IN 718 Part 1: History, Applications, and Production

February 24, 2026 / ENERGY HEAT TREAT TECHNICAL CONTENT, FOUNDRY CASTING TECHNICAL CONTENT, MANUFACTURING HEAT TREAT TECH, VACUUM FURNACES TECHNICAL CONTENT

Today’s Technical Tuesday highlights this first installment in a multi-part series by Nikolai Alexander and The Heat Treat Doctor® Daniel H. Herring, which introduces Inconel® Alloy 718, one of the most widely used nickel-based superalloys, tracing its history, applications, and production fundamentals. Understanding why this alloy performs so well in extreme environments is critical as manufacturers consider material choices available for demanding components, especially alloys more typically sourced outside of one’s own industry. As demanding performance capabilities are being required of new engineered solutions, selecting the right alloy becomes a strategic decision to meet the need for higher temperatures, pressures, and corrosive environments.

This informative piece is from Heat Treat Today’s February 2026 Annual Air & Atmosphere Heat Treating print edition.

History

Inconel® Alloy 718 (IN 718) is a nickel-iron base superalloy known for its exceptional strength, resistance to high temperatures and ability to withstand harsh environments, where oxidation, creep, and corrosion resistance are paramount. The alloy was created by Dr. Herbert L. Eiselstein, who began his research in 1958, culminating in a patent assigned to The International Nickel Company in 1962 (U.S. Patent No. 3,046,108). In the many years since its creation, IN 718 remains the most widely used of all superalloys due to its availability in both wrought and cast products with high strength and stress-rupture life up to 650°C (1200°F), good hot working characteristics, castability, weldability, and cost effectiveness — all in an alloy with nominally 18% iron! The alloy’s superior performance is due in large part to its unique strengthening mechanisms.

There are different classifications of a superalloy, all based around the predominant metal present in the alloy. These categories include (Akca and Gursel 2015):

Nickel-based
Iron-based
Cobalt-based

The microstructural design makes IN 718 one of the best alloys for service applications below 650°C (1200°F) (Loria 1988, Herring 2011). It is widely used in extreme environments where components are subjected to high temperature, pressure, and/or mechanical loads. When heated, IN 718 forms a thick, stable, passivating oxide layer that protects the surface from further attack.

The alloy retains strength over a wide temperature range, making it attractive for high-temperature applications where materials like aluminum and steel would fail due to creep caused by thermally induced crystal vacancies. Inconel’s high-temperature strength is developed through heat treatment by solutionizing and precipitation hardening.

IN 718 is an alloy used around the world, but you might know it better by one of a variety of trade names (see sidebar).

The alloy has been modified numerous times to extend its operating temperature and service life. The alloy is readily available in all of these modified variations, each having slight differences in chemistry, cast and wrought processing methods, and heat treatments.

Applications

There is a wide variety of IN 718 applications across many industries, including aerospace, nuclear, oil and gas, automotive, motorsport, chemical processing, non-nuclear power generation, medical, tooling and molds, and fire protection systems.

In the automotive and motorsport industry, IN 718 is used for turbocharger rotors, exhaust manifolds, and valve springs in high-performance engines, such as those found in Formula 1 or the 24 Hours of Le Mans race cars. Naval warships are also purported to use IN 718 for components in their nuclear reactors (Table A).

Table A. Possible Uses of IN 718 in Naval Warship Nuclear Reactors

Table B. Oil & Gas Industry Use Examples for IN 718

Figure 1. A “Christmas tree”: the complex assembly of valves, gauges, and controls installed at the surface of a completed oil or gas well which has the primary function of regulating and controlling the flow of oil from the well. | Image Credit: Croft Systems

Perhaps surprisingly, IN 718 is also widely used in the oil and gas industry, which in addition to its many other benefits has remarkable resistance to sulfide and chlorine stress corrosion cracking at both high and low temperatures (Table B). Stress corrosion cracking is a failure mechanism that is caused by a combination of environment, a susceptible material, and the presence of tensile stress. Oil and gas applications like downhole tools, wellhead components, and subsea equipment benefit from IN 718’s other valuable properties as well, some of which include:

High strength and toughness at temperatures up to 700°C (1290°F)
Excellent resistance to pitting, crevice corrosion, and stress corrosion cracking
Sustained strength in hydrogen sulfide (H₂S) and CO₂-rich environments
Good weldability and fabrication

Continuous innovations in processing and material chemistry have enhanced superalloy properties resulting in the extension of its use into other industries, such as the energy and more conventional transportation sectors (Loria 1988).

Production Methods

IN 718 is available in cast and wrought alloy form and follows a stringent production process (Figure 2). Basic melt practices are used, such as vacuum induction melting (VIM), vacuum arc remelting (VAR), and electro-slag remelting (ESR).

Figure 2. Flow diagram of processes widely used to produce superalloys (Data reference: Akca and Gursel 2015)

VIM

The VIM process produces liquid metal under vacuum in an induction-heated crucible. It is used as a primary melting step in the route to producing wrought and cast products. Before being melted, the raw material can be refined and purified, and its composition can be controlled. VIM has been widely used in the manufacture of all types of superalloys, which must be melted under vacuum or in an inert gas atmosphere because of their reactivity with atmospheric oxygen and nitrogen.

VAR

The VAR process, a secondary melting technique, converts VIM-processed electrodes into ingots whose chemical and physical homogeneity have been significantly improved. In this process, a stub is welded to one end of an electrode, which is then suspended over a water-cooled copper crucible. Next, an arc is struck between the end of the electrode and the crucible bottom. Maintaining the arc generates the heat required to melt the electrode, which drips into the crucible and can subsequently be poured into molds. Many inclusions can be removed by flotation or chemical and physical processes before the molten material solidifies.

ESR

The ESR process, another secondary melting technique, is similar to the VAR process, but with notable differences. Remelting does not occur by striking an arc under vacuum. Instead, an ingot is built up in a water-cooled mold by melting a consumable electrode that is immersed in a slag, which is superheated by means of resistance heating. Rather than operating in a vacuum, the process is conducted in air under the molten slag. During melting, metal droplets fall through the molten slag, and chemical reactions reduce sulfur and nonmetallic inclusions. Both ESR and VAR processes allow directional solidification of an ingot from bottom to top, yielding high density and homogeneity in its macrostructure, as well as an absence of segregation and shrinkage cavities.

Casting Methods

IN 718 can also be produced by several casting methods. The most common of these are investment casting and (vacuum) die casting:

Investment casting: This process involves creating a wax pattern, coating it with a ceramic shell, melting out the wax, and then pouring molten IN 718 into the ceramic mold.
Vacuum die casting: This method uses a vacuum to fill the mold, resulting in a refined grain structure, minimal porosity, and good dimensional reproducibility, making it suitable for components like airfoils.
Sand casting: This method is far less common due to its inherent limitations in precision and surface finish, but the technology has been used for large castings.

A Metallurgical Perspective: The Role of Gamma Prime and Double Prime

IN 718 is a precipitation hardening superalloy. Its principle strengthening phases are gamma prime (γ′) or Ni3Al and gamma double prime (γ″) or Ni3Nb. The relationship between these precipitates (and others) and the gamma (γ) nickel matrix is critically important. For example, the coherency strain (i.e., the elastic deformation that occurs between two phases when their lattice structures do not perfectly match) is due to the fact that γ′ is face-centered cubic and γ″ is body centered tetragonal. In the case of IN 718, these strengthening effects are influenced more by γ″ than γ′ (ASM International 2016, Lee et al. 2023).

In addition, IN 718 has a natural tendency to precipitate rapidly by homogeneous nucleation in the noncompressible γ matrix. Depending on chemistry, γ′ volume percentage can vary over a wide range (3%–65%). Practically speaking, creep strength is proportional to volume percent over this range at temperatures between 700–980°C (1290–1800°F). As a result, the ratio of titanium to niobium/aluminum is key to hardening. High ratios imparted by niobium assure high strength at intermediate service temperatures around 600°C (1110°F). For higher service temperatures, higher aluminum content and molybdenum additions minimize the γ and γ′ mismatch, thus contributing to more stable alloys (Decker 2006, Guan et al. 2023).

Finally, the size and shape of these precipitates is important; larger precipitates enhance the strengthening effect. Key to the formation of these two precipitates is the aging treatment temperature, time, and alloy composition. According to existing research, higher aging treatment temperatures and longer times can lead to an increased amount of γ″ while extended aging coarsens the γ′ and γ″ particles, potentially leading to a reduction in strength and creep resistance. Furthermore, the composition ratios of Al, Ti, and Nb in the alloy influence the shapes of γ′ and γ″ precipitates, forming so-called co-precipitates that also affect the properties (Table C).

*SS = solid solution; + = enhancement; — = negative effect
Table C. Effect of Various Alloying Elements (Data Reference: Decker 2006)

The highest strength and hardness, coupled with reduced impact toughness, have been observed after heat treatment at 718°C (1325°F), due to an increase in the size and quantity of γ′ and γ″ precipitates.

In addition, as a result of surface analysis of Charpy bars, intergranular fracture occurs due to abundant small-sized precipitates formed within the boundary. In the case of the Charpy impact test, the absorbed energy decreases as the aging temperature increases. The formation of carbide, γ′ and γ″ precipitates can reduce the impact toughness of materials because precipitates may cause more obstacles to dislocation movement and promote crack initiation and propagation (Lee et al. 2023).

This article’s discussion continues in Heat Treat Today’s Annual Aerospace Heat Treat (March 2026) print edition to address heat treatment methods for this superalloy.

References

Akca, Enes, and Gursel, Ali. 2015. “A Review on Superalloys and IN718 Nickel-Based INCONEL Superalloy.” Periodicals of Engineering and Natural Sciences 3 (1): 15–27.

ASM International. 2016. ASM Handbook, Volume 4E: Heat Treating of Nonferrous Alloys. ASM International.

