featured

SECO/WARWICK Group Expands US Footprint

The SECO/WARWICK Group, the parent company of SECO/VACUUM Technologies and SECO/WARWICK USA, has announced plans to bolster its production capacity in the U.S., increasing its footprint and workforce. The expansion will include relocating a portion of its manufacturing and a metallurgical lab for vacuum furnaces from its headquarters site in Poland to Crawford County, Pennsylvania.

The 120,000-sq ft facility located in Meadville, PA, will house equipment for furnace production and serve the company’s North American customers through the addition of parts, service, and training capacity, resulting in an increase in its heat treat manufacturing workforce. an international furnace manufacturer

SECO/WARWICK Group announced that this expansion received support from the Commonwealth of Pennsylvania through a $2 million package of matching fund grants from the Department of Community and Economic Development (DCED) through its Redevelopment Assistance Capital Program (RACP). The primary use and intent of RACP funds is for reimbursement of eligible construction costs which SECO/WARWICK Group companies will match on a 1:1 basis. The Commonwealth will also provide an additional $69 thousand in matching funds for job training through the Workforce & Economic Development Network (WEDnet).

Employees of SECO/VACUUM Technologies and SECO/WARWICK at the announcement of the Meadville, PA, site expansion, held jointly by The SECO/WARWICK Group and the Commonwealth of PA Department of Community and Economic Development
Source: Heat Treat Today

State, county and local officials as well as representatives from the international and US-based offices of the SECO/WARWICK Group were present at an event marking the expansion.

“Governor Shapiro is committed to making Pennsylvania an economic leader by investing in the growth of businesses like SECO/VACUUM and SECO/WARWICK,” stated the Commonwealth in the grant award letter. “In addition to the financing package outlined above, the Governor’s Action Team is prepared to provide both companies with any assistance that may be required throughout the application process, as well as to coordinate the involvement of all other state agencies in the project.”

“We look forward to working with our local partners including the City of Meadville, the Economic Progress Alliance of Crawford County (EPACC), the Workforce and Economic Development Network (WEDnet), and the Pennsylvania Department of Community and Economic Development (DCED) to make this expansion happen!” said Piotr Zawistowski, president and managing director of SECO/VACUUM.

Pictured in feature image (L to R): Don Marteeny, vice president of engineering; Slawomir Wozniak, president and CEO, SECO/WARWICK Group; Piotr Zawistowski, president and managing director of SECO VACUUM Technologies

The press release is available in its original form here.



SECO/WARWICK Group Expands US Footprint Read More »

Overcoming Quality Challenges for Automotive T6 Heat Treating

Three elements in the T6 aluminum heat treatment process — high temperature solution heat treatment, drastic temperature change in the water quench, and a long age hardening process — challenge accurate temperature monitoring. Thru-process technology gives in-house heat treaters the power to control these variables to overcome the unknowns. In the following Technical Tuesday article, Dr. Steve Offley, “Dr. O”, product marketing manager at PhoenixTM, examines the path forward through the challenges of aluminum heat treating.


Aluminum Processing Growth

In today’s automotive and general manufacturing markets, aluminum is increasingly becoming the material of choice, being lighter, safer, and more sustainable. Manufacturers looking to replace existing materials with aluminum are needing new methodology to prove that thermal processing of aluminum parts and products is done to specification, efficiently and economically.

To add strength to pure aluminum, alloys are developed by the addition of elements dissolved into solid solutions employing the T6 heat treatment process (Figure 1). The alloy atoms create obstacles to dislocate movement of aluminum atoms through the aluminum matrix. This gives more structural integrity and strength.

FIgure 1. Critical temperature phase transitions of the T6 aluminum heat treatment process
Source: PhoenixTM

Process temperature control and uniformity is critical to the success of T6 heat treat to maximize the solubility of hardening solutes such as copper, magnesium, silicon, and zinc without exceeding the eutectic melting temperature. With a temperature difference of typically 9–15°F, knowing the accurate temperature of the product is essential. Control of the later quench process (Figure 1, Phase 3) is also critical not only to facilitate the alloy element precipitation phase but also to prevent unwanted part distortion/warping and risk of quench cracking.

