One Minute Mentor: Process Control in Nitriding Systems

Modern gas nitriding and nitrocarburizing furnaces are equipped with sensor systems and a process control unit that allow the measurement and automatic control of the nitriding potential (KN). The figure shows an example of how the process control can be carried out. 

Defined amounts of ammonia, nitrogen, and—for nitrocarburizing processes—carbon dioxide, can be chosen for each step in the program and fed into the furnace via mass flow controllers. The gas composition in the retort is measured via a nitriding probe. For the measurement of nitrocarburizing processes two different probes are needed. The control unit calculates the nitriding potential according to the measured values and controls the mass flow of ammonia to meet the requested set point of KN. During the nitriding process the gasifying amount of ammonia can just be reduced to a certain limit. To keep the KN value low, therefore, precracked ammonia must be added. It must be mentioned that there are some more simple control systems available, which also produce good results.

For more information, click on the link below (subscription required). Then scroll to Figure 25. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014  https://doi.org/10.31399/asm.hb.v04d.a0005958

Solar Manufacturing ships Mentor Pro Furnace to a global leader of wire mesh products

Solar Manufacturing, Sellersville, PA, has shipped a Mentor Pro Model HFL-3036-2IQ vacuum furnace to a customer specializing in engineered knitted wire mesh solutions. 

They are a USA-based company and a global supplier for the automotive, food service, and janitorial industries. The furnace will be primarily utilized for vacuum annealing materials that are susceptible to adverse effects of their mechanical properties when exposed to any levels of oxygen or nitrogen.

The Mentor® Pro features a molybdenum shielded hot zone measuring 18” wide x 18” high x 36” deep, capable of operating temperatures up to 2400°F, and a workload weight capacity of up to 1,000 lbs and includes the SolarVac® Essentials PLC-based control system. The internal gas cooling system with a 50 HP drive motor is capable of quenching workloads at 2-bar positive pressure in either nitrogen or argon.

Jason Davidson, regional sales manager, said that, “Our customer started running trials with our affiliate commercial heat treater, Solar Atmospheres. Once the trial results proved the heat-treat cycle, and the furnace demonstrated it could process the required quantities, the customer had confidence to place the purchase order with us.”

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One Minute Mentor: High performance line with hydrogen quenching

For stainless martensitic grades and carbon steel up to certain thickness, the two-stage molten metal quenching is successfully converted into hydrogen quenching with big advantages in quality, including oxide-free and lead-free surfaces. Cooling gradients of up to 300 K/s are possible. Martensitic chromium steels with 13% Cr and 0.2 to 0.4% C are used to manufacture various stainless steel components, knives, and tools, as well as parts for the cutlery industry.

 

A special application for producing high-quality heavy-duty strapping band in bainitic condition is a line with high throughput and low-energy consumption. The steel grade AISI 1536/DIN EN 36Mn5 is usually preheated to approximately 400 °C (750 °F) in a compact two–stage molten metal quench, acting as the secondary winding of the transformer fed. The strip is raised to austenitizing temperature at 900 °C (1650 °F) and then quenched in the molten lead/bismuth. The thermal energy dissipated during quenching is used to preheat the incoming strip.

 

For more information, click on the link below (subscription required). Then scroll to Figure 12. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014  https://doi.org/10.31399/asm.hb.v04d.a0005958

Harper Furnace Technology enables high performance silicon anodes

Harper Furnace Technology, Buffalo, NY, announced the development of high temperature thermal process solutions to enable production at several silicon anode battery material companies in 2024. Silicon anode material offers significantly higher specific capacity than traditional graphite anode materials enabling higher power density, faster charge times and smaller carbon footprint than current batteries. 

 

Harper has entered engineering design and equipment supply contracts for pilot and production scale equipment with its USA-based customers, many of whom are funded in part by grants from the U.S. Department of Energy. The Harper technology includes indirect electrically heated, continuous rotary, vertical and horizontal conveyor furnace systems for each customer’s unique thermochemical processes. The Harper furnaces include tight control of the process atmosphere enabling safe and reliable continuous operation, are rated for temperatures between 800˚C and 1,800˚C and will have capacity up to 1,000 metric tons per year. Beyond the pilot-scale equipment projects, Harper is actively engineering the next generation of equipment solutions for these customers whose commercial scale plants will require capacity of 20,000 – 40,000 metric tons per year for the electric vehicle (EV) market.

 

https://www.harperintl.com/

Friction testing of electrically heated Nitinol shape-memory alloy wires

TU Dresden, Germany,  has developed a test scenario for the friction testing of electrically heated shape-memory alloy (SMA) wires against polymer surfaces. As alloy, Nickel-Titanium (Nitinol, NiTi) was specially selected due to its high working capacity, the good corrosion resistance and the quick actor response at low bias forces. 

As the materials in contact with the actuator must resist friction forces and elevated temperatures up to 200 °C, a combination with high performance polymers is preferable. In many applications, the actuators use redirections to enhance the actuator capabilities or enable the use in complex structures. To better understand and compare the tribological properties of Nitinol against various polymer materials, it was needed to manufacture a customized testing device.

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Lehigh’s summer engineering institute students tour Solar Atmospheres

Solar Atmospheres, Souderton, Pa., hosted over 40 high school students enrolled in the Summer Engineering Institute (SEI) at Lehigh University. The SEI program, under the guidance of Director Dr. Laura Moyer, is a two-week residential program, running two sessions back to back. 

Students are nominated by faculty of local high schools, and the program specifically targets under-represented groups including girls, first-generation students, and students who might otherwise have limited opportunities to study in the fields of science, technology, engineering, and math (STEM).

Solar Atmospheres provided a tour of the campus, exhibiting materials and processes for intriguing applications in a variety of markets. The students experienced a manufacturing setting encompassing related topics from their curriculum, gaining a better understanding of heat treating and manufacturing, and how cutting edge technology reshapes centuries-old processes.

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Testing from webkul

Testing from webkul

Testing from webkul

Testing from webkul

Testing from webkul

Testing from webkul

Testing from webkul

Testing from webkul

Testing from webkul

Testing from webkul

Particle Trajectories in Plasma Spray

The diagram illustrates the various trajectories that particle distributions may follow. Each trajectory shown represents extremes in particle heating, and this affects the average condition of the particles on impact (liquid, solid + liquid).

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