Technical Education Sessions

Transcription

1 Technical Education Sessions OCTOBER 4 EQUIPMENT/MAINTENANCE TRACK 9:15 am 9:45 am PdMetrics Case Studies: Implementing Predictive Maintenance in the Thermal Processing Industry Jim Grann Ipsen Providing a fresh look at predictive maintenance and the Internet of Things (IoT), this presentation discusses the ways in which predictive maintenance is emerging in the thermal processing industry as a powerful tool for analyzing performance and efficiency. We will examine specific data gathered from several heat treatment furnaces integrated with Ipsen s PdMetrics software platform. As illustrated by this data, we will then discuss how the use of predictive maintenance results in numerous benefits. 10:00 am 10:30 am Efficient Gas Heating of Industrial Furnaces Steven Mickey WS Thermal Process Technology Even at times when fuel prices are very low, energy costs represent a large fraction of operating costs for an industrial furnace. Electricity is widely used in industrial applications, however, it is typically too expensive to provide process heat if it could also be provided by a gas heating system. Even though the prices for natural gas are currently extremely low, using it as efficiently as possible is still favorable both economically and environmentally. 10:45 am 11:15 am A Case Study: Effective Furnace Atmosphere Circulation with New Furnace Technologies Akin Malas Linde Gas Atmosphere uniformity plays an important part in achieving metallurgical requirements during a heat treatment process. Linde developed a technology called CARBOJET, a special gas nozzle in order to improve the circulation and uniformity of the furnace atmospheres, therefore the interaction of heat and chemistry of atmosphere is achieved, as well as some of the issues associated with fans are eliminated. The presentation will describe the technology with practical experiences from the industry. 1

2 OCTOBER 4 INDUCTION TRACK 9:15 am 9:45 am Induction and Furnace Tempering of Martensitic Steels Richard Sisson, Jr. Center for Heat Treating Excellence AISI 4140 steel that was quenched and tempered by induction and furnace tempering to the same hardness were characterized and tested for mechanical properties and impact toughness. The effects of the different microstructures will be presented and discussed in terms of microstructure and performance. PRESENTER 10:00 am 10:30 am Induction Process Monitoring Interpower Induction Many induction processors know that adherence to customer driven compliance to standards and specifications can be a daunting task. Ensuring that the part was processed to meet these standards is part of the day-to-day operations. Process monitoring is more important than ever, and in order to provide products to these customers (even internal customers) you must be able to document that the process was sound. Methods and requirements are covered in this presentation. 10:45 am 11:15 am Induction Heat Treat - Shortening the Time to PPAP Sandra Midea, P.E. - Induction Tooling, Inc. Induction heat treating relies on well-designed inductors. Most IH process development is trial and error, often resulting in numerous iterations between inductor company and heat treater. Inductor/process development can be performed and validated at the inductor company, mirroring production conditions at the heat treater. Wheel bearing spindle and roller path examples illustrate the intricacy of IH process development with insights into common root causes and how development at the inductor company shortens the pre-ppap cycle. 2

3 OCTOBER 4 EMERGING TECHNOLOGY 9:15 am 9:45 am Machine Learning and Furnace Performance - A Powerful Future Peter Sherwin - Eurotherm by Schneider Electric Looking back to FNA14 it is difficult to imagine how far technology would progress in a short 2- year period, aiding continuous improvement and efficiency in furnace use. Gartner (2015) predicts that organizations making the best use of modern data systems will outperform their peers by 20%. This presentation will cover an introduction to Machine Learning, and how it can be applied to improving performance in the day-to-day operation of a furnace. 10:00 am 10:30 am Vacuum Heat Treatments of Additive Manufactured Components Bob Hill Solar Atmospheres of Western PA Additive Manufacturing is an emerging technology that has taken the world by storm. The ability to "print" 3D complex shapes with various materials such as plastics, composites, and even human tissue, has now matured into the metallic arena. Typically metallic structures are printed layer by layer with either powdered metal or with wrought wire. This presentation will review the various methods of AM production along with multiple examples of vacuum heat treated AM components. 10:45 am 11:15 am Modeling Surface Engineering Processes in Steels Richard D. Sisson, Jr. - Center for Heat Treating Excellence CHTE has developed and verified carburizing (CarbTool ) and carbonitriding (CarboNitrideTool ) simulation tools to predict the carbon and nitrogen concentration profiles in glass and low-pressure heat treating systems. In this paper, several enhancements to these models to predict the microstructure and microhardness profiles will be presented. The use of these models will be demonstrated. 3

