Mark Hemsath

Nitriding vs. FNC

OCHow well do you know hardness processing? Can you draw the line where nitriding and ferritic nitrocarburizing (FNC) differ? In this Technical Tuesday feature, skim this straight forward data that has been assembled from information provided by four heat treat experts: Jason Orosz and Mark Hemsath at NitrexThomas Wingens at WINGENS LLC – International Industry Consultancy, and Dan Herring, The Heat Treat Doctor at The HERRING GROUP, Inc.

Let us know what you think! What is the next comparison you'd like to see? What facts were you surprised by? Email Heat Treat Daily editor Bethany Leone at bethany@heattreattoday.com.

Nitriding Descriptor Ferritic Nitrocarburizing
480º-590C (896º-1094ºF) typical Temperature Range 565º-590ºC (1049ºF-1094ºF) typical
Wrought and powder metallurgy materials including alloy steels (e.g., 4140), stainless steel (e.g., 304L, 420), tool steels (e.g., H11, H13) and special nitriding steels (e.g,, Nitralloy 135M, Nitralloy EZ) are typical examples. Many other steel grades are possible. Materials Commonly Processed Plain and medium carbon steels (e.g., 1015, 1018, 1045), alloy steels (e.g., 4140, 4340) and tool steels (e.g., H11, H13) are typical examples. Many other steels grades are possible.
Wear (as in abrasion resistance), bending, torsional and rolling contact, fatigue resistance, lubricity, and adhesive strength improvements. Materials Commonly Processed: Why to Process Them with These Methods Wear resistance, lubricity, fatigue, and corrosion resistance are primary benefits with improved fatigue strength and adhesive strength possible.
3-48 hours at temperature. May be up to 72 hours. Relative Cycle Times 2-6 hours at temperature.
Pit retort furnaces and front load retort furnaces for gas nitriding, although bell retort furnaces have also been used. Equipment Types Used for the Process Pit retort furnaces and front load retort furnaces for gaseous ferritic nitrocarburizing. Bell retort furnaces have also been used.
Ammonia and nitrogen or ammonia and dissociated ammonia. Atmospheres Used/Required Ammonia and nitrogen and carbon-bearing gas such as CO2, CO, or endothermic gas.
Dies, gears, pump bodies, springs, gun barrels, shafts and pinions, pins, brake rotors and may other types of component parts produced from bar, plate, rod, forgings and castings formed by stampings, machining, rolling, forging, casting, etc. Typical Parts Processed Wear plates, washers, clutch plates, gas pistons, brake pistons, brake rotors, barrels, slides, differential cases and other types of component parts produced from bar, plate, rod, etc., and formed by stampings, rolling, machining, casting, etc.
Automotive, aerospace, oil & gas, industrial machinery (e.g., pumps), and tool & die. Typical Industries Served Automotive and industrial machinery hydraulics.
Cost is often higher for gas nitriding as opposed to other case hardening processes (including FNC) based on the type of component parts run. In many cases, cost is a function of the longer cycle time and/or more labor involved. Relative Cost Per Unit Cost is often lower than many other case hardening processes (including gas nitriding) based on the type(s) of component parts run. In many cases, cost is a function of a shorter cycle time and/or less labor involved.
Basic specifications are easily achieved with good equipment and/or controls; difficulty increases when attempting to produce specialized layer compositions/phases. Ease of Use/Control Basic specifications are easily achieved with good equipment and/or controls; difficulty increases when attempting to produce specialized layer compositions/phases. Hardware/control requirements are more complicated than for nitriding when controlling for carbon potential.
It can range from very simple to medium-high depending on application. Relative Expertise Necessary to Perform Medium-high depending on the application. The user will want to look for clean parts, a good loading system, and PLC controlled cycle.
Aqueous (clean chemistry) including rinse/dry, vapor degreasing (clean chemistry). Cleaning Requirements Aqueous (clean chemistry) including rinse/dry, vapor degreasing (clean chemistry).
White glove Handling Requirements White glove
Pre- and post-oxidation Process Options Pre- and post-oxidation
AMS 2759, AMS 2759/10, (latest revisions) Applicable Specifications AMS 2757, AMS 2759/12, AMS 2759/13 (latest revisions)
Time, temperature, gas flow, nitriding potential (Kn) and/or percent dissociation, hydrogen sensors. Controls Time, temperature, gas flow, nitriding potential (Kn), carbon potential (Kc) and oxygen potential (Ko). Hydrogen sensor and oxygen (carburizing) sensor may be used.
electric and gas-fired equipment Fuel Source electric and gas-fired equipment
Hardness (surface, core), case depth determination (via microhardness – typically core hardness + 50 HV), microstructure (compound and diffusion zone depths), composition, core structure, presence of absence of nitride networking (aka nitride needles), and the presence or absence of cracking or spalling of the case. Testing Required Hardness (surface, core), case depth determination (via microhardness – typically core hardness + 50 HV), microstructure (compound and diffusion zone depths), composition, core structure, porosity (type and depth), and the presence or absence of cracking or spalling of the case.
Warm wall plasma nitriding, as well as advances in controls, sensors, temperature uniformity, and reduced gas volumes. Latest Advances Black oxide, hydrogen sensors, and fast cooling techniques as well as advances in controls, sensors, and temperature uniformity.
(1) simple equipment, (2) can offer beneficial tribological changes part/metal, (3) performed after part machining, (4) little-to-no distortion. Pros (Strengths) (1) fast, cheap, repeatable results, (2) excellent corrosion resistance, especially with (black) oxide, (3) performed after part machining, (4) minimal distortion/almost distortion free
(1) long cycle time, sometimes a multi-day process if deep case is required, (2) effective pre-cleaning required, (3) weldability becomes reduced, (4) ammonia is used, (5) embrittlement with too much white layer. Cons (Weaknesses) (1) Focused on part surface, mainly with inexpensive materials, (2) effective pre-cleaning required, (3) weldability becomes reduced, (4) ammonia is sometimes a concern.

 

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Heat Treat Radio #56: Metal Hardening 101 with Mark Hemsath, Part 3 of 3

Heat Treat Today publisher Doug Glenn finishes his conversation with Mark Hemsath about metal hardness basics. Mark, the vice president of Sales - Americas for Nitrex Heat Treating Services, was formerly the vice president of Super IQ and Nitriding at SECO/WARWICK. Learn all about the what, why, and how of hardening. This episode builds upon previous episodes in Part 1 and Part 2.

Below, you can either listen to the podcast by clicking on the audio play button, or you can read an edited transcript.

 



The following transcript has been edited for your reading enjoyment.

Doug Glenn (DG):  This is our third episode with you, Mark, and the first episode basically we were just dealing with very general, kind of like “Hardness 101” – what is it, why is it important, what materials can be hardened, etc.  The second episode we delved a little bit further into specifics processes like carburizing, nitriding, etc.  If any of the listeners are listening now, they haven't listened to episode one and two, I would recommend that they go back and take a listen to those at their leisure.  What we wanted to do today really was just deal with some of the newer advances, why we're seeing some of those newer advances, why some of the processes are having a bit of a resurgence and talk through some of those things.

What we want to do today is to just deal with some of the newer advances, why we're seeing some of those newer advances, why some of the processes are having a bit of a resurgence and talk through some of those things.

Before we start, I'll just ask you straight up, is there anything from the last episodes that you think we need to reiterate or review, or do you think we did okay on those last ones?

Mark Hemsath (MH):  I think we did well, and I just wanted to say thank you, again, for letting me talk about this.  I think these are some great subjects and I really enjoy doing this.

". . . nitriding, and really its cousin FNC (ferritic nitrocarburizing), are actually fairly inexpensive treatments and they can be performed on final dimension parts.  There is no post machining and there is minimal distortion.  That's kind of my opinion of why it has done well."

DG:  Let's talk about this:  From my perspective, from what I hear around the industry, nitriding seems to be getting a lot of play time, to throw in a radio term.  You hear it a lot.  Why is that?  Why is it that nitriding seems to be growing in popularity?

MH:  Well, Doug, if you were to ask me, which you did, I think it's mainly due to the discovery that nitriding, and really its cousin FNC (ferritic nitrocarburizing), are actually fairly inexpensive treatments and they can be performed on final dimension parts.  There is no post machining and there is minimal distortion.  That's kind of my opinion of why it has done well.  Like I said, nitriding, not quite as much as FNC; they get lumped together but they are distinctly different.

DG:  So, FNC is really the most cost saving?

MH:  Yes, you're going to get a fairly hard surface on the part at fairly short cycle times and low temperature.  So, again, you can use that final dimension part.  You can control that white layer or compound zone, not only in terms of thickness, but also in terms of composition, in other words, how much epsilon versus gamma prime, and its porosity.  This allows for repeatable results and repeatable performance today.  This was not as easy 20 years ago, but it is today.

DG:  And that's because?

MH:  The enhancements of the equipment and controls technology.  We've come a long way with process control, and that sort of thing; it's substantially different.  I always make a joke when we do proposals for equipment, the thing that changes all the time is controls.  Electronics are constantly changing and improving.

DG:  One other question about nitriding before we move off of that:  Are we seeing that growth in popularity in any particular industries or any particular types of products, or would you classify it as across the board?  You and I have spoken before about brake rotors and things of that sort.

Find out more on nitrocarburizing by clicking the image above.

MH:  It has, you're correct.  They've found new uses for it, and brake rotors are one excellent example.  Whole new companies have emerged just to do that sort of process because of the volumes that are out there.  I think a lot of things are being done.  The nice thing about FNC white layer generation on a part is it also has corrosion control, and for automotive that makes a lot of sense.  They're discovering new uses for FNC.   And then nitriding, in general, has the ability in a lot of instances, as well as FNC, to replace carburizing, depending upon how you engineer the part.  There are a lot of reasons to be using nitriding.