T6 Process Monitoring Challenges

The T6 solution reheat process comes with many technical challenges where temperature profiling is concerned. The need to monitor all three of the equally important phases — solution treatment, quench, and the age hardening process — makes the trailing thermocouple methodology impossible.

Figure 2. Thru-process temperature monitoring of the three T6 heat treatment phases
Source: PhoenixTM

Even when considering applying thru-process temperature profiling technology, sending the data logger through the process, protected in a thermal barrier (Figure 2), the T6 heat treat process comes with significant challenges. A system will not only need to protect against heat (up to 1020°F) over a long process duration but also withstand the rigors of being plunged into a water quench. Rapid temperature transitions create elevated risk of distortion and warping which need to be addressed to give a reliable and robust monitoring solution.

Certain monitoring systems can provide protection to the data logger at 1022°F for up to 20 hours (Figure 3).

Figure 3. Thru-process temperature profiling system installed in the product cage monitoring the T6 heat treatment (solution treatment, quench, and age hardening) of aluminum engine blocks

Thermal Protection Technology

To meet the challenges of the T6 heat treat process, the conventional thermal barrier design employing microporous insulation is replaced with a water tank design, with thermal protection using an evaporative phase change temperature control principle. Evaporative technology uses boiling water to keep the high temperature data logger (maximum operating temperature of 230°F) at a stable operating temperature of 212°F as the water changes phase from liquid to steam. The advantage of evaporative technology is that a physically smaller barrier is often possible. It is estimated that with a like for like size (volume) and weight, an evaporative barrier will provide in the region of twice the thermal protection of a standard thermal barrier with microporous insulation and heat sink. The level of thermal protection can be adjusted by changing the capacity of the water tank and the volume of water. Increasing the volume of water increases the duration at which the T6 temperature barrier will maintain the data logger temperature of 212°F before it is depleted by evaporation losses.

The TS06 thermal barrier design (Figure 4) incorporates a further level of protection with an outer layer of insulation blanket contained within a structural outer metal cage. The key role of this material is to act as an insulative layer around the water tank to reduce the risk of structural distortion from rapid temperature changes both positive and negative in the T6 process.

Figure 4. TS06 thermal barrier design showing water tank, housing the data logger at its core, installed within structural frame containing the insulation blanket surface layer; water tank shown with traditional compression fitting face plate seal
Source: PhoenixTM

Obviously, the evaporative loss rate of water is governed by the water tank geometry. A cube shaped tank will provide the best performance, but this may need to be adapted to meet process height restrictions. A TS06 thermal barrier with dimensions 8.5 x 18.6 x 25.2 inches (H x W x L) offering a water capacity of 3.5 US gallons provides 11 hours of protection at 1022°F. A larger TS06 with approximately twice the capacity 12.2 x 18.6 x 25.2 inches (H x W x L) and 7.7 US gallons gives approximately twice the protection (20 hours at 1022°F).

Innovative IP67 Sealing Design

Passing through the water quench, the data logger needs to be protected from water damage. This is achieved in the system design by combining a fully IP67 sealed data logger case and water tank front face plate through which the thermocouples exit. Traditionally in heat treatment applications, mineral insulated thermocouples are sealed using robust metal compression fittings. Although reliable, the compression seals are difficult to use, requiring long set-up times. The whole uncoiled straight cable length must be passed through the tight fitting which, for the 10 x 13 ft thermocouples, takes some patience. Thermocouples can be used and installed for multiple runs, if undamaged. Unfortunately, as the ferrule in the compression fitting bites into the MI cable, removal of the cable requires the thermocouple to be cut, preventing reuse.

To overcome the frustrations of compression fitting, an alternative innovative thermocouple sealing mechanism has been designed for use on the T6 thermal barrier (Figure 5).

Figure 5. TS06 thermal barrier IP67 bi-directional rubber gasket seal; installation of mineral-insulated (MI) thermocouples and RF antenna aerial

Thermocouples can be slotted easily and quickly, tool free, into a precision cut rubber gasket without any need to uncoil the thermocouple completely. The rubber gasket has a unique bi-directional seal, allowing both sealing of each thermocouple but also sealing of the clamp face plate to the data logger tray, which is then secured to the water tank with a further silicone gasket seal. The new seal design allows thermocouples to be uninstalled and reused, reducing operating costs significantly.