Babu, S. S., N. Raghavan, J. Raplee, S. J. Foster, C. Frederick, M. Haines, R. Dinwiddie, M. K. Kirka, A. Plotkowski, Y. Lee, and R. R. Dehoff. 2018. “Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification.” The Minerals, Metals & Materials Society and ASM International: 3764–3780.

Bradley, Elihu F., ed. 1988. Superalloys: A Technical Guide. ASM International.

Chandler, Harry, ed. 1996. Heat Treater’s Guide: Practices and Procedures for Nonferrous Alloys. ASM International.

Croft Systems. n.d. “The Difference between a Wellhead & Christmas Tree.” https://www.croftsystems.net/oil-gas-blog/the-difference-between-a-wellhead-christmas-tree/

Decker, R. F. 2006. “The Evolution of Wrought Age-Hardenable Superalloy.” Journal of The Minerals, Metals & Materials Society, September: 32–36.

del Bosque, Antonio, Fernández-Arias, Pablo, and Vergara, Diego. 2025. “Advances in the Additive Manufacturing of Superalloys.” Journal of Manufacturing and Materials Processing 9 (215): 1–31.

Eliasen, K. M., T. L. Christiansen, and M. A. J. Somers. 2010. “Low-Temperature Gaseous Nitriding of Ni-Based Superalloys.” Surface Engineering 26 (4): 248–255.

Guan, Hao, Wenxiang Jiang, Junxia Lu, Yuefie Zhang, and Ze Zhang. 2023. “Precipitation of δ Phase in Inconel 718 Superalloy: The Role of Grain Boundary and Plastic Deformation.” Materials Today Communications 36 (August).

Herring, Daniel H. 2011. “Stress Corrosion Cracking.” Industrial Heating, October: 22–24.

Herring, Daniel H. 2012. Vacuum Heat Treating: Principles, Practices, Applications. BNP Media II, LLC.

Herring, Daniel H. 2019. “The Heat Treatment of Inconel 718.” Industrial Heating, June: 12–14.

Lee, Gang Ho, Ang Ho, Minha Park, Byoungkoo Kim, Jong Bae Jeon, Sanghoon Noh, and Byung Jun Kim. 2023. “Evaluation of Precipitation Phase and Mechanical Properties According to Aging Heat Treatment Temperature of Inconel 718.” Journal of Materials Research and Technology 27 (Nov–Dec): 4157–4168. https://doi.org/10.1016/j.jmrt.2023.10.196

Lee, Shin-Chin, Shih-Hsien Chang, Tzu-Piao Tang, Hsin-Hung Ho, and Jhewn-Kuang Chen. 2006. “Improvements in the Microstructure and Tensile Properties of Inconel 718 Superalloy by HIP Treatment.” Materials Transactions 47 (11): 2877–2881.

Loria, Edward A. 1988. “The Status and Prospects of Alloy 718.” Journal of Materials, July: 36–41.

Polasani, Ajay, and Vikram V. Dabhade. 2024. “Heat Treatments of Inconel 718 Nickel-Based Superalloy: A Review.” Metals and Materials International: 1204–1231.

Sharghi-Moshtaghin, Reza, Harold Kahn, Yindong Ge, Xiaoting Gu, Farrel J. Martin, Paul M. Natishan, Arrell J. Martin, Roy J. Rayne, Gary M. Michal, Frank Ernst, and Arthur H. Heuer. 2010. “Low-Temperature Carburization of the Ni-Base Superalloy IN718: Improvements in Surface Hardness and Crevice Corrosion Resistance.” Metallurgical and Materials Transactions A 41A (August): 2022–2032. https://doi.org/10.1007/s11661-010-0299-y

Shipley, Jim. 2023. “Hot Isostatic Pressing and AM: How to Improve Product Quality and Productivity for Critical Applications.” Metal AM 9 (3).

U.S. Patent No. 3,046,108.

Acknowledgments: This paper would not have been possible without discussions, guidance and contributions from a number of individuals in both the heat treat industry and academia.

Special Note: Inconel® is a registered trademark of Special Metals Corporation group of companies.

About the Authors:

Dan Herring
“The Heat Treat Doctor®”
The HERRING GROUP

Dan Herring, who is most well known as The Heat Treat Doctor®, has been in the industry for over 50 years. He spent the first 25 years in heat treating prior to launching his consulting business, The HERRING GROUP, in 1995. His vast experience in the field includes materials science, engineering, metallurgy, equipment design, process and application specialist, and new product research. He is the author of six books and over 700 technical articles.

Nikolai Alexander Hurley
Intern
The Heat Treat Doctor®

Nikolai Alexander Hurley is a young academic, interning with The Heat Treat Doctor®.

For more information: Contact Dan at dherring@heat-treat-doctor.com.

IN 718 Part 1: History, Applications, and Production Read More »

Experts Anticipate Key Heat Treat Technology Adoptions

January 28, 2025 / MANUFACTURING HEAT TREAT TECH, TECHNOLOGY

Industry experts agree: 2025 is a year of significant, high-tech developments. In this Technical Tuesday, hear from three heat treat industry consultants on current and incoming technological advances, from miniaturization and customization to artificial intelligence.

Michael Mouilleseaux, general manager at Erie Steel, Ltd, opens the discussion by asking what role AI has in a perfect world of heat treating; Thomas Wingens, president of Wingens Consultants, predicts six major technologies to look for in 2025; and Dan Herring, a.k.a. The Heat Treat Doctor® and owner of The HERRING GROUP, Inc., points out how the trend toward smaller is affecting the heat treat industry.

This informative piece was first released in Heat Treat Today’s January 2025 Technologies To Watch in Heat Treating print edition.

AI’s Place in Heat Treating?

by Michael Mouilleseaux

The benefits of AI are purported to be the ability to reduce the time required to complete complex tasks, such as data analysis, while reducing human error and providing both unbiased decision making and data-driven system enhancements … and by the way, it can operate 24/7 without breaks!

Does AI have a place in heat treating?

Here’s what I would want my heat treat AI (HT AI) to be able to do with a gas-fired atmosphere furnace.

Combustion System:

My HT AI will continuously monitor the free oxygen of all the burners and keep them at a perfect ratio, thereby optimizing performance and gas consumption. It will track these changes and provide analysis of any trends that it “perceives,” so to speak.
My HT AI will continuously monitor combustion air pressure and message me in time to have the air filters changed before it affects performance. It will track this and provide historical and prescriptive information.
My HT AI will periodically perform a “tube check,” whereby it will shut off combustion in a tube and monitor the free oxygen, recognizing that any diminishment from “atmospheric” O2 levels indicate the potential of a tube leak. It will track this and provide analysis of any trends that it perceives.
My HT AI will track when system thermal stasis is achieved, monitor gas consumption for each discrete heat treat cycle, provide analysis of trends that it perceives, and recommend thermal cycle changes to optimize these cycles.

My HT AI will facilitate the optimization of the critical human assets in process engineering, product quality and equipment maintenance.”
Michael Mouilleseaux

Atmosphere Control System:

My HT AI will continuously monitor the atmosphere flows required to achieve the requirements for each heat treat cycle. It will track “atmosphere recovery” and provide analysis of any trends that it perceives (i.e., increased usage as a precursor to a furnace leak).
My HT AI will periodically perform a furnace check, whereby it compares the composition of the Endo gas in the furnace to that exiting the generator, providing a measure of furnace integrity. It will track this and provide analysis of any trends that it perceives.
My HT AI will confirm “tube check” data (see above) with atmosphere usage to evaluate its potential effects on process integrity and make actionable recommendations. It will track these incidents and provide analysis of any trends that it perceives.
My HT AI will provide assurance of system performance and actionable information.

Shoot for the Moon:

My HT AI will have the unique ability to integrate metallurgical results with process information and thereby provide the ability to optimize the heat treating process AND metallurgical results.
My HT AI will allow me to input material chemical and hardenability data and, by comparing actual results with the calculated, or prospective results, provide confirmation of the thermal and quenching segments of the process.
My HT AI will be able to correlate IGO results with furnace integrity checks (i.e., leaks) and over time establish hard limits for allowable leak rates.
My HT AI will be able to correlate actual retained austenite levels in carburized case with furnace carbon potential and make data-driven process modifications to optimize this.
My HT AI will be able to correlate the shape of the case depth curve with the carburizing cycle and the material type, and it will make data-driven process modifications to optimize this.
My HT AI will have the ability to develop new heat treat thermal cycles specific to my furnaces extrapolated from existing data.

My HT AI will provide a level of system performance heretofore not achieved, that not only assures adherence to established standards but provides a clear path of continuous improvement via data analysis and actionable actions. Product results will be validated by total process control, and total process control will assure attainment of product results.

My HT AI will facilitate the optimization of the critical human assets in process engineering, product quality and equipment maintenance.

In short, my HT AI will afford the heat treating community the ability to finally jettison the mantle of “black art” and join the community of high-tech engineered processes.

About the Author:

Michael Mouilleseaux
General Manager
Erie Steel, Ltd

Michael Mouilleseaux has been at Erie Steel in Toledo, OH, since 2006 with previous metallurgical experience at New Process Gear in Syracuse, NY, and as the director of Technology in Marketing at FPM Heat Treating LLC in Elk Grove, IL. Having graduated from the University of Michigan with a degree in Metallurgical Engineering, Michael has proved his expertise in the field of heat treat, co-presenting at the 2019 Heat Treat show and currently serving on the Board of Trustees at the Metal Treating Institute.

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

Future Outlook for 2025

by Thomas Wingens

2025 will be the year of invention and application. There are six major technologies to be looking out for: AI management software, giga casting for the EV industry, high-pressure quench furnaces, thermal processing specialty materials, processing for steel enrichment, and practices for cleaning consistency.

AI Management Software

Some new heat treat shop management software is now available. It utilizes artificial intelligence to save labor while documenting all processes in real time. The software easily adapts to the way we work and is much easier to learn and implement than the software of the past. I see this as the number one investment item for commercial heat treaters in 2025, as it is the cheapest and easiest way to automate with a great ROI while increasing quality and customer service.