DG:  You mentioned carburizing, so let's talk about the next process that I'm hearing a lot about, and that's low pressure carburizing.  Is it actually growing in popularity?  Are we hearing more about it?  And if so, why?

MH:  This is when I think it's a bit different, in my opinion.  I think the surge came many years ago when automakers discovered LPC and it had a lot of good benefits at the same time.  Now, aerospace has discovered it but the volumes aren't as high as they were with automotive.  LPC is a great process, however, I have been scratching my head as to why it has not become more prevalent, and I think I might have some answers for that.

DG:  What are they?  Why not more prevalent?

MH:  First, many applications of LPC, being vacuum in nature, were performed with high pressure gas quenching.  Quenching with high pressure gas limits both load size and materials that you can use that can be quenched in gas, as well as some part geometries, thicker cross sections, etc.  They're very hard to quench when you're dealing with certain steels or alloys with high pressure gas quenching.  Carburizing, which LPC is trying to replace or compliment, it's really a high volume championing of surface hardening.  Hence, per pound, prices are low.  Loads are large and dense and you bring in a better quality methodology but you have a lot of limitations on productivity.  It's going to get more expensive.

DG:  So, you're saying the reason LPC (low pressure carburizing) hasn't taken off is because of the high pressure gas quenching essentially, because you have to do smaller loads?

MH:  Yes.  To get good quenching with gases because of the nature of how the gases flow around the parts and quench them, even at 20 bar nitrogen or helium, it's just extremely difficult to get the quench rates for certain steels that are required.  It is very easy with liquids.

DG:  Right.  So, you've got to either lighten the density of the load so you get more of the gas flow, or more loads or whatever.

MH:  Yes.  In vacuum processing typically they spread the parts out further.  You have to do that for gas quenching because, depending upon where the gases come from, you don't want to be having one part in the path of another part because you're not going to get the same quench rate.  That's still somewhat possible with liquids like oil or water polymer, but certainly not as predominant.

DG:  So that begs the question: Can we do LPC with an oil quench or some sort of quench?  It's not high pressure gas?

MH:  Yes.  And it's been done for quite a long time.  They call it low pressure carburizing or vacuum oil quenching.  You can do both through hardening and carburizing in a vacuum chamber and then you can transfer to oil quenching.  Typically, the way that's been done, over all the years, is you transfer it in-vacuum from the vacuum heating chamber to the vacuum that's over the oil and then you put it into the oil.  That's what you call classical vacuum oil quenching.

DG:  We're talking about high pressure gas quenching and density of loads and things of that sort.  One of the things I have been hearing about is companies trying to do more either small lot semi-continuous processes or, in fact, single piece flow so that they can get around the issue of having to oil quench, they can, in fact, do single parts, high pressure gas quenching and things of that sort.  Comment on that for a little bit.  Are you seeing a growth there?

MH:  As you know, we do offer that product line for single piece flow, so yes, we've been working at it for many years.  One of the driving forces behind single piece flow is that people are already doing it with so-called press quenching.  In those instances, they're taking it out of, typically, a reheat furnace, taking the part out one by one and putting it into a fixture and then quenching it with oil in the fixture to stop distortion as that product cools.

That's a very slow process, very expensive, and very labor intensive unless you can automate that with robots etc.  It typically, like I mentioned, involves, if you're surface hardening, you're probably going to do that in a separate unit, carburize that, slow cool it and then you're going to put it back into a reheat furnace.  So, it really adds to the cost of those parts, but you get some tremendous distortion control on the parts.

"What we're seeing with [press quenching] is the distortion is very, very low, we're not using any oils, we're not using a press quench, we have very low labor inputs and we can put it in line with the manufacturing cell.  The only issue with that technology, and one of the reasons it's been a little bit slow to grow, is that you need relatively uniform part sizes and shapes and pretty large volumes.  But this would usually be part of the process plan."

DG:  That's in press quenching you're talking?

MH:  Yes, that's in press quenching.  Now, what we've come up with is something that we call a UniCase Master when you're doing case hardening with it, we also utilize what we call our 4D Quench.  The 4D Quench is a high pressure gas quench that actually takes many, many nozzles of high pressure gas and puts it right on the part.  The fourth dimension is that we actually spin that part.  If you have an irregular gear, you're getting that gas distribution that's coming out of many, many nozzles, distributed very uniformly all over the part.

What we're seeing with that process is the distortion is very, very low, we're not using any oils, we're not using a press quench, we have very low labor inputs and we can put it in line with the manufacturing cell.  The only issue with that technology, and one of the reasons it's been a little bit slow to grow, is that you need relatively uniform part sizes and shapes and pretty large volumes.  But this would usually be part of the process plan.  We've come up, now, with some varieties of that where we can actually change that 4D press quench to cover a range of sizes and you can program that into the software.

DG:  And on the 4D Quench or the UniCase Master in the quenching process, are you able to treat most of the grades of steel, even oil quench graded, most of those, or is it fairly limited?

MH:  No, it's actually very good.  What we've found is, because we're concentrating that cooling of the high pressure gas is very close to the surface.  I've mentioned before- you're in a batch load, let's say you're in a 24 x 24 x 36 inch load geometry with high pressure gas quench, well those gas nozzles are coming from very far away.  If you go to more standard large size, like a 36 x 36 x 48 inch, the nozzles are even further away from the source.  So, yes, you're getting mass flow across the products, but you're not getting much impingement.  In convective cooling you need jet impingement.  I spent my whole life on this.  As you may recall, I was involved with my father and he had patents on jet impingement.  We come from a long history of working with convection and jet impingement.  Our 4D Quench perfectly optimizes those gas jets coming out and at 4, 6 or 8 bar, we can do the same cooling rate on a gear that you can get with oil.  That's phenomenal.

DG:  How about some of the other advances that we've seen?  I've got a couple of others thrown down here that I'd like you to comment on.  Again, for the listeners, I want the listeners to know that Mark's a very gracious guy.  Even though he works with Seco Vacuum, I've asked him to comment on some other products that are not his, but he'll give you a good perspective on these things, at least an introductory perspective.

Let's talk about hybrid systems, if we can.  We're talking about an integral quench-type system which is where a lot of this hardening process goes on that we've been talking about.  Talk about the hybrid system.

MH:  As we talked before, the vacuum oil quenching has been done for a long time as has integral quench furnaces.  Gas carburizing or gas integral quench furnace has remained pretty much the same for 50 years.  You utilize an oil quench, you try to get as quickly as you can into that oil quench, you have agitation in the oil, which gives you pretty decent quenching.  When you do that in a vacuum oil quench, because you're putting a vacuum over the oil, you'll get too much out-gassing with standard oil so they've had to develop special oils for vacuum oil quenching.

A couple things with vacuum oils: Number one is they're not as fast, they're slower quenching because of the nature of how they make them and the other thing is they're kind of hard to wash off.  They tend to varnish on and give you more problems with that.  People that have to do vacuum oil quenching have learned to like it and do it, but people that are used to doing standard interval quench furnaces, if they like oil at all, which a lot of them don't, a standard oil integral quench furnace has fairly fast oil.  That allows you to put some pretty good sized loads, a lot of productivity, through a standard interval quench furnace.

What we decided to do was, we said, we want to keep that standard interval quench, and if we do that and marry it to a vacuum chamber that can do low pressure carburizing, how would we go about employing that?  We were able to create a furnace that did that.  We're using a standard quench standard oils and instead of having endogas as a blanket atmosphere, we use only nitrogen, dry pure nitrogen.

Then, in the heating chamber, number one is that if you're doing through hardening, you don't have any atmosphere; you're under vacuum.  The good news with being under vacuum is that you don't have any problem with decarb or picking up carbon of your part.  Under vacuum, the nature is that the carbon does not move around, it does not leave the part, and it does not go into the part.  It becomes very easy.  Regular integral quench furnace, you have to condition it and try to get it at the same carbon potential that you have in your part.  It gets a little tricky.  With this furnace, it's very, very simple.

As far as carburizing, when you do it in a low pressure mode – what we call LPC (low pressure carburizing) use only acetylene – you're doing it at fairly low pressure levels, typically in the 5-10 bar range and you're using just acetylene.  You're using what they call a boost diffuse.  Now the key to doing low pressure carburizing, and one of the reasons I think that it has had some issues is in the past, is you need good simulation software.  We happen to offer one called SIM-Vac* and it has years and years, if not decades, of experience behind it so that it's now a very handy tool for the heat treater to know what his cycles and recipes are going to look like in an LPC type furnace.

DG:  Basically, you're doing a vacuum heat cycle, pulling it out of vacuum into a nitrogen chamber and dunking it into a standard oil quench.

MH:  Yes.  We will back-fill with nitrogen at the end of the cycle.  You typically want to drop a little in temperature anyway before you quench, so there's no problem putting cold nitrogen in there.  You get to your transfer temperature and you transfer into the oil.

DG:  Cost comparison between a full vacuum oil quench and this hybrid type system?

MH:  We've done quite a few.  We have two things going against us.  We have electric heating and we're using nitrogen.  However, the gas guys have quite a bit of gas usage because they're using endo generators and there is quite a bit of energy consumed in those endo generators.  When you do the comparison, in a same temperature processing scenario, it's about equal.

However, because our equipment can go to higher temperatures without any challenge at all to our heating furnace, we can go with much faster carburizing cycles.  So, when you start those shorter carburizing cycles, you're using less energy and you're using less gases.  We actually will end up being a little more competitive.  It's kind of counter intuitive, but this is how it really is helping us.  Only going 100 degrees Fahrenheit higher, which is not very uncommon going from 1700 to 1800 degrees Fahrenheit, results in almost 50% faster carburizing times.

