Bhuj Polymers, an established precision components manufacturer, is expanding its manufacturing capabilities through the acquisition of a state-of-the-art vacuum furnace. This investment will enable the company to meet growing demands while providing advanced vacuum hardening services that comply with global quality standards.
Maciej Korecki Vice President of Vacuum Business Segment SECO/WARWICK
SECO/WARWICK, a heat treat solutions provider with locations in North America, supplied the vacuum furnace that will be used to process tool steels with high thermal requirements, such as H13, H11 and D2. Prior to this acquisition, production capabilities were constrained by existing equipment limitations. The company’s locally manufactured furnace operated with a cooling pressure of up to 4 bar. This specification prevented effective processing of components requiring high-pressure gas hardening. Increasing production loads and customer requirements prompted Bhuj Polymers to invest in next-generation vacuum technology.
“The furnace delivered combines 15-bar high-pressure gas cooling with perfect temperature uniformity and precise control of thermal processes. This solution meets NADCA (tool & die global standard) requirements and is ready for Nadcap (aerospace global standard) certification, enabling Bhuj Polymers to expand their manufacturing services to the most demanding customers from industries such as automotive and aerospace,” says Maciej Korecki, vice president of the Vacuum Segment of the SECO/WARWICK Group.
This installation represents a significant advancement in local manufacturing capabilities. As part of SECO/WARWICK’s strategy to strengthen local production competencies, the furnace was manufactured entirely in India, reducing logistical costs, increasing competitiveness, and eliminating challenges associated with global customs policy.
Arvind Agarwal Managing Director of SECO/WARWICK India
“Bhuj Polymers is a partner who trusted that our vacuum project, carried out entirely in India, was the correct solution for their manufacturing needs. This trust is of great value to us, as it opened a new chapter in the history of SECO/WARWICK India. This installation is an important step towards building a strong and independent technological infrastructure in India. We are pleased to be part of the growth of companies like Bhuj Polymers, who choose world-class technology produced locally,” said Arvind Agarwal, managing director of SECO/WARWICK India.
This event may serve as a significant impetus for other companies, not only in the state of Gujarat. This expansion demonstrates the importance of local production and support for manufacturers of aluminum die-casting molds, plastic processing tools, or precision components.
Press release is available in its original form here.
Nadcap certifications are integral to aerospace heat treating. Maintaining compliance, however, can be a headache. Learn how a new technology is streamlining Nadcap certifications.
This article by Chantel Soumis was originally published inHeat Treat Today’s March 2024 Aerospace Heat Treatprint edition.
Challenges to Capture Nadcap Certifications
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The Nadcap certification (National Aerospace and Defense Contractors Accreditation Program) plays a critical role in maintaining the integrity of heat treating processes, especially in the aerospace and defense industries. Recognized globally, the certification sets rigorous standards for heat treatment facilities, ensuring that heat treating processes produce parts and materials with the necessary strength, durability, and reliability.
The certification addresses the data that needs to be documented concerning all aspects of the heat treat processing, such as temperature control, process documentation, and quality management. A survey from the Performance Review Institute (PRI) indicates that 80% of aerospace and defense companies consider Nadcap accreditation as a requirement when selecting suppliers, and 90% of aerospace and defense prime contractors would disqualify a supplier without Nadcap accreditation. And when such a strict standard is implemented and then subject to regular audits, a 40% reduction in nonconformance costs are likely, as was reported by companies in the aerospace and defense sector in a study by the National Center for Manufacturing Sciences (NCMS).
While compliance with Nadcap and other heat treat certifications demonstrates a commitment to quality and opens doors to lucrative contracts with aerospace, defense, and other precision industries, actually capturing the data can be tedious. The effort and cost of employing disconnected systems — capturing measured data from system A, making the certification documents in system B, and then emailing the certification results to clients from system C — can be cut by synthesizing these actions into one system.
Digitizing Certification Management for Complete Compliance Control
Many organizations facilitate the certification process via digital means. This may be through the use of digital quality management systems (QMS) or enterprise resource planning (ERP) software that includes modules designed for certification management. These tools help automate record keeping, provide alerts for upcoming certification renewals, and streamline the overall certification tracking process, ensuring that heat treating operations remain compliant and efficient.
Nadcap Scanner tracking a process via QR code
But more should be done.
Veterans Metal, a metal finishing plant in Clearwater, Florida, was driving manual processes: everything was written down and data was being entered into spreadsheets for tracking purposes. Like many heat treaters, each step the company took to process a part required manual intervention to write down 20+ line items of information and then incorporate the associated data entry into spreadsheets.
The company was looking to modernize their plant.
After careful evaluation of Veterans Metal’s processes and needs, Steelhead Technologies developed and deployed the Steelhead Certification Scanner (or Nadcap Scanner) line that includes a handheld scanner and a system of QR codes to facilitate an easier user experience, including an interface that allows for swift operator proficiency, typically within minutes. This digital interface allows users to measure data, create certifications, and email this from the one system.
Smart Scanning in Action
The metal processing company received a 15-minute walk-through of the Nadcap Scanner, how to process parts, and where to find the data within the system. Using the handheld device, operators scanned QR codes (specifically created by Steelhead Technologies) that were placed on processing stations. As parts were moved from one process station to the next manually, a user would scan the accompanying QR code on the next current station, locking in data from the previous process and automatically reflecting that the next step was in process.
When operators scanned a process station, the device showed the remaining time in the process and displayed all parts being processed, custom instructions, and key data collection, such as oven temperature. This timer automatically starts when a process station QR code is scanned, gives a one minute warning when the process is nearing completion, and stops automatically when the next process station QR code is scanned.
Chet Halonen, a plant optimization expert for Steelhead Technologies, presented the “Powered by Steelhead” certification to the Veterans Metal team.