Giga Casting

With Tesla as the main driver, very large so-called “GIGA” H13 aluminum dies of 3 to 8-ton weight have really taken off in the last years, in particular for new electric car models, and the demand for very high pressure quench furnaces is increasing in the U.S. (more to come in a later article).

Vacuum Oil Quenching

However, even with the most advanced designs and high-pressure efforts, gas quenching with nitrogen has its limits, and the use of helium is not considered anymore because of its immense cost, even with a recycling system in place. Vacuum oil quenching has become a viable alternative in recent years not only in combination with LPC (low-pressure carburizing) but also with the use of materials like AISI 52100 that would be typically heat treated in atmosphere integral quench furnaces but show lesser distortion with the variation of pressures over the oil bath, which can shift the oil boiling phase peak to lower temperatures (e.g., from 650°C (1200°F) at atmospheric pressure to 400°C (750°F) at 1 mbar pressure). Some new modern vacuum oil quench furnace designs have recently entered the market, showing excellent surface cleanliness and distortion results. Aside from the better quality, they offer a much safer, cleaner and more pleasant work environment.

Specialty Materials

In general, we see a higher demand for the thermal processing of specialty materials; for example this is seen with the hydrogen decrepitation of titanium, tantalum, niobium, or rare earth element materials, powder processing or sinter processes, and surface diffusion processes.

Steel Enrichment

Enriching stainless steel with nitrogen is not new, but it is gaining momentum and more applications. One method for\ low-temperature processes on austenitic stainless steels around 370°C (690°F) is called S-phase case hardening, and the high temperature version around 1100°C (2010°F) is called solution nitriding. Both processes were initially established in the early 90s in Europe but seem to be gaining momentum and more comprehensive applications worldwide over the last years.

Figure 1. For 2025, “We see more fully enclosed vacuum solvent cleaning in heat treat shops to ensure a higher standard and consistency of the surface cleaning results compared to the fading of water cleaners.” – Thomas Wingens, WINGENS CONSULTANTS

Cleaning Consistency

Speaking of surface processes: The cleaning of components has been a thankless process, especially in commercial heat treatment, as it is seen as a necessity that is not necessarily paid for by the clients but is necessary to have uniform dissociation on the surface of a part to ensure a uniform case (e.g., nitriding case). There are well-defined standards for temperature uniformity and hardness testing, but cleaning consistency needs to be addressed, as it can be very impactful. We see more fully enclosed vacuum solvent cleaning in heat treat shops to ensure a higher standard and consistency of the surface cleaning results compared to the fading of water cleaners.

About the Author:

Thomas Wingens
President
WINGENS CONSULTANTS

Thomas Wingens has been an independent consultant to the heat treat industry for nearly 15 years and has been involved in the heat treat industry for over 35 years. Throughout his career, he has held various positions, including business developer, management, and executive roles for companies in Europe and the United States, including Bodycote, Ipsen, SECO/WARWICK, Tenova, and IHI-Group.

For more information: Contact Thomas at www.wingens.com.

Miniaturization and the Heat Treat Industry

by Dan Herring

Everywhere we turn today, the products we use are getting smaller, more compact and more powerful. This is true across all industries, from aerospace to automotive, from medical to electronics, and from energy to semiconductors to name a few. Today, miniaturization, portability and customization have become major design objectives for almost all manufacturing segments.

These trends are irreversible and are, or will be, found even in the most unlikely of places — both in mining of resources taking place deep under the ocean floor and eventually on other planets. The key question then becomes, how will all of this influence our heat treating operations?

Miniaturization, Portability and Customization Today

Given the ever-increasing demand for higher performance in a smaller footprint, we have often focused our energies on taking existing products and adapting them for use. But in the long term, this is not sustainable. For example, not only is gear noise reduction critical in our submarines, but the medical and robotics markets are continuously searching for smaller, more efficient, more application specific and more intelligent drive systems and motors with increased torque density.

Heat treatment will experience a metamorphosis and emerge more broadly as thermal treatment. The age of metals as we have known it has become the age of materials: ceramics, composites, powder materials, glasses, polymers, fiber-reinforced plastics, and even nanomaterials.
Dan Herring, The Heat Treat Doctor®

Another example, although not new, is miniaturization in vehicle electronics, especially as it relates to data collection where demand is high for smaller, more powerful and, yes, cheaper components. Integration into the electronic control units via on-board power systems has seen the need for more cables in vehicles and positioning connectors, which means more contacts/connections on the electronic components without significantly increasing the installation space.

Similarly, there is a huge demand for portability. This is true not only in our electronics (just think about how cell phones or computers have changed over the last ten years), but there is a growing need for portable medical devices so that medical care can be brought to the patient rather than the other way around. For example, longer battery life and lighter weight are critical for devices such as portable oxygen concentrators.

What Does This Mean for the Heat Treatment Industry?

Looking ahead, we will see both short and long-term changes to our industry. Happening today and continuing in the near term, heat treaters are working closer than ever with design and manufacturing engineers as they focus on products that reduce environmental impact, are produced at lower unit cost, and with improved part quality. Still, the era of mass recalls must come to an end. And the cost of heat treating is less than it was even a decade ago. But as manufacturing demand evolves due to consumer expectation, process and equipment flexibility will become keys to meeting the highest quality standards in an on-demand world.

Historically, changes in the heat treat industry has been evolutionary and incremental in both nature and effect. There have been notable exceptions such as the invention of the oxygen probe or low pressure vacuum carburizing. But to meet the manufacturing demands of the future, change will need to be more revolutionary and abrupt in nature, a game changer.

Given the ever-increasing demand for higher performance in a smaller footprint, we have often focused our energies on taking existing products and adapting them for use. But in the long term, this is not sustainable. For example, not only is gear noise reduction critical in our submarines, but the medical and robotics markets are continuously searching for smaller, more efficient, more application specific and more-intelligent drive systems and motors with increased torque density.
Dan Herring,
The HERRING GROUP, Inc.

Heat treatment will experience a metamorphosis and emerge more broadly as thermal treatment. The age of metals as we have known it has become the age of materials: ceramics, composites, powder materials, glasses, polymers, fiber-reinforced plastics, and even nanomaterials. As a result, we will find ourselves needing, for example, to expand our heat treat capability and equipment to deal with such items as process temperature ranges from -200°C to 1850°C (-330°F to 3360°F) or greater or at pressure/vacuum levels heretofore only achievable in laboratories or specialty applications.

As product sizes decrease, load sizes will become smaller out of necessity. And as a result, our heat treat equipment must be small lot capable with tighter controls to achieve higher quality along with tremendous process flexibility.

Final Thoughts

History’s enduring legacy is that change is inevitable. Just think back to how the heat treatment industry has evolved, from the campfire to the blacksmith to the modern heat treater, from the artisan to the era of mass production, from the art of heat treating to the science of heat treatment. The lesson is that to adapt, one must constantly innovate and invent. Miniaturization, portability and customization in whatever form they take are here to stay. Perhaps even teleportation (the ultimate miniaturization?) isn’t that far off after all, considering flight was unheard of a little over a century ago.

About the Author:

Dan Herring
(The Heat Treat Doctor®)
The HERRING GROUP, Inc.

Dan Herring has been in the industry for over 50 years and has gained vast experience in fields that include materials science, engineering, metallurgy, new product research, and many other areas. He is the author of six books and over 700 technical articles.

For more information: Contact Dan at herring@heat-treat-doctor.com.

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Ask the Heat Treat Doctor®: How Do Parts Fail?

October 22, 2024 / AEROSPACE HEAT TREAT TECHNICAL CONTENT, ATMOSPHERE AIR FURNACES TECHNICAL CONTENT, Manufacturing Heat Treat Technical Content

The Heat Treat Doctor® has returned to offer sage advice to Heat Treat Today readers and to answer your questions about heat treating, brazing, sintering, and other types of thermal treatments as well as questions on metallurgy, equipment, and process-related issues.

Product failures (Figure 1) can often be traced to deficiencies in design, materials, manufacturing, quality, maintenance, service-related factors, and human error to name a few. Examples of failures include misalignment, buckling, excessive distortion, cracking, fracture, creep, fatigue, shock, wear, corrosion, and literally hundreds of other mechanisms. Let’s learn more.

Figure 1. Image of damage to left fuselage and engine; fire damage to nacelle.
Source: National Transportation Safety Board

Figure 2.: Model of material science depicting— key interactions and /interrelationships
Source: The HERRING GROUP, Inc.

Whatever the source, it is important to recognize that it is next to impossible to separate the product from the process. Performance, design (properties and material), metallurgy (microstructure), heat treatment (process and equipment), and maintenance are all interconnected (Figure 2).

When considering ways to prevent failures from occurring, one must determine the factors involved and whether they acted alone or in combination with one another. Ask questions such as, “Which of the various failure modes were the most important contributors?” and “Was the design robust enough?” and “Were the safety factors properly chosen to meet the application rigors imposed in service?” Having a solid engineering design coupled with understanding the application, loading, and design requirements is key to avoiding failures. If failures do happen, we must know what contributed to them.

Let’s review a few of the more common failure modes.

Fracture Types on a Macroscopic Scale

Applied loads may be unidirectional or multi-directional in nature and occur singularly or in combination. The result is a macroscopic stress state comprised of normal stress (perpendicular to the surface) and/or shear stress (parallel to the surface). In combination with the other load conditions, the result is one of four primary modes of fracture: dimpled rupture (aka microvoid coalescence), cleavage, decohesive rupture, and fatigue.

Virtually all engineering metals are polycrystalline. As a result, the two basic modes of deformation/fracture (under single loading) are shear and cleavage (Table 1). The shear mechanism, which occurs by sliding along specific crystallographic planes, is the basis for the macroscopic modes of elastic and plastic deformation. The cleavage mechanism occurs very suddenly via a splitting action of the planes with very little deformation involved. Both of these micro mechanisms primarily result in transgranular (through the grains) fracture.