DG:  You're actually being more efficient with your equipment.

MH: Very efficient.  And you'll actually get more productivity out of our units if you take advantage of the higher temperature.  By going 100, 150, 200 degrees higher in Fahrenheit, you're not going to hurt the furnace, unlike a gas fired radiant tube where you're going to tear it up.

DG:  Comment a little about the true vacuum oil quench systems.

MH:  They are wonderful systems.  We make a great one called Case Master Evolution and we've had that for over 10 years.  It's a great product line.  A lot of other furnace companies have it.  I just read that one vacuum furnace company is going to be offering it in the next year or so.  I saw another vacuum furnace came out with a new line kind of touting the ecological aspects of it.  But we've been doing it for a long time, so we know how good it is.

The only issue with the vacuum oil quench is the equipment is a little more expensive.  For aerospace, that's not a problem.  The equipment is typically not quite as productive and it costs maybe 50% more than standard, basic integral quench furnaces.  That's why we came up with, what we call, our super IQ- try to get the costs down and have the benefits.

Then, based on that, can we also increase the productivity?  We found that we could and it turns out to be much more advantageous money-wise.  However, there are still specifications, there are still people that want to have that vacuum to vacuum transfer.  There are people that want to have that type of aerospace grade type processing.  Our equipment has done very well and I'm sure some of the other guys are selling theirs as well.

DG:  So, there is still a place, obviously, for a full vacuum oil quench system.  Back on the hybrid then, are there other companies that you know of?

MH:  No, I'm not aware of any.

DG:  So, the hybrid system, basically at this point, you guys are the only ones doing it.

MH:  There are two barriers to entry, obviously, into that market.  One obviously is having the vacuum oil quench technology and then converting that technology to what we have which is nitrogen gas, etc.  The other thing is, as I mentioned before, if you don't have the simulation programs, it's going to be hard for you to place it into very high production shops.  In an aerospace shop, you've got a lot of high end people around that can do that for you, that can set up the recipes, etc.  If you're in a basic commercial heat treat shop, you're not going to have that kind of personnel who can be doing that on cycles that change fairly rapidly, without a good tool, and we have that tool.

DG:  I want to ask you one last question.  It's kind of unrelated, kind of related, a little bit different.  We had a podcast we did recently, a four part series we did with Joe Powell with Integrated Heat Treat Solutions.  I'm curious your opinion on this.  He talked about this process of basic quenching, getting the whole surface of the part down to the martensite start temp which basically forms a case around the part and then you can, basically, slow conductive cool from the core inside out.  It has to do with hardening, so I wanted to just throw it out to you.  Did you get a chance to listen to those podcasts or parts of them, and what do you think of that whole process?

MH:  I did.  As you requested, I looked at the podcast on intensive quenching by Joe Powell.  I'll tell you that, I actually can't remember which show it was, one of the last or two heat treat shows, I actually ended up sitting next to him out in the hall somewhere and he handed me a piece of paper and said, “Here!  This is what we're doing.”  I was exposed to it before, but I got into it more now that you showed it to me.  It certainly is science based and he understands the issue of quenching very well.  I point out that our 4D Quench solves many of these issues, but he's coming from his angle on it, and I certainly agree with him.

As you may recall, I probably mentioned it before, my father was in the industry and had 65 patents, mostly heat treat related inventions.  Rarely did we make money off of these ideas.  So, I'm used to a lot of great ideas, but you can't make money.  I think it's challenging in this world of mass production heat treating, where we have carburizing being performed at 50 cents a pound to get engineers, like Joe is wanting to do, to focus on the whole part life cycle and combining that final quench phase with the part design.  I think it's a great idea but I just think it's hard to do.

We kind of know this from experience, and I won't get into it too much, but I think you may know that we have a process called PreNite where we prenitride our parts.  That is a similar type thing where we're trying to take advantage of things that we know are possible in heat treating and prenitriding it allows the grains to not grow when you go to higher temperature to try to get more productivity out of a piece of equipment.

The one thing you've got to do, though, is convince the engineer to use a different alloy so that you don't get grain growth in the core.  Convincing those guys is tough.  We just don't see engineers engaged enough to do this complex reengineering.  That's my opinion only.  I think that's where Joe is going to get some resistance.  I think his ideas are great, and of course, I totally agree with his approach to it.  I could go through some other ideas that I came up with just reading his is almost like should you misquench first before you dunk it in the oil so you get that outer case, as he talked about.  I think it's a lot of great of ideas.

What we need to do is find some really good engineers to break the barrier of those low risk takers that we have in engineering, and I think that's possible.  You may know everybody's out there talking to people like Tesla and SpaceX and some aerospace companies.  These guys are starting to break some of these barriers.  They're starting to saying we don't want to do the status quo, we want to do something different.  If we can do that, a lot more of these technologies will take off.

DG:  We need some early adopters to step up.

MH:  Early adopters.  And people who want to not just be yes-men but really think it through – the whole life cycle of a part, how it's designed and everything else.

DG:  So, dear listener, if you are one of those people, please call us.  We're interested.  We've got a couple of different technologies.  Mark, thanks a lot for your Hardness 101 and helping us out on these three.  I think we covered some good ground.

Doug Glenn <br> Publisher <br> Heat Treat Today
Doug Glenn
Publisher
Heat Treat Today

 

 

 

 

 

 

 

 

 

 

 

 


To find other Heat Treat Radio episodes, go to www.heattreattoday.com/radio and look in the list of Heat Treat Radio episodes listed.

 

 

Heat Treat Radio #56: Metal Hardening 101 with Mark Hemsath, Part 3 of 3 Read More »

Heat Treat Radio #54: Metal Hardening 101 with Mark Hemsath, Part 2 of 3

Heat Treat Today publisher Doug Glenn talks with Mark Hemsath about hardening basics. Mark was formerly the vice president of Super IQ and Nitriding at SECO/WARWICK, and is now the vice president of Sales - Americas for Nitrex Heat Treating Services Learn all about the what, why, and how of hardening. This episode builds upon the first conversation in Part 1.

Below, you can either listen to the podcast by clicking on the audio play button, or you can read an edited transcript.

 



The following transcript has been edited for your reading enjoyment.

Doug Glenn (DG):  We're here talking about hardness, as it pertains to the metals world, metallurgy, and things of that sort.  First off, Mark, welcome back.

Mark Hemsath (MH):  Thanks, Doug, it's nice to be here.

DG:  For the record, we're recording this thing right before Thanksgiving, the day before Thanksgiving, so we've got turkey on the mind here.  I've known Mark for many, many years, in fact, I would say a couple of decades now, when he was with other companies and doing other things.  He's a very well-rounded person in the industry.  He's able to speak intelligently about a lot of different things, including surface hardness, through hardness and that type of stuff.

Last time, we talked about what hardness was and why it's important.  Afterwards, you and I had some conversations and there were a couple of things I think we wanted to supplement onto that first episode.  One of those things had to do with hardness testing.  Throw out what you were thinking about that.

MH:  I think on testing, the point here is that there are many scales for testing because we have many different types of material with different hardness.  When we start getting into some of the other materials, it changes a little bit.  In the steel realm of things, the most typical is to use a diamond tip weight to try to indent the material.  Based on the pressure it takes, we get a reading.  For instance, a very thin layer may require a different type of test because one style of test may not be set up to measure such a thin hardness.  This is typical in something like nitriding where you have a white layer.  Different types of testing methodologies – there is the Brinell, Vickers, Rockwell and Newage hardness testers, and there are a lot of other things out there, as well.  In general, we are trying to test the surface hardness and then also the hardness as it traverses through the material.

DG:  The other thing that you and I were talking about was other materials besides steels that were hardenable.

MH:  I'm not an expert on aluminum, but one of the materials that we talked about is aluminum, and quite frankly, SECO/Warwick has a separate division just dedicated to aluminum because it is different.    Let's take a look at aluminum first.  Aluminum is actually rather soft and has many other benefits.  It is very commonly used in aerospace and companies like Tesla are using it today, almost predominantly, for their cars.  Just like in steels, it can get harder by using alloying elements.  Most common alloying elements are copper, manganese, silicon, magnesium, zinc and lithium.  Hardening is typically by a precipitation or age hardening.  Tempering is also very common.  So, not all aluminum alloys can be heat treated, per se, but as I was mentioning, it is a whole different world and it requires a whole different set of expertise because it is kind of a unique metal.

DG:  How about titanium?

MH:  Titanium is an increasingly popular alloy.  It is expensive and it has very high strength to weight ratio.  It is almost as light as aluminum but much stronger and also has great resistance to corrosion.  Titanium can be alloyed to add properties to the metal and it can be nitrided at higher temperature making a very thin, hard layer that is gold in color, something that I've done a little bit of in the past.

On of the other materials that you asked about are stainless steels, and this is also a whole different breed.  Recently, in the last 5 – 10 or so years, surface hardening is being applied with great success and it is actually done at low temperatures to make a very hard surface and still retain the corrosion resistance.  When you harden stainless steels via nitriding at the higher temperatures, you do get high hardness but you lose corrosion resistance.  They've made quite a bit of inroads at the low temperature end of things, so called S-phase hardening.  Certain stainless steels, martensitic stainless steels, are actually hardenable by heating and quenching.  Those have, commonly, 11 – 17% chromium and no nickel and they have a higher carbon.  Austenitic stainless steels, typically at 300 series with nickel, do not harden by heating and quenching.  These steels, as I mentioned, can be surface hardened.  Ferritic stainless steels, which is another breed, are commonly a lot of the 400 series stainlesses have 10 – 30% chromium and they do not harden by normal means.  Then, we have some special so-called alloy 17-4 PH and some of the other ones are hardenable by aging.  So, I wanted to go through some of that.  There is a lot there.  But just to discuss all of the variety of different steels out there.