With the intuitive layout and guided steps, operators were easily able to navigate the accreditation process, significantly reducing time spent on extensive training. More importantly, the Nadcap Scanner line eliminated handwritten data entry, margin of error, and additional time needed to develop certifications since the scanner automatically generates them from the data and sends them to clients. The scanner has since been adopted by many other Nadcap-compliant operations across the United States.
Take Nadcap Digital
Achieving Nadcap accreditation is crucial for showcasing a commitment to quality, aligning with industry benchmarks, and accessing lucrative business opportunities. With the advent of digitized solutions like the Nadcap Scanner implemented within a comprehensive manufacturing ERP, companies will streamline the accreditation process, enhance operational efficiency, and bolster compliance with a system that’s “literally just button clicking,” as one manufacturer observed.
Embracing innovative tools not only saves time and resources, but also strengthens market positioning and client relationships. By merging the prestige of Nadcap accreditation with digital advancements, heat treaters can elevate their operations to reach new heights of excellence.
About the Author
Chantel Soumis, Head of Marketing, Steelhead Technologies
Chantel Soumis is serving as the head of Marketing at Steelhead Technologies. With a robust background in manufacturing technology and strategic partnerships, she leverages over 15 years of experience to shape the company’s marketing landscape.
For more information: Contact Chantel at chantel@gosteelhead.com.
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How often do you think about the intelligent designs controlling the thermal loop system behind your heat treat operations? With ever-advancing abilities to integrate and manage data for temperature measurement and power usage, the ability of heat treat operations to make practical, efficient, and energy-conscious change is stronger than ever. In part 1, understand several benefits of thermal loop systems and how they are leveraged to comply with industry regulations, like Nadcap.
This Technical Tuesday article by Peter Sherwin, global business development manager – Heat Treatment, and Thomas Ruecker, senior business development manager, at Watlowwas originally published inHeat Treat Today’sJanuary/February 2024 Air & Atmosphere Heat Treat print edition.
Introduction
Heat treatment processes are a crucial component of many manufacturing industries, and thermal loop solutions have become increasingly popular for achieving improved temperature control and consistent outcomes.
A thermal loop solution is a closed loop system with several essential components, including an electrical power supply, power controller, heating element, temperature sensor, and process controller. The electrical power supply provides the energy needed for heating, the power controller regulates the power output to the heating element, the heating element heats the material, and the temperature sensor measures the temperature. Finally, the process controller adjusts the power output to maintain the desired temperature for the specified duration, providing better temperature control and consistent outcomes.
Performance Benefits
Heat treatment thermal loop solutions offer several advantages over traditional heat treatment methods, including improved temperature control and increased efficiency. The thermal loop system provides precise temperature control, enabling faster heating and cooling and optimized soak times. In addition, the complete design of modern thermal loop solutions includes energy-efficient heating and overall ease of use.
Figure 1. Watlow Industry 4.0 solution (Source: Watlow)
Heat treatment thermal loop solutions are integrated with Industry 4.0 frameworks and data management systems to provide real-time information on performance. Combining artificial intelligence and machine learning algorithms can also provide additional performance benefits, such as the ability to analyze data and identify patterns for further optimization. Ongoing performance losses in a heat treatment system typically come from process drift s. Industry 4.0 solutions can explore these drift s and provide opportunities to minimize these deviations.
Heat treatment thermal loop solutions can be optimized using Failure Mode and Effects Analysis (FMEA). FMEA is a proactive approach to identifying potential failure modes and their effects, allowing organizations to minimize the risk of process disruptions and improve the overall efficiency of their heat treatment processes. Historically, this was a tabletop exercise conducted once per year with a diverse team from across the organization. Updates to this static document were infrequent and were primarily based on organization memory rather than being automatically populated in real time with actual data. There is a potential to produce “live” FMEAs utilizing today’s technology and leveraging insights for continuous improvement.
Th e effectiveness of heat treatment thermal loop solutions can be measured using metrics such as overall equipment effectiveness (OEE). OEE combines metrics for availability, performance, and quality to provide a comprehensive view of the efficiency of a manufacturing process. By tracking OEE and contextual data, organizations can evaluate the effectiveness of their heat treatment thermal loop solutions and make informed decisions about optimizing their operations.
Regulatory Compliance
Nadcap (National Aerospace and Defense Contractors Accreditation Program) is an industry-driven program that provides accreditation for special processes in the aerospace and defense industries. Heat treatment is considered a “special process” under Nadcap because it has specific characteristics crucial to aerospace and defense components’ quality, safety, and performance. Th ese characteristics include:
Process sensitivity: Heat treatment processes involve precise control of temperature, time, and atmosphere to achieve the desired material properties. Minor variations in these parameters can significantly change the mechanical and metallurgical properties of the treated components. This sensitivity makes heat treatment a critical process in the aerospace and defense industries.
Limited traceability: Heat treatment processes typically result in changes to the material’s microstructure, which are not easily detectable through visual inspection or non-destructive testing methods. Th is limited traceability makes it crucial to have strict process controls to ensure the desired outcome is achieved consistently.
Critical performance requirements: Aerospace and defense components often have strict performance requirements due to the extreme conditions in which they operate, such as high temperatures, high loads, or corrosive environments. The heat treatment process ensures that these components meet the specifications and can withstand these demanding conditions.
High risk: The failure of a critical component in the aerospace or defense sector can result in catastrophic consequences, including loss of life, significant financial loss, and reputational damage. Ensuring that heat treatment processes meet stringent quality and safety standards is essential to mitigate these risks.
Nadcap heat treatment accreditation ensures suppliers meet industry standards January/February and best practices for heat treatment processes. The accreditation process includes rigorous audits, thorough documentation, and ongoing process control monitoring to maintain high quality, safety, and performance levels.