Fracture Types — Ductile and Brittle

Numerous factors influence whether a fracture will behave in a ductile or brittle manner (Table 2). In ductile materials, plastic deformation occurs when the shear stress exceeds the shear strength before another mode of fracture can occur, with necking typically observed before final fracture. Brittle fractures occur suddenly and exhibit very little, if any, deformation before final fracture. (The following is based on information found in Wulpi, 1985.)

Ductile fractures typically have the following characteristics:

Considerable plastic or permanent deformation in the failure region
Dull and fibrous fracture appearance

Brittle fractures typically have the following characteristics:

Lack of plastic or permanent deformation in the region of the fracture
Principal stress (or tensile stress) is perpendicular to the surface of the brittle fracture
Characteristic markings on the fracture surface pointing back to where the fracture originated

When examined under a scanning electron microscope, fracture surfaces seldom exhibit entirely dimpled rupture (i.e. ductile fracture) or entirely cleavage (i.e. brittle fracture), although one or the other may be more prevalent. Other fracture modes include intergranular fractures, combination (quasi-cleavage) fractures and fatigue fractures.

Fracture Types — Wear

Wear (Table 3) is a type of surface destruction that involves the removal of material from the surface of a component part under some form of contact produced by a form of mechanical action. Wear and corrosion are closely linked, and it is important not only to evaluate the failure but to take into consideration design and environment and have a good understanding of the service history of a component.

Fracture Types — Corrosion

Corrosion is the destruction of a component by the actions of chemical or electrochemical reactions with the service environment. The major types of corrosion include galvanic action, uniform corrosion, crevice corrosion, stress-corrosion cracking, and corrosion fatigue. The mechanisms and effects created by each of these are well documented in the literature, as in Fontana and Greene’s Corrosion Engineering (1985) and Uhlig’s Corrosion and Corrosion Control (1985). It is critical to understand that the effects of corrosion are present to some degree in every failure analysis, which is one of the reasons why protecting fracture surfaces is so critical when sending parts for failure analysis.

Table 1. Differences between shear and cleavage fracture (Data referenced from page 23 of Wulpi, see References.)
Source: The HERRING GROUP, Inc.

Table 2. Typical characteristics of ductile and brittle fractures
Source: The HERRING GROUP, Inc.

Table 3. General categories of wear
Source: The HERRING GROUP, Inc.

Final Thoughts

To avoid failures or their reoccurrence, it is important to document each step in the design and manufacture process (including heat treatment). In addition, careful documentation of failures if/when they occur is of critical importance as is assembling a team of individuals from different disciplines to perform a comprehensive investigation. This includes a thorough failure analysis to assist in determining the root cause (there is only one) and to avoid it from happening in the future.

References

Airline Safety. www.AirlineSafety.com. Accessed September 2024.

Fontana, M. G., and N. D. Greene. Corrosion Engineering, 3e. McGraw-Hill Book Company, 1985.

Herring, Daniel H. Atmosphere Heat Treatment, Volume Nos. 1 & 2. BNP Media, 2014/2015.

Lawn, B.R. and T. R. Wilshaw. Fracture of Brittle Solids. Cambridge University Press, 1975.

Shipley, R. J. and W. T. Becker (Eds.). ASM Handbook, Volume 11: Failure Analysis and Prevention. ASM International, 2002.

Uhlig, H. H. Corrosion and Corrosion Control. John Wiley & Sons, 1963.

Wulpi, Donald J. Understanding How Components Fail. ASM International, 1985.

About the Author

Dan Herring has been in the industry for over 50 years and has gained vast experience in fields that include materials science, engineering, metallurgy, new product research, and many other areas. He is the author of six books and over 700 technical articles.

For more information: Contact Dan at dherring@heat-treat-doctor.com.

For more information about Dan’s books: see his page at the Heat Treat Store.

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3 Aspirational Heat Treat Legends

September 19, 2022 / FEATURED NEWS, MANUFACTURING HEAT TREAT

What makes the North American heat treat industry of 2022 what it is? As with any industry, the heat treating world is made up of the people who now inhabit it and the people who paved the way for them. Let’s take a moment to think about the past and what we owe to the industry giants, those trailblazers who have guided so many. In that spirit, enjoy the life stories of these three Heat Treat Legends from Heat Treat Today's September 2022 print edition. After all, the industry is only as good as the people in it.

To listen to the life stories on Heat Treat Radio, click the section headings below.

Heat Treat Legend: Bill Jones, Solar Atmospheres Group of Companies

Lost patents, risking a million dollars, and unleashing an entrepreneurial spirit he didn’t know he had. These are just a few things that characterized Bill Jones’ life.

“First, you want to do something that you’re happy doing . . . Then, you must be properly prepared for it. You must have enough education to go forward.” So says Bill Jones, CEO of Solar Atmospheres Group of Companies. A self-proclaimed “technocrat,” Bill remembers being interested in technology from an early age. Technology was the “something” Bill was happy doing.

Throughout Bill’s career, his love of technology often led his peers to complain, “You know, Bill, you’re always interested in technology, and you’re not interested in whether you’re making money or losing money.” The complainers may have been right about Bill’s interests, but they were wrong about how much his love of technology would hinder his ability to make money. Today, Bill and his wife Myrt are the sole owners of four successful, family-owned heat treat companies based in North America: Solar Atmospheres, Solar Manufacturing, Magnetic Specialties, and Vacuum Furnace Systems.

"There is nothing that beats hard work and dedication to what you are trying to do." - William Jones

How did Bill go from being simply a technocrat to the owner of multiple businesses? Bill’s answer: work ethic and education. There is no substitute for being willing to put in more than 40 hours a week and to dedicate yourself to your work. But, Bill says, education is also a must: “We, as practical people in the heat treat industry, tend to pooh-pooh education,” and “[the] basis of what we do comes from chemistry. Metallurgy grew out of chemistry. If you don’t have a decent educational background, then you don’t know the basis of where we came from because that’s the basis of where we’re going.”

Armed with his education and his work ethic, Bill began his journey into the world of technology by working with dew point analyzers. At the time, there was no way to continuously monitor dew point or moisture, and Bill’s first project was to produce a dew point analyzer that could measure one to two parts per million. From measuring dew point, Bill moved on to measuring temperature, and this was his introduction into the furnace industry. In 1963, Bill began a career at Abar, where he used his experience designing optical pyrometers to produce thermocouples that could be used at above 4000°F.

At Abar, Bill worked as the equivalent of a chief engineer on a project that he would later characterize as one of the greatest accomplishments of his life: designing a vacuum furnace with a horizontal ring hot zone. When the new furnace started up for the first time, Bill saw what a ring hot zone could do. Bill still remembers the experience: “When I tested that first round hot zone, I did it by myself at night in a plant where I was the only one there. We had a big sight glass in the front of the furnace, and I could see the entire hot zone, the heating element, the heat shield, the ring and so forth, and I was able to measure the temperature and it was [like] ‘WOW. This thing works!’”

True to his technocrat identity, Bill views this furnace as his greatest accomplishment, not the success of starting his own companies. Along with the development of this furnace, Bill helped to develop the graphite hot zone, which later replaced the metal hot zones at Abar. With graphite hot zones, riveting was unnecessary, and the elements could be bolted together with graphite screws and nuts. One of Bill’s greatest regrets in life was not patenting the horizontal ring furnace. “We should have,” Bill says, “but we didn’t know what we had, honestly, and then it got out into the fi eld anyway and we couldn’t patent it.”

Lost patents, however, did not get in Bill’s way. Bill is also proud of the car bottom furnaces built at Solar’s Hermitage location in Western Pennsylvania. Bill remembers the weekly design meetings and running the furnace for the first time. The car bottom furnace was designed to process heavy titanium coils, and Bill was so confident in his work that he insisted on running the furnace for the first time with a million dollars of titanium coils inside. A coworker, Bob Hill, said, “Bill, you’re not going to run the final product first. I think we should make a run with just some scrap steel that we have around.” Bill replied, “No, Bob. I am thoroughly convinced this furnace is going to work and work right.”

Today, Bill and his wife Myrt are the sole owners of three successful, family-owned companies based in North America: Solar Atmospheres, Solar Manufacturing, and Magnetic Specialties.

Bill’s confidence paid off ; the car bottom furnace worked correctly the first time.

Chronicling his experiences, Bill wrote The Golden Nugget: An Entrepreneur Speaks. Bill’s identity as an entrepreneur was a surprise to him. Bill credits Dr. George Bentley with inspiring his entrepreneurial spirit: “Bill, I want to tell you something,” Dr. Bentley said, “I have observed you over the years and I can tell you, you are never going to be happy until you run your own business.” At the time, Bill did not realize the wisdom of the advice, he did not see himself as an entrepreneur. But now, Bill realizes, “Until you’re sitting in the top chair and until you’re making the decisions of winning and losing, you don’t know what it’s all about.”

Entrepreneurship (no matter how unplanned), innovation, valuing education, worth ethic, and above all else, a love of technology all helped Bill Jones along the road to success. And the main motivation? “Well, it’s very simple: Money is not a driving factor in my life or in my wife’s life. Money is not it. You know, the old saying is, when you go to the grave, there’s not going to be a U-Haul behind you.”

Heat Treat Legend: Dan Herring, The Heat Treat Doctor®, The HERRING GROUP, Inc.

What’s the job of a good doctor? First, do no harm. This mantra, combined with Dan Herring’s love of doing good by solving critical problems, made him what he is today: The Heat Treat Doctor®.