DG:  Let's dive into these five different hardening processes, which we want to talk about, to give our listeners a little better sense of exactly what the process is and how they might differ from one another.  The five we're going to cover are carburizing, nitriding, carbonitriding, FNC, or ferritic nitrocarburizing, and LPC, meaning low pressure carburizing.  Let's go back and just start with, probably, what I think, is the most popular or common one, which is carburizing.  Do you agree?

MH:  Yes, I would tend to agree, especially by pounds.

DG:  First off, what is it?  We covered this last time, but just briefly, let's talk about what carburizing is.

MH:  Very briefly, carburizing is the addition of carbon which adds hardness to the surface and, as I probably mentioned before, it needs to be done at elevated temperatures.  The higher the temperature, the faster the process.

DG:  Basically, break it down.  How's it done? What's the temperature?  What's the atmosphere? What are the times?  General things like that.

MH:  Typically, it's done above 1600 degrees F, which is the austenitic temperature range, and more commonly done at 1650 – 1750 F, which is 900 – 950 C.  In the old days, they put charcoal powder, which is a carbon, near the steel or maybe in a box, and they heated it and that's how they got carbon.  They actually got carbon monoxide gas to form at high temperature and got it to go into the steel.  This will actually crack the charcoal and give you the gas.  Some people still use this, especially if they've got some very big odd shapes; it's the only way to do it.  Somewhat, it is done in other countries, but not as much here.

There is also obviously the gaseous form which is called gas carburizing.  That is typically done with carbon monoxide gas, which is typically created from cracking natural gas or using a nitrogen methanol.  For endothermic gas, it's basically about 40% nitrogen, 40% hydrogen and 20% CO.  In order to increase the carbon content of that gas, people will inject a carbon containing gas like propane or natural gas, etc.

One other method that is still in use is salt bath.  It is also somewhat common and here they use a sodium cyanide (NaCN).  Basically, most of it being done today is with gas carburizing.

DG:  As far as the actual materials?  I assume most of it's going to be your steels being carburized?

MH:  Yes.  Virtually any steel or alloy can be carburized to some extent if it has iron in it.  Iron carbides will form.  Mostly less expensive steels are done.  The so-called low carbon, low alloy steels are typically the ones that are most frequently carburized to get high surface hardness and because they kind of like the core properties that come with it.

DG:  Equipment.  You already hit on this some, but obviously for salt bath, which you mentioned, you're going to have a salt bath piece of equipment to do it.  Gas carburizing is obviously done just inside of an atmosphere furnace, in some capacity, I assume.  Can it be done continuous and/or batch?

MH:  Yes.  The most popular is batch.  The integral quench furnace, which is usually an in-and-out furnace where you have endothermic gas both in the vestibule where you put it where the quench oil is.  Then you go into the furnace, you do your hot temperature carburizing in the same gas, and then you come out hot and you're protected and then you go into the oil quench, and everything is within that atmosphere.  That's the most common.  But, as you mentioned, continuous is very viable.  The only issue with continuous is it's pretty high production and it's usually the same process over and over.  That way you can maximize the use of your quench.  Because quenching might only be 20 – 30 minutes tops, whereas the carburizing cycle might be 8, 10 or 12 hours, you're not using that quench very often.  Continuous will allow you to use a quench much more frequently and that quench might be fairly expensive, so that makes sense for doing the same parts over and over.

DG:  Right.  If you've got super high production, that would be the way to go.  And, it is probably notable to point out here, that quenching is an important part of the carburizing process.  This is not true with some of the other surface modification stuff we're going to talk about down the road, correct?

MH:  Yes.  Quenching is usually done right afterwards, to save money and to make it economical.  That's not to say that there aren't many people, like in press quenching, that will actually carburize it, slow cool it and then heat it up again and then individually quench each part.  There are also some benefits to grain growth.  If you've got a very deep case, that carburizing might cause some growth in your grains.  If you slow cool it and then heat it up quickly again and quench it, you'll transform all that back to the properties that you want.  But, yes, typically all done together.

DG:  Can we carburize using induction technology?

MH:  I'm not familiar with carburizing. . . Induction is typically heating the outer surface and cooling it very quickly and keeping that very hard and then the core will still maintain its property.  That's a thermal surface engineering process induction.  I had an old engineering friend of mine, metallurgist expert, PhD, who calls it surface engineering or thermal chemical surface engineering, because we're using both a chemical process and a temperature process.

DG:  Anything else notable on carburizing before we move on to nitriding?

MH:  The only thing is the alloying elements are common in steels.  I mentioned before low alloy steels and high alloy steels.  Alloying elements common in steels are nickel, silicon, chromium, manganese and molydenum.  Silicon and nickel are less prone to absorb carbon, whereas the carbon potentially atmosphere is increased with elements like chromium, manganese and molydenum which form more stable carbides than iron.  Alloying elements can adjust the ability to carburize.

DG:  That's the basics on carburizing.  Let's move on to nitriding.  If you can, Mark, as we plow through this, maybe draw a bit of a comparison on, for example, temperature ranges and maybe cycle times and materials, and things of that sort.  So, what about nitriding?

MH:  Nitriding is a process where nitrogen atoms are diffused into the steel surface.  I believe that nitriding is more complex than carburizing because hardness, and the types of nitrides created, are dependent on a number of different factors.  So, depending on the process, either ammonia is used or an excited nitrogen atmosphere via a plasma generator can diffuse the nitrogen into the steel surface.  What's common with nitriding is it's done at a lower temperature.  The diffusion of nitrogen is a time and temperature dependent process, so the higher you take the temperature, the faster the process will go.  But, it's still performed at much lower temperatures than carburizing.  It's actually done in the ferritic range and not in the austenitic range, typically, 915 degrees Fahrenheit up to just under 1100 degrees Fahrenheit which is 490 C to 590 C.

Nitriding is a process where nitrogen atoms are diffused into the steel surface. I believe that nitriding is more complex than carburizing because hardness, and the types of nitrides created, are dependent on a number of different factors.

DG:  You're talking 500 – 600 degrees F, roughly, lower temperature than carburizing?

MH:  Yes.

DG:  That's the temperature range.  Obviously, the atmosphere is different because we've got nitrogen as opposed to carbon, but how about process time?

MH:  We talked about the temperature.  Obviously, if you're at the higher end of that temperature, you can go a little faster, but nitriding has been known to be slower than carburizing, and it is.  The diffusion process is slower.  Gas nitriding and plasma nitriding are the two main processes.  There is also ferritic nitrocarburizing, which is a form of nitriding with salts.  But gas nitriding uses ammonia as a nitrogen donor and plasma nitriding uses nitrogen at a partial pressure with a plasma excited atmosphere.  Nitrogen creates iron nitrides in various forms in the white layer as either, what we call, an epsilon layer or a gamma prime layer.  In some instances, people don't even want that layer, they only want the nitrogen to go into the steel and create nitrides with some of the alloying elements.  This is what we call the diffusion into the alloy into the steel into the alpha.

DG:  What about case steps between carburizing and nitriding?  If you want a deeper case step do you tend to go carburizing or is there a difference in the case depth actually?

MH:  It is much more possible to do a deep case step than carburizing.  You can basically keep sending it in there and, if you can go a little bit higher temperature, you can get some pretty deep case steps with carburizing.  The difference between the nitriding, is that it's a different process.  It's a lower temperature process so it's a little bit slower, but you get a pretty hard case with the right alloy with the nitrided case.  In many instances, you can get a pretty similar performance of the part, or something that performs very well, with maybe only one-third of the case.

DG:  When we talked about carburizing, we talked about materials that were 'carburizable'.  How about in nitriding?  What materials are easiest to be nitrided and are there some that we really can't nitride?

MH:  Nitriding is kind of opposite from carburizing.  Most people will carburize the more low alloy or plain steels, whereas in nitriding, we really want to deal with alloy steels that have alloys in it that will be friendly to absorbing nitrogen.  Now, on plain hardened steels, you can get the white layer on there, but you're basically limited to just the white layer for your surface engineering, and you don't get much depth, depending upon what type of alloying elements you have.

DG:  Mark, talk for just a second about this white layer in non-technical terms, if you don't mind.  Is it, simply, the accumulation of nitrogen above the 'surface' of the metal?  What is that white layer?

MH:  No, it actually reacts with the metals in the surface layer.  Because the surface is being hit with a lot of nitrogen, the reactions there will create what we call a white layer where there is a lot of nitrogen activity and those are iron nitrides.  They also will get some carbon that will react in there.  That's a very hard layer, somewhat brittle; it is resistant to corrosion and it also has very low friction property.  A lot of people want that often but when you're going with the higher alloyed steels, there are some applications where you don't want that, let's say, bearing types et cetera where you don't want any small parts that could come off.  The white layer is prone to chipping or coming off, so you wouldn't want that in a bearing, because it's very hard and if it comes off, it can cause problems with your bearing.

DG:  I assume, with all the modern day technology and whatnot, we're able to control that white layer and/or depth of nitriding layer through your process controls and things of that sort.