The aerospace industry’s AMS2750G pyrometry specification and the automotive industry’s CQI-9 4th Edition regulations are crucial for ensuring consistent and high-quality heat treated components. Adherence to these regulations is essential for meeting the stringent quality requirements of the aerospace and automotive industries and other industries with demanding specifications.
Temperature uniformity is a crucial requirement of both AMS2750G and CQI-9 4th Edition, mandating specific temperature uniformity requirements for heat treating furnaces to ensure the desired mechanical properties are achieved throughout the treated components. AMS2750G class 1 furnaces with strict uniformity requirements +/-5°F (+/-3°C) provide both quality output and predictable energy use. However, maintaining this uniformity requires significant maintenance oversight due to all the components involved in the thermal loop.
Calibration and testing procedures are specified in the standards to help ensure the accuracy and reliability of the temperature control systems used in heat treat processes.
Detailed process documentation is required by AMS2750G and CQI-9 4th Edition, including temperature uniformity surveys, calibration records, and furnace classifications. This documentation ensures traceability, enabling manufacturers to verify that the heat treat process is consistently controlled and meets the required specifications.
Figure 2. Eurotherm data reviewer (Source: Watlow)
Modern data platforms enable the efficient collection of secure raw data (tamper-evident) and provide the replay and reporting necessary to meet the standards.
The newer platforms also offer the latest industry communication protocols – like MQTT and OPC UA (Open Platform Communications Unified Architecture) – to ease data transfer across enterprise systems.
MQTT is a lightweight, publish-subscribe-based messaging protocol for resource-constrained devices and low-bandwidth, high-latency, or unreliable networks. IBM developed it in the late 1990s, and it has become a popular choice for IoT applications due to its simplicity and efficiency. MQTT uses a central broker to manage the communication between devices, which publish data to “topics,” and subscribe to topics that they want to receive updates on.
OPC UA is a platform-independent, service-oriented architecture (SOA) developed by the OPC Foundation. It provides a unified framework for industrial automation and facilitates secure, reliable, and efficient communication between devices, controllers, and software applications. OPC UA is designed to be interoperable across multiple platforms and operating systems, allowing for seamless integration of devices and systems from different vendors. The importance of personnel and training is emphasized by CQI-9 4th Edition, which requires manufacturers to establish training programs and maintain records of personnel qualifications to ensure that individuals responsible for heat treat processes are knowledgeable and competent. With touchscreen and mobile integration, a significant development in process controls has occurred over the last decade.
Figure 3. Watlow F4T® touchscreen and Watlow PM PLUS™ EZ-LINK®
mobile application
By integrating these regulations into a precision control loop, heat treatment thermal loop solutions can provide the necessary level of control and ensure compliance with AMS2750G and CQI-9 4th Edition, leading to the production of high-quality heat treated components that meet performance requirements and safety standards.
Continuous improvement is also emphasized by both AMS2750G and CQI-9 4th Edition, requiring manufacturers to establish a system for monitoring, measuring, and analyzing the performance of their heat treatment systems. This development enables manufacturers to identify areas for improvement and implement corrective actions, ensuring that heat treat processes are continuously improving and meeting the necessary performance and safety standards.
To Be Continued in Part 2
In part 2 of this article, we’ll consider the improved sustainability outcomes, potential challenges and limitations, and the promising future this technology offers to the heat treat industry.
About the Authors
Peter Sherwin, Global Business Development Manager – Heat Treatment, WatlowThomas Ruecker, Senior Business Development Manager, Watlow
Peter Sherwin is a global business development manager of Heat Treatment for Watlow and is passionate about offering best-in-class solutions to the heat treatment industry. He is a chartered engineer and a recognized expert in heat treatment control and data solutions.
Thomas Ruecker is the business development manager of Heat Treatment at Eurotherm Germany, a Watlow company. His expertise includes concept development for the automation of heat treatment plants, with a focus on aerospace and automotive industry according to existing regulations (AMS2750, CQI-9).
For more information: Contact peter.sherwin@watlow.com or thomas.ruecker@watlow.com.
This article content is used with the permission of heat processing, which published this article in 2023.
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In December 2022, the first HIP batch on Latin American soil was performed. The journey to success in HIP, as any HIP user will agree, is a bumpy road. What are the challenges that aerospace manufacturers with in house heat treating should be aware of when considering HIP processing? Learn how HT-MX Heat Treat & HIPing — the heat treater who ran the first HIP batch in Latin American history — navigated the transition from small tooling jobs to HIP processing for aerospace parts.
Read the English version of the article below, or find the Spanish translation when you click the flag above right!
This original content article, first published in English and Spanish translations, is found in Heat Treat Today's March Aerospace Heat Treatingprint edition.
Writing this story as the first Latin American company to offer Nadcap accredited hot isostatic pressing brings a flood of memories and images to mind. HT-MX’s beginnings were simple, but also filled with challenges, failures, and lessons. When the company began, we were certain that, though small, we were still a “heat treat plant” and not just a shop.
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Being located in Mexico means that there were large companies with headquarters located far away — potential customers — that would be deciding on their heat treat supplier close to their location. We worked hard to be and to present ourselves as being very professional. But a lesson soon learned was that achieving trust with partners takes a lot more than a good speech and a clean plant.
Unsurprisingly, the first jobs were simple tooling work, like quench and tempering tooling and carburizing gears. A junior engineer and I would drive around in my old hatch-back to local machine shops and pick up a small shaft or gear and bring it back to the plant. We would get so excited when we got the case depth right.
With minimal resources, we decided to complete quality control ourselves. We became friends with a quality manager from a local company, and he came over to help on weekends and after 6:00pm until the audit date came. His knowledge is still in use at HT-MX to this day. I remember celebrating with a “Carne Asada” (a Mexican style barbecue) when we finished that first audit, thinking we had just made a huge step forward, not realizing how far away we still were from our vision.