The Heat Treat Doctor® has worn many, many hats throughout his more than 50 years in the heat treating industry. He was a metallurgist, a corporate trainee, an international marketing worker, an applications engineer, a technical director, a research and development director, a product manager, a chief engineer, and finally: an entrepreneur, the owner of his own consultancy, The HERRING GROUP, Inc. In Dan’s own words: “You might say that I’ve been chief cook and bottle washer of the industry, if you will.” These various jobs, and the multitude of different responsibilities that went along with them, taught Dan everything he knows today, developed him into The Heat Treat Doctor®, and made him worthy of being a Heat Treat Legend.

Looking back on his success, Dan points first to his parents for helping him to become the best version of himself. Dan grew up with one parent that gave him a love of technology and equipment and with one parent that give him a love for language and writing. Dan’s father, a machinist, was a hands-on worker and “one of the most inventive people that I ever met.” Later, Dan combined the technical skills he learned from his father with his education as an undergraduate in engineering and a graduate student at the Illinois Institute of Technology.

Dan’s mother, a registered nurse, was “an English teacher in disguise.” She gave Dan a love of writing. For over 10 years, Dan authored a monthly column for Industrial Heating. Columns, however, are not the extent of Dan’s writing expertise. He has also authored: Vacuum Heat Treating, Volumes I & II, and Atmosphere Heat Treating, Volumes I & II. These four books are excellent resources for heat treaters, both novices and experienced industry professionals. Dan has written 10 books in total, six of which deal with the heat treating field. Dan is proud of these books because he can share what he knows with others forever, just as others passed knowledge to him.

“I think it’s interesting,” Dan says, “I have had the extremely good fortune of working for two or three people that actually fell in the genius category. These people were absolutely, positively of genius intellects and they worked within the heat treating industry.” During Dan’s time at Lindberg, he met Hobart Wentworth. Wentworth taught Dan the discipline of engineering, taking Dan’s university knowledge into the real world. Also at Lindberg, Dan was introduced to Russ Novy, chief metallurgist. Dan commends Novy for his “infinite patience . . . to tell you what he had learned and explain things and talk about the root cause of things.” When Dan worked at C.I. Hayes, he met Herb Western, a man who holds over 300 patents in the state of Rhode Island. Western showed Dan how to be creative and inventive within the heat treating industry.

Vacuum Heat Treating, Volumes I & II
Atmosphere Heat Treating, Volumes I & II
(For more information: www.heatreattoday.com/industryresources/books/herring-books)

One of Dan’s greatest accomplishments was establishing The Heat Treat Doctor® brand. “The brand,” Dan says, “has brought heat treating into the forefront of manufacturing, into the forefront of the industry, into the forefront of engineering, that yes, there is something called heat treating and it is a solution to your needs. So, I view the brand as not so much a personal accomplishment but as an industry accomplishment.”

Dan’s love of words gives him a unique skill set. Not only does he understand metallurgy and engineering, but he is also patient enough to explain it and has the communication skills to explain it well.

When it comes to business, Dan’s main rule is: “Be honest . . . be ethical, be fair, try hard, communicate well and have infinite patience. In other words, not everyone understands what you’re saying. You must take the time to explain what you mean to the people you’re dealing with. Although that’s a strange answer on the business side, I think it’s most impactful.” Dan takes pride not only in doing good throughout the industry, but also, like a good doctor, doing as little harm as possible. Helping others with critical problems, getting companies back in operation, and preventing layoffs are events that stand out the most to Dan.

When it comes to life, Dan’s mantra is: Enjoy the moment. “I remember the first day I started to work at Lindberg,” Dan says, “I took the train to work, it was right across the street from the train station, I was walking across the street, I was 21 years old, and I said to myself, ‘Only 44 years to go.’ And I turn around and the 44 years have disappeared like it was yesterday. So, you must enjoy what you do, and you’ll never work a day in your life.”

Dan attributes his success in the industry to the people around him. He points not only to his parents for his success, but also to the “geniuses” he has worked with along the way, and to the industry at large. Speaking of his entry into Heat Treat Legend status, Dan says, “I just want to say that I consider this a distinct privilege to be considered one the Heat Treat Legends. But I’d also like to point out to everyone . . . that no one individual can do it by themselves. So, I’m accepting this accolade, if you will, on behalf of the many men and women who toiled in, what I’m going to call, relative obscurity and who made this industry what it is today. On their behalf, I’m more than willing to be considered one of the Heat Treat Legends.” Spoken like a true legend.

Heat Treat Legend: Suresh Jhawar, G-M Enterprises

“Happy, happy, happy.” In Suresh Jhawar’s experience, the best way to run a business is to focus on happy employees, happy customers, and happy bottom lines.

What happens when a young man comes to the United States against his parents’ wishes to earn a bachelor’s degree in Engineering? He becomes the sole owner of G-M Enterprises and gets the title of Heat Treat Legend. At least, that is what happened for Suresh Jhawar, a self-proclaimed “average student in India.”

Without the support of his parents, Suresh weighed the odds of coming to America versus studying in Germany or the U.K. and applied for his visa and passport in a library, away from his parents. When Suresh discovered he could earn his degree in half the time with his advanced credit, he chose the United States and boarded a plane, arriving in the States in 1962. At Marquette University in Milwaukee, Suresh went on to earn a master’s degree in Mechanical Engineering and an MBA in Marketing.

Before taking ownership of G-M Enterprises, the two heat treating companies that were most influential for Suresh were Abar and Ipsen. Suresh began his time with Ipsen in 1970 as a project engineer for vacuum furnaces. Suresh was in the top five at Ipsen, and, looking back, he sees himself driving the company in cost savings, product improvement, and customer relationships.

As the assistant to the president at Ipsen, Suresh traveled extensively to Poland to visit a facility for steel milling and annealing silicon steel coils for transformer steel. During this time of heavy travelling both at Ipsen and later at Abar Furnaces — Suresh visited Poland ten times in less than two years — he remembers the difficulty of keeping a healthy work/life balance. But he succeeded most of the time: “[W]hen Andy [Suresh’s son] was getting an award at his high school, I was coming from Europe . . . I missed my connection. Now it became difficult as to how to get to Philadelphia to attend that awards ceremony for my son . . . I went from one airline to another. I got on a plane, reached Philadelphia airport at the time when the program started, but I was at the school at the right moment when Andy’s name was called. I was there!”

Difficult though it may have been, Suresh often succeeded in keeping work and life in balance. At Ipsen, work consisted of many projects, one of which involved helping Ipsen book an order for 10 large car bottom furnaces. While Ipsen’s president handled the commercial aspect of the order, Suresh handled the technical side of things. He had to make sure the company had the right product and the right solution. And the 10 car bottom furnaces — 84 inches wide by 45 inches high by 32 feet long, made in four bolted sections — were indeed the right solution.

“What I believe is ‘happy, happy, happy’: happy employee, happy customer, happy bottom line.” - Suresh Jhawar

It was at the same time as this project that Suresh was also working on Ipsen’s license agreement with Elterma, which later became SECO/WARWICK. Suresh’s work at Ipsen lasts to this day. Without Suresh, Ipsen would have no manufacturing base in India. Suresh enlisted Wessman Engineering as a sales agent for Ipsen, which began Ipsen’s history in India.

Abar was Suresh’s act two. Suresh wanted to run the entire operation, and Abar gave him the opportunity to do this. Under Suresh’s leadership, Abar increased its profit significantly, and Suresh was asked to write a justification for the merger between Ipsen and Abar. At G-M Enterprises, Suresh’s skills were on full display. Suresh entered G-M Enterprises as a partner holding 15% interest. Within a year, Suresh bought out one of the other partners, and later, in 2005, Suresh took full ownership of the company. He changed the official name of the company to Jhawar Industries and continued to do business as G-M Enterprises. When Suresh joined G-M Enterprises, it was a break-even company. By the time he retired, it was doing business all over the world. “I’m pretty sure,” Suresh says, “that we had the highest bottom line in the industry.” In 2005, Suresh hired his wife, Veena Jhawar, as the director of supply chain, enabling him to focus entirely on developing customers and innovating vacuum furnaces. Suresh’s innovation did not stop there as he was also instrumental in developing the MIM furnace. By 2018, G-M Enterprises was a leading supplier to GE from Singapore to Japan and Brazil.

How did he do it?

“What I believe is ‘happy, happy, happy’: happy employee, happy customer, happy bottom line.” When it comes to happy employees, Suresh says, “The most important thing is to treat your employees like you treat yourself. When I worked at G-M, out of any of the other places, I didn’t work as being ‘the boss’ or on a high platform; I worked shoulder to shoulder with them.” In order to be successful, Suresh believes you must respect your employees and reward them for their contribution, and hopefully, they will be loyal to the company.

Loyal employees make for happy customers. Happy customers, in Suresh’s thinking, have to feel they are a critical part of the solution. This was one of G-M Enterprises’ best qualities. If a customer had a problem, someone from G-M would jump on a plane and fix it, attending to the problem first and worrying about the terms later. Listening to what customers actually wanted, rather than simply giving them what the company already had, was a crucial part of building customer loyalty. With these two principles in place — happy employee and happy customer — the bottom line grew happier and happier.

With these two principles in place — happy employee and happy customer — the bottom line grew happier and happier.

Along the way to a happy bottom line, Suresh discovered the importance of meeting deadlines. Suresh remembers showing up to a production control meeting with no drawings in hand and the others in the room laughing at him. Suresh could tell they were thinking, “He puts pressure on us, but he doesn’t do his own job.” And so, Suresh never went home that day, but instead worked through the night. In the morning, he put all the drawings into the hands of the engineering crew. “Meeting deadlines and commitment, to me, is always number one. No excuses . . . That helps you to expect [the same] from other people, [because] when they see you — that you do that — they follow.”

Reminiscing, Suresh remarks, “We always treated our employees as family members and gave them due respect for their contribution.” For Suresh Jhawar, success in business is all about happiness.

