Presented by: ALD Vacuum Technologies, Inc

In many applications the high demands regarding fatigue properties of transmission components can be reached only by the application of a customized case hardening. This case hardening process results in a wear resistant surface-layer in combination with a tough core. However as a side-effect the components get distorted during heat treatment. This distortion has a significant cost-impact, because distorted components need to be hard-machined after heat treatment. Therefore the proper control of distortion is an important measure to minimize production costs. By applying the technology of Low Pressure Carburizing (LPC) and High Pressure Gas Quenching (HPGQ) heat treat distortion can be significantly reduced. HPGQ provides a very uniform heat transfer coefficient. The predictability of movement during quenching is more certain and uniform throughout the load. Further improvements can be achieved by "Dynamic Quenching" processes where the quenching severity is varied during the quench sequence by step control of the gas velocity. Proper fixturing is another factor for distortion control. Modern CFC materials (carbon reinforced carbon) are well suited as fixture-material for gas quenching. When compared to traditional alloy CFC demonstrates no deflection or distortion after many subsequent years of use.

Cost:  $19.95

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Presented by: dibalog USA Inc.

Reducing your Electrical Costs/Energy Optimization Systems. Electrical bills around the world are composed of two parts, total energy usage and peak demand charges which takes into account the highest 15 minutes of electrical usage for any given month (this time period can vary depending upon the electrical provider). By reducing peak demands, electrical bills are reduced. This is done by monitoring total electrical usage plant wise while at the same time electrical usage is monitored on each individual piece of electrically heated equipment. Physically this is done by a module installed in each control panel which feeds the information back to a central processor on a continuous basis. With this information the system can automatically and continuously make small adjustments to heating rates to insure that peaks are reduced and consequently the bill is lowered. Systems such as this have been in place in Europe for over 40 years but it wasn't until recent increases in electrical rates in North America that systems such as this became economically viable in North America. The system works in the background making adjustments as needed on a second by second basis and will only adjust power during ramp ups not during a soak or quench cycle.

Cost:  $19.95

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Presented by: Eurotherm Inc.



With the improvements in materials and machining technology and the elimination of stocked components, the value of batches treated in both captive and commercial heat treat furnaces are becoming more and more valuable. Heat Treaters need to ensure their Furnace operating systems do not let them down while treating critical batches. Recent improvements in control technology now allow cost effective redundant control. The redundancy can be at the power supply level, thermocouples, other sensors level (carbon/vacuum) and even Processor level for PLC's or PAC's and data capture level.

Cost:  $19.95

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Presented by: Fluxtrol Manufacturing, Inc.



The time between a product's definition and production is constantly shrinking. To meet these requirements, extensive use of virtual prototyping has replaced physical models in the mechanical design process. As a result of this, the induction heat treating process developer will oftentimes not receive a quantity of parts for heat treatment until a few weeks prior to having to deliver samples. This makes it nearly impossible to produce good quality parts on time using a traditional test and trial method. The development focus shifts to "just getting a pattern" rather than developing a robust production process. To meet the modern development requirements, the same methods that have led to significant improvements n the mechanical design process are applied to induction heat treating. Virtual prototyping tools include electromagnetic, thermal and metallurgical finite element analysis along with 3-D CAD software. Virtual prototyping allows for the study of a much larger design space in a shorter period of time at lower cost. Final process validation is preformed on real equipment. A case story of an induction heat treating process of wheel hub hardening developed with virtual prototyping is presented. Savings achieved with the virtual tools are
discussed.

Cost:  $19.95

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Presented by: Inductoheat



Presentation discusses several recently developed innovations related to induction heat treating of metals, including:

1. Patented FluxManager® systems for effective tempering/stress relieving/ annealing of steel tubular goods for oil and gas industries.
2. Advanced technologies for induction hardening of critical automotive components:
2a. Contour hardening of small and medium size gears and gear-like components with minimum distortion utilizing single coil simultaneous dual frequency induction systems.
2b. Induction hardening of wide-face hypoid, spiral and bevel gears with diameters from 6"/150mm to 8.5"/220mm.
2c. Patented SHarP-C™ non-rotational induction crankshaft hardening and tempering technologies (band hardening and fillet hardening).
3. Novel scan hardening of complex shape parts. Introduction of novel inverter technology capable to independently controlling both frequency and power (STATITRON - IFP inverters) during the heating cycle.

Cost:  $19.95

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Presented by: INEX, Inc.

Typical heat treat furnaces, whether atmosphere or vacuum, often use trays, fixtures, baskets, transfer mechanisms, and radiant tubes made of nickel chrome alloys. The high temperatures involved in most metallurgical processes have the undesirable effect of accelerating the rate of creep or deformation of alloy components. This presentation will explore the use of alternate materials which an minimize creep failure. Substitute non metallic materials are examined with an emphasis on both the advantages and disadvantages. The presenter will draw on personal experiences in, on and around heat treat furnaces for over forty one years.

