
Understanding CMMC 2.0
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CMMC 2.0 simplifies the original five-tier framework into three levels:
Level 1: Basic cyber hygiene for contractors handling Federal Contract Information (FCI).
Level 2: Advanced practices for those working with Controlled Unclassified Information (CUI).
Level 3: Stringent requirements for contractors involved in national security projects.
Compliance is mandatory for any contractor bidding on DoD contracts, including those working indirectly for federal contractors and subcontractors. SMBs should anticipate customers clients inquiring to inquire about their compliance as these standards will soon impact their business relationships. Achieving compliance is a lengthy process, typically taking 12 to 18 months.
Low Readiness and Risks
The lack of readiness among SMBs threatens both business continuity and national security. Many smaller contractors lack the resources and expertise to meet CMMC 2.0’s standards. Given the defense sector’s reliance on a wide variety of contractors, this gap could create widespread repercussions.
Financial Implications of Non-Compliance
Irreversible consequences from waiting to comply
Compliance with CMMC 2.0 can be financially burdensome. Implementing measures such as multi-factor authentication, encryption and continuous monitoring can be costly, especially for businesses with limited resources. The lack of in-house cybersecurity expertise compounds this issue, requiring companies to hire or train specialized personnel, further increasing costs.
Failing to comply with CMMC 2.0 could result in losing valuable DoD contracts, which can be a significant portion of SMB revenue. Such losses could lead to layoffs, revenue declines or even business closures.
Challenges to Compliance
Several challenges contribute to the widespread unpreparedness among SMBs:
Unclear timelines: Uncertainty surrounding DoD’s compliance timelines complicates planning and prioritization for SMBs.
Complexity of requirements: While CMMC 2.0 simplifies the original framework, its specific requirements remain difficult to interpret for many SMBs, particularly in identifying necessary security measures.
Resource limitations: The cost of achieving and maintaining compliance strains smaller businesses, which often lack the budgets for the required technology and expertise.
Lack of cybersecurity expertise: A shortage of qualified personnel poses a significant obstacle, as demand for cybersecurity professionals is high across industries.
Government Support Initiatives
To help SMBs, the DoD has introduced various programs, including training, grants and educational resources. A phased implementation timeline also provides additional preparation time. However, industry experts suggest that further support, such as tax credits or subsidies, could help SMBs offset the costs of compliance. Clearer guidance from the DoD would also be beneficial in helping businesses navigate the certification process.
Path Forward for SMBs
Click image to download a list of cybersecurity acronyms and definitions.
To secure future contracts, SMBs must prioritize cybersecurity. This involves conducting internal risk assessments, identifying vulnerabilities, and creating compliance plans. Partnering with cybersecurity experts or managed service providers can help SMBs develop cost-effective strategies. Additionally, leveraging government resources and adopting critical security measures early will better position SMBs for CMMC 2.0 certification.
Conclusion
The widespread lack of preparedness for CMMC 2.0 poses significant risks to both SMBs and the defense supply chain. As deadlines approach, proactive measures from both businesses and the government are necessary to close the readiness gap and ensure the continued participation of SMBs in the defense sector.
About the Author
Joe Coleman Cyber Security Officer Bluestreak Consulting Source: Bluestreak Consulting
Joe Coleman is the cybersecurity officer at Bluestreak Compliance, which is a division of Bluestreak | Bright AM™. Joe has over 35 years of diverse manufacturing and engineering experience. His background includes extensive training in cybersecurity, a career as a machinist, machining manager and an early additive manufacturing (AM) pioneer. Joe presented at the Furnaces North America (FNA 2024) convention on DFARS, NIST 800-171, and CMMC 2.0.
The Heat Treat Doctor® has returned to offer sage advice to Heat Treat Today readers and to answer your questions about heat treating, brazing, sintering, and other types of thermal treatments as well as questions on metallurgy, equipment, and process-related issues.