HT-MX Team
Source: HT-MX Heat Treat & HIPing
But as time passed, we turned our attention to the aerospace industry in Chihuahua, a city with four OEMs. We received the AS9100 certification and started working on Nadcap accreditation. This required time, but by then, a pretty strong engineering team was in action, and successfully obtained Nadcap accreditation in late 2019. Again, we celebrated with a Carne Asada, this time, with a better understanding on where we were and what future challenges we needed to face.
Taking On Hot Isostatic Pressing
HIP system at HT-MX
Source: HT-MX Heat Treat & HIPing
The pandemic hit. Boeing’s 737 Max crisis continued to impact the industry. Moving into aerospace was slow with limited volume, especially compared to what we had seen in the automotive and oil and gas industry. But by now, international companies were more willing to transfer heat treat operations to Mexican suppliers, and we were ready, beginning with running aluminum batches, precipitation hardening, annealing, and other standard processes. It was during this early start to serve the aerospace industry that we heard about hot isostatic pressing (HIP).
Around 2019 during an aerospace cluster event, an OEM with a local presence approached us with their HIP requirements. I had only heard of HIP, but I was immediately interested — until I found out how much one of those machines cost!
But good financing through government programs helped make this HIP project a reality. Timing was not the best, as the federal election in Mexico caused a temporary Mexican currency depreciation, handicapping the project at its beginning.
Getting the proper certifications and validations proved to be a long and complex process, too. Theoretically, we knew what to expect, in terms of getting the Nadcap checklist approved, but the reality was a little different. Gaining Nadcap certification slowly builds a certain culture into any company in its day-to-day activities. Translating that culture into a completely different business unit, new crew, and new process proved to bring its own challenges.
HIP Challenges: Pressure, Temperature, Thermocouples, and Argon Supply
Heat treating usually handles temperature, atmosphere control (or lack of), and regular traceability requirements. HIP, however, adds a few new dimensions to what we usually see: internal pressure, very high temperatures — up to 3632°F (2000°C) — and argon supply. It was the first time HT-MX dealt with a process that incorporated up to 30,000 psi and also used a lot of high purity argon.
Pressure has its own challenges, though the HIP press takes care of those challenges. Still, the internal workings on these kinds of presses are fundamentally different than that of a regular heat treat furnace. Yes, you need to heat it up, but apart from that, it’s not even a furnace but a press. Understanding how the machine works, what happens inside with all that pressure, how it affects the components undergoing hot isostatic pressing, and how it affects the baskets you’re using is a critical learning curve.
High temperatures change everything about running these types of cycles. We work with metals, which means temperatures range between 1832°F and 2372°F (1000°C and 1300°C). This has an impact on thermocouple selection, calibration, and more; with the company’s thermocouple product suppliers based in the U.S., this entails more challenges and extra costs. I have lost count on those urgent same-day trips to the border to retrieve critical spares in time. It’s an 800-km/498-mi roundtrip! We have fortunately found a great supplier that has offered the technical feedback we needed, and we have started to finally understand and control our thermocouple consumption. Although, I must be honest here, we still have a lot to learn in this aspect.
Then, there’s the argon supply. HT-MX never expected it to be a challenge, but it turns out getting the proper supplier — one that understands the requirements and is willing to work with you from validation to production — is key. You might be able to start your validation process using argon transported in gas containers but eventually you will need to switch to liquid argon. That proved to be more difficult than expected. There are not many projects requiring these kind of alliances locally. Getting the right supplier was key and more of a challenge than expected. And then came the lessons on efficiently using the liquid argon, avoiding excessive venting of the tank, and being all around smart with the HIP schedule. This has been a constant learning process, one that has high costs.
Final Hurdles: Certifications, Current Events, and Energy Costs
Once our company had the Nadcap certification, we still needed to get the OEM’s approval for the HIP process, then the approval for the specific version of the HIP process, and then the actual approval for the part numbers.
These approvals were handled by the headquarters’ engineering department and not locally. It was a time-consuming process, with several test runs, lab testing, multiple audits, visits, and more testing, etc. And while all of this was happening, we still had to design the operation, locate critical suppliers not available in Mexico, create alliances with suppliers, etc. Writing this down in a few lines makes it seem simpler and quicker than it really was.
Additionally, in instances like this, Mexican companies, especially small ones, face much more scrutiny than U.S. or European-based companies, and must prove themselves in every single step. It makes sense, even if it feels a little unfair, as HT-MX had no proven track record of high tech processes such as HIP. It does cost extra time, extra care, and sometimes extra testing, but it is the reality we face and we must overcome the extra hurdles.
While navigating HIP approval, the pandemic hit. Months later, the war in Europe began with significant impacts on the cost of energy. Our main clients were high volume and low margin, and with energy prices rising, our competitiveness began to diminish. To adapt and evolve, we decided to add some smaller furnaces for smaller parts, invest in training and increased sales efforts, and focus on AMS/Nadcap-based customers, letting go of major clients. Slowly, things began to turn around.
The First Official HIP Batch in Latin America History
In December 2022, HT-MX ran the first official HIP batch in Latin American history. It was a long time coming. I always thought that running that first batch would feel like reaching the Everest summit. When the day came, it just felt like reaching Everest’s base camp. We still have a long way to go to be truly an established HIP supplier. Now, it’s back to climbing and shooting for that summit, that summit that will perpetually precede the next summit.
There are still several challenges: stabilizing new processes and improving established ones. But I am confident we will move forward in this new stage. And I am so looking forward to the next Carne Asada.
About the Author: Humberto Ramos Fernández is a mechanical engineer with a master’s degree in Science and Technology Commercialization. He has over 14 years of industrial experience and is the founder and current CEO of HT-MX Heat Treat & HIPing, which specializes in Nadcap-certifi d controlled atmosphere heat treatments for the aerospace, automotive, and oil and gas industries. With customers ranging from OEMs to Tier 3, Mr. Ramos has ample experience in developing specific, high complexity secondary processes to the highest requirements.