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Nitriding vs. FNC

August 10, 2021 / FEATURED NEWS, MANUFACTURING HEAT TREAT, NITRIDING TECHNICAL CONTENT, NITROCARBURIZING TECHNICAL CONTENT

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

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

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

original content

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Heat Treat Radio (Special Video Edition): Heat Treat Tomorrow – Experts Look Forward 10 Years

August 3, 2021 / FEATURED NEWS, HEAT TREAT RADIO

Doug Glenn, publisher of Heat Treat Today, moderates a panel of 5 experts who address questions about the next 5-10 years in the heat treat industry. What are the trends and what should you prepare for. Experts include Peter Sherwin, Eurotherm by Schneider Electric; Janusz Kowaleski, Ipsen Group; Andrew Bassett, Aerospace Testing & Pyrometry; and Dan Herring, the Heat Treat Doctor from The HERRING GROUP, Inc.

You can view this special video edition of Heat Treat Radio by clicking the button below.

Watch Now!

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State of Industry 4.0 in the North American Heat Treat Market

January 19, 2021 / CONTROLS TECHNICAL CONTENT, FEATURED NEWS, MANUFACTURING HEAT TREAT

State of Industry 4.0 in the North American Heat Treat Market: What’s Being Done and Who’s Using It?

What is “Industry 4.0” and how is this new technology being used in the heat treat industry? Industry experts spoke with Heat Treat Today about their involvement with this cutting-edge application of technology. To learn how you can implement Industry 4.0 at your plant, read what experts have to say about the problems, solutions, and the future of Industry 4.0.

In this Heat Treat Today Original Content article, Peter Sherwin at Eurotherm, Aymeric Goldsteinas at Ipsen, Robert Szadkowski at SECO/WARWICK Group, and Dan Herring at The HERRING GROUP, Inc. bring varied perspectives as they tackle this topic.

“I think IoT should be better applied – period!”

– Peter Sherwin, Global Business Development Heat Treatment Executive, Eurotherm

Industry 4.0 and “the internet of things” (IoT) were hot topics in the crammed online chatrooms of this year’s heat treat events. But exactly what are these technologies in the world of heat treat? What are the current applications that three leaders in Industry 4.0 have applied? What are some problems and solutions that this new tech brings? And lastly, what is the future of Industry 4.0?

This article will begin by explaining and defining a few prominent technologies before answering each of these questions. Then, read a few thoughts from The Heat Treat Doctor® as you think about application to your heat treat process.

What Is It and Why Does It Matter?

Basically, the term “Industry 4.0” refers to the Fourth Industrial Revolution. See the chart for a breakdown of major topics of the first three industrial revolutions.

Infographic of the four industrial revolutions. Source: Heat Treat Today (images ref. 11)

The idea of new communication is sometimes referred to as cyber-physical connections. This is occurring right now! For example, a sensor (cyber) can monitor a furnace (physical) and send information about the furnace’s conditions to a central data sorting location (connection) for a human to synthesize and respond. The Fourth Industrial Revolution – Industry 4.0 – refers to how the communication between the physical world and the digital world are seamlessly connected.

A key feature of Industry 4.0 is the internet of things (IoT), but other technologies like artificial intelligence (AI), augmented reality (AR), virtual reality (VR), and machine learning also play a part. Let’s define a few of these Industry 4.0 terms that you will see later in the article:

IoT: refers to the physical networking of objects via internet-supported software. Similarly, the “industrial internet of things” (IIoT) refers to these systems supporting industrial purposes, like synthesizing information from furnace sensors on a central app.
artificial intelligence (AI): machines which can process and perform complex directions in a way that mimics natural intelligence.
augmented reality (AR): digital enhancement of a real-world environment. Think of phone apps which can portray a digital overlay on a video feed, like Snapchat lenses.
virtual reality (VR): digital experience that may be interactive with the real-world environment, or completely simulated.
machine learning: an extension of AI, machine learning describes the result of computer algorithms which modify their performance based on repeated input.

While engineers have been pursuing these new applications for several years, COVID-19 has been a driving factor for businesses to pursue technical options in their daily operations due to limits on travel and physical contact.

[blockquote author=”Robert Szadkowski, VP of Aftermarket Sales, SECO/WARWICK Group” style=”1″]Remote acceptance testing is a highly requested service today. I could say that the financial rationale for such action has always existed, while the epidemiological threat has been the catalyst for change. It is a win-win action.[/blockquote]

According to Aymeric Goldsteinas, project development manager at Ipsen, customers are becoming more willing to implement Ipsen’s Industry 4.0 endeavors, even cloud-based solutions, a willingness that was not present just one decade ago. So how is the heat treat market responding?

Current Applications

We asked suppliers how they implemented Industry 4.0. What follows is how they responded.

Ipsen | PdMetrics

Ipsen launched a software system in 2016. The company continues to develop and improve its predictive maintenance capabilities to service many of their current customers.

Part of the system’s customer appeal, said Aymeric Goldsteinas, product development manager at Ipsen, is that it can “minimize high-cost events and maximize furnace up-time.”

This is done by using sensor technology and gathering data in their PdMetrics database, which then anticipates future furnace problems. This reduces unplanned downtime and could help heat treaters avoid scrapping loads of high-value parts.

From a consumer perspective, this IoT technology solution leads to improved part quality and part performance.

How it works: PdMetrics assigns a variety of sensors to each system in the heat treat process. For example, a quench system sensor checks vibrations, cooling motor temperature, and water temperature.

Source: Ipsen Harold
Click the image to read 5 case studies on PdMetrics.

On Ipsen’s client digital dashboard via PdMetrics, Goldsteinas showed the heat treating systems depicted with a green-yellow-red gauge to portray the working condition of that system. Green indicates that the system is well-maintained, yellow indicates a system needs to be maintained soon, and red means that maintenance is needed immediately. This easy-to-use display is also an example of how Industry 4.0 technologies create user-friendly experiences and cut out excess human input.

This product was used by an aerospace manufacturer to update their systems, integrating this software with their heat treatment process. The results were noticeably increased efficiency of parts and less unplanned downtime. The company was able to schedule maintenance at off-peak hours and plan for future needs by using the platform’s ability to identify maintenance trends, deteriorating conditions, and more.

Check out the post to the side to see how a heat treater was able to save thousands to tens of thousands of dollars with PdMetrics system.

While this company has set the pace with their early adoption of IoT in the heat treat industry, it is worth noting that other companies also offer similar products.

Eurotherm | Cloud-based advisors, visualization software, edge-computing technology

EcoStruxure: Manufacturing Compliance Advisor
Source: Eurotherm.com

In 2013, Eurotherm began their transition to IoT technologies.

“One of our first true cloud-based solutions focused on improving the efficiency of the calibration process,” said Peter Sherwin, global business development heat treatment executive of Eurotherm. He continued, “This system connects third-party calibration providers with their end-customers and provides an enterprise-wide web view of the calibration status (via dashboards) and access to reports. The smart-tablet app provides an easy-to-follow workflow for conducting a compliant calibration and produces an instant report along with the associated QR-code label.”

Referring to their web-based systems and use of cloud platforms, Sherwin said, “along with our parent, Schneider-Electric, we have developed a range of edge-computing solutions to allow simple transfer of data from the plant-floor to cloud-based advisors and visualization software.”

Sherwin says that their systems are being used globally. “Our enterprise calibration platform,” he shared, “is being utilized by several partner companies as well as in Schneider Electric GSC (Global Supply Chain) Manufacturing plants worldwide.”

Sherwin also noted a variety of IoT applications that Eurotherm provides:

A cloud-hosted digital services platform, EcoStruxure™ Manufacturing Compliance Advisor uses asset compliance to “reduce testing costs, increase productivity and be audit-ready with a robust scheduling and testing process.”
A system called EcoStruxure™ Machine Advisor “allows OEMs to track, monitor and fix equipment remotely.” Additionally, operators can predict and execute maintenance schedules, which improves machine availability.
On a mobile device, EcoStruxure™ Augmented Advisor combines “contextual and local information… creating a fusion of the physical, real-life environment with virtual objects.”

Case in point: “An OEM machine manufacturer in the ceramics industry helps customers reduce their energy consumption by 30% by leveraging our IoT software,” Sherwin shared.

SECO/WARWICK | Remote Factory Acceptance and Activation Tools

Recently SECO/WARWICK publicized the fact that they successfully conducted several international and remote factory acceptance tests. Two customers from China, one from South Korea, and one from Mexico all participated. Each customer was able to remotely approve the furnace construction and performance work of their new furnaces while the furnaces were still on the shop floor in SECO/WARWICK’s European manufacturing facility. No customer engineers were involved on-site at the factory.

Recordings from individual cameras, sensors and viewfinders were downloaded to secure servers and made available to customers. The tests were successful, and the adopted procedures guarantee the reliability and completeness of the data, according the company report.

The company has been using these technologies for “internal device supervision for at least ten years,” according to Robert Szadkowski, VP of Aftermarket Sales at SECO/WARWICK. “In our work,” he continued, “we use remote supervision tools and applications, we report overall equipment efficiency (OEE) indicators, and we conduct optimization processes in terms of batch queuing or energy factor consumption.”

Szadkowski at SECO/WARWICK remarked that for most systems, distance furnace commission is very likely. He explained, “It starts at the stage of making arrangements regarding the expected technical and technological parameters, continues throughout the production and commissioning period, and then during the warranty and post-warranty period. The participation of the customer, the end user of the furnace, in the acceptance tests is required, as is training of the operating personnel […]. There are exceptions to this when dealing with high-risk systems, but for many systems this would be perfectly acceptable.”

Still, Szadkowski noted that “this will be primarily a challenge to our ideas and internal acceptance, rather than to technical limitations.”

C3 Data | End-User System Compliance

Finally, the C3 Data application for furnace compliance is an example of an interrelated, stream-lined, digital solution that provides customers with clear, “real-time” data.

12 Second SAT.mp4 from C3 Data on Vimeo.

Digitizing data ahead of time integrates testing processes. The system scheduler allows compliance tests to be planned ahead of time. Digitizing the calibration data allows for technicians to scan QR codes attached to test instruments and test sensors to access that data as they test for compliance.

