Manufacturing data together with heat treating knowledge can be synthesized with physics and data-based modeling approaches in a closed loop to provide insight for improving process efficiency and product quality for overall reduction in operating and energy costs. This article provides case studies of data analytics for coil batch annealing and batch carburizing.

This study looks at whether adding an annealing step to the heat treating process has an effect on residual stress and distortion on hypoid gear sets. Test results indicate that the annealing heat treatment introduced between gear set soft cutting and case carburizing helped to minimize distortion.

This article compares heat treat processes and furnace types that are typically used to harden gears.

An in-depth understanding of technology trends not only keep materials engineers relevant, but also puts them in the driver’s seat when it comes to formulating strategies and executing projects. Some of today’s technology trends that are relevant to materials engineers include data analytics, artificial intelligence (machine learning and deep learning), blockchain, digital thread and digital twins, Internet of Things (IoT) or Industry 4.0, additive manufacturing, electric vehicles, and autonomous vehicles.

Data obtained from thru-process profiling is used to calculate performance against specification, investigate process problems, and optimize the heat-treating process.

Tests conducted on vacuum carburized and quenched shafts identify variables that increase distortion and the magnitude of residual stresses.

Preventive multi-frequency testing using eddy current ensures heat-treated parts meet specifications.

Intensive quenching enables manufacturers to improve part performance at a lower cost than other available methods. This article describes how using direct-from-forge intensive quenching can significantly reduce the cost of manufacturing steel products when engineered into the lean part-making process.

An ultrafast, efficient industrial-scale boriding process can drastically reduce costs, increase productivity, and improve the performance and reliability of a variety of machine parts. This article describes a novel, environmentally friendly technology that enables treating thousands of industrial components in one batch, without creating solid or liquid waste and gaseous emissions.

Engineers at the Ford Motor Co. are using integrated computational materials engineering (ICME) tools, allowing them to accurately simulate the heat treatment of gears and predict phase transformation kinetics and distortion.

This article focuses on five common reasons for distortion and cracking during heat treatment and recommended remediations: (1) Nonuniform and uncontrollable heat transfer during heating and cooling; (2) Structural changes during phase transformation; (3) Residual stresses in the part that occur due to forming, welding, or machining before heat treatment; (4) Macro or micro steel structure; and (5) Fixturing and loading errors.

Active screen plasma nitriding and nitrocarburizing are relatively new processes in which a plasma discharge is applied to a metal screen surrounding the workload, generating highly reactive gas species that flow to the component surface. The active screen also radiates heat, resulting in a uniform temperature throughout the load. This article provides an overview of the two processes and presents examples of their use on stainless steel piston rings (nitriding) and 4142 and 1045 steels (nitrocarburizing).

Industry 4.0 is an emerging technology trend in the manufacturing arena that emphasizes the connectivity of physical and digital process across product development cycles. This article presents some examples of how Industry 4.0 will affect heat treating operations.

Today’s materials engineering leadership role is expected to expand and have a greater impact on evolving the organizational, technological, and strategic initiatives of original equipment manufacturers.

The second article in this series looks at materials testing, microstructural evaluation, mechanical testing, and residual stress and distortion using the DANTE Controlled Gas Quenching process.

Integral quenching (IQ) is a widely adopted heat treatment technique known for its efficient and rapid quenching capabilities. Vertical vacuum IQ furnaces give heat treaters a larger working zone for efficient and rapid quenching. This article describes the elements of a vacuum IQ furnace line and describes its operational workflow and process control.

Properties and performance of lower cost “simple” alloy steels processed using induction coupled thermomagnetic processing can rival those of conventionally processed, expensive specialty alloys. This article discusses some of the demonstrated improved mechanical properties achieved for steels in a industry-government project that evaluated the viability of processing metals in a strong magnetic field.

Martempering involves cooling steel from the austenitizing temperature and rapidly cooling into either specially formulated petroleum oil or a molten salt bath with a specific composition to a temperature slightly above the martensite start (Ms) transformation temperature of the steel. Martempering is performed to reduce distortion problems that may be encountered with conventional quenching methods. This article, adapted from the latest ASM Handbook on quenching and quenchants, describes suitable steels for martempering and variables that influence the process.

Accurate and continuous dew point measurement is key to maintaining the atmosphere required to achieve high quality and consistency of sintered products in powder metallurgy processing.

Automotive designers and heat treaters have many choices when it comes to the materials and processes that will meet their overall needs. This article reviews some of the major trends affecting automotive heat treating.