SECO/WARWICK

Eurometal S.A. Heat Treating Expands with Annealing Atmosphere Furnace

HTD Size-PR LogoEurometal S.A., member of the Eko-Świat Group and manufacturer of highly processed aluminum products, purchased an aluminum coil annealing atmosphere furnace. This solution will be used by the only rolling mill currently in operation in Poland, with Polish-owned equity.

The new equipment is the third for this client from the parent company of North American furnace manufacturer, SECO/VACUUM. The SECO/WARWICK solution will consist of a Vortex® furnace for aluminum coil annealing and will be equipped with an external cooling system. The by-pass cooler will be for cooling under a nitrogen atmosphere, and SeCoil® — the control and simulation software — enables aluminum coil manufacturers to significantly shorten the production cycle.

The SECO/WARWICK solution will be used by the only rolling mill currently in operation in Poland, with Polish-owned equity.

As a result, Eurometal S.A. will benefit from the system in energy saving, increased productivity, and improved the surface quality of the processed coils. The key feature of the system is the increased heat-transfer coefficient, due to directing the atmosphere at a high speed simultaneously on both sides of the coil.

Sławomir Woźniak, SECO/WARWICK Branded
Sławomir Woźniak
CEO
SECO/WARWICK
Source: secowarwick.com

Aluminum is an extremely plastic and light material, resistant to corrosion and many chemicals. Precise parameters of aluminum sheet enable its use for manufacturing various types of products and semi-finished mill products. Aluminum is used in the aerospace, automotive and machinery industries. Also, the construction sector uses aluminum sheet made with alloys characterized by high corrosion resistance and good forming ability. The ship building industry has also many applications for this alloy. Aluminum is certainly a crucial material for the development of many sectors.

"Aluminum replaces other conventional metals, in particular in modern state-of-the art products," commented Jarosław Śliwakowski, Eurometal S.A. "The automotive industry, with the dynamically growing share of aluminum, is at the forefront of replacing conventional metals[. . .] We have chosen Vortex due to the shortening of the total process time, even heating of the batch and reduced natural gas, protective atmosphere and electricity consumption in comparison with the products proposed by the competition."

"Eurometal has been our partner for many years," said Sławomir Woźniak, CEO of SECO/WARWICK Group. "[. . . ] From the very beginning, our cooperation has been based on trust. We always focus on approaching each order individually. We create a flexible system design, custom-made for the needs of a particular rolling mill."

Eurometal S.A. Heat Treating Expands with Annealing Atmosphere Furnace Read More »

Aalberts Surface Technologies Heat To Receive a Vacuum Furnace with Nitrogen Quenching

HTD Size-PR LogoGlobal commercial heat treater with 17 locations in North America, Aalberts Surface Technologies Heat in Kalisz (Poland), will receive a vacuum furnace with nitrogen quenching and an atmosphere furnace at their specialized commercial hardening plant. This expansion of its production line builds on their acquisition of a high vacuum furnace at their Dutch branch in Eindhoven last year.

The new SECO/WARWICK furnaces, added to the furnace that they had supplied last year, will create a production line that will be used for successive vacuum carburizing (LPC) and gas quenching (with the new CaseMaster Evolution-T vacuum furnace, or CMe-T furnace), followed by annealing (with the new BREW atmosphere furnace) to reduce the internal stress of the treated metals. Performing so many processes is possible thanks to the combination of vacuum technology with atmosphere technology.

The commercial heat treater believes that this expansion in capabilities will progress their mission. "According to our mission statement," said Wojciech Matczak, plant manager at Aalberts Surface Technologies Heat Kalisz, "‘Best-in-class’ is not about our core technologies but about our commitment to do everything we can to make our clients successful."

Maciej Korecki
Vice President of the Vacuum Furnace Segment
SECO/WARWICK
(source: SECO/WARWICK)

The three-chamber CaseMaster Evolution-T furnace has 1 ton per batch capacity and an annual output of up to 2,000 tons of parts. It can replace 3 conventional atmosphere furnaces. Additionally, it has fast cooling nitrogen chamber, achieving results similar to helium and oil cooling, creating an environmentally friendly system. Using the nitrogen taken from and discharged to the air eliminates both the use of expensive and difficult to obtain helium and harmful quenching oil. This makes it possible to reduce CO2 emissions by 300 tons annually, which is the amount generated by three standard atmosphere furnaces.