Leszek Maldzinski
Professor at Poznań University of Technology
Project Leader and Scientific Adviser at SecoWarwick

MH:  Yes.  Nitriding has been around a long time, but one of the problems that they had was controlling the white layer.  Because they basically would just subject it to ammonia and you kind of got what you got.  Then they learned that if you diluted it, you could control it.   That's with gas nitriding.  Then plasma nitriding came around and plasma nitriding is a low nitriding potential process.  What that means is it does not tend to want to create white layer as much.  It's much easier to control when the process itself is not prone to creating a lot of white layer, unlike gas.  Now, in the last 10 – 15 years, people have gotten really good at controlling ammonia concentrations.  They've really learned to understand that. One of the people who was instrumental in understanding that is the inventor of our zero flow control technology, Leszek Maldzinski. Understanding how you change the ammonia nitriding potential to get the type of steel layers that you want is rather complex, but once you understand it and have the tools, you can craft the layer exactly the way you want it with ammonia gas.

DG:  You did talk about the types of equipment that can do nitriding, but just hit on those again.

MH:  Gas nitriding is typically done in a retort to safely hold the ammonia and once the gases start dissociating, we also have hydrogen in there.  Also, ammonia gas is very noxious and can be deadly, so you need something tight to hold it, and that's why they'll do it in a very tight retort.  Plasma nitriding is done under vacuum, partial pressure.  You can do that either in a hot retort or a cold wall vacuum type furnace.  Those are the two main processes.

DG:  If you had a similarly sized carburizing furnace and a nitriding furnace, would you expect that the nitriding furnace would cost more than the carburizing furnace, or vice versa?

MH:  Carburizing furnaces are a little more expensive because you have the addition of the quench and you're also at fairly high temperature.  Those are two cost drivers in carburizing.

DG:  This next one has always been a little confusing for me. Let's see if you can straighten me out:  We talked about carburizing, which is carbon.  We talked about nitriding, which is nitrogen.  And now we go to something called carbonitriding, which sounds to me like the two are holding hands and performing the process.  So, what is it?

"It can be confusing because here in the US we call it carbonitriding and we call the form of nitriding that is FNC (ferritic nitrocarburizing), nitrocarburizing.  In Europe, I've heard them exchange those names.  But, typically, in the US, we call the high temperature process, which is similar to carburizing, we call carbonitriding.  The ferritic, which usually means the low temperature, not austentitic, ferritic nitrocarburizing is a low temp form of nitriding and adding carbon.

MH:  It can be confusing because here in the US we call it carbonitriding and we call the form of nitriding that is FNC (ferritic nitrocarburizing), nitrocarburizing.  In Europe, I've heard them exchange those names.  But, typically, in the US, we call the high temperature process, which is similar to carburizing, we call carbonitriding.  The ferritic, which usually means the low temperature, not austentitic, ferritic nitrocarburizing is a low temp form of nitriding and adding carbon.  Let's go to carbonitriding which is the high temperature version.  It's typically done in low or unalloyed steels that have rather low hardenability.  Increasing the quench rate is rarely possible, so what we do is we add nitrogen and carbon to the surface to increase the surface hardness substantially.  It actually makes a very hard surface.  I usually say this is done for the cheaper steels.

DG:  Meaning the less hardenable steels?

MH:  Yes, and it's done in less alloyed steels, too, because we're just trying to get a thin hard surface on the outside, for whatever application it is.

DG:  And temperature range?  Does it tend to be similar to carburizing, up in the 1600 range?

MH:  It is, but because ammonia breaks down very rapidly at higher temperatures, we like to do this at the lower end of the austenitizing temperature, so in the 1600 – 1650 range, as opposed to the 1700 – 1800 range of carburizing.  Now, that means that the carbon transport to carbon diffusion into your steel surface will be slower, but what we're trying to do is we're trying to get both in there, the carbon and the nitrogen to make that very hard, thin surface.  And, we're trying to do it quickly, because we want to do it cheaply.

DG:  Is carbonitriding kind of an inexpensive way, if you can do it, of carburizing?

MH:  That's what I typically look at it as, yes.  And, it's possible to do a lot of these parts.  Let's say they're stampings or low expense steels.  You can sometimes do that also with ferritic nitrocarburizing if you change the steel grade a little bit.  There are a lot of different ways of hardening some of these small parts or clips or what have you.  Also very common in screws, roofing screws, etc, to get that hard point on there.  It doesn't need to be very thick, it only needs to be drilled into the roof one time.

DG:  So that's carbonitriding.  We talked about temperature ranges.  We talked a bit about the steels that we would use for that.  Equipment that is being used for carbonitriding?  I assume it's more along the lines of the carburizing?

MH:  It's virtually identical.  It's either gas atmosphere, integral quench batch furnace or can be done in continuous fashion.  A lot of people use mesh belts for it, too.

DG:  I neglected to ask you this, back on nitriding.  No quench is involved there, correct?

MH: Correct.  Nitriding has no quench.

DG:  But carbonitriding, you're quenching, because it's kind of a cheap man's carburizing.

Anything else we should know about carbonitriding?

MH:  Just that steels like 1018, 1022, the low end, there are other ones that obviously can be done, but that's typically what's being used.

DG:  Let's go on to the second to last.  We've got two more left.  Nitrocarburizing, or as it's commonly or often referred to, FNC    (ferritic nitrocarburizing), let's talk about it.

MH:  Unlike carbonitriding, which is often confused with ferritic nitrocarburizing, FNC is performed at lower temperatures just like nitriding, but it's typically done a little bit higher temperature than nitriding and it's done just below the initial austenitizing temperature which is around 570 C/1060 F, just below 1100 F you can go to if you're equipment is fairly uniform.  The reason they do that is because in ferritic nitrocarburizing, you're trying to create white layer, and white layer will be much more aggressively created at higher temperatures and also with higher levels of ammonia.

DG:  So, the temperature is the same.  Cycles times.  Obviously, the atmosphere is predominantly nitrogen with a little bit of carbon mixed in, I assume.

MH:  Right.  The nitrogen comes from the ammonia, unless it's a plasma type process, but let's talk gaseous ferritic nitrocarburizing first.  You can put a carbon gas in.  This can be an endogas to get CO, it could be CO2 injected where the CO2 actually will convert to a CO gas, and people have used other gases, but those are the two most popular forms of carbon gas.  What that does, again, because we have typically cheaper steels, they don't have a lot of carbon in the surface, so we want to have a little extra carbon there to get that really hard and aggressive epsilon layer.

DG:  Equipment to be used.  In nitriding, we were potentially using a vacuum furnace, at times.  Do we use vacuum for FNC?

MH:  Well, FNC, just like nitriding, you don't need vacuum for our nitriding furnace, we use vacuum purge.  Because we want the vessel retort to be very tight, making it a vacuum capable vessel, means it's, by definition, tight because you don't want ammonia to leak out.  But, for FNC, people have done this in any number of ways.  For example, bell furnace or tip up furnace.  I've seen people use their integral quench furnaces, the heating chamber.  All you have to do is get to that temperature just below 1100 F, get your ammonia in there and get some sort of carbon gas, and you're going to get a white layer.

DG:  I know when we were talking about nitriding earlier, you mentioned that it was done mostly in a retort, one reason was to contain the ammonia, but you don't necessarily need that in FNC?  Or, is it pretty common that you would use a retort furnace?

MH:  It's commonly done in a retort and commonly done in a pit furnace, but there are people who do it in tip up furnaces.  Like I said, there are people who do it integral quench furnaces, people do it continuously.  Obviously, when you have ammonia involved, the retort makes the environment that you're standing there much nicer, because you can put the ammonia in the furnace as opposed to around you.  Small amounts of ammonia can become choking.  I don't like other furnace designs because they're hard to seal.

DG:  Anything else you think we should know regarding nitrocarburizing?

MH:  It can be done in plasma.  It's less common.  They typically use a carbon gas like methane, or something, to put in there to try to promote some more white layer.  Like I mentioned before, plasma process is typically not very white layer friendly.  But if you put that carbon gas in there and increase the temperature, you can get some pretty decent white layer with it in a plasma setting.

DG:  Let's move on to the last one: low pressure carburizing.  Let's talk about that.

MH:  Again, carburizing is the addition of carbon, right?  So, the difference here is that when we talk low pressure, it's just like a mentioned before with plasma nitriding, it's done at a negative pressure, less than atmosphere.  We call this either low pressure carburizing or vacuum carburizing; it's the same process.  This takes place at pressures typically in the 1 to 15 torr range, which is about 1 to 20 millibar range of pressure.  If you know one atmosphere is 760 torr, so when we're going down to 1 – 15 torr, we're at pretty good vacuum.  Just like with gas carburizing, the higher the temperature, the faster the process.  What's unique with vacuum equipment, is that vacuum equipment is typically capable of going to higher temperatures which adds to the speed of carburizing.  Now, we didn't discuss the design of gas carburizing furnaces that much, but typically they're gas fired and they have radiant tubes.  In the interior of the furnace, the higher temperature you go with the really nasty carburizing atmosphere, it reduces the life of those furnaces substantially, so the people that own the furnaces don't want to go to high temperature.  If you can go 100 degrees higher in temperature, like you can with the vacuum carburizing furnace, the process gets much faster.  That means higher productivity.

One more feature, as well: the initial carburizing of steel at low pressures is actually faster than gaseous  carburizing.  The carbon flux of the surface is very high in LPC.  The diffusion is the same, once you get into the steel itself, but the flux to the surface is very high.  So, shorter, shallower cases are quick, and then, like I said, if you can increase the temperature to increase the diffusion into the steel, on deep cases you can get the cycle less than half.

DG:  How long has LPC been around?

MH:  Technically, it's been around since probably the late 60s.  It had a very slow introduction, in my mind.  That's only because they had trouble really getting it to work reliably.

DG:  Anything else we should be asking?  I assume the steels that can be carburized with LPC are essentially the same?