This informative piece was first released in Heat Treat Today’sDecember 2024 Medical & Energy Heat Treat print edition.
The subject of thermal expansion and contraction is a very important one to most heat treaters given that the materials of construction of our furnaces and our fixtures experience these phenomena every day. However, to find a simple explanation of what it is and how we can help minimize the issues caused by it can be difficult. What we need is an explanation in laymen’s terms, along with some simple science and a few examples. Let’s learn more.
Thermal Expansion Effects
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When exposed to a change in temperature, whether heating or cooling, materials experience a change (increase or decrease) in length, area, or volume. This not only changes the material’s size but also can influence its density. The freezing of ice cubes is a common example of a volume expansion (on freezing or cooling), while as they melt (on heating), we see a volume contraction.
As most of us recall from our science classes, as temperature increases, atoms begin to move faster and faster. In other words, their average kinetic energy increases. With the increase in thermal energy, the bonds between atoms vibrate faster and faster creating more distance between themselves. This relative expansion (aka strain) divided by the change in temperature is what is known as the material’s coefficient of linear thermal expansion.
We must also be aware, however, that a number of materials behave in a different way upon heating. Namely, they contract. This usually happens over a specific temperature range. Tempering of D2 tool steel is a good example (Figure 1). From a scientific point of view, we call this thermal contraction (aka negative thermal expansion).
Figure 1. Change in length of D2 tool steel as a function of tempering temperature (Image courtesy of Carpenter Technology — www.carpentertechnology.com)
A related fact to be aware of is that thermal expansion generally decreases with increasing bond energy. This influences the melting point of solids, with higher melting point materials (such as the Ni-Cr alloys found in our furnaces and fixtures) more likely to have lower coefficient of thermal expansion. The thermal expansion of quartz and other types of glass (found in some vacuum furnaces) is, however, slightly higher. And, in general, liquids expand slightly more than solids.
Effect on Density
As addressed above, thermal expansion changes the space between atoms, which in turn changes the volume, while negligibly changing its mass and hence its density. (In an unrelated but interesting fact, wind and ocean currents are, to a degree, effected by thermal expansion and contraction of our oceans.)
What Is the Effect of the Coefficient of Thermal Expansion?
In laymen’s terms, the coefficient of thermal expansion (Table 1) tells us how the size of an object changes with a change in temperature. Specifically, it measures the fractional change in size per degree change in temperature at a constant pressure. Lower coefficients describe lower tendency to change in size. There are several types of thermal expansion coefficients — namely linear, area, and volumetric. For most solid materials, we are typically concerned in the heat treat industry with the change along a length, or in some cases a change in volume (though this is mainly of concern in liquids).
Table 1. Comparative values for linear and volumetric expansion of selected materials
Heat Treat Furnace Examples
When calculating thermal expansion, it is necessary to consider whether the design is free to expand or is constrained. Alloy furnace muffles, retorts, mesh and cast link belts, and radiant tubes are good examples. The furnaces that use them must be designed to allow for linear growth and changes in area or volume. If not, the result is premature failure due to warpage (i.e., unanticipated movement).
If a component is constrained so that it cannot expand, then internal stress will result as the temperature changes. These stresses can be calculated by considering the strain that would occur if the design were free to expand and the stress required to reduce that strain to zero, through the stress/strain relationship (characterized by Young’s modulus). In most furnace materials it is not often necessary to consider the effect of pressure change, except perhaps in certain vacuum furnaces or autoclave designs.
A Little Science
For those that are interested, here are the formulas most often used by heat treaters to calculate the coefficient of thermal expansion.
Estimates of the Change in Length (L), Area (A), and Volume (V)
Linear expansion is best interpreted as a change in only one dimension, namely length. So linear expansion can be directly related to the coefficient of linear thermal expansion (αL) as the change in length per degree of temperature change. It can be estimated (for most of our purposes) as:
where:
ΔL is the change in length
ΔT is the change in temperature
αL is the coefficient of linear expansion
This estimation works well as long as the linear expansion coefficient does not change much over the change in temperature and the fractional change in length is small (ΔL/L <<1). If not, then a differential equation (dL/dT) must be used.
