Ambrell Corporation

6 Heat Treat Tech Trends Fulfilled in 2022. . .Thus Far

/ FEATURED NEWS, MANUFACTURING HEAT TREAT

OCWhat are the heat treat tech trends we're seeing in Heat Treat Today? Perhaps you read the Tech Trends article earlier this year predicting what trends in the industry will continue to develop in 2022. We can see that a point made by Jim Oakes, president of Super Systems, Inc., overlaps all of the trends in this line up: "The pillars in technology remain quality and efficiency with a growing emphasis on connectivity and carbon footprint visibility." Check out the 6 trends below!

Thermal Efficiency To Decrease Carbon Footprint

The technical thoughts that we're seeing surrounding this awareness for thermal efficiency surround the technology of induction. "[Induction] is also a very efficient process," commented Michael J. Zaharof, manager customer information & marketing at Inductoheat, "as induction power supplies are only powered on when needed compared to batch processing (like those requiring an oven)." Additionally, Girish Dahake, senior vice president of Global Applications at Ambrell Corporation, describes this efficient process saying, "The workpiece is placed in the coil where this field induces a current, generating heat in the workpiece. The water-cooled coil is cool to the touch and is placed around or adjacent to the work piece. It does not touch the workpiece and heat is generated by the induced current flowing in the workpiece."

Contact us with your Reader Feedback!

In the news, there have been companies looking to replace old gas generators with no automatic process controls and lacking in dew point efficiency. The resulting significant CO2 savings for  heat treating operations is in line with the trend of pursuing efficiency for the sake of decreasing carbon footprint.

Read more: "Tempering: 4 Perspectives — Which makes sense for you?" and Why Induction Heating Is a Green Technology

Technology for Remote Monitoring and Integrated Control 

We've seen this in the episode with Matt Wright at C3 Data in his description of integrated control of various systems. Additionally, he related that flow of information in heat treat facilities is a major challenge: "When I look at our industry, one of the things that is the biggest challenge is the flow of information — getting information from where it resides to where it needs to be in the format that it needs to be. I think the technologies that have been successful in our industry are technologies that help lubricate that flow, if you will."

Read more: "Heat Treat Radio: Reimagining Furnace Compliance with C3 Data’s Matt Wright"

Molten Salt Quenchants and Salt Reclamation

This hot -- or rather salty -- topic appeared on Heat Treat Radio with Bill Disler at AFC-Holcroft noting that modern processes allow for 99% of salt in quenching to be reclaimed. The manner that salt is used as a quenchant is different from oil: "With salt, you’ll come out of the quench with some liquid salt on it, you’ll go into a washer but that salt then dissolves back into the water. Generally, there is a multiphase wash with a wash/rinse/rinse. Then, after we get a certain percentage of salt in the wash solution, we thermally evaporate the water off leaving the salt back where it can be reintroduced into the quench tank."

Another representative from the company, Bill Coburn, was recently quoted in a press release that highlighted this feature in a recent installation at an agricultural product manufacturer. While these examples are so far quite consistent within the company, we expect more conversations about this reuse-and-recycle opportunity to be forthcoming.

Read more: "Heat Treat Radio: The Greenness and Goodness of Salt Quenching with Bill Disler" and "Batch Austemper Heat Treat Line for Agricultural Equipment Supplier"

Focus on Vacuum Furnaces

Looking back at the months of June and July, the press release ratio of atmosphere to vacuum furnace focus was 3:9. Check out the latest news in the industry in these press releases:

Electric Heating Systems

One of our partners, heat processing interviewed Mark Bula at H2 Green Steel in a feature revealing how the company was commited to electric generation as part of the industrial process. While there is a fair amount of criticism from the energy sector about what this conversion value could realistically look like, the attempts to make electric happen continue to grow.

Read more: "Going Carbon Free: An Interview with H2 Green Steel"

Digital Transformation and Application of IIoT Technologies

This trend will take a variety of forms, particularly with the catchy term, "predictive maintenance." Learn more about IIoT here, but for some technical conversations that have continued into 2022, turn to the Heat Treat Radio podcast with Fives North American Combustion.