4 OCTOBER 4 MATERIALS TRACK 9:15 am - 9:45 am Theory of Graphite, Carbon Fiber & Ceramic Fiber Jamie Kuriger - Toyo Tanso USA A thorough introduction of graphite, carbon fiber, and ceramic fiber, and how it is used in the furnace industry. Graphite & CFC Hot Zones, Fixtures & Ceramic Fiber Technology will be introduced and discussed, as well as advantages and disadvantages of using these materials in certain thermal processes. 10:00 am 10:30 am Hybrid Fixturing Bill Warwick - Schunk Carbon Technology A discussion of various fixture materials and the effects offered by combining these materials to improve the heat treating process. This discussion will focus on the use of combining Carbon/Carbon, Ceramics, and Alloy materials to improve heat treating processes. Using benefits of each of these materials can help the user improve furnace cycle times, distortion control, product throughput, and energy use. 10:45 am 11:15 am Metallurgy and Processing Experiences with High Temperature RA602CA Heat Treating Baskets Marc Glasser Rolled Alloys / Roger Jones Solar Atmospheres, Inc. High temperature processing of materials above 2275 degrees F can be detrimental to heat treat baskets. This presentation will review the metallurgy of the material and alloy. Discussion will include oxidation, atmosphere, creep and rupture strength, embrittlement, and thermal cycling/ expansion. Basket construction and life of the baskets will be reviewed. Also processing temperatures, cycles, and atmospheres of the alloy will be reviewed. Applications and life studies of the baskets during processing will be demonstrated. 4

5 OCTOBER 4 COMPLIANCE TRACK 9:15 am - 9:45 am The Cost of (poor) Quality Todd Wenzel - Throughput Bluestreak The Cost of Quality (CoQ) is a hot topic right now for MTI members. How do you know if you are spending enough, or too much on quality? What is your cost of poor quality? What does quality quantitatively mean? With a company-wide QMS approach, you can dramatically reduce your cost of quality. Attend this session to learn how. 10:00 am - 10:30 am AMS-2750 Interpretation Challenges Colin Thomas/Andrew Bassett - Aerospace Testing & Pyrometry, Inc. Examples will be provided of AMS2750 interpretations exposed during Nadcap audits and other pyrometry assessments, with the aim of providing needed knowledge to the aerospace heat treat community. Those aerospace heat treat suppliers who have experienced Nadcap audits are aware that there are many hidden requirements and interpretations within the specification that may only be exposed during the Nadcap audit. Examples and explanations will be provided of many hidden requirements and interpretations, that have been identified during Nadcap audits and other pyrometry assessments with the aim of providing needed knowledge to the aerospace heat treat community. 10:45 am 11:15 am Principles of Pyrometry Jason Schulze - Conrad Kacsik Instrument Systems The Principles of Pyrometry session will help Nadcap suppliers use tools which will ensure conformance. Understanding AMS2750E and Nadcap requirements regarding pyrometry and applying that understanding internally will get suppliers on a path to not just merit, but expertise. Suppliers will be presented with techniques and tools, which can be used during internal pre-audits. 5

6 OCTOBER 5 FIRE SAFETY TRACK 8:00 am 8:30 am Fire Safety in the Heat Treat - Part 1 Jason Safarz CEC Combustion Safety/ Jim Roberts - Honeywell This session talks about what you need to know about what is being piped into your plant. It's Gas! and, it needs to be treated differently than your other utilities. This session talks about the safety checks needed from the street to your pressure regulators...and a little bit beyond. Some case study examples may drive the point home. 8:45 am 9:15 am Fire Safety in the Heat Treat - Part 2 Jason Safarz CEC Combustion Safety / Jim Roberts Honeywell As a continuation of "Fire Safety in the Heat Treat-Part 1" This session will move from the gas pressure regulator on the outside of your plant, to the piping on the inside. What do all those valves do? What is the useful life of some of the safety equipment? Fire is your most useful tool, what is the best way to keep it your friend? A primer course on fire safety codes as well. 9:30 am 10:00 am Explosions - Where Do They Start? Jason Safarz CEC Combustion Safety / Jim Roberts Honeywell Explosions!! The mere word sends chills through any heat treater's mind. This session will talk about examples of how simple mistakes can lead to big noises, and bigger headaches for the business owner. We'll map out some case studies and do a post mortem review of what could have been done to prevent this from happening in each case, and how to teach your workers to help prevent it again. This session will discuss the methods and protocols behind explosion prevention in the heat treat. There are several big areas to discuss, and they include valve maintenance, chemical storage, quench procedures, and furnace seals. All of these can be quickly discussed showing how to make sure we don't set the table for an explosion and, who do we share this info with to prevent it from getting worse. 10:15 am 10:45 am Fire! Who You Gonna Call? Jason Safarz CEC Combustion Safety / Jim Roberts Honeywell The alarms go off, and the scramble is on! We have a fire somewhere in the plant. This presentation will address the preparation that you need to have in place. With your facility, employees, and the people that are rushing to help you. Descriptions of how to prepare, and make sure the Fire Department is ready for your specific plan. 6