Cost:  $19.95

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Presented by: Nitrex Metal, Inc.



Controlled ferritic nitrocarburizing processes such as Nitreg®-C, when followed by post-oxidizing, are known to yield a very high esistance to corrosion. The control equipment and software used for Nitreg®-C processes meet the aerospace specification MS2759/12A, making it possible to consistently achieve the required metallurgical results. Currently, this standard limits process recipes to be controlled via Kn and Kc set points for each stage of the process. That is, they do not take into account the dynamic shift of reactions occurring at different temperatures, and consequently they do not produce a niform nitrided structure. On the other hand, our new concept of phase control takes into account the dynamics of dissociation and diffusion that shift with temperature. In other words, Nitrex is now able control the process parameters via floating set points that follow phase boundaries throughout the process. This approach opens a wide field in nitriding and nitrocarburizing process control specifically aimed at a number of factors such as a defined porosity, but also obtaining monophase white layers, high carbon epsilon phases, and low carbon white layers. In this presentation we will show how such control is applied, and how it leads to optimum corrosion resistance by dense white layers with controlled magnetite oxide layers in the newest Nitreg®-C/ONC® technologies.

Cost:  $19.95

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Presented by: Process-Electronic



Control of compound layer in the FNC process has traditionally been accomplished by fixed flow of process gasses. Inherent difficulty of measuring he process by extractive sampling, or the lack of in-situ sensor technology has eliminated the possibility of closed loop control, as well as documentation of the process that would aid in compliance to specifications such as CQI-9, and SAE AMS 2759/12. This presentation will explore a modern approach that will improve compound layer control as well as provide accurate process documentation.

Cost:  $19.95

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Presented by: Radyne Corporation



Speaker will discuss new variable frequency induction heating techniques that allow heat treaters to create varying hardness and case depths; provide optimum case profiles in shoulder areas and diameter steps, edges, corners and holes; avoid cracking risk in notch effect areas. Examples of variable frequency induction hardening will be shown along with the variable frequency recipies that were used.

Cost:  $19.95

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Presented by: Seco/Warwick Corporation

Typical heat treatments performed in vacuum furnaces today include high pressure gas quenching (HPGQ), low pressure carburizing LPC and high temperature low pressure carburizing with pre-nitriding. This session will explore a new technology, low pressure nitriding, particularly useful for high alloy steel treatment. A universal vacuum furnace may be used to accommodate all above applications in a single furnace, a practical solution for commercial heat treating. This vacuum nitriding process allows the complex processes to be achieved within a single furnace: quenching, tempering, and nitriding of tool steels, for example die blocks, pressure casting dies and injection molds.

Cost:  $19.95

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Presented by: Super Systems, Inc.

According to the Department of Energy, most high temperature direct-fired furnaces, radiant tubes and boilers operate with about 10 to 20% excess combustion air at high fire to prevent the formation of dangerous CO and "soot" deposits. It is estimated that changing this practice and delivering precise control of air to fuel ratio will yield 5 to 25% savings in heat generation. This saving delivers operational and energy efficiencies. This presentation will provide you with how this can be performed and case studies on the benefits achieved.

Cost:  $19.95

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Presented by: Surface Combustion, Inc.

Emission standards affect the heat treat industry. It is important to keep current with current emission rules, whether they are state statutes SCAQMD or national regulations (EPA). By being aware of these standards, heat treaters can be ready to meet future requirements today. Energy efficiency technologies and control strategies which have an impact on emissions will be reviewed and discussed. The investigation summary will be shared and air quality rules will be highlighted. Testing options and benchmarks will be noted. Options to incorporate emission reductions into new heat treat equipment as well as retrofit packages for older equipment will also be discussed.

Cost:  $19.95

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Presented by: Throughput Consulting, Inc.

With increased demands on manufacturing operations, quality managers/business owners are finding themselves subject to stricter guidelines from both their customers and quality accreditations like NADCAP. Businesses are now required to take proactive approaches to ensure they are meeting the variety of requirements that are imposed on them and have the proper processes, such as Nonconformance's, Customer Complaints, Corrective Actions (CAPA), Specifications, Data Collection, etc., in place to meet the new
requirements. In today's world, the role of a quality manager/business owner has become much more complex, learn how to leverage

Cost:  $19.95

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Presented by: Waukee Engineering Company, Inc.

Companies have increasing pressure for specification compliance to NFPA, CQI9, and AMS2750D, and the need for continuous improvement with cost reductions. This paper will explore the latest technologies in flow measurement and control to satisfy specification compliance, and provide cost reductions in the operation of endothermic generators.

Cost:  $19.95

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