[blockquote author="Justin Dzik, Fives North American Combustion" style="1"]The CertiFire™ is, as you already stated, an automated tuning device for temperature uniformity certifications. I think pretty much everybody that’s going to watch this podcast is probably going to know that they can be extremely time consuming to do, they take a lot of time and a lot of intelligence to actually tune the process. This device takes all of that and does it all itself. It does all the automated burner tuning, all the valve adjustments, it locks it all in and tunes it for whatever class uniformity you need.[/blockquote]

Read more: "Heat Treat Radio: Algorithmic Combustion Tuning With Justin Dzik and Ben Witoff at Fives"

Find heat treating products and services when you search on Heat Treat Buyers Guide.com

 

6 Heat Treat Tech Trends Fulfilled in 2022. . .Thus Far Read More »

Why Induction Heating Is a Green Technology

/ FEATURED NEWS, INDUCTION HEATING EQUIPMENT TECHNICAL CONTENT, MANUFACTURING HEAT TREAT

OCIt seems like the world is going green! Induction heating is in the game with its green technology. It does not consume fossil fuels, nor does it produce any hazardous emissions or carbon dioxide (CO2). When compared to gas heating, induction offers a safer, cleaner, and more comfortable work environment. In this comprehensive article by Girish Dahake, Ph.D., senior vice president of Global Applications at Ambrell Corporation, discover more green benefits of induction heating that could make a difference for your business.

This Technical Tuesday article first appeared in Heat Treat Today’s May 2022 Induction Heating print edition.

Girish Dahake, Ph.D.
Senior Vice President, Global Applications
Ambrell Corporation

What Is Induction Heating?

Induction heating is a fast, efficient, precise, repeatable, non-contact method for heating metals or other electrically conductive materials.

An induction heating system includes a power supply which converts line power to an alternating current. This current is delivered to a workhead and work coil creating an electromagnetic field within the coil. The workpiece is placed in the coil where this field induces a current, generating heat in the workpiece. The water-cooled coil is cool to the touch and is placed around or adjacent to the work piece. It does not touch the workpiece and heat is generated by the induced current flowing in the workpiece.

The workpiece can be a metal such as steel, copper, aluminum or brass, or a semiconductor such as carbon, graphite, or silicon carbide. Nonconductive materials such as plastics or glass are inductively heated using an electrically conductive susceptor, typically graphite.

Steel tube assembly
Photo Source: Ambrell Corporation

What Makes Induction Heating Green?

Along with the many environmental benefits, induction heating offers numerous benefits to employees and the organization using the technology. It eliminates smoke, waste heat, noxious emissions, and loud noise.

Many processes that produce emissions can be converted to induction heating including:

  • Flame preheating
  • Flame brazing
  • Flame melting
  • Flame hardening
  • Flame shrink fitting
  • Gas fired oven heating
  • Welding torches (for joining)

Along with improved air quality, there are several other safety benefits. They include:

  • Reduction in risk of contact burns: Since induction heats only a zone of the workpiece, there are limited hot areas which lessens the risk of employee contact. This significantly reduces the risk of contact burns when compared to the outside of gas-heated ovens or exhaust systems.
  • Zero explosive gases: Induction uses electricity for the energy source. This eliminates the handling of high-pressure explosive gases. Often these gases are transported in a hot crowded environment which increases the risk of catastrophic failure
  • No ultraviolet (UV) exposure: Unlike flame heating, induction releases no UV into the environment. This eliminates the risk of UV damage that can occur to the skin and eyes of employees from flame heating sources.

Of course, with induction heating there are safety considerations. Proper installation, signage, employee training, personal protective equipment, and lockout procedures can help mitigate risk.

Eliminate smoke, waste heat, noxious emissions, and loud noises.
Photo Source: Ambrell Corporation

Induction Heating Is More Efficient

Induction is a uniquely energy-efficient heating process that converts 70–90% of the energy consumed into useful heat. When compared to electrical ovens, which are generally only 45% energy efficient, induction heating has two times the overall efficiency. Gas oven efficiency is typically only 25–30% energy efficient, indicating induction can be up to three times as efficient. Since induction requires no warm-up or cooldown cycle, startup and shutdown heat losses are eliminated. The repeatability and consistency of the induction heating process make it highly synergistic with energy-efficient automated systems.

Induction Supplies More Consistent Output Than Oven Heating

The use of constant flow induction heating results in significantly higher efficiency than batch oven heating. Losses in both energy and time due to oven loading and unloading are eliminated with induction heating. Induction enables a consistent flow of parts which is even more critical if onward steps in the manufacturing process require heated parts. This reduces the heat loss from the part when it reaches the next step, thus increasing the overall efficiency of the cycle. This overall savings is not only realized in production efficiency but also results in the better use of heating energy.

Induction Can Be More Cost Effective Than an Oven

Figure 1
Photo Source: Ambrell Corporation

In this scenario (Figure 1), a client using an oven switches to induction. The environmental benefits are considerable. Given the inputs you see in the image, induction heating saves 128 lbs. of CO2 per day and over 46,899 lbs. per year. This is the equivalent of removing five internal combustion engine cars from the road.

The cost savings of induction heating compared to a gas oven are often considerable too, and the difference compared to an electric oven is typically even more significant. The cost variables depend on local rates, so we recommend using an energy calculator to apply your current rates. We have created one that is available at http://green-energy.ambrell.com.