“Aalberts Surface Technologies Heat had special requirements," explained Maciej Korecki, VP, of the Vacuum Business Segment at SECO/WARWICK, "regarding the components and solutions used, and thus [the vacuum furnace] will replace the existing semi-continuous processes under protective atmosphere followed by oil quenching with complete vacuum heat treatment with low pressure carburizing and nitrogen quenching (25 bar!), delivering process precision and repeatability. . ."

The second furnace, the BREW 6810 solution, will make it possible to perform the annealing process immediately after vacuum carburizing. It can operate between 572 and 1382°F (300 and 750°C) and is equipped with a system to enable treatment under nitrogen atmosphere, preventing oxidation on the heat-treated workpieces.

Aalberts Surface Technologies Heat To Receive a Vacuum Furnace with Nitrogen Quenching Read More »

Heat Treater Expands Controlled Atmosphere Brazing Capabilities

HTD Size-PR LogoAn industrial heat exchanger manufacturer based in the UK will receive a new controlled atmosphere aluminum brazing line. This system will allow the manufacturer to expand its range of sizes and dimensions of aluminum heat exchangers that can be brazed using the CAB technology.

The supplier of the system, North American manufacturer SECO/VACUUM parent company SECO/WARWICK, shared that the Active Only line offers the greatest flexibility within the CAB furnace range while maintaining the same performance as larger continuous lines. These capabilities were important in order to accommodate the manufacturer's wide ranging portfolio, which includes heat exchangers for various industries.

Piotr Skarbiński
Vice President of the Aluminum Process and CAB Business Segments
SECO/WARWICK Group
Source: SECO/WARWICK

The line will consist of a degreaser with afterburner and integrated energy recovery system, a spray fluxer, and an Active Only semi-continuous furnace. The system is composed of a dryer, a purging chamber, a convection-heated brazing furnace, a protective atmosphere cooling chamber, and a final cooling chamber. This will be complemented by an integrated system for loading, sequencing, stacking, transferring, and unloading the work in progress.

"We delivered our first furnace to this company 17 years ago, in 2004," says Piotr Skarbiński, Vice President of the Aluminum & CAB Products Segment at the SECO/WARWICK Group. "It was a furnace designed for the cutting-edge copper brazing technology of that time."

Heat Treater Expands Controlled Atmosphere Brazing Capabilities Read More »

Heat Treat Expansion for Defense and Aviation

HTD Size-PR LogoIndian manufacturer in the defense and aviation sector TATA Advanced System Ltd. (TASL) will receive a solution heat treatment line. It is dedicated for the aviation industry and will meet the requirements of the latest aviation (AMS2750F) and material (AMS2770) standards.

This order, the third of its type from North American manufacturing parent company SECO/WARWICK to TASL, will be the largest production line for aircraft skins in the history of both companies. The equipment will be used for the production of aircraft skins, empennage and center-wings boxes. The line includes a rapid quench VertiQuench® electric furnace (drop-bottom type), mobile quenching tank, rinsing tank and additional equipment including a chiller and loading baskets.

Piotr Skarbiński
Vice President of the Aluminum Process and CAB Business Segments
SECO/WARWICK Group
Source: SECO/WARWICK

The working zone of the furnace is L7500 x W3000 x H3000mm, with the capacity to process huge sheets of aluminum. Such a large working zone reduces the number of joints in the skin. The line, as designed, will meet the client's requirements, ensuring a guaranteed +/- 5°C load temperature uniformity, load cooling in either a polymer or a water quench, and will remove the polymer sediment remaining after quench. Additionally, the system can be used for artificial aging in the furnace.

Abhishek Paul, manager and head of supply chain management of TASL said, "The new line, apart from its size, will meet a number of guidelines that will allow us to produce the highest quality airplane components that will meet the expectations of our final customers - a vast portfolio of OEMs and Tier-1s in the aerospace and defense industry. We are also confident that [the company] will be able to meet the project timelines and handover the line well within our project timelines."

"For us," explains Piotr Skarbiński, vice president of the aluminum process and CAB business segments at the SECO/WARWICK Group, "this continued cooperation directly means that the client is satisfied with the quality and efficiency of [our] equipment, services and our partnership. We hope that this partnership will continue into the future."