Accurate Process Data considerations

The T6 applications come with a series of monitoring challenges which need to be considered carefully to guarantee the quality of the data obtained. Although the complete process time of the three phases can reach up to 10 hours, it is necessary to use a rapid sample interval (seconds) to provide a sufficient resolution. The data logger is designed to facilitate this with a minimum sample interval of 0.2 seconds over 20 channels and memory size of 3.8 million data points, allowing complete monitoring of the entire process. A sample interval of 0.2 seconds provides sufficient data points on the rapid quench cooling curve. The high resolution allows full analysis and optimization of the quench rate to achieve required metallurgical transitions yet avoid distortion or quench cracking risks.

Employing the phased evaporation thermal barrier design, the high temperature data logger with maximum operating temperature of 230°F will operate safely at 212°F. During the profile run, the data logger internal temperature will increase from ambient temperature to 212°F. To allow the thermocouple to accurately record temperature, the data logger offers a sophisticated cold junction compensation method, correcting the thermocouple read out (hot junction) for anticipated internal data logger temperature changes.

Data logger and thermocouple calibration data covering the complete measurement range (not just a single designated temperature) can be used to create detailed correction factor files. Correction factors are calculated by interpolation between two known calibration points using the linear method as approved by CQI-9 and AMS2750G. This method ensures that all profile data is corrected to the highest possible accuracy. 

Addressing Real-Time, Thru-Process Temperature Monitoring Challenges

For a process time as long as the T6, real-time monitoring capability is a significant benefit. The unique two-way RF telemetry system used on the PhoenixTM system helps address the technical challenges of the three separate stages of the process. The RF signal can be transmitted from the data logger through a series of routers linked back to the main coordinator connected to the monitoring PC. The wirelessly connected routers are located at convenient points in the process (solution treatment furnace, quench tank, aging furnace) to capture all live data without any inconvenience of routing communication cables.

A major challenge in the T6 process is the quench step from an RF telemetry perspective. An RF signal cannot escape from water in the quench tank. To overcome this limitation, a “catch up” feature is implemented. Once the system exits the quench and the RF signal is re-established, any previously missing data is retransmitted guaranteeing full process coverage.

Process Quality Assurance and Validation

In the automotive industry, many operations will be working to the CQI-9 special process heat treat system assessment accreditation. As defined by the pyrometry standard, operators need to validate the accuracy and uniformity of the furnace work zone by employing a temperature uniformity survey (TUS).

The thru-process monitoring principle allows for an efficient method by which the TUS can be performed employing a TUS frame to position a defined number of thermocouples over the specific working zone of the furnace (product basket). As defined in the standard with particular reference to application assessment process Table C (aluminum heat treating), the uniformity for both the solution heat treatment and aging furnace needs to be proven to satisfy ±10°F of the threshold temperature during the soak time.

Complementing the TUS system, the Thermal View Survey software provides a means by which the full survey can be set up automatically allowing routine full analysis and reporting to the CQI-9 specification as shown in Figure 6.

Figure 6. View of TUS for T6 aluminum processing in Phase 1 Solution Re-heat
Source: PhoenixTM

Interestingly, a significant further benefit of the thru-process principle is that by collecting process data for the whole process, many of the additional requirements of the process Table C can be achieved with reference to the quench. From the profile trace, key criteria such as quench media temperature, quench delay time, and quench cooling curve can be measured and reported with full traceability during the production run.

Summary

To fully understand, control, and optimize the T6 heat treat process, it is essential the entire process is monitored. Thru-process monitoring solutions, designed specifically, allow not only product temperature profiling of all the solution heat treatment, water quench, and age hardening phases, but also comprehensive temperature uniformity surveying to comply with CQI-9.