En diciembre de 2022, se realizó la primera horneada de HIP en suelo latinoamericano. El camino hacia el éxito en HIP, como cualquier usuario de HIP estará de acuerdo, es un camino lleno de baches. ¿Cuáles son los desafíos que deben tener en cuenta los fabricantes aeroespaciales con tratamiento térmico interno al considerar el procesamiento HIP? Aprenda directamente de HT-MX Heat Treat & HIPing, un tratador térmico que ejecutó la primera horneada de HIP en la historia de Latinoamérica, cómo navegaron la transición desde trabajos pequeños de herramentales hasta el procesamiento HIP para piezas aeroespaciales.
Read the Spanish translation of this article in the version below, or see both the Spanish and the English translation of the piece where it was originally published: Heat Treat Today's March Aerospace Heat Treating print edition.
Si quisieras aportar otros datos interesantes relacionados con HIP, nuestros editores te invitan a compartirlos para ser publicados en línea en www.heattreattoday.com. Puedes hacerlos llegar a Bethany Leone al correo bethany@heattreattoday.com
De herramientas simples al tratamiento térmico aeroespacial
Humberto Ramos Fernández Founder and CEO HT-MX
Escribir esta historia de como llegamos a ser la primera compañía latinoamericana en ofrecer prensado isostático en caliente acreditado por NADCAP trae a la mente una avalancha de recuerdos e imágenes. Los comienzos de HT-MX fueron simples, pero también llenos de desafíos, fracasos y lecciones. Cuando comenzamos la compañía, estábamos seguros de que, aunque éramos pequeños, éramos una “planta de tratamiento térmico” y no solo un taller.
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Estando ubicados en México quiere decir que hay grandes plantas con corporativos lejos de aquis — clientes potenciales — que estarían decidiendo sobre su proveedor de tratamiento térmico lejos de nuestra ubicación. Trabajamos arduamente para ser y presentarnos como profesionales y confiables. Pero pronto aprendimos que lograr la confi anza con los clientes requiere mucho más que un buen discurso y una planta limpia.
Como era de esperar, los primeros trabajos fueron trabajos simples de herramentales, algunos templados y revenidos de herramentales y carburizado de engranes. Recuerdo como un ingeniero junior y yo dábamos la vuelta en mi viejo hatchback alrededor de talleres locales y recogíamos un pequeño eje o engranaje y lo llevábamos de regreso a la planta. Nos emocionábamos mucho cuando lográbamos la profundidad de capa correcta.
HT-MX Team Source: HT-MX Heat Treat & HIPing
Con recursos mínimos, decidimos implementar el sistema de calidad nosotros mismos. Nos hicimos amigos de un gerente de calidad de una empresa local, venía a ayudarnos los fines de semana o después de las 6:00 p.m. hasta que llegó la fecha de la auditoría. Su enseñanzas aún se usan en HT-MX hasta el día de hoy. Recuerdo celebrar con una “Carne Asada” cuando terminamos esa primera auditoría, pensando que habíamos dado un gran paso adelante, sin darme cuenta de lo lejos que aún estábamos de nuestra visión.
Con el tiempo, dirigimos nuestra atención a la industria aeroespacial en Chihuahua, una ciudad con cuatro OEMs. Recibimos la certificación AS9100 y comenzamos a trabajar en la acreditación NADCAP. Esto requirió tiempo, pero para entonces contábamos con un equipo de Ingenieros bastante sólido y obtuvimos con éxito la acreditación de NADCAP a finales de 2019. Nuevamente, celebramos con una Carne Asada, esta vez con una mejor comprensión de dónde estábamos y qué futuros desafíos tendríamos que enfrentar.
Entrándole al Prensado Isostático en Caliente
La pandemia llegó. La crisis del 737 Max de Boeing continuó afectando a la industria. Empezar en sector aeroespacial fue lento y con un volumen limitado, especialmente en comparación con lo que habíamos visto en la industria automotriz y de oil&gas. Pero para entonces, las empresas internacionales estaban más dispuestas a trasladar las operaciones de tratamiento térmico a proveedores mexicanos, y estábamos listos, comenzando a procesar aluminio, endurecimiento por precipitación, recocido y otros procesos estándar. Fue durante estos inicios en la industria aeroespacial que escuchamos hablar del prensado isostático en caliente (HIP) por primera vez.
Alrededor de 2019, durante un evento del Cluster Aeroespacial de Chihuahua, un OEM con presencia local se acercó a nosotros con sus requerimientos de HIP. No conocíamos mucho de HIP, pero de inmediato me interesé . . . ¡hasta que descubrí cuánto cuesta una de esas máquinas!
Pero un buen financiamiento a través de programas gubernamentales ayudó a hacer realidad este proyecto de HIP. El momento no fue el mejor, ya que las elecciones federales en México causaron una depreciación temporal de la moneda mexicana, lo que obstaculizó el proyecto al principio.
HIP system at HT-MX Source: HT-MX Heat Treat & HIPing
Obtener las certificaciones y validaciones adecuadas resultó ser un proceso largo y complejo también. Teóricamente, sabíamos qué esperar en términos de obtener la aprobación para el checklist de NADCAP, pero la realidad fue un poco diferente. Obtener la certifi cación de NADCAP construye lentamente una determinada cultura en cualquier empresa en sus actividades diarias. Traducir esa cultura a una unidad de negocio completamente diferente, con un nuevo equipo y un nuevo proceso, demostró traer sus propios desafíos.
Retos en el HIP: presión, temperatura, termopares y argon
El tratamiento térmico generalmente trata de temperatura, control de la atmósfera (o la falta de ella) y los requisitos regulares de trazabilidad. HIP, sin embargo, agrega algunas dimensiones nuevas a lo que normalmente vemos: presión interna, temperaturas muy altas, de hasta 3632°F (2000°C) y suministro de argón. Fue la primera vez que HT-MX lidiaba con un proceso que incorporaba hasta 30,000 psi y también usaba mucho argón de alta pureza.