By comparison, the area thermal expansion coefficient (αA) relates the change in a material’s area dimensions to a change in temperature by the following equation:
where:
ΔA is the change in area
ΔT is the change in temperature
αA is the coefficient of area expansion
Again, this equation works well as long as the area expansion coefficient does not change much over the change in temperature ΔT(ΔT), if we ignore pressure and the fractional change in area is small (ΔA/A <<1)ΔA/A<<1. If either of these conditions does not hold, the equation must be integrated.
For a solid volume, we can again ignore the effects of pressure on the material, and the volumetric (or cubical) thermal expansion coefficient can be written as the rate of change of that volume with temperature, namely:
where:
• ΔV is the change in volume • ΔT is the change in temperature • αV is the coefficient of volumetric expansion
In other words, the volume of a material changes by some fixed fractional amount. For example, a steel block with a volume of 1 cubic meter might expand to 1.002 cubic meters when the temperature is raised by 90°F (32°C). This is an expansion of 0.2%. By contrast, if this block of steel had a volume of 2 cubic meters, then under the same conditions it would expand to 2.004 cubic meters, again an expansion of 0.2% for a change in temperature of 90°F (32°C).
Thermal Fatigue
In many instances, we must consider the effect of thermal fatigue as well as thermal stress. One example is on the surface of a hot work die steel as H11 or H13: one must ensure that in service, when it experiences a (rapid) change in temperature, it will avoid cracking.
The equation for thermal stress is:
where:
σ is the thermal stress
E is the Young’s modulus of the material at temperature
α is the coefficient of linear thermal expansion at temperature
ΔT is the change in temperature
Here both E and α depend on temperature and the resultant stress will either be compressive if heated or tensile if cooled, so we must use these constants at both maximum and minimum temperatures. Considering the temperature dependent stress-strain curve, this stress may exceed the elastic limit (tensile or compressive) and contribute eventually to thermal fatigue failure. There are software programs to aid in the calculation of the resultant thermal stresses. Thermal expansion at a surface at a higher temperature than the core results in a compressive stress, and vice versa.
Final Thoughts
The effects of thermal expansion will be highlighted in a forthcoming article in Heat Treat Today, but it suffices for all heat treaters to remember that this phenomenon is responsible for a great deal of downtime and maintenance in our equipment. It also can affect the end product quality (disguising itself as distortion) and hence create additional cost or performance issues for our clients.
References
Chandler, Harry, ed. Heat Treater’s Guide: Practices and Procedures for Irons and Steels, 2nd Edition. ASM International, 1995.
Herring, Daniel H. Vacuum Heat Treatment. BNP Media, 2012.
Herring, Daniel H. Vacuum Heat Treatment Volume II. BNP Media, 2016.
Special thanks to Professor Joseph C. Benedyk for his input on the topic.
About the Author
Dan Herring “The Heat Treat Doctor” The HERRING GROUP, Inc.
Dan Herring has been in the industry for over 50 years and has gained vast experience in fields that include materials science, engineering, metallurgy, new product research, and many other areas. He is the author of six books and over 700 technical articles.
Your Heat Treat Todayteam will be celebrating the holidays with our families, and our offices will be closed from December 21 to January 1. Look for your next Heat Treat Daily e-newsletter on January 2nd! Until then, we hope this message encourages you and directs you to the true source of hope during this season.
Room with Him
In the next few days, it’ll be easy to get overwhelmed with all the activities, the gatherings, the lights and colors, crinkly wrapping paper and Christmas songs . . . and the movies. Who doesn’t settle down at least once during the season to watch a favorite Christmas movie? Some folks prefer the classics like White Christmas or It’s a Wonderful Life. Others love the new seasonal specials, like Home Alone or Elf. Maybe it’s Rudolph the Red-Nosed Reindeer that reigns in your house. My family’s favorite is The Muppet Christmas Carol.