About the Author:

Dr Steve Offley (“Dr O”), Product Marketing Manager, PhoenixTM

Dr. Steve Offley, “Dr. O,” has been the product marketing manager at PhoenixTM for the last five years after a career of over 25 years in temperature monitoring focusing on the heat treatment, paint, and general manufacturing industries. A key aspect of his role is the product management of the innovative PhoenixTM range of thru-process temperature and optical profiling and TUS monitoring system solutions.

For more information: Contact Steve at Steve.Offley@phoenixtm.com.


Find Heat Treating Products And Services When You Search On Heat Treat Buyers Guide.Com


Overcoming Quality Challenges for Automotive T6 Heat Treating Read More »

Piston Rings Manufacturer Bolsters Production with 3rd Nitriding System

Asimco Shuanghuan Piston Ring Co., Ltd. has added a third nitriding system to its heat treating operations, enhancing piston ring production capabilities to serve a range of applications, including the automotive, commercial vehicle, construction machinery, and marine sectors. The compact furnace system was installed in line with two identical systems acquired in 2018 and 2021.

Nitrex installed the latest nitriding system in June, 2024, and Asimco began production in July with a goal to increase its annual production capacity of 180 million pieces and over 4,800 different varieties and specifications. Nitrex’s NITREG®-S stainless steel nitriding technology improves wear resistance, corrosion resistance, fatigue strength, surface hardness, and dimensional stability of piston rings, while reducing friction. These improvements result in better sealing, lower oil consumption, and overall enhanced engine efficiency and durability.

Nikola Dzepina
Nitrex Regional Manager – Asia
Source: NITREX

“The addition of the NXK-812 furnace aligns with Asimco Shuanghuan’s objectives to boost production volume and ensure precision and reliability in high-volume manufacturing,” said Tao Liu, sales manager at Nitrex China.

“By incorporating an additional Nitrex system into their operations, Asimco enhances its ability to produce stainless-steel piston rings with superior performance, durability, and reliability. This advanced treatment makes their products exceptionally suited for high-demand engine applications,” said Nikola Dzepina, account executive at Nitrex.

The press release is available in its original form here.



Piston Rings Manufacturer Bolsters Production with 3rd Nitriding System Read More »

Heat Treater Launches Expanded HIP Capacity Production at South Carolina Facility

A U.K.-based thermal processing service provider announced it has begun production at its facility in Greenville, SC, where it recently expanded its hot isostatic pressing (HIP) services. The site houses heat treating operations, EDM, and other capabilities to serve the aerospace, defense, power generation, medical, and general industries.

HIP Product Fabrication – metal part from powder metal
Source: Bodycote

The additional HIP capacity at Bodycote‘s Greenville location was commissioned to service the development and processing of advanced materials for industries situated within the Southeastern U.S. as well as other Bodycote facilities in the supply chain. With HIP capacity now in full production, Bodycote is able to meet the rising demand for highly reliable additive manufacturing post-processing. The company has more than HIP vessels of varying sizes in multiple locations. Processing capability can accommodate components nominally up to 6.5ft in diameter by 12ft high, and weighing over 30,000kg.

The press release is available in its original form here.

Featured photo: HIP furnace being lowered into place



Heat Treater Launches Expanded HIP Capacity Production at South Carolina Facility Read More »

Heat Treat Economic Indicators: August 2024 Results

The four heat treat industry-specific economic indicators have been gathered by Heat Treat Today each month since June 2023. In previous months, the economic indicators have mostly fallen in the growth column, with a midsummer “calm” in July when most suppliers to the heat treat industry expected contraction in all four categories. However, this month, suppliers are reporting that they anticipate most indicators to grow in August.

The numbers, which were compiled in the first week of August, show that responding parties expect the economy to experience rebounding growth in three of the four indices, settling in each at their highest point since May. The expectation for growth in number of inquiries reveals the most significant jump over July’s responses. Anticipation for growth is also positive for value of bookings and health of the manufacturing economy, the latter with positive expectations falling just above the “neutral” x-axis, indicated by the number “50.” The size of backlog indicator, though improved over July, remains the indicator suppliers anticipate contraction.