MH:  Yes.  Steels are the same.  Typically, you want to go a little higher temperature than you would with gas carburizing, so typically above 1700 F and more likely 1750 F – 1850 F.  The big difference is with gas carburizing, as I mentioned, we use endothermic gas which comes from natural gas and then with some enrichment, here the carbon carrier is typically acetylene and that's put in at low pressure.

The other thing is, in gas carburizing, they use oxygen probes and they try to figure out exactly what the carbon potential of the atmosphere is.  It's totally different with low pressure carburizing.  With low pressure carburizing, because you can't really measure it reliably and accurately, we use process simulation software to create the recipes.  By being able to model the surface area of the parts and the total weight of the parts and the material, the temperature and the case thickness that you want, the LPC process becomes very reliable and can perform very well.

DG:  We've had conversations with folks over at Dante Solutions and they say that this LPC is one of the most read items on their website; people are trying to figure out how to do it and how to avoid the carbides and things of that sort.  It sounds like an interesting process.

Anything else we need to talk about on LPC?

MH:  I would like to point out that most LPC has been done in vacuum furnaces in the past with high pressure gas quenching.  You mentioned it's been around a long time.  What they found with high pressure gas quenching is, number one, you can't have a lot of parts in the furnace, which means you have smaller load sizes.  In order for the gases to quench, you have to have very high pressure and also, the parts can't be that thick.

Over time, it really hasn't taken off the way I think it should have.  And some of the equipment was kind of problematic.  There was always done vacuum and oil quenching, but when they combined, and a few manufacturers do this, vacuum and oil quenching with LPC, then the oil quenching allows you basically to use the same steels to get the quench rates and to start to get some heavier loads in your furnace so that you can get the productivity.

This has now driven, what I consider to be, a viable option to gas carburizing.  For instance, with our Super IQ furnace, we use a conventional oil quench.  It's no different than the standard oil quench that most people use in their integral quench furnace.  However, the heating is done in LPC.  The difference is, instead of transferring the load in vacuum, which is what a conventional vacuum furnace will do, or transferring it in a hydrogen and nitrogen atmosphere, we transfer it only in nitrogen.

We have found out that there is no added IGO or any other problems with doing that.  What ends up happening is you can make a less expensive furnace and you don't have to use vacuum quench oils, which are a different breed- they're not as fast, they're more difficult to wash off and clean off.  We think that combination of LPC and standard oil quench makes a very high performing furnace with LPC.  So, it puts LPC into a new interest level, in my mind.  But, again, you still have to have very reliable simulation software.  We have over 10 years of experience putting that software together, so it's very reliable.

DG:  Just so the listeners know, we're doing a 3-part series and we're in #2 right now.  Next time we are going to talk about some of the more conceptual things regarding nitriding LPC and we're going to even talk a little bit about single piece flow because there's been a demand for single piece flow.  We're going to talk about some of the recent advances in some of these systems which we've hit on here just briefly.

Mark, I appreciate it.  This time, I think we've done a good job at covering carburizing, nitriding, carbonitriding, nitrocarburizing and a little bit on LPC.  Next time, we'll look forward to talking with you more about some of these other things.

Doug Glenn, Publisher, Heat Treat Today

Doug Glenn, Heat Treat Today publisher and Heat Treat Radio host.


To hear this episode and other Heat Treat Radio podcasts, please check out www.heattreattoday.com/media/heat-treat-radio

Heat Treat Radio #54: Metal Hardening 101 with Mark Hemsath, Part 2 of 3 Read More »

Heat Treat Radio #49: Metal Hardening 101 with Mark Hemsath, Part 1 of 3

Heat Treat Radio host Doug Glenn and Mark Hemsath, talk about hardening basics. What is it, why does it matter, and how do we do it? This is a great primer episode to kick off our three-part series with Mark. Listen and learn!

Mark was formerly the vice president of Super IQ and Nitriding at SECO/WARWICK, and is now the vice president of Sales - Americas for Nitrex Heat Treating Services.

Below, you can either listen to the podcast by clicking on the audio play button, or you can read an edited transcript.

 



The following transcript has been edited for your reading enjoyment.

Doug Glenn (DG):  Mark, I want to welcome you to Heat Treat Radio.  Welcome!

Mark Hemsath (MH):  Thank you, Doug.  It's nice to be with you today and thanks for having me on the show to talk about this interesting subject.  I'm not quite sure if I'm an expert on it, but we will certainly try to talk about it.

DG:  I'm sure you know more than most of us – that's why you're here!  First of all, as I mentioned, you are the VP of Super IQ, IQ being integral quench, not necessarily intelligence quotient – although, you are a smart guy.  You are the VP of Super IQ and nitriding for SECO/VACUUM.  Both of those are processes and both of those are dealing with hardening.  Tell us a little bit of your background and then we'll jump into the topic of hardness of metals.

MH:  I'm not a metallurgist.  I did take metallurgy at college and I've been living it most of my life, but I didn't train to be a metallurgist.  Instead, I got involved in the furnace business, and being involved with furnaces you have to do something with those furnaces.  Typically, those furnaces allow you to do different things, like soften and harden metals.  My background is that for many years, I worked with my father helping to design furnaces for the industry and we developed different furnaces.  Some furnaces were for annealing, some for tempering, some vacuum processes, you name it.  I joined SECO/WARWICK a number of years ago and I spent quite a bit of my early days in ion nitriding and SECO/WARWICK was involved with gas nitriding. That was of extreme interest to me.  I took a liking to that and decided to become a subject expert on nitriding.  Now, I've been asked to also get involved with our carburizing product, which is breaking into the market – we call it Super IQ.  That is obviously carburizing as a surface hardening process.  Not to mention, we also do through hardening in those furnaces, and we can go into some of those details a little bit more here today.

DG:  For people who might not know, when we talk about hardness, we're talking about the hardness of a metal.  Most people would think, all metal is hard. I mean, that's one of the characteristics of metal, but if you wouldn't mind, give us the “hardness 101” class: What is it and why is it important when you talk about hardness for metals?

MH:  I think the most important thing is that with metals, you're trying to get certain features that allow it not to wear over time.  At the same time, you want the part to last.  You don't want it to break, you don't want it to chip, you don't want it to seize up, so there are a lot of different things you can do with the parts to give them certain wear characteristics and hardness.  There are other things – anti-friction, etc. – that you can do with surface finishes, such as with nitriding, which offer hardness to the part, but in a slightly different way than you might think, just on basic hardenbility.  But, whatever we're talking about, we're trying to prevent parts from wearing, and that's typically why you try to harden the parts.

DG:  How do we measure hardness, or what are the units that we typically measure?

MH:  You have different scales out there, depending upon what you're trying to measure.  If you're just trying to measure the surface, you might go with the file hardness or you might go with a test where you don't have such a heavy hardness on there.  There are different Brinell hardnesses: You've got the HRC, the HRB, and different scales out there.  You've got the Vickers hardness, and all different types of equipment designed to very accurately measure the hardness of a part and also to try to figure out how that hardness is changing throughout the material.

Typically, in most materials and in the processes that you're doing, because you have some thickness of material and a lot of it is related to both the quench rates etc., you're going to get hardness that varies throughout the part.  So, they have come up with different ways of measuring that and there are a number of different scales out there.  You can look that up and decide.  Some people like to use one over the other, but typically, they are all designed to do the same thing: try to get an accurate reading of what the hardness is.

DG:  I've heard the more common ones, I think you've mentioned them: Rockwell is a hardness measurement, Vickers is a hardness measurement, and Brinell is a hardness measurement.  So, those are the scales that are used.  We're not going to get into how those tests are done and things of that sort, but we certainly could at some point in time.

[blocktext align="right"]“I think the most important thing is that with metals, you're trying to get certain features that allow it not to wear over time.  At the same time, you want the part to last.”[/blocktext]

MH:  I'm not an expert on doing the tests.  I've seen them done many times, but there are guys that are really good at that.  Same with microstructures, right?  Looking at that and understanding how things change within the steel and seeing it under different magnification, gives the scientists some really good knowledge about what's going on within the steel.

DG:  Again, “hardness 101”:  A person often hears, when dealing with metals and hardness, about surface hardness or through hardness.  Can you tell us about those things?   What's the difference?  Why is that important?

MH:  A part that you make, in a lot of instances, you want it to be as hard as possible for wear characteristics, but at the same time you don't want the part to fail because the core properties are too hard and can be brittle.  Typically, what you have is people trying to impart certain types of features onto the surface and still retain the so-called core properties of that material.  Obviously, you heat it up to austenitic temperatures and you quench it and you try to transform as much of that steel as possible to martensite, and then you try to temper it back.

A number of things that you're doing there are going to change the properties of the steel.  That's why people will use different tempering temperatures to get different core properties.  They'll use different surface treatments, whether carburizing (which will give you a higher surface hardness by driving more carbon into the surface) or induction hardening, in which you're heating up just the outer part of the steel and then quenching the outer part.  Obviously, you can only go so deep because you're quenching it from the outside, but that will give you almost a double type of feature within the material.  You're starting out with the core properties that you want – a certain hardness, a certain ductility, and a certain capability to function, let's say, a shaft – and then you want to give it some hardness.  If you have the right steel, you can harden that just by taking it up to temperature with induction heating or with flame heating and then quickly quenching it to get the properties that you want on that outer.

DG:  There are some properties in there that I want to make sure our listeners understand.  You mentioned the idea of hardness and ductility.  Those two things tend to be on opposite ends.  I know there are much more technical descriptions of this, but the harder something is, the more brittle it tends to be, and when it's brittle, it takes less to crack it or break it.  Whereas if it's ductile, it's softer, it can take more of an impact without breaking.  For example, let's just use a gear: On the gear teeth, on the outer edge of the gear, you want that to be very hard so there's good wear, but you don't want it to crack so you keep the inside of that gear, (that's away from the surface side of the gear), soft.  Yes?