La presión tiene sus propios desafíos, aunque la prensa de HIP se encarga de ellos. Aún así, el funcionamiento interno en este tipo de prensas es fundamentalmente diferente al de un horno de tratamiento térmico regular. Sí, necesitas calentarlo, pero aparte de eso, no es ni siquiera un horno, sino una prensa. Comprender cómo funciona la máquina, qué sucede dentro con toda esa presión, cómo afecta a los componentes sometidos a prensado isostático en caliente y cómo afecta a las canastas y fi xtures que estás utilizando, es una curva de aprendizaje crítica.
Las altas temperaturas cambian todo sobre el funcionamiento de estos tipos de ciclos. Trabajamos con metales, lo que significa que las temperaturas oscilan entre 1832°F y 2372°F (1000°C y 1300°C). Esto tiene un impacto en la selección de termopares, calibración y más; con los proveedores de termopar basados en EUA, esto implica más desafíos y costos adicionales. He perdido la cuenta cuantos viajes urgentes de ida y vuelta por refacciones a la frontera he hecho. ¡Es un viaje redondo de 800 km! Afortunadamente, hemos encontrado un gran proveedor que nos ha ofrecido la retroalimentación técnica que necesitábamos, y finalmente hemos comenzado a comprender y controlar nuestro consumo de termopares. Aunque, debo ser honesto aquí, todavía tenemos mucho que aprender en este aspecto.
Luego está el suministro de argón. En HT-MX nunca esperamos que fuera un desafío, pero resulta que conseguir el proveedor adecuado, un que entienda los requisitos y esté dispuesto a trabajar contigo desde la validación hasta la producción, es clave. Es posible que puedas iniciar tu proceso de validación usando argón transportado en contenedores de gas, pero eventualmente necesitarás cambiar a argón líquido. Eso resultó ser más difícil de lo esperado. No hay muchos proyectos que requieran este tipo de alianzas a nivel local. Conseguir el proveedor adecuado fue clave y resultó ser un desafío mayor de lo esperado. Y luego vinieron las lecciones sobre cómo utilizar eficientemente el argón líquido, evitar el excesivo venteo del tanque y ser inteligente con el calendario de HIP en general. Esto ha sido un proceso de aprendizaje constante, uno que tiene altos costos.
Últimos obstáculos: certificaciones, eventos globales y costos energéticos
Una vez que nuestra empresa obtuvo la certificación NADCAP, todavía necesitábamos la aprobación de los OEM para el proceso HIP, luego la aprobación para la versión específica del proceso HIP y luego la aprobación real para los números de parte.
Estas aprobaciones fueron manejadas por el departamento de ingeniería del corporativo y no localmente. Fue un proceso que consumió mucho tiempo, con varias pruebas, pruebas de laboratorio, múltiples auditorías, visitas y más pruebas, etc. Y mientras todo esto sucedía, todavía teníamos que diseñar la operación, localizar proveedores críticos que no estaban disponibles en México, crear alianzas con proveedores, etc. Escribir esto en pocas líneas parece más simple y rápido de lo que realmente fue.
Además, en casos como este, las empresas mexicanas, especialmente las pequeñas, enfrentan mucho más escrutinio que las empresas estadounidenses o europeas, y deben probarse en cada paso. Tiene sentido, aunque se siente un poco injusto, ya que HT-MX no tenía un historial comprobado de procesos de alta tecnología como HIP. Cuesta tiempo extra, cuidado adicional y a veces pruebas adicionales, pero es la realidad que enfrentamos y debemos superar los obstáculos adicionales.
Mientras navegábamos en la aprobación de HIP, llegó la pandemia. Meses después, comenzó la guerra en Europa con impactos significativos en el costo de la energía. Nuestros principales clientes eran de alto volumen y bajo margen, y con el aumento de los precios de la energía, nuestra competitividad comenzó a disminuir. Para adaptarnos y evolucionar, decidimos agregar algunos hornos más pequeños para piezas más pequeñas, invertir en capacitación y aumentar los esfuerzos de ventas y enfocarnos en clientes basados en AMS / NADCAP, dejando ir a clientes principales. Poco a poco, las cosas comenzaron a mejorar.
La Primera Horneada Ofi cial de HIP en la Historia de Latinoamérica
En diciembre de 2022, HT-MX llevó a cabo la primera horneada oficial de HIP en la historia de Latinoamérica. Tomo bastante tiempo. Siempre pensé que hacer esa primera horneada se sentiría como llegar a la cima del Everest. Cuando llegó el día, solo se sintió como llegar al campamento base del Everest. Todavía nos queda mucho camino por recorrer para ser realmente un proveedor de HIP establecido. Ahora, volvemos a escalar y apuntamos a esa cima, esa cima que perpetuamente precederá a la próxima cima.
Todavía hay varios desafíos: estabilizar nuevos procesos y mejorar los establecidos. Pero estoy seguro de que avanzaremos en esta nueva etapa. Y estoy muy emocionado por la próxima Carne Asada.
Acerca del Autor:Humberto Ramos Fernández es un ingeniero mecánico con una maestría en Ciencia. Tiene más de 14 años de experiencia industrial y es el fundador y actual CEO de HT-MX Heat Treat & HIPing, que se especializa en tratamientos térmicos de atmósfera controlada, con certifi cación NADCAP, para las industrias aeroespacial, automotriz y de petróleo y gas. Con clientes que van desde OEM hasta Tier 3, el Sr. Ramos tiene una amplia experiencia en el desarrollo de procesos secundarios específi cos de alta complejidad para los requisitos más exigentes.
What is the connection between AMS2750 specifications and furnace classifications? With tight specifications, what does the heat treater need to know to be compliant? Follow along as we take a brief look into this often-overlooked topic.