Induction heating wastes little heat due to the direct transfer of energy to the workpiece, resulting in significant energy savings.

Is Induction Right for My Process?

Now that you have learned about the environmental benefits of induction heating that can result in utility savings, the question becomes: is induction right for your process? Induction is particularly ideal when you have a high-volume process that requires consistent part quality. That said, there are many scenarios where induction can be optimal. Induction manufacturers often offer complimentary feasibility testing. That is a great place to begin when determining if induction is the right fit for your process.

About the Author: Dr. Girish Dahake, senior vice president, Global Applications for Ambrell Corporation, has over 25 years of induction experience and leads a worldwide team of induction application experts. He holds multiple industry-related patents, has authored numerous papers, and frequently presents at professional conferences on topics such as induction heating, nanoparticle heating, and heat staking. He holds a Ph.D., in Mechanical and Aerospace Engineering from the University of Rochester.

Find heat treating products and services when you search on Heat Treat Buyers Guide.com

 

Why Induction Heating Is a Green Technology Read More »

15 Quick Heat Treat News Items to Keep You Current

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

15 Quick Heat Treat News Items to Keep You Current

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry.

Personnel and Company Chatter

  • ThermTech of Waukesha, Wisconsin, celebrates the groundbreaking of a 10,500-square-foot manufacturing addition. Construction is expected to be completed in December 2018. 
  • An Ohio-based engineering firm, Dana Incorporated, announced a new series of Brevini™ heavy-duty winch drives for marine and offshore applications.  This new series of lightweight winch drives have been engineered with a sealing system designed to withstand harsh marine environments, and with improved power density, housing made from either cast iron or steel, and high-radial load bearings to deliver reliable lifting performance for heavy loads.
  • Brunel University London opened its Advanced Metal Processing Centre (AMPC) at the Brunel Center for Advanced Solidification Technology (BCAST), which will enable R&D activity to enable innovations, such as lightweight car parts, to make the leap from the lab to full-scale industrial trials. The 1,500 sq m AMPC facility includes industrial and pilot-scale equipment for processing and fabrication of extruded metals (novel bending processes, machining, and advanced joining); additional casting processes (gravity die casting and sand casting, etc.), and supporting materials characterization technologies (strength and fatigue testing and 3D x-ray tomography).
  • A global leader in manufacturing and overhauling aerospace structures, systems, and components, Triumph Group, Inc., based in Berwyn, Pennsylvania, recently announced that its Aerospace Structures business has been awarded a multi-year airframe component contract for Lockheed Martin’s C130J Super Hercules program. Under initial terms of the contract, Triumph Fabrications in San Diego, California will provide 108 different part numbers for the C130J program. The parts include fabricated sheet metal structures made from a combination of aluminum, steel and titanium materials that will be fitted to the nacelle, wing and fuselage sections of the aircraft.
  • Aerospace equipment manufacturer Liebherr Aerospace has been awarded another contract from Boeing Commercial Airplanes for their 777 and 777X programs. Liebherr-Aerospace will deliver two electronic components of the main gear steering system for the two wide-bodies: the main gear steering control unit and the nose gear steering position transducer.
  • Engineered bearings and power transmission manufacturer, The Timken Company, based in Canton, Ohio, recently completed the acquisition of Rollon Group, a leader in engineered linear motion products. Rollon specializes in the design and manufacture of engineered linear guides, telescopic rails and linear actuators used in a wide range of industries such as passenger rail, aerospace, packaging and logistics, medical and automation.
  • Gear Motions, which has divisional offices in central New York, recently appointed to executive positions: Dan Bartelli to Director of Operations of Nixon Gear, a division of Gear Motions, and Anna Pastore to Corporate Controller. Bartelli, who began his career as a machinist, also recently celebrated his 30th anniversary with Nixon Gear, a division of Gear Motions. He is responsible for all Nixon Gear Division Operations including Manufacturing, Quality, and Engineering. Pastore previously served as Director of Finance for Cascade & Maverik Lacrosse, and Vice President of Finance of the Produce and Technology Division at Agway.
  • Worthington Industries, a metals manufacturing firm based in Columbus, Ohio, announced today that Mark Russell, president and COO is retiring. Andy Rose has been named president and will continue as chief financial officer (CFO). Geoff Gilmore has been named vice president and chief operating officer (COO) and will also continue to lead the Pressure Cylinders business.