The results from this month’s survey (August) are as follows; numbers above 50 indicate growth, numbers below 50 indicate contraction, and the number 50 indicates no change:

  • Anticipated change in the Number of Inquiries from July to August: 57.8
  • Anticipated change in Value of Bookings from July to August: 56.1
  • Anticipated change in Backlog Size from July to August: 49.3
  • Anticipated change in the Health of the Manufacturing Economy from July to August: 50.6
  • Data for August 2024

    The four index numbers are reported monthly by Heat Treat Today and made available on the website. 

    Heat Treat Today’s Economic Indicators measure and report on four heat treat industry indices. Each month, approximately 800 individuals who classify themselves as suppliers to the North American heat treat industry receive the survey. Above are the results. Data started being collected in June 2023. If you would like to participate in the monthly survey, please click here to subscribe.


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


Heat Treat Economic Indicators: August 2024 Results Read More »

Aluminum Parts Manufacturer Increases Capacity with Melting Furnace

A melting and holding furnace with a preheat hearth and a maximum temperature rating of 1,450°F (788°C) has been shipped to a manufacturer to increase capacity for processing aluminum parts.

Lindberg/MPH announced the shipment of a gas-fired reverberatory aluminum melting and holding furnace with a total holding capacity of 85,000 lbs based on 155 lbs per cubic ft. of molten aluminum and a melt rate of 10,000 pounds per hour. A full width vertically rising air operated door provides access to load the preheat hearth and a full width cleanout door at the rear allows for unloading.

Kelley Shreve
General Manager
Lindberg/MPH
Source: Lindberg/MPH

This melting furnace is designed with an elevated base and bottom mounted magnetic stirring mechanism. An air pressure pump well for dispensing molten aluminum provides the operator with greater ease of use and allows the unit to stand idle over long periods of time such as weekends without having a large temperature differential between the pumper and the furnace.

“This aluminum melting furnace design provides maximum melting efficiency and large capacity. The customer supplied magnetic stirring mechanism helps reduce damaging oxide growth,” said Kelley Shreve, general manager at Lindberg/MPH.

The press release is available in its original form here.



Aluminum Parts Manufacturer Increases Capacity with Melting Furnace Read More »

Humidity Got You (and Your Furnace) Down?

Source: Ipsen

Here in the northern hemisphere, the dog days of summer are upon us. This folksy phrase has come to signify the months when humidity weighs heavily in the air, but it’s got a lot more history to it than that. According to the ancients of Rome and Greece, the dog days not only brought drought and heat but also caused man and his best friend to go mad. Madness may not be the result of seasonal humidity, but manufacturing disruptions could be.

Humidity affects nearly all processing environments, but some, like heat treating, are more prone to humidity-related disruptions This question was submitted to the Ask the Expert team at Ipsen: Operating a furnace in an environment that has been dealing with high heat and humidity has posed more challenges than we’ve experienced in the past. What are some things that we should be watching out for when operating our furnaces to make sure they’re running efficiently despite the temperature and humidity?

In this best of the web article, consider the damage humidity can do to your vacuum furnace and gather some tips to maintain your vacuum furnaces during hot, muggy weather.

An excerpt:

“High temperatures cause changes in electricity flows, which increase resistance. Additionally, excessive humidity reduces transformer insulation and resistance, while oxidizing electrical conductors. And the difference between cooling water temperature and ambient temperature with high humidity can cause the vacuum vessel to “sweat,” affecting the entire furnace’s electrical system and transformers’ performance.

Here are nine key things you can do to maintain vacuum furnaces during hot, muggy weather:

  • Clean the hot zone, check insulation and ceramics, and repair if necessary. Run periodic burnout cycles.
  • Check, secure, and mark all electrical connections. Apply conductive copper grease to improve electrical contact between surfaces.
  • Clean all vents in the control cabinet without the air-conditioning. Use silica gel to reduce moisture.” 

Read the rest of the list and the entire article from Ipsen by clicking here: “Ask the Expert: Protecting Your Vacuum Furnace from Humidity (Part 2)”

Read Part 1 (about air curtains that protect equipment from humidity just like the air curtains you encounter when walking from a hot parking lot into a cold grocery store) here and Part 3 (about vacuum cool events) here.