7 OCTOBER 5 PROCESSES TRACK 8:00 am 8:30 am High Nitrogen Carbonitriding Improving Energy Efficiency of Powertrain Components Michael Winter United Process Controls In this presentation we introduce a new controlled way of carbonitriding that is opening up the possibility of designing smaller components for internal combustion engines and power transmission capable of withstanding the same, or even higher forces. We also describe how this new process can be designed by using a mathematical model, and how the atmosphere potentials CP and NP can be measured and controlled in typical carburizing furnaces using readily available equipment. 8:45 am 9:15 am Controlled Nitriding of Stainless Steels Jack Kalucki Nitrex Metal, Inc. In the presentation we discuss improvements in controlled gas nitriding technology applied to stainless steels in different temperature ranges: low temperatures to hinder the formation of chromium nitrides, improving wear resistance in austenitic stainless steel, while mostly eliminating the loss of corrosion resistance, and regular temperatures for deeper diffusion layer with or without white layer. Both benefit from the flexibility and perfect process control. Similar improvements are obtained for martensitic and precipitation hardening stainless steels. 9:30 am 10:00 am Recent Developments in Modern Heat Treatment Processes Thomas Metzger - PVA Industrial Systems GmbH In this presentation, you will learn developments in the following three processes: Vacuum brazing: What are the challenges for mass production brazing processes, why can filler metal pastes save money, which problems can arise from using filler metal pastes, and how to overcome these problems. Diffusion bonding: Which are potential products for large scale diffusion bonding, what are the technical challenges in producing such parts, what does this mean for the design of diffusion bonding equipment, what is diffusion bonding/what are the physics behind it, where are the technical limits with respect to process and equipment, and what will future bring for diffusion bonding applications. 7

8 PulsPlasma nitriding: What is plasma nitriding and which parts can it be used for, what are the key advantages of PulsPlasma nitriding, why is PulsPlasma nitriding pollution-free and energy saving, what are the technical basic conditions for the nitriding process, and how can sintered materials be treated. 10:15 am 10:45 am How to Control Process and Equipment Variability Dan Herring The HERRING GROUP, Inc. The consequences of process and/or equipment introduced variability into heat-treating will be discussed through practical examples designed to illustrate the effect of questionable practices, methods, and techniques on the quality of parts produced. The consequences of poor heat treatment will be reviewed from the perspective of the end-use application, and the economic impact of product recalls, lost market share, and lost business to competition. OCTOBER 5 VACUUM TRACK 8:00 am - 8:30 am Low Pressure Carburizing with Oil and Gas Quenching Dennis Beauchesne ECM USA, Inc. This presentation will discuss the latest information and designs for Low Pressure Vacuum Carburizing (LPC) systems for heat treaters' facilities. Data will be shared of parts being heat treated using LPC with distortion and metallurgical results, comparing oil and gas quenching along with atmosphere carburizing and oil quench comparisons. Join us for this presentation as we will also provide cost analysis of the loads processed. 8:45 am 9:15 am Modern Vacuum Instrumentation: What to Consider When Upgrading Super Systems, Inc. This presentation will outline the key benefits of retrofitting vacuum furnaces (vintage 10+ years old) to meet 2016 AMS and NADCAP requirements. Common furnace designs will be reviewed to determine what to look for when determining what instrumentation to replace and what to reuse. Recommended (new) instrumentation will outline methods to connect to existing SCADA software and key benefits for production, maintenance, and audits. 8

9 9:30 am 10:00 am Vacuum Heat Treatment Harden & Temper Ben Bernard - Surface Combustion Vacuum heat treatment can be utilized to harden, quench, and temper, just as in atmosphere heat treatment. The vacuum process is usually chosen for bright color work, materials that require austenitize, or solution temperatures, or to eliminate high temperature oxidation. There are many advantages and pitfalls in choosing vacuum heat treatment. The discussion will focus on hardening or annealing and subsequent tempering in vacuum furnaces: productivity, process, and furnace designs. 10:15 am 10:45 am New Developments in Vacuum Furnace Hot Zone Designs Bill Jones Solar Manufacturing, Inc. Vacuum furnace manufacturers and heat treaters are continually looking for ways to improve the thermal efficiencies of the furnace hot zone as electrical power costs continue to escalate, resulting in higher operating costs. Recent new developments in the manufacture of a more efficient graphite insulation board have created great interest in applying these new materials to current furnace designs. We will introduce the new board material and highlight its advantageous properties. OCTOBER 5 HEAT TREAT SYSTEMS TRACK 8:00 am 8:30 am Nitriding Using ZeroFlow Technology Mark Hemsath SECO/WARWICK The consumption of nitrogen while nitriding has typically been heavy and consistence of results have varied. A new heat treating technology reduces both the consumption of gases drastically to near zero levels as well as significantly eliminating the inconsistencies in case depths and metallurgical results. This talk on ZeroFlow nitriding will give the technical and commercial justifications for implementing this new nitriding technology 9