Heat Treat Expansion for Defense and Aviation 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 »

SonFlow to Receive Vacuum Furnace for New Brazing Solutions

HTD Size-PR LogoA Scandinavian manufacturer of heat exchangers, SonFlow will receive a vacuum furnace from the parent company of a North American manufacturer for copper brazing adapted to the individual needs of the company's clients. A special nozzle design and electrical penetration assembly will ensure that the device is specific for the production of the latest, high-capacity plate heat exchangers for industrial, HVAC, off-shore and sanitary purposes to be manufactured in the Kolding plant.

Maciej Korecki
Vice President of the Vacuum Furnace Segment
SECO/WARWICK
(source: SECO/WARWICK)

SonFlow is a European manufacturer which has historically been known for manufacturing high-capacity industrial pumps. The company is now expanding into the plate heat exchanger business. Manufacturing state-of-the-art, powerful heat-exchangers has provided the incentive for the plant to purchase a furnace from SECO/WARWICK that will satisfy the current production challenges associated with the brazing process.

The working area of the device (900 x 900 x 1200) will enable the plant to perform in-house brazing, without the need to outsource work to third-parties. Power savings, one of the pillars of their mission, is ensured by the graphite chamber, and the shortened cycle time is guaranteed, thanks to the vacuum level of 10-3 mbar.

"Years of experience," explained Maciej Korecki, VP of the Vacuum Business Segment at SECO/WARWICK Group, "and the above approach have resulted in developing a special design of the cooling nozzles, optimum for brazing companies. This dedicated solution consisting of the special nozzle design for these radiator applications prevents excessive deposits of brazing residues in undesired areas of the heating chamber. With this design, the risk of damaging the device during the brazing process is eliminated."

SonFlow to Receive Vacuum Furnace for New Brazing Solutions Read More »

International Military Equipment Heat Treaters Receive Vacuum Furnace

Maciej Korecki
Vice President of the Vacuum Furnace Segment
SECO/WARWICK
(source: SECO/WARWICK)

AHTD Size-PR Logon international arms and military equipment manufacturer in Brazil needed to quickly expand and was recently able to receive a new vacuum furnace to meet their manufacturing demands.

The solution was provided by the parent company to North American SECO/VACUUM, SECO/WARWICK. Their furnace, the VECTOR®, is a single-chamber vacuum furnace that uses gas quenching and can be used for multiple metal heat treatment applications and processes. In this configuration, equipped with a round graphite heating chamber, it may be used for most standard processes including hardening, tempering, annealing, solutionizing, brazing and sintering.

"A situation where we have a product almost ready to be collected is rare. This time, the customer was indeed looking for a standard solution," said Maciej Korecki, vice president of the Vacuum Furnace Segment at the SECO/WARWICK Group.

(source: vidar nordli mathisen at Unsplash.com)

(source: SECO/WARWICK)

 

 

 

 

 

 

 

International Military Equipment Heat Treaters Receive Vacuum Furnace Read More »

“It’s Electric!”

OCHeat treaters, beware: there is a new trend that "ooh! It's shocking . . . It's electric!"

"Boogie woogie" or not, the industry is sliding into the electric trend both in how heat treaters process parts, and in the end-product of what they are processing. This original content article takes several anecdotes from within the industry to keep you up-to speed on this developing interest. Despite what the singer Marcia Griffiths says, if you do see this electric trend in other industries, email us at editor@heatreattoday.com or @HeatTreatToday when you're on social media to give us the heads up.


The electric shift is proliferating the current dialogue. Is it because it's Earth Month in the US? Perhaps, but we don't think so. Heat treaters and industry suppliers continue to promote sustainable practices, from Buehler's "Sustainable, Long Lasting, Metallurgy Supplies" list to a recent Heat Treat Today article on diffusion bonding due to changes in heat treated products.

Electric Processes

In terms of industry processes, Kanthal says "It’s time to electrify the steel industry." The goal, the company continues, is to create heat treating services that are precise and which eliminate CO2 emissions and energy consumption. In an industry which needs to use a lot of energy, viable solutions are needed to make the shift.