In most Christmas movies, there’s always a special scene that moves viewers, reinforcing the themes of Christmas: hope, love, hospitality, faith, generosity, thankfulness. One scene from Rudolph moves me more than most, but I bet it’s not the one you’re thinking of.
Do you remember the residents of the Island of Misfit Toys? Dolly, and Charlie-in-the-box, and the boomerang who wouldn’t come back — toys that weren’t wanted because they didn’t do what was expected of them, or they were a little different in their design. Exiled to the Island of Misfit Toys, they waited and hoped for a chance to be enjoyed, appreciated and loved. However, the island was so far off course that they were forgotten year after year, and they were never given the opportunity to brighten a child’s Christmas morning.
Disappointments, slights, brokenness are felt, even at this time of year. Dolly’s words resonate with us when she says, “I just don’t feel like I have any more hope left in me.” Our hearts are troubled, and our coordinates don’t register on the radar. We might feel lost and forgotten along with the misfit toys.
This season is about more than parties, gifts, and decorations, as we all know. Jesus, the Son of God, became man, taking the form of a baby and living as the God-man, the perfect redemption for the lost, the broken, the misfits.
It is striking that at the end of his ministry, as he was wrapping up his time with his disciples before he went to the cross, Jesus assured them, “In my Father’s house are many rooms. If it were not so, would I have told you that I go to prepare a place for you? And if I go and prepare a place for you, I will come again and will take you to myself, that where I am you may be also.” (John 14:2-3) Jesus wandered about without a place to lay his head, yet he is quick to promise his troubled people not merely shelter, any shelter, but a room in the Father’s house.
Although the Savior came to no room at his birthplace, he has gone on to prepare rooms for us, and it’s not just a room, that is, a designated space with measurements and coordinates. He will be there also. And not just a room with him there — that would be awesome enough, but he also prepares for us, his followers, to be with him, to abide with him, to reside in him. He is what makes up the features, the atmosphere, the feng shui of the room. He is home. He is the where of kicking off our shoes and settling down with a cuppa joe. He is comfort food, a soft blanket, and a wagging tail at the door. This is what Christians mean when we say Jesus is our Sabbath.
A popular saying at this time of year is “Make room in your heart for Jesus.” Notwithstanding we can’t make the room, but he must, the truer saying is that “Jesus has made room for us.”
Hear his tender words of encouragement, which come after his prediction that Simon Peter will fail and deny him, just as we do in unbelief and discontentment: “Let not your hearts be troubled.” What follows next is his exhortation: “You believe in God? Believe also in me.” (John 14:1)
He doesn’t leave us to our own devices or our own means of finding our way to him. He comes to dwell with us; he becomes our dwelling place. And now, he is preparing an eternal dwelling place for his people. That’s the hope he gives the disciples as their steps falter under the burden of their troubled hearts, “that where I am you may be also.”
Know Jesus, and we can be assured we won’t be left on this island of misfit toys forever. We have a home.
And that makes for a merry Christmas message!
Here at Heat Treat Today, we are looking to 2025 with much anticipation and hope for more opportunities to work together and challenge ourselves and others with new ideas in the North American heat treat industry. Thank you for the opportunities every day to serve and encourage you in our heat treat corner of the world.
From the entire Heat Treat Todayteam, we wish you a very joyous and restful Christmas celebrating the birth of Jesus Christ!
In this installment of the Controls Corner, we are addressing inductance in a furnace heating system, and the critical role it plays in various industrial systems, including furnace load systems. Impedance acts as a measure of how much a circuit resists the flow of AC current. In this guest column, Brian Turner, sales applications engineer at RoMan Manufacturing, Inc., explains how impedance applies in electrical circuits.