Humidity Got You (and Your Furnace) Down? Read More »

Furnace Manufacturer Consolidates Operations With $4M Facility, Creates 25 new jobs

A Missouri-based furnace manufacturer for the foundry, die casting and metal forming industries recently announced plans to expand its footprint in the St. Louis area with a new facility. The $4M investment in O’Fallon, Missouri, will create 25 new jobs and result in the consolidation of operations located in two Missouri counties with room to grow.

“We’ve seen explosive growth over the past few years, which initiated an extensive search for a new location,” said Joe Slattery, president and COO of SINC Thermal. “Our new, consolidated facility in O’Fallon will allow us to successfully address the current needs of our customers and position us for future growth.”

Mike Parson
Governor of Missouri
Source: flickr

“It’s exciting to see yet another Missouri-made business like SINC Thermal thriving in the St. Louis region. We look forward to the company’s continued success in O’Fallon as it expands and strengthens the area’s vibrant manufacturing sector,” said Missouri Governor Mike Parson.

Bill Hennessey
Mayor
O’Fallon, Missouri
Source: www.ofallon.mo.us

For this expansion, SINC Thermal will benefit from the Missouri Works program, a tool that helps companies expand and retain workers by providing access to capital through withholdings or tax credits for job creation.

“We are thrilled that SINC Thermal has joined O’Fallon’s vast number of advanced manufacturers, and proud of the Select O’Fallon team’s work in making it happen,” said O’Fallon Mayor Bill Hennessy. “I also wish to thank our county, regional, and state partners for their support of SINC Thermal and help in reaffirming O’Fallon as a place where businesses can succeed.”

SINC Thermal president and COO Joe Slatterly is a member of Heat Treat Today‘s 40 Under 40 Class of 2020. Click here to learn more.

The press release is available in its original form here.



Furnace Manufacturer Consolidates Operations With $4M Facility, Creates 25 new jobs Read More »

$2.5B Acquisition Expands Steelmaker’s North American Reach

Cleveland-Cliffs Inc, a major supplier of steel to the automotive industry with heat treat capabilities, has announced its acquisition of Stelco Holdings Inc, an integrated steelmaker with two operational sites in the province of Ontario. The $2.5B (USD) transaction will bring 1,800 workers into the Cleveland-based steelmaker’s current workforce of 18,000 employed across its facilities in the United States and Canada.

Cleveland-Cliffs Inc. (Cliffs) recently released its definitive agreement to acquire Stelco Holdings Inc, increasing its steelmaking footprint and doubling the company’s exposure to the flat-rolled spot market, which includes raw materials, energy, and healthcare. Stelco adds capabilities that complement Cliffs’ existing operations, confirming the Cleveland-based steelmaker’s commitment and leadership in integrated steel production in North America.

Lourenco Goncalves
Chairman, President and CEO
Cleveland Cliffs

Stelco’s facilities consist of Lake Erie Works, a new integrated steelmaking facility in North America, and Hamilton Works, a downstream finishing and cokemaking facility, adding capabilities that complement Cliffs’ existing operations and product portfolio, while diversifying its market industries. Upon completion of the transaction, Cliffs shareholders will own approximately 95% and Stelco shareholders will own approximately 5% of the combined company, on a fully diluted basis.

“We did this deal the way it should be done, reaching a respectful agreement between the two parties that keeps national interests at the forefront and recognizes the importance of the workforce,” said Lourenco Goncalves, chairman, president and CEO of Cliffs. “The enterprise value of this transaction is significantly lower than the cost of building an equivalent replacement mill in the United States, and the cost structure is lower than what a new U.S. mill would provide us. Stelco is a company that respects the Union, treats their employees well, and leans into their cost advantages. With that, they are a perfect fit for Cleveland-Cliffs and our culture. We look forward to proving that our ownership of Stelco will be a net benefit for Canada, the province of Ontario, and the cities of Nanticoke and Hamilton.”