Equipment Chatter

  • An electric box furnace has been supplied to a plant located in Louisiana that is a global supplier of large industrial valves for various industries. L&L Special Furnace Co., Inc., shipped this furnace, which is the fifth supplied by the company to this facility. The furnace is used to both heat treat and temper various rings and seals deployed in the manufacturing of valves used in the power-generation field. It is also used for general heat treating of various steels prior to machining.
  • Two furnaces have recently been shipped to customers from Grieve Corporation. No. 1040 is a 2200°F (1204°C), inert atmosphere pit furnace, currently used for heat treating automotive parts in baskets at the customer’s facility. No. 989 is an electrically heated, 2,000°F (1,093°C) inert atmosphere furnace from Grieve, used to process fabricated parts at the customer’s facility.
  • A leader in the technology industry recently purchased an electrically heated enhanced duty walk-in oven from Wisconsin Oven Corporation to be used for composite curing small parts. The batch oven has the capability to heat 16,000 pounds of a composite material from 70° F to 350° F within 6-7 hours.

Kudos Chatter

  • Akron Steel Treating celebrated its 75th anniversary August 31, 2018, with guests, officials, employees, customers, and suppliers in attendance, as well as the deputy mayor for economic development, Samuel D. DeShazior, who presented AST president Joseph Powell with a letter of congratulations from Mayor Daniel Horrigan. Joe’s grandfather, Prosper P. Powell, founded the company in 1943, and his daughter, Christina Somogye, recently purchased a 10% interest in ASTC and is an integral part of the succession plan.

  • For the second year in a row, GKN Aerospace has received a supplier award from Spirit AeroSystems. Spirit recognized GKN Aerospace with a Collaboration Values Partner award for superior performance at the 2018 Spirit AeroSystems supplier recognition banquet in Wichita, Kansas. In addition, GKN Aerospace also recently announced via Stratasys that the company is improving production times and removing design constraints for multiple tooling applications since integrating additive manufacturing at its Filton manufacturing site in the UK.
  • Retech Systems, a SECO/WARWICK company based in Mendocino County, California, recently won North Bay Maker Award for “best manufacturing process innovation”.
  • Induction heating company Ambrell Corporation is the honoree for the Global Advancement Award and Ambrell President Tony Mazzullo is a finalist for CEO of the Year at the Technology and Manufacturing Awards, created by the Rochester Business Journal and Rochester Technology and Manufacturing Association. The Global Advancement Award is given to a company that demonstrates dynamic growth through expansion of export opportunities and participation in new global markets. The CEO of the Year demonstrates leadership in the industry, commitment to staff development, and dedication to the Greater Rochester/Finger Lakes Region. Tony Mazzullo is one of two finalists and the winner will be announced on October 23rd.

Heat Treat Today is pleased to join in the announcements of growth and achievement throughout the industry by highlighting them here on our News Chatter page. Please send any information you feel may be of interest to manufacturers with in-house heat treat departments especially in the aerospace, automotive, medical, and energy sectors to the editor at editor@heattreattoday.com.

 

15 Quick Heat Treat News Items to Keep You Current Read More »

Induction Heating Manufacturer Doubles Facility Space to Meet Demand

/ FEATURED NEWS, INDUCTION HEATING NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

Tony Mazzullo, president of Ambrell

An induction heating manufacturer has moved its operations to a facility twice the size of the previous location to accommodate increased demands for its products and industry solutions.

Ambrell Corporation, the thermal segment subsidiary of inTEST Corporation, which designs and manufactures thermal management products, recently broke ground on the new 80,000 sq ft facility in Rochester, New York. The $2.1 million project, which started in September 2017, included a complete company relocation from its previous manufacturing facility in Scottsville, New York.

“This is an exciting time for Ambrell and marks a huge milestone for the company, its employees, and customers who will all benefit from the opportunities this expansion presents,” said Tony Mazzullo, president of Ambrell, at the previous ribbon-cutting ceremony. “This new facility adds floor space to our Applications Laboratory to provide our customers with access to all of Ambrell’s products when they visit The Lab at Ambrell. The addition of floor space and equipment will also enable us to manufacture more products to meet the growing demands of our customers. In addition, our highly efficient manufacturing floor will enable us to maximize throughput while continuing to manufacture solutions that are innovative, of very high quality, and reliable.”

James Pelrin, inTEST president and CEO

“The new facility is designed to meet the demands of Ambrell’s growing business, increasing current capabilities for both product design and manufacturing,” commented James Pelrin, inTEST president and CEO. “To accommodate this rapid company growth, we are expanding from approximately 40,000 square feet at the previous facility to 80,000 square feet at the new location.”

inTEST designs and manufactures induction heating products for joining and forming metals for use in a variety of industrial markets, including automotive, aerospace &defense, machinery, wire & fasteners, medical, and semiconductor.

 

 

Photo caption and credit: Ribbon-cutting ceremony with Ambrell and inTEST representatives and local and state officials; Twitter

Induction Heating Manufacturer Doubles Facility Space to Meet Demand Read More »