Pit furnace for ingot heating with Kanthal® Super electric heating elements
Source: Kanthal; Photographer, Evelina Carborn

The company claims that their initiative provides that balance of economic viability and powerful heat treating. "There are many misconceptions about electric heating – that it’s not able to reach certain temperatures, for instance," says Anders Björklund, president of Kanthal. "But with our technology, you can electrify any heating process in steelmaking. As we have proved, Kanthal has the technology, the thermal expertise, the resources and the global footprint to electrify all the highly energy-intensive heating processes."

The benefits of electric heating include reducing CO2 and NOx emissions, improving thermal efficiency, and precise temperature control. Additionally, the company notes that the reduction of noise and exhaust gases means a cleaner, quieter production process and work environment. Not as hardcore, but I guess it's nice to sometimes be able to hear the person next to you.

Electric Products

According to SECO/WARWICK, "Heat treatment is used by the automotive industry to manufacture gears, bearings, shafts, rings, sleeves, and batteries for electric cars. What is most important to this sector is the reliability of solutions, their efficiency, and process repeatability. This is why the solutions addressed for this market sector must take into consideration the need to reduce distortion, lower the process costs, shorten the process time, use efficient and effective carburizing technologies, and lower CO2 emissions."

Sławomir Woźniak, SECO/WARWICK Branded
Sławomir Woźniak
CEO
SECO/WARWICK
Source: secowarwick.com

Specifically related to Europe, "The ACEA (European Automobile Manufacturers' Association) report shows that as much as 29% of all EU R&D spending in the year preceding the pandemic was made by automotive players," Sławomir Woźniak, CEO, SECO/WARWICK Group revealed. "This is an industry that is open to novelties, which is why we are actively looking for solutions that will effectively support production in the automotive area."

And there is an alphabet of applications to look for. The above company points to low-pressure carburizing and high-pressure nitrogen quenching technologies in their CaseMaster Evolution–T as one option that has been popular for automotive heat treaters in the past. The same company had also reported a major sale last year to a manufacturer who would be brazing electric car batteries with controlled atmosphere brazing, or CAB, technology. Lastly, diffusion bonding -- as mentioned earlier in the article -- may be a new process for treating new products like electric vehicles since "several unique advantages for complex geometric structures and materials that can operate under strenuous high-performance conditions" (The “Next Leap”: Diffusion Bonding for Critical Component Manufacturing).

Conclusion

With a new administration in the United States heavily pushing for certain new energy outlets, there are mixed reactions and questions. One commenter on a recent Industry Week piece commented, "as I drive to work every morning I pass 6 or 7 privately owned fracking wells operating safely at full tilt right down the road from one abandoned solar mirror plant built in 2010 at a wasted cost of over $20 mil to the taxpayer... and I ask myself which of these assets was the 'smart investment of the future,' and which proved the fool's errand?" Still, electric processing and products seems to be receiving a huge push in industry, with both private individuals and political pressures emphasizing the virtues of electric.

To read more about caveats to this trend and what may pose a challenge to a purely electric revolution, check out this opinion editorial by WS Thermal on green gases.

(source: Markus Winkler at unsplash.com)

 

 

 

 

 

 

 

“It’s Electric!” Read More »

Aerospace Manufacturer Expands Heat Treat Abilities with Single-Chamber Furnace

HTD Size-PR Logo

Maciej Korecki
Vice President Vacuum Business Segment
SECO/WARWICK
(source: SECO/WARWICK)

A global aerospace manufacturer ordered a single-chamber gas quench furnace for their US plant. The turn-key solution also includes auxiliary equipment, such as a closed-loop water system, a gas reservoir, a loader, and carbon fiber fixturing.

The Vector® 2-bar quenching unit from North American based SECO/VACUUM is equipped with high vacuum diffusion pump and convection heating for improved performance at low temperatures. It meets class 2 requirements per AMS2750F (temperature uniformity +/- 6°C (+/- 10°F)). It will be installed in the company’s Center of Excellence and will be used to heat treat 3D printed parts.

This expansion of capabilities continues the relationship that SECO/WARWICK Group has with the manufacturer, who has been expanding their heat treat capabilities with the Group for the last 10 years at locations in Poland, Indonesia, Singapore, France, and the US.

The partnership, commented Maciej Korecki, VP of the Vacuum Business Segment at SECO/WARWICK Group, is a confirmation that the company continues to deliver “products that not only fulfill but exceed their needs.”

Aerospace Manufacturer Expands Heat Treat Abilities with Single-Chamber Furnace 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 »

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