When compliance is tested, the results are immediate for the technician and the quality assurance manager (QAM). The technician uses a portable device to complete these tests, scanning the test instrument and the test sensor, and then inputting the stabilized temperatures from the test instrument and the furnace instrument. In twelve seconds, a technician can complete a system accuracy test (SAT); watch the video above to see the SAT Additionally, the system automatically populates paperless reports to be signed and sent to the QAM. This allows the quality assurance manager to check the reports in real time.

Similar to earlier products, a digital dashboard depicts furnace compliance data. The graphic visualizations allow users to quickly evaluate which furnaces are in compliance, and, if not, why.

Problems // Solutions

Businesses have experienced a few problems with integrating the technology. But there are solutions.

Aymeric Goldensteinas
Product Development Manager
Ipsen
Source: padtronics.com

The first problem is data storage. Like all storage, data storage is finite, and therefore costly. The use of interrelated systems that require high volumes of data to flow between sensors and central systems necessitates investment on the front end for storing data. Additionally, having limited bandwidth to keep digital communication lines open can cause blackouts and connectivity issues. But after acquiring storage, there are practices to use that storage as efficiently as possible.

A solution that Ipsen implements to alleviate this active/working storage stress is “the frequency rule.” This rule establishes a rate of data movement to allow data to move across system memory.

A second issue is privacy/security. It is necessary that the heat treater’s product or process data is properly secured, and while the supplier has certain responsibilities to mitigate this issue, heat treaters should be aware of ways to safeguard their intellectual property. One option, which Ipsen suggests, would be to purchase a unique VPN to ensure better data security. Some companies, including Ipsen, use a stand-alone system that works independent of the PLC, which ensures proprietary data is kept private while following secure industry software standards.

A third issue is user acceptance or, simply put, how comfortable you are with 4.0 technologies. If a heat treater is not comfortable with the technology itself, then Industry 4.0-related tech can be more difficult to implement. On the flip side, suppliers — regarding all processes — must be ready and able to meet the customer’s demands for new products, as Dan Herring, The Heat Treat Doctor®, has indicated. (Ref. 5) An example of digital demands is the AMS2750F requirement that paper chart recorders be replaced with digital data acquisition systems by June 29, 2022.

User acceptance relates to the final problem: relationship with the supplier. While not a bad thing in and of itself, if your relationship with your supplier is not good, then it will be a challenge to develop an effective Industry 4.0 solution process. Be sure you develop an open, communicative relationship with your supplier so that they can offer you unique solutions for your plant’s operation.

The Future of Heat Treat

Here are some interesting applications that people in the industry are looking to with the progression of Industry 4.0:

1. Increased Servitization

Robert Szadkowski
Director, Vice President of the Aftermarket Sales Segment
SECO/WARWICK
Source: Robert Szadkowski

Szadkowski at SECO/WARWICK emphasized that these rapid changes to heat treat systems makes it likely that the servitization — the selling of services rather than products — of the heat treat industry is likely to develop in the near future.

“I am strongly convinced,” Szadkowski wrote, “that sooner or later the servitization will cover the heat treatment industry. When looking at the potential benefits, it’s basically inevitable. The customer, user of the furnace, will be able to focus on their core business instead of worrying about the operation of the furnaces. The manufacturer of the device will be keenly interested in ensuring that its furnace works flawlessly (so that the availability is as high as possible) and brings business benefits to the user. What’s more, with a correctly prepared PaaS (Product as a Service) contract, the OEM will also be interested in improving the operating parameters of such a device after delivery.”

He continues that “Such solutions have existed in the industry for years, e.g. the Rolls-Royce model of selling aircraft engines known as Power-by-the-Hour. The benefits are on both sides; both parties can focus on what they are best at and what is their core business, reducing costs and increasing efficiency. Both parties are interested in long-term cooperation, not a one-off transaction. In light of global problems with access to service engineers, including maintenance staff, the shift of responsibility for the operation of devices from the user to the manufacturer is a natural direction of change.”

2. Augmented Reality / Mixed Reality / Virtual Reality Glasses

There are a few hypotheses revolving around the use of AR service glasses. SECO/LENS augmented reality is currently being explored. This would help in providing remote field service support to the heat treater.

Ipsen’s Goldsteinas has also noted several benefits. He explains the application working by connecting a customer or field service engineer who is at the site with an expert from Ipsen or another service provider. This remote assistance wherein an informant is able to see a problem and give first-hand direction is a common example used to describe the benefits of AR. This application could, for example, decrease the down-time if a furnace were to unexpectedly fail.

Additionally, Goldsteinas envisions training sessions that are conducted in mixed reality. Using virtual reality with an oculus — a type of goggle that digitally enhance or recreate a digitally interactive, environment — companies could reduce training time by recreating experiences, like meetings or practical training sessions, that could be collaborative or solitary. Mixed reality devices like the HoloLens may also be integrated for similar purposes. (Watch video to the right to see examples of Microsoft’s HoloLens and other enhanced reality examples.)

5 examples of #AugmentedReality and #VirtualReality #technology changing the way we #learn and #work #VR #AR #IoT #AI #FutureofWork #DigitalTransformation #CES2021
cc @GlenGilmore @SpirosMargaris @jblefevre60 @Paula_Piccard @pascal_bornet @kuriharan

pic.twitter.com/a8RwPkuYnO

— Harold Sinnott #CES2021 ? (@HaroldSinnott) December 13, 2020

The future could also involve virtual collaboration in the form of an augmented reality meeting room to allow employees from across different Ipsen facilities to discuss and interact with the same content in real-time

3. Efficient Cloud Capabilities

Peter Sherwin personally foresees that attention to the Cloud’s abilities and security will be leveraged in new ways: “An example of this is looking at some of the cost-effective modern-day instrument SCADA [supervisory control and data acquisition] offerings that can provide an on-premise hub for certain applications while managing security policies for linking to cloud based IoT offers.”

4. Increased Systemwide Application

Specifically looking at IoT technologies, Sherwin shared, “I think an expanded view of IoT that encompasses automation across the enterprise (termed as Intelligent Automation or Hyperautomation) is more useful if you really want to achieve significant returns on investment [of IoT technologies]. IoT solutions can improve speed and reduce costs across sales, operations, maintenance, quality, service and administration.”

Advice: To Use or Not To Use

Dan Herring, The Heat Treat Doctor®, has written about Industry 4.0 and how thinking about seven considerations in any continuation of or change to one’s heat treating process is essential. Ask yourself:

Do I understand what I want to accomplish metallurgically?
Can I predict the outcome of the heat treatment operation?
Can I build repeatability into the process?
Am I using state of the art heat treating equipment?
Am I aware of changes to manufacturing operations?
Am I compromising on quality?
Do I know the costs?

At the end of the day, noted The Heat Treat Doctor®, heat treaters need to know that what they are doing is being done the right way, the first time with the best procedures and processes for their particular operation.

Reflections on The Heat Treat Doctor®

Peter Sherwin of Eurotherm commented on the seven-part advice of The Heat Treat Doctor®, noting, “I think it is very appropriate to look at the value of IoT through the seven considerations that [he] outlines. Building these solutions requires heat treat know-how and an understanding of the data to be captured in order to provide valuable solutions. Value is unlocked in the following categories:

“Right first-time quality improvements. A good heat treater will have quality costs <1% of turnover. The MTI suggests that the cost of quality (all activities) can hit $750k for a decent-size heat treat operation. The knock-on [effects] of poor quality impacts customer satisfaction through delayed deliveries and costs in rework/rejects.”
“Maintenance. These costs can fluctuate – but lets assume a well run plant with fairly modern equipment has costs around 5% of turnover. Significant purchase/cost savings can be made via remote support as well as an understanding of remaining useful life of key components (and avoiding panic purchases).”
“Energy. Again this can fluctuate, but let’s say 10% of turnover. Modern efficient solutions (gas or electric) can significantly reduce the cost of energy and this can be further optimized via IoT solutions.”
“Labor Costs. Say an average of 20% of turnover. Some of the modern XR offers (Extended reality – covers AR, MR, VR etc.) can definitely speed up training, help retention of knowledge, and reduce the time and costs in troubleshooting as well as aiding remote support.”

“It won’t be too long before IoT offers enhanced decision support to heat treaters to aid making profitable decisions,” Sherwin concludes.

Concluding Thoughts

Peter Sherwin
Global Business Development Heat Treatment Executive
Eurotherm

Whether we like it or not, Industry 4.0 related digital integration is becoming essential rather than simply a better option. Again, the recently published AMS2750F revision highlights this shift for heat treaters.

[blockquote author=”Peter Sherwin, global business development heat treatment of Eurotherm” style=”1″]I think it is important that we use IoT where it can truly bring value and don’t view it as a silver-bullet for everything.[/blockquote]

That does not mean you need to scramble to jump on the bandwagon, but strategically assess your position, your operations, and your options to identify what option is best. Look to other examples in the industry and heat treating tech insiders to inform these new, powerful realities.