MH:  Yes.  And there is a lot that goes into gear design.  You don't want high impacts, obviously, you want the teeth to mesh together.  There are people that induction harden gear teeth, there are people that carburize gear teeth and there are people that nitride gear teeth.  They're all trying to do something on the teeth, and even though you're doing something on the teeth, you still have to also impart certain properties to the core part of the gear itself to make sure that nothing breaks or falls apart on the gear, the main core part of the gear itself.

(Source: Inductotherm)

DG:  You did also mention the fact that there are some steels that are more easily hardenable than other steels.  I've heard there are high hardenability steels and there are low hardenability steels.  What's the difference?

MH:  In general, iron is an element that is common to all steels.  Now, there is tremendous science that has happened over the last decades on putting different alloying elements into the steels, whether it's chromium or titanium or vanadium or you can name all the different ones.  Some of them are called micro alloy and some of them are more main alloys, but they all provide different types of properties to that alloy steel which then gives that steel certain characteristics.  There are more steels created today than I could ever mention.  You can buy huge books on that from ASM and get all of the different properties of the steels.  Tool steels have quite a few alloying elements in them, and they have a very high hardenability.  They're also more expensive, so people are not going to want to use expensive steels with all of those expensive alloying elements for basic automotive transmissions, or what have you; it just gets too expensive.

I should also say that carbon makes up a big part of that, too.  The carbon in the steel is, obviously, why we call it carburizing because it will put hardness into it.  But we also have what we call low carbon steels, medium carbon steels and high carbon steels.  Then you start throwing in the alloying elements with that and you get all kinds of variations.

DG:  So, typically, a high carbon steel is going to be much more easily hardened because it's got more carbon in it to start with and you don't necessarily have to add carbon into it during the heat treating process.

MH:  Right.  But when you heat and quench those parts, they also have different properties, as well.

DG:  Is it only steels that can be hardened?

MH:  I'm not an expert on it, but there are other types.  There are some stainless steels – martensitic stainless steels – and there are different age hardening steels… which are still steels.  There is aluminum, which has different properties depending upon what other elements they put in that; they can do some different types of hardening on those.  Titanium by itself is a fairly hard metal, etc.  Most of the people that we deal with, or whom we're talking about, are the people who are using steels to start with, a lot of times fairly inexpensive steels.  But, we also, in vacuum furnaces, do very high-end steels, such as tool steels, like H13 air hardenable tool steels, etc.

DG:  Let's jump back to steels.  What are the typical heat treatment processes that enhance hardness, that increase the hardness?

Microstructure of the carburized steel.
Source: Surface Hardening Vs. Surface Embrittlement in Carburizing of Porous Steels - Scientific Figure on ResearchGate. Available from: https://www.researchgate.net/figure/Microstructure-of-the-carburized-steel_fig2_326653574 [accessed 3 Mar, 2021]
MH:  First of all, we have carburizing.  As we spoke before, when you have a steel and you impart carbon into that steel, it tends to make it harder.  What carburizing does, is it focuses that effort of putting carbon only into the surface.  This means that you can have different core properties of that steel versus the outer properties.  Then you can drive that carbon fairly deep into the surface, if you want.  Now, deep means something like 2 mm, and above that are starting to get fairly deep cases.  2 millimeters is .079 inches.  You do this by putting the part, at austenizing temperatures, into an atmosphere which is rich in carbon.DG:  Let's stop here to define.  Again, this is a non-technical definition of austenizing.  To me, when I think of an austenizing temperature, that means even though that part is still “solid”, the fact of the matter is, that piece of metal is kind of in solution; things are moving around inside.MH:  You've changed the structure.  Then, when you quench it, you're trying to cool it very quickly so that you can get different structures out of that steel.We're talking here surface hardening or surface engineering.  There are quite a few, actually.  Some of the more common, obviously, are the ones we talked about here.  There are basically four very common ones:  carburizing, nitriding, carbonitriding, and nitrocarburizing.  They are different.  (Although, in Europe, sometimes they reverse those names a little bit between carbonitriding and nitrocarburizing.)  I'll explain to you what, I believe, those are and why we call them that.

Carburizing is just as I was saying: driving carbon into the surface of the steel.  It gets a very high hardness in the steel, depending upon what type of steel you have.  It's typically done with lower carbon steels so that you can put the carbon into the surface.  That's why we do it, because it's a lower carbon steel.

Nitriding is not an austenitic process; it is a lower temperature process.  It's called a ferritic process.  What that means is you don't go into the phase transformation where you have to go and quench the steel to get those properties.  You're not going to get much in the way of dimensional shift or growth that you would get from the austenizing steel, and that's very beneficial.  By driving nitrogen into the surface, you get a very high hardness.  Now, you also need to have things in that surface of the steel other than just iron.  You have different alloying elements which combine very easily with nitrogen, such as chromium, titanium, aluminum, vanadium, and some of those other things which will combine with the nitrogen, which either comes from an excited nitrogen atom via ion nitriding or comes from the disassociation of ammonia from gas nitriding where the nitrogen then transports itself into the steel surface and making those hard items.

[blocktext align="left"] “Nitriding is not an austenitic process; it is a lower temperature process.  It's called a ferritic process.  What that means is you don't go into the phase transformation where you have to go and quench the steel to get those properties.”[/blocktext]

In carbonitriding, it's identical to carburizing except you throw some ammonia in there.  This is typically done at a lower temperature because ammonia breaks down very quickly at high temperature, so you're trying to stay right at the lower edge of that.  You're throwing ammonia in there because the nitrogen will impart a very hard surface along with the carbon.  It doesn't go in as deep but it's usually done as a 'down and dirty' very hard surface on a part, typically, a fairly inexpensive part.

Nitrocarburizing is like nitriding, but the focus is on the white layer, on the compound zone, which is a very hard layer of iron nitrides and iron nitrogen carbides.  You get a very hard layer.  They call it the compound zone because you have both a gamma prime zone, which is one element, and you have an epsilon zone, and those have very unique properties for the surface of the steel.

DG:  Those are the main carburizing processes – carburizing, nitriding, carbonitriding, and nitrocarburizing.  We'll dig deeper into those in our next episode, and also cover the processes, perhaps the types of equipment that those processes are done in, just for a little bit more education.  Then, we’ll do a third episode where we'll talk about why we're hearing more recently about nitriding, low pressure carburizing, and single piece flow – and perhaps something that is near and dear to your heart, Mark, and that is some hybrid systems of a batch interval quench, which your company happens to call the Super IQ. Thanks for being here today.

Doug Glenn, Publisher, Heat Treat Today

Doug Glenn, Heat Treat Today publisher and Heat Treat Radio host.


To find other Heat Treat Radio episodes, go to www.heattreattoday.com/radio and look in the list of Heat Treat Radio episodes listed.

Heat Treat Radio #49: Metal Hardening 101 with Mark Hemsath, Part 1 of 3 Read More »

Nitrocarburizing for Automotive and Large-Volume Production

Mark Hemsath

Conventional wisdom says that batch processing is for smaller volumes. Anytime large volumes of 1 million or more parts per year are envisioned, for instance with ferritic nitrocarburizing, the go-to technology is a roller hearth or other continuous systems like rotary retort or mesh belt furnace. In this article, which originally appeared in Heat Treat Today’s June 2019 Automotive print edition, Mark Hemsath urges end-users and engineers who use, or specify, continuous systems to not undervalue automated batch processing for large volume production.


There are a number of trends in the automotive arena:

  • More parts are being light-weighted. This means they need more precise and repeatable heat treating.
  • Parts need to be cheaper and lighter. The trend we see are increased and more sophisticated stampings.
  • The trend is away from carbonitriding and toward ferritic nitrocarburizing due to less distortion on lighter parts.
  • Gears and such are smaller and require exact carburizing, minimized quench distortions, and less hard machining.

A deep discussion of all of these is beyond this article, but we will touch on each as we focus on nitrocarburizing for large-volume production.

Batch v. Continuous

What is the difference between a classic “batch” furnace and a classic “continuous” furnace? The answer is material handling. By definition, heat treating is a “batch” operation. In virtually all instances, the product must be brought to temperature and held—or “soaked”—for a specific time. Ferritic nitrocarburizing is no different. This ramp heat, hold, and cool is a “batch”. Thus, virtually all heat treating is batch and only material handling is the difference. The basic difference is that in batch we move the product in its cold state and heat it in one place (batch). In continuous furnaces, we move it while it is heating.

Advances in Material Handling

Figure 1: Roller hearth conveyor furnace with heating section, cooling tunnel and after cooling. Note the right angle turn via automatic conveyors to meet space requirements.

Advanced, fully automated, and reliable material handling has made great advances over the last two decades from more recent industries like Amazon, where millions of packages need to be moved through the shipping process, to older industries like heat treating which moves steel parts through furnaces and other equipment. Automation, such as conveyors with self-driven rollers and photo sensors or proximity switches, or robots and automated self-guided vehicles—all coordinated by a PLC—have made material handling more reliable. Manufacturers have a lot of options.

A continuous furnace like a roller convey-or—or “roller hearth”—furnace conveys the product while it is heating (Figures 1, 5 & 8). A mesh belt furnace conveys parts while heating, and a rotary retort furnace (Figure 4) moves parts via a heated rotating barrel to the next process step which is typically cooling or quenching. Moving parts while hot is a challenge, but reliable high volume heat treating is why these furnaces have seen such success over the years. Roller furnaces and rotary retort furnaces are still built and used in a wide variety of industries, and they make sense for a number of reasons. Lower energy use is one main factor.