Inductance is a fundamental concept in electrical engineering, and it plays a critical role in various industrial systems, including furnace load systems. In furnaces used for heating, inductance is a key factor influencing the system’s electrical performance, energy efficiency, and overall operational behavior.
To talk about inductance, let’s first address impedance and how it applies:
In electrical circuits, impedance refers to the total opposition to the flow of alternating current (AC), which is a combination of both resistance (from resistors) and reactance (from inductors), essentially acting as a measure of how much a circuit resists the flow of AC current, taking into account both the resistive component (like a resistor) and the reactive component (like an inductor at a specific frequency) within the circuit.
Load configuration, power source (IGBT, VRT, ERT) to the furnace feedthrough Source: RoMan Manufacturing Inc.
Inductance
Inductance is the property of an electrical conductor that opposes a change in the current flowing through it. It arises from the magnetic field generated around the conductor when an electric current passes through it. The unit of inductance is the Henry (H).
In an AC circuit, inductance creates a phenomenon known as inductive reactance, which resists the flow of current. Inductive reactance (XL) is given by the formula:
XL= 2πƒL
Where: • XL is the inductive reactance (in ohms) • f is the frequency of the AC supply (in hertz) • L is the inductance (in Henrys)
This reactance influences how the current behaves in the system, which is particularly important in furnace load systems where high current flows are common.
Resistance
Electrical resistance is the opposition that a material offers to the flow of electric current. It is measured in ohms (Ω) and depends on factors such as the material’s properties, its temperature, and the geometry of the conductor (length, cross-sectional area). In heating systems like vacuum furnaces, resistance is harnessed to convert electrical energy into heat through Joule heating (also known as resistive heating).
The relationship between electrical power, voltage, current, and resistance is governed by Ohm’s law:
V = IR
Where: • V is the voltage across the heating element(in volts) • I is the current through the element (inamperes) • R is the electrical resistance of theelement (in ohms)
The heat generated by the furnace’s heating elements is a function of the power dissipated in the resistance, given by the equation:
P = I2 x R
This shows that the heat produced is directly proportional to the resistance and the square of the current flowing through the heating elements
Close Couple
Reducing the material in the secondary* reduces resistance (HEAT = I2 x R)
Reducing the area in the secondary reduces inductive reactance increasing power factor
To be most efficient, use the shortest amount of conductor material from the electrical system secondary to the furnace feedthrough. Additionally, keep the distance between those conductors as small as possible.
Power Factor and Efficiency
Inductance in a furnace load system causes the current and voltage to be out of phase. This phase difference results in a lower power factor, which is a measure of how effectively the system converts electrical power into useful work. A lower power factor means that more apparent power (the combination of real power and reactive power) is required to achieve the same level of heating.
In practical terms, a furnace with a high inductive load will draw more current from the power supply for a given amount of heating, leading to increased energy losses and inefficiency.
In practical terms, a furnace with a high inductive load will draw more current from the power supply for a given amount of heating, leading to increased energy losses and inefficiency. Power factor correction techniques, such as the use of capacitors, are often employed to counteract the effects of inductance and improve system efficiency.
Conclusion
Inductance is a fundamental factor in the operation of furnace load systems, influencing everything from heating performance to energy efficiency and power quality. By understanding and managing inductance, furnace operators can optimize their systems for maximum performance while minimizing energy losses and operational costs. Controlling inductance is essential for ensuring that furnace load systems operate reliably and efficiently in demanding industrial environments.
*The connection from a vacuum power source to the furnace’s feedthroughs, this connection can be made using air-cooled cables, water-cooled cables, or copper bus.
About the Author:
Brian Turner Sales Applications Engineer RoMan Manufacturing, Inc.
Brian K. Turner has been with RoMan Manufacturing, Inc., for more than 12 years. Most of that time has been spent managing the R&D Lab. In recent years, he has taken on the role as applications engineer, working with customers and their applications.