This Technical Tuesday article, written by Douglas Shuler, owner and lead auditor, Pyro Consulting LLC, was first published in Heat Treat Today's March 2023 Aerospace Heat Treating print edition.
Doug Shuler Lead Auditor Pyro Consulting
AMS2750 is the specification that covers pyrometric requirements for equipment used for the thermal processing of metallic materials. AMEC (Aerospace Metals Engineering Committee) is one of the committees which oversees the changes and revisions of AMS2750. There are five main sections in the technical requirements of the specification: sensors, instrument calibrations, thermal processing classification, SAT (system accuracy testing), and TUS (temperature uniformity surveys). Additionally, there are quality provisions that detail what happens if a calibration or test is either past due or fails.1
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Revisions to the original requirements have occurred over the years, with the newest being Revision G. The structure of Revision G has carried over from Revision F and has remained the current structure of the AMS2750 specification. This structure includes furnace classes, which are based on the minimum requirements for temperature uniformity.
Furnace classes are defined in Figure A of Revision D Figure 1.
Figure 1. AMS2750G furnace class uniformity tolerances Source: Doug Shuler
Originally, furnace classes were based on temperature uniformity, but also subzero transformation, refrigerated storage of aluminum alloys, and embrittlement relief, Figure 2.
Figure 2. Original AMS2750 instrument accuracy requirements, no class structure Source: Doug Shuler
AMS2750 Revision C was released in May 1990 and started to implement the class and instrumentation type structure and differentiated between furnaces for heat treating parts versus furnaces for heat treating raw materials. Furnaces for heat treating parts were classified based on uniformity, but also on a readability requirement. Furnaces for heat treating raw materials were classified based on a readability requirement alone.
AMS2750 Revision D was released in September 2005 and continued to define equipment class (Figure A)* and instrumentation type (Section 3.3.1.1)*. It also clarified chart recorder resolution (Table 4)*, print and chart speed (Table 5)*, and testing frequencies for SAT (Tables 6, 7)* and TUS (Tables 8, 9)* for the processing of parts versus raw materials.
AMS2750 Revision E was released in July 2012 and continued to build on the clarity presented in Revision D by adding an instrumentation type table (Figure 3)* instead of a simple text description in the body of the specification.
Figure 3. AMS2750 Revision C: distinguishment between furnaces for heat treating parts versus raw materials Source: Doug Shuler
Moving to AMS2750 Revision F, the specification saw a major rewrite and restructuring where the tables were moved from the end of the document to the first area text that called out the specific table. Revision F also put into place a sunset date for analog instruments.
That brings us to the current revision of AMS2750, Revision G, which has carried forward the structure of Revision F and only sought to further clarify the intent of the requirements.
Over the years, the technology of sensor, instrument, and furnace manufacture and capability has continued to produce better and tighter controls for the process of heat treating. The evolution of AMS2750 has recognized these advancements and has kept pace with them in technology. The understanding of the origins of AMS2750 and how it has evolved is vital in understanding its application to today’s heat treat special processes.
*Specified figure, table, or section is associated with the AMS2750 revision being discussed.
About the Author: In 2009, Douglas (Doug) Shuler became the owner of Pyro Consulting LLC and also began working with Performance Review Institute (PRI), first as an instructor and course developer and later as an auditor for the Nadcap program. As a lead auditor for Nadcap, he has conducted over 380 Nadcap special process and aerospace quality management system audits on behalf of the Aerospace Primes over the past 10+ years. Doug continues to focus on instruction, training, and education for the heat treat industry, developing courses, authoring exams, and employing the PIE method: “Procedures that Include all requirements, and Evidence to show compliance.”
Heat Treat Today publishes eight print magazines a year and included in each is a letter from the publisher, Doug Glenn. This letter first appeared in Heat Treat Today's February 2023 Air & Atmosphere Furnace Systems print edition.
Doug Glenn Publisher and Founder Heat TreatToday
When dealing with temperatures in excess of 1000°F, one would think that a ±0.1°F variation would not be a big deal. Apparently, not!
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As of the most recent AMS2750 standard, 1/10th of a degree Fahrenheit matters — and if your process recorders are not recording temperatures down to 1/10th of a degree, you are out of compliance.
This is a big deal and a real hardship for many in the Heat Treat Today audience.
At the most recent Nadcap meeting held in Pittsburgh this last October, I had the chance to discuss this most recent stringent requirement with some of the people who were responsible for putting it in the standard. Even after talking to them, I’m not sure I fully understand why it is we went in this direction, and I’m not alone.
The Background
"the new AMS2750 standard requires accuracy to 1/10th of degree." Source: Heat TreatToday
Here’s a very short explanation of how we got here. Both Revision D and E of AMS2750 required compliance temperatures to be ±2°F or ±1.1°C (“or ±0.2%” was added in Revision E). That pesky “.1” in ±1.1°C appears to be the source of this most current “situation.” The folks using °C were recording temperatures down to 1/10th of a degree, while the folks using °F — which was not a small number of people — were
not. So, the standards committee needed to make a decision on what to do about this discrepancy. The options were to round up or down or to the nearest integer for both °F and °C people OR require EVERYONE to record their temperatures down to 1/10th of a degree. After surveying end-users, the committee decided that end-users wanted to be required to record the 1/10th of a degree rather than round it up or down to the nearest integer. Thus, the new AMS2750 standard requires accuracy to 1/10th of a degree.
Thoughts
Even as I type it, it doesn’t make sense. Why would end-users want to record temperatures down to 1/10th of a degree? If you’re at 1750°F, a full 1°F amounts to only 0.05% of your total temperature. It is inconceivable that 1% makes that much of a difference in nearly 100% of all standard heat treat processes. In those very few processes where temperature tolerances ARE required to be that tight, SAE’s AMEC committee could have come up with a separate standard.