Read/Watch More:

Pascal Bornet, Ian Barkin, Jochen Wirtz, Intelligent Automation. Suggested by Peter Sherwin at Eurotherm.
C3 Data testing video, “12 Second SAT (C3 Data FNA 2020).” Vimeo. https://vimeo.com/462483080/50e1e1e490
IIoT World, “Augmented Reality in Manufacturing: implementations that provide the most benefit,” YouTube (15 November 2018). https://www.youtube.com/watch?v=njOMv1liNag&ab_channel=IIoTWorld.
Lindsay Glider, “Rockwell Automation’s 4-Step Guide to Starting Your Digital Transformation Journey,” com (13 October 2020). https://tinyurl.com/yynfoufs.
Aymeric Goldsteinas, “Optimizing Thermal Processing Operations with Predictive Maintenance Software,” IpsenUSA.com. https://www.ipsenusa.com/resources/articles-and-white-papers/optimizing-thermal-processing-operations-with-predictive-maintenance.
Dan Herring, “Industry 4.0 and Seven Key Considerations.” Industrial Heating (November 2017).
Bernard Marr, “What Is Industry 4.0?,” YouTube (July 11, 2019). https://www.youtube.com/watch?v=yKPrJJSv94M&ab_channel=BernardMarr.
Metal Treat Institute, “FNA 2020 Virtual Session: Jack Kalukci – Nitrex Metal,” YouTube. (Sep 29, 2020). https://www.youtube.com/watch?v=mZ5ipkj44-0&feature=emb_logo&ab_channel=MetalTreatInstitute. This video explains IIoT networks very well and describes the human factors needed in integrating these solutions.
NASSCOMVideos, “Unlocking the Value of Industry 4.0 with 5G,” YouTube (Oct 13, 2020). https://www.youtube.com/watch?v=2sQr9fkLbRM&ab_channel=NASSCOMVideos
Ted Institute, “Markus Lorenz: Industry 4.0: how intelligent machines will transform everything we know,” YouTube (Sep 4, 2015). https://www.youtube.com/watch?v=uBZmJOHIN8E&ab_channel=TEDInstitute.
Image References: https://www.loc.gov/resource/cph.3b51661/; https://www.loc.gov/item/2011661021/; https://en.wikipedia.org/wiki/Process_control#/media/File:Leitstand_2.jpg; and https://www.heattreattoday.com/equipment/heat-treating-equipment/ovens-high-temperature/wisconsin-oven-introduces-iot-technology-for-industrial-oven-performance-monitoring/.

State of Industry 4.0 in the North American Heat Treat Market Read More »

Heat Treat Tips: How to Install an Ammonia System

March 26, 2019 / BULK GASES & SYSTEMS TECHNICAL CONTENT, FEATURED NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

During the day-to-day operation of heat treat departments, many habits are formed and procedures followed that sometimes are done simply because that’s the way they’ve always been done. One of the great benefits of having a community of heat treaters is to challenge those habits and look at new ways of doing things. Heat Treat Today‘s 101 Heat Treat Tips, tips and tricks that come from some of the industry’s foremost experts, were initially published in the FNA 2018 Special Print Edition, as a way to make the benefits of that community available to as many people as possible. This special edition is available in a digital format here.

In today’s Technical Tuesday, we continue an intermittent series of posts drawn from the 101 tips. The category for this post is Industrial Gases, and today’s tip #39 comes from Dan Herring, “The Heat Treat Doctor®”, of The Herring Group.

Heat Treat Tip #39

How to Install an Ammonia System

Dan Herring, “The Heat Treat Doctor®”, of The Herring Group

One of the keys to any successful ammonia system installation in the heat treat shop is to find a supplier who is capable of providing premium grade (also known as metallurgical grade) anhydrous ammonia. This product has little or no water, which could contaminate your process. Look for a specification of 99.995% ammonia.

Once you have picked a supplier, there are several choices when it comes to ammonia storage. For the lowest product price, you should consider a tank of at least 10,000 gallons (43,000 pounds of ammonia.) This allows you to purchase full 38,000-pound tanker trucks of ammonia to reduce your supply costs. One pound of ammonia yields 22.5 cubic feet of vapor or 45 cubic feet of dissociated ammonia (75% H2, 25% N2).

In most states, you must comply with these standards if you have more than 10,000 pounds of anhydrous ammonia on site. So, you need to make sure you comply with OSHA’s Process Safety Management (PSM) and EPA’s Risk Management Plan (RMP).

The second option is to keep below the 10,000-pound threshold by installing a 1,000 gallon (4,400-pound capacity) or a 2,000 gallon (8,800-pound capacity) storage tank. Pricing for ammonia into these tanks runs about 50% higher in the smaller quantities. Even with the lower inventory, you will need to comply with OSHA 1910.111 and any applicable state, city, or county laws. It is critical to check with local agencies to make sure you are in full compliance with these regulations.

Another option for smaller usages are ammonia cylinders, but if stored inside the factory, special containment cabinets are required. Check with your ammonia supplier for the details.

With regard to the installation, in most cases, you need to pour a foundation for the tank, provide electricity to the tank for a sidearm vaporizer (used to maintain pressure in the tank since you will be withdrawing ammonia vapor to the process) and provide piping from the tank to your process. Most suppliers can lease the tank and valves/attachments for a nominal monthly fee depending on your ammonia consumption. You can also add a telemetry unit that allows your supplier to monitor your tank level via an Internet site. You will need to install a water shower near the tank and have gas masks close to the tank. It is a good idea to provide a fence around the tank if your company does not have security. Your supplier should provide hazardous awareness training for ammonia.

You can expect relatively trouble-free operation from a properly installed and well-maintained ammonia supply. Maintenance problems, other than an occasional paint job, are usually minimal but good inspection (including all valving) and frequent leak checks are mandatory. The tank should be visually inspected yearly, probably by your supplier, and the pressure relief valves should be changed every five years.

Submitted by The Herring Group

Photo credit: Video Stock Footage from QuickStock.com

If you have any questions, feel free to contact the expert who submitted the Tip or contact Heat Treat Today directly. If you have a heat treat tip that you’d like to share, please send to the editor, and we’ll put it in the queue for our next Heat Treat Tips issue.

Heat Treat Tips: How to Install an Ammonia System Read More »

Heat Treat Tips: Quenching

December 18, 2018 / FEATURED NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS, QUENCHING TECHNICAL CONTENT

In today’s Technical Tuesday, we continue an intermittent series of posts drawn from the 101 tips. The category for this post is Quenching, and today’s tips–#8, #38, and #81–are from three different sources: Dan Herring, “The Heat Treat Doctor®”, of The Herring Group; Combustion Innovations; and Super Systems, Inc.

Heat Treat Tip #8

14 Quench Oil Selection Tips

Here are a few of the important factors to consider when selecting a quench oil.

Part Material – chemistry & hardenability
Part loading – fixturing, girds, baskets, part spacing, etc.
Part geometry and mass – thin parts, thick parts, large changes in section size
Distortion characteristics of the part (as a function of loading)
Stress state from prior (manufacturing) operations
Oil type – characteristics, cooling curve data
Oil speed – fast, medium, slow, or marquench
Oil temperature and maximum rate of rise
Agitation – agitators (fixed or variable speed) or pumps
Effective quench tank volume
Quench tank design factors, including number of agitators or pumps, location of agitators, size of agitators, propellor size (diameter, clearance in draft tube), internal tank baffling (draft tubes, directional flow vanes, etc.), flow direction, quench elevator design (flow restrictions), volume of oil, type of agitator (fixed v. 2 speed v. variable speed), maximum (design) temperature rise, and heat exchanger type, size, heat removal rate in BTU/hr & instantaneous BTU/minute.
Height of oil over the load
Required flow velocity through the workload
Post heat treat operations (if any)

Submitted by Dan Herring, “The Heat Treat Doctor®”, of The Herring Group.

Heat Treat Tip #38

Oil and Water Don’t Mix

Keep water out of your oil quench. A few pounds of water at the bottom of an IQ quench tank can cause a major fire. Be hyper-vigilant that no one attempts to recycle fluids that collect on the charge car.

Submitted by Combustion Innovations

Heat Treat Tip #81

Quench Oil Troubles

According to Super Systems, Inc., there are one of three problems to consider if your quench is just not cutting it. Although SSI focuses more on atmosphere control systems, when parts come out soft, the problem isn’t always the atmosphere – sometimes it’s the quench. Here are three things to consider regarding your quench:

First, check the composition of the quench media. Is it up to spec? Does it need to be refreshed?
Is the quench receiving adequate agitation to thoroughly quench the load?
Is the quench at the right temperature? If the bath is too warm when the load enters, quenching won’t go well!

Submitted by Super Systems, Inc.

Photo credit: Heat Treat Today FNA 2018; Super Systems, Inc.

Heat Treat Tips: Quenching Read More »

The Herring Group

History

Applications

Production Methods

VIM

VAR

ESR

Casting Methods

A Metallurgical Perspective: The Role of Gamma Prime and Double Prime

References

About the Authors:

AI’s Place in Heat Treating?

About the Author:

Future Outlook for 2025

AI Management Software

Giga Casting

Vacuum Oil Quenching

Specialty Materials

Steel Enrichment

Cleaning Consistency

About the Author:

Miniaturization and the Heat Treat Industry

Miniaturization, Portability and Customization Today

What Does This Mean for the Heat Treatment Industry?

Final Thoughts

About the Author:

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

Fracture Types on a Macroscopic Scale

Fracture Types — Ductile and Brittle

Fracture Types — Wear

Fracture Types — Corrosion

Final Thoughts

References

About the Author

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

Heat Treat Legend: Bill Jones, Solar Atmospheres Group of Companies

Heat Treat Legend: Dan Herring, The Heat Treat Doctor®, The HERRING GROUP, Inc.

Heat Treat Legend: Suresh Jhawar, G-M Enterprises

original content

– Peter Sherwin, Global Business Development Heat Treatment Executive, Eurotherm

What Is It and Why Does It Matter?

Current Applications

Ipsen | PdMetrics

Eurotherm | Cloud-based advisors, visualization software, edge-computing technology

SECO/WARWICK | Remote Factory Acceptance and Activation Tools

C3 Data | End-User System Compliance

Problems // Solutions

The Future of Heat Treat

2. Augmented Reality / Mixed Reality / Virtual Reality Glasses

3. Efficient Cloud Capabilities

4. Increased Systemwide Application

Advice: To Use or Not To Use

Reflections on The Heat Treat Doctor®

Concluding Thoughts

Read/Watch More:

Heat Treat Tip #39

How to Install an Ammonia System

Heat Treat Tip #8

14 Quench Oil Selection Tips

Heat Treat Tip #38

Oil and Water Don’t Mix

Heat Treat Tip #81

Quench Oil Troubles

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