Alan Kestenbaum
Executive Chairman & CEO
Stelco Holdings

“I am proud of what we have accomplished over the past seven years, and the value we have generated,” said Alan Kestenbaum, executive chairman and CEO of Stelco. “Most importantly, we have revitalized Stelco and restored it to its iconic status in Canada. I know thac Cliffs will continue to build upon the excellent work and life environment we have created for all of our employees and continue to be a reliable supplier to our valued customers, while maintaining Stelco’s stature and reputation in Canada and maintaining our Canadian national interests. One of the important drivers for this transaction was receiving a meaningful portion of the consideration in Cliffs shares. I have strong belief and optimism in the North American steel market. I believe that Lourenco and his team have created a winning platform, and I intend to remain an investor in Cliffs for a long time to come as he and his team continue to build out their platform and business.”

Pictured in featured image: Lourenco Goncalves

The press release is available in its original form here.



$2.5B Acquisition Expands Steelmaker’s North American Reach Read More »

US DOE Strategy: Why the Heat Treating Industry?

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 two previous articles in this continuing series, guest columnist Michael Mouilleseaux, general manager at Erie Steel, Ltd., discussed the U.S. Department of Energy’s initiative related to the decarbonization of industry and its potential impact on the heat treating industry.

The first installment, US DOE Strategy Affects Heat Treaters, appeared on April 10, 2024, in Heat Treat Today, as well as in Heat Treat Today’s March 2024 Aerospace print edition. The second in the series, “U.S. DOE Strategy: Ramifications for Heat Treaters“, appeared on June 18, 2024, and in the May 2024 Sustainability print edition. This informative conclusion to the series was first released in Heat Treat Today’s June 2024 Buyer’s Guide print edition.


The endeavor to reduce greenhouse gas emissions (GHGE), albeit noble in intent, begs the question: Why is the heat treating industry being asked to reduce its greenhouse gas emissions?

Some background:

  • The United States’ GHGE account for approximately 14% of the total worldwide emissions.
  • According to the U.S. DOE, U.S. industry accounts for approximately 23% of the total U.S. GHGE.
  • According to the U.S. DOE, “process heating” accounts for approximately 43% of the total GHGE generated by U.S. industry.
  • According to the U.S. DOE, heat treating accounts for approximately 2.8% of the GHGE they have attributed to process heating.
  • In sum, heat treating accounts for 0.3% of the total U.S. GHGE (23% x 43% x 2.8%), and 0.04% of the worldwide GHGE (14% x 23% x 43% x 2.8%).

Why is the Department of Energy imposing natural gas restrictions on an industry that they have calculated to be responsible for 0.3% of the country’s total emissions?

The answer has two parts. First, natural gas has been deemed “unacceptable” due to its generation of CO2 as byproducts of combustion, and our industry has been swept up in an uninformed effort to stem global warming (or as it is now known, climate change). Remember: Heat treating accounts for just 0.04% of global GHGE!

Second, this administration has spent something between several hundred billion and a trillion U.S. dollars to incentivize power, transportation, and industrial sectors in their effort to stem global warming. Years from now, we will look back at this as one of the greatest capital reallocations in our history. If we can accept that the “past is a prologue,” we have a storied history of government failures to determine the future of the agricultural, aircraft, and financial sectors. This is already happening in Western Europe: Power is substantially more expensive, and industrial output has dropped nearly 6% for the past two years — the European Investment bank attributes the reduction in industrial output to “elevated energy costs.”

Perhaps it’s time for us to take notice and slow down this effort until such a time that we have the technology in place to accomplish decarbonization without eviscerating our industrial, transportation, and power industries. A greatly overused term today is “existential threat” — but our livelihood, our national security, and our way of life are, in fact, on the line.

Attend the SUMMIT to find out more about the DOE’s actions for the heat treat industry.

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.


I want to thank Heat Treat Today for providing me with this forum to speak on this issue, as I believe this needs to be said.

I want to thank Surface Combustion, Gasbarre, and Super Systems Inc. for the guidance they provided me with in navigating the technology of this subject matter.

Any errors contained herein are mine and mine alone.

About the Author:

Michael Mouilleseaux
General Manager at Erie Steel, Ltd.
Sourced from the author

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.

For more information: Contact Michael at mmouilleseaux@erie.com.  


US DOE Strategy: Why the Heat Treating Industry? Read More »