Most temperature recorders and reporting devices don’t currently allow for the display of anything to the right of the decimal, especially above temperatures at or above 1000°F. That’s because no instrumentation company in the history of heat treating ever anticipated that end-users would want to know, much less be required to record, anything to the right of the decimal.
Even if recorders and other instruments were capable of displaying 1/10th of a degree readings, most temperature sensing devices are nowhere near that accurate. Special case T/Cs can do it in certain situations, but by and large, thermocouples are calibrated to ±2°F or higher. How much sense does it make to worry about recording 1/10th of a degree accuracy from a thermocouple (and wire) that is rated at ±2°F or ±5°F.
Let’s pretend for a minute that our thermocouples could accurately and consistently record temperatures down to 1/10th of a degree. The question that really needs to be asked is: Just because we CAN do it, does that mean we SHOULD do it? As stated earlier, for that vast majority of heat treatment processes a full degree of temperature variance won’t typically make a difference.
As some of the people I’ve talked to about this situation have readily admitted, well-intended quality committees such SAE’s AMEC committee, who have inadvertently started this little kerfuffle, are not perfect. This would be a case in point. The men and women who make up the heat treat industry’s quality systems are excellent people: highly detailed and well-motivated. But, as all of us are, they are prone to over-do the things they’re good at. In this case, that’s deciding to take it down to 1/10th of a degree when rounding to the next closest integer probably would have done the trick.
Postscript: I’m open to your responses to this column, positive or negative. And, assuming there is no foul language or threats of physical violence (!), we would be glad to publish your comments. Please let us know what you think: htt@heattreattoday.com
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The Metal Treating Institute (MTI) hosted a special meeting for members at the Embassy Suites by Hilton in Downtown Pittsburgh, PA, on Monday, October 17, to review key Nadcap and AMEC topics. During the meeting, members addressed challenges that heat treaters face in Nadcap/audit compliance, how to navigate audits more effectively, and what suggestions to present to the Nadcap committee so that heat treaters would be better equipped for audits.
MTI’s Technical Standards Committee Co-Chairs Bob Ferry, VP of Engineering and Quality at FPM Heat Treat, and Edward (Ed) Engelhard, VP of Corporate Quality at Solar Atmospheres, facilitated the meeting. It was hosted by Tom Morrison, CEO MTI Management, and Jim Orr, president of Penna Flame Industries and current president of MTI. Several attendees who made particularly significant contributions to the discussion were; Doug Shuler, lead auditor at Pyro Consulting, LLC; and Roy Adkins, director of Corporate Quality at Braddock Metallurgical and recipient of the 2022 MTI Award of Industry Merit.
A Room Full of MTI members Including (l-r): Doug Glenn, Ed Engelhard, Bob Ferry, and Doug Shuler
At the meeting, attendees identified the number one challenge in Nadcap/audit compliance is understanding and implementing new Nadcap revisions; a close second was the challenge of ensuring quality when auditors give different feedback. These challenges were addressed in the meeting, especially when discussing two specific topics: first, Auditee Advisories – Type P (Potential Product Impact) and Type C (Confirmed Product Impact) as well as Audit Observations.
Several key points that came out of these discussions were to (1) always read up on the most recent revisions in order to be confident in your compliance with quality standards; (2) be sure to reference objective evidence on the Nadcap Checklist questions to help facilitate the audit; (3) let the Nadcap auditor do their job but address any clarifications/follow-ups to the staff engineer immediately; (4) investigate immediately when receiving a Type P write-up so that you can ask the auditor to add a comment on the limits of that product impact; and finally (5) always push-back on findings that are clearly not valid so that they are “voided” by the Performance Review Institute (PRI).
Another main point of the meeting was to address AMS2750H, an update consisting of editorial and language updates for added clarity.
Lastly, the facilitators of the meeting addressed aerospace standard AS13100: AESQ Quality Management System Requirements for Aero Engine Design and Production Organizations. The standard seeks to harmonize and simplify supplier quality requirements among the major aero engine manufacturers, supplemental to standard AS9100. This standard is in the process of being flowed down to the supply chain and compliance is required January 1 of 2023, meaning that heat treaters have a couple months to get up to standard.
This special meeting happens each year during the October Nadcap meeting in Pittsburgh, PA. MTI encourages heat treaters to attend the Nadcap meetings to share their invaluable voice to guide industry standards.
Photo caption for main image: Jim Orr speaks to members of MTI.
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Shopping for a new heat treat vacuum furnace? Much thought and research goes into preparing for such an investment. Expanding heat treat capabilities or replacing current equipment are big decisions in business growth. Take the time to ensure wise decision making. This best of the web article helps examine what specifically is needed in the vacuum furnace purchase. Following these tips will help you make an informed and industry-savvy furnace purchase.
First, the article encourages knowing what the new furnace's "process and production" specifically will be. Next, a list of many of the furnace's capability options is examined. Finally, choices regarding technology on the furnace are presented.
"Always keep in mind your process, parts and industry regulations as you begin your research. Choosing a furnace is a big investment, one that, if chosen wisely, can streamline your processes and save critical time and resources."
Each Nadcap audit is different, but each accreditation involves key elements that help heat treaters maintain quality and safety standards. Finding instances of nonconformance and implementing corrective actions are two main ways the Nadcap process helps heat treaters keep a high standard. What are the steps needed to complete the Nadcap process?
In this best of the web article, read a break down of the entire Nadcap process. From practical tips like performing a few internal audits before submitting one for review to understanding the difference between minor and major nonconformances, this article will be your go-to on all things Nadcap.
An excerpt:
[blockquote author="" style="1"]Focusing on maintaining global quality standards not only helps ensure the safety of all who use these products, but also helps you continually improve and refine your heat-treatment processes to provide your customers with the best product quality possible.[/blockquote]
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