10 8:45 am 9:15 am Increasing Productivity in Atmospheric Carburizing Curt Colopy INEX Incorporated More than ever product throughput and profitability depends on accomplishing more with less. This often requires that effective cycle time be reduced within the constraints of existing furnace equipment and floor space. This focus must be on faster-up/cool-down rates coupled with reduction of carburizing soak time, while still achieving the required ECD and/or other metallurgical specifications. Current technology and tactics to attain these goals will be surveyed and examined. 9:30 am 10:00 am Modular Batch Austemper Line Improves Utilization and Energy Efficiency and Supports Flexible Manufacturing Patrick Weymer JL Becker / Gasbarre Furnace Group Austempering is used to increase hardness, ductility, and toughness of components. As demand for this process has increased so too has demand increased for equipment that supports flexible manufacturing. To this end, a line has been developed which incorporates an atmosphere box furnace, multiple salt quench tanks, washer, as well as other typical companion equipment. The atmosphere box furnace can travel between multiple salt quench tanks to increase utilization, ease maintenance, and reduce energy consumption. PRESENTERS: 10:15 am 10:45 am Next Generation Industrial Furnace Systems Joe Saliba Can-Eng Furnaces International Ltd. Heat Treatment Processes have evolved over the years. However, the high demand for manual labor has remained constant, or even increased for commercial heat treaters. This presentation will outline innovative new strategies for streamlining product flow within a heat treating cell. The improvements outlined can lead to reduced labor inputs, enhanced safety, improved product quality, and higher margins. 10

11 OCTOBER 5 OPERATIONS TRACK 8:00 am 8:30 am Using, Saving, and Managing Energy in a Heat Treat Facility Michael Stowe Advanced Energy Industrial processes, especially heat treating, require significant amounts of energy to transform raw materials into finished products. Understanding industrial processes, equipment, and support systems is key to finding energy efficient solutions. This presentation will explore using, saving, and managing energy in industrial processes with a focus on heat treating facilities. You will learn about energy usage, areas to save energy in both processes and facilities, and methods to manage your energy consumption. 8:45 am 9:15 am Hydrogen/Nitrogen Recovery System John McPhearson - Lectrodryer The design of a Hydrogen/Nitrogen Recovery System for a Bright Strip Annealing Furnace is presented. This system removes Hydrogen/Nitrogen from the stabilizer section of the furnace at 400 C. The Hydrogen/Nitrogen Gas is then cooled, filtered, and dried to a 70 C dewpoint. The Hydrogen/Nitrogen mixture is then reintroduced to the heating section of the furnace. Oxygen content in the Hydrogen/Nitrogen Gas mixture is monitored to insure safety. Options for this system would include variable dewpoint control and gas reheat prior to the furnace. 9:30 am 10:00 am Total Plant Scheduling Becki Kerr Cornerstone Systems, Inc. Total Plant Scheduling is an entirely new software product that allows orders to have all the processing steps automatically scheduled. The steps will be scheduled within the constraints of equipment capacities and working hours. Airport display screens allow real-time monitoring of the orders throughout the plant. In this presentation, you will learn the possibilities surrounding the ability for you to schedule your entire plant's workload. 10:15 am 10:45 am Zero inventory Hydrogen Eases Compliance David Wolff - Proton OnSite Among the challenges to siting or expanding a thermal processing facility, NFPA flammables siting compliance may be one of the most difficult. The less flammable inventory, the easier the compliance challenge. Presentation will review the experiences of several customers in siting and compliance with hydrogen generation technology instead of stored hydrogen. In this 11

12 presentation, you will learn NFPA Codes and Standards that affect the storage of hazardous gases and liquids of relevance to metal heat treating and sintering, several approaches to providing reducing atmospheres for heat treating furnaces, and the raw material gases and storage quantities required, how on-site gas generation may reduce the site area required for atmosphere gas delivery and storage, compare cost, schedule and project risk implications of generated gas versus stored gas for new and expanding thermal processing facilities, and evaluate actual experience across several recent projects PRODUCED BY 12