With robots placing the load, both batch and continuous processes can be fully automated. With such options, batch processing has increased in use.

Automated Batch

Figure 2: The doors have actuators for automatic opening.

A leading manufacturer of heat treating furnaces has implemented the high volume automation approach many times using batch technologies. In 2013, a fully automated batch FNC installation for gears was installed for processing 1 million gears annually.[1] As a result of this success, the customer added more batch furnaces to the line.

The furnaces in Figures 2 and 3 are retort-based nitriding and ferritic nitrocarburizing furnaces. With automatically opening doors, complete PLC control, and automated batch load movement, no humans are needed. A load car operates in both directions for a heavy load of two metric tons or more, allowing furnaces to be placed facing each other.

Automated, High-Volume System Design

Figure 3: This line consisted of pre-oxidizing ovens on one side to save time in the more expensive FNC furnaces. Cooling stations after heating are also added to reduce time in the batch furnace and make the parts safe for handling.

As mentioned, the company supplied nitrocarburizing technology using its ZeroFlow™ method (Figures 2 and 3) for an automated thermal treatment line for the production of a variety of gears. The line consisted of six large, front-loaded retort-style batch furnaces, a four-chamber vacuum washer, two ovens for pre-activation in air, additional post-cooling of the furnace charges, and an automatic robotic loader/unloader, which ensured charge transport within the system (seen in Figure 3). The automated line also included safety monitoring. System workload dimensions were 32″ wide x 32″ high x 60″ long with a gross workload capacity of 4,400 pounds. Production totaled 2,000 pounds of gears per hour. Good equipment design, retort technology, and use of ZeroFlow control technology resulted in a very successful project.

Cooling the Load and Vacuum Purging

Figure 4: Whirl-Away Quench on a Rotary Retort line for small part efficient quenching/cooling.

There are advantages to continuous furnaces like a conventional roller hearth furnace; however, special options like fast cooling and vacuum purging present challenges to these conventional furnace designs. In batch, this is usually not a problem. Vacuum (and even cooling) is more difficult to attempt in continuous variations due to sealing challenges in the chamber designs. An example of a good solution is the rotary retort furnace shown in Figure 4, which offers single piece quenching where each piece falls into a water or oil quench and is “whirled-away,” a continuous furnace design which works well for small parts with a relatively small footprint. In batch, the whole load needs to be quenched together; this can present challenges that understanding the part needs and configurations can lead the process engineer to different solutions.

In a roller furnace, slow cooling means the furnace gets longer (Figure 1).

Variations in Continuous Batch – Semi-Continuous Processing

Figure 5: Hardening roller conveyor furnace with integral pre-heat and oil quench system

In Figure 6, an automated batch hardening line is shown. In Figure 7, the same process is shown, but with an added pre-heat chamber to allow faster processing via the pre-heat and use the single quench in a more productive manner. An oil quench is an expensive piece of equipment. The cycles are also always much shorter for quenching than heating, so we want to maximize the use of the quench. In a pure batch system, you need one quench per furnace. In the semi-continuous approach, the quench is used more frequently and there is higher productivity per capital dollar invested. In a roller hearth or rotary retort installation, the quench can be properly sized to handle all of the heating production. In an installation using pure batch systems, there might be 3 to 6 quench tanks. In a fully continuous roller furnace, there would be one quench (see Figure 5).

Figure 6: This automated batch line is for low pressure carburizing and vacuum hardening, with oil quench, automated washer, and batch temper furnace. The smart loader makes the cell fully automated.

Case History and Take-Aways

The automated batch system referred to in Figures 2 and 3 went online in 2014 and is currently operating at full capacity, while meeting the stringent requirements of the automotive industry. It achieved the planned production goal of 1 million gears per year with 99% process reliability and 98% equipment availability. The customer previously had a continuous conventional pusher furnace. The new line achieved an 80% reduction in the consumption of ammonia from that consumed using in the pusher furnace to nitrocarburize. Endothermic gas was also eliminated by the supply of a new methanol CO generator as the carbon source in the process.[1]

Figure 7: Triple chamber vacuum hardening line with oil quench and pre-heat chamber. Tray flow is right to left.

The take-away from this successful project is that in order to increase production even more, automated batch systems need to exhibit two factors to compete with a continuous system like a roller hearth furnace. First, the loads need to be optimized and very densely packed. Second, the batch loads need to be larger than the continuous loads. A standard size of 40″ x 40″ x 60″ has since been created which has 50% more volume than the unit in the example above. Making the furnace a bit larger is not that difficult. Additionally, in a recent application, CFC tooling has been utilized to assure more dense loading geometry with much lighter parts, giving reliable rack geometry for a load of 1,000 pieces.

Gas Usage – Benefit Batch

Figure 8: Cooling tunnel and exit of continuous roller hearth furnace for instrument transformer electrical steels annealing.

The biggest advantage of batch furnaces is the lower process gas usage. In continuous furnaces, in order to keep the process safe and clean, pressure must be maintained by flowing a significant volume of gases. With the constant opening of doors during the process and the need to keep operating pressures high enough to prevent air infiltration, atmosphere gas usage is always high. To keep the costs down, gases are typically generated with the use of an endothermic generator (40% Nitrogen, 40% Hydrogen, and 20% CO) or a lean exothermic generator with a low dewpoint. In all instances, the generator is another piece of thermal equipment to maintain and purchase.

Energy Costs – Benefit Continuous

In most instances, batch processing uses more energy—or more expensive energy—such as electricity. Electricity costs can vary tremendously from location to location whereas natural gas prices are more consistent and lower. Batch nitriding furnaces are available in gas-fired heating options at an added capital cost. However, the batch process still uses more energy per pound. If electricity is available at a reasonable rate, then the difference is not as great on a per pound basis. In a recent analysis, it was estimated that an electrically heated batch system came to cost the equivalent of about $0.06 per pound of FNC operating costs, versus $0.03 per pound of FNC operating costs in a continuous gas-fired variation (energy and consumables only).

Summary

Batch or continuous in large volume scenarios is no longer a clear-cut answer. Your heat treating professional and your furnace suppliers should understand this. There are literally dozens of variables that need to be assessed, and only after a careful analysis tailored for each customer can an optimized solution be designed with either batch or continuous furnace solutions.

Notes

1. Hemsath et al, “Nitrocarburizing Gears using the ZeroFlow Method in Large-Volume Production”, Thermal Processing, 10/2015

About the Author: Mark Hemsath is Director of Nitriding and Special Vacuum Furnaces at SECO/VACUUM Technologies, LLC and acting Thermal General Manager at SECO/WARWICK Corp. in Meadville, Pennsylvania. With 30 years of experience in the industrial furnace and heat treat equipment market, he is in charge of all North American atmosphere furnace sales, gas nitriding, and gas carburizing. This article originally appeared in Heat Treat Today’s June 2019 Automotive print edition and is published here with the author’s permission.

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A Baker’s Dozen Quick Heat Treat News Items to Keep You Current

A Baker’s Dozen 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

  • Based in Lima, Ohio, Heat Treating Technologies recently installed its third heat treating furnace as the final step of a $3 million expansion project, to be used to process parts for agriculture and automotive industries.
  • Mark Hemsath has been hired as director of nitriding and special vacuum furnaces at SECO/VACUUM Technologies, LLC. Hemsath has previously worked with SECO/WARWICK Corp. and Advanced Heat Treat Corporation in Waterloo IA, and operated his own heat treat furnace manufacturing and alloy fabricating company. He will be the primary contact for gas nitriding furnace applications in North America and will handle special vacuum furnace products throughout North America.
  • The new president and chief executive officer of Norsk Titanium AS, an aerospace-grade titanium components manufacturer based in Plattsburgh, New York, will be Michael J. Canario.
  • A company that manufactures high-temperature refractories and specializes in the toll firing business serving a variety of industries such as aerospace, automotive and petrochemical recently completed the task of relining the bricks on one of their roller hearth kilns, which can now reach greater operating temperatures – up to 2,650 ºF (1,454ºC). In addition, Ipsen Ceramics has also announced a collaboration with ceramics distributor, Carpenter Brothers, based in Milwaukee, Wisconsin.

Equipment Chatter

  • PJSC Magnitogorsk Iron and Steel Works’ (“MMK”) most powerful unit, hot-rolled products Mill 2000, produced 527,500 tonnes of metal in May 2018, setting an all-time record for monthly output. It was the highest production volume at the mill since its commissioning in 1994, beating the previous monthly record of 526.2 ths tonnes set in January 2015.
  • Solar Atmospheres of Western PA recently continued its merit status for NADCAP Nondestructive Testing for penetrant inspection. Solar Atmospheres specializes in Method A (water washable) Fluorescent Penetrant inspection and is able to accommodate parts of varying sizes in their world class NDT cell. Solar has its own in-house Level 3 inspector as well as six Level 2 inspectors and one Level 1 inspector.
  • Professional fastener manufacturer ARP is celebrating its 50th anniversary in 2018. “It was 1968 when Gary Holzapfel—whose background was in aerospace fastener manufacturing—developed some bolts and studs for his racer friends that were a marked improvement over what was available at the time. This lead to the founding of Automotive Racing Products Inc. … ARP proudly does everything in-house, which includes engineering, R&D, forging, heat-treating, machining, finishing, packaging and distribution in its ISO 9001:2008 and AS9100 registered California facilities.”

Heat Treat Today celebrates with our heat treatment industry partners by highlighting their accomplishments and announcements 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.

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