Heat Treating : Proceedings of the 24th ASM Heat Treating Society Conference

446 Pages·2007·46.408 MB·English

by  Herring, Daniel, Williams, Dan

Heat Treating

Proceedings of the
24th ASM Heat Treating Society Conference

September 17–19, 2007
COBO Center
Detroit, Michigan, USA

Edited by:
Daniel Herring
Scott Mackenzie
Dan Williams

Published by
ASM International
Materials Park, Ohio 44073-0002
www.asminternational.org
Copyright © 2007
by
ASM International®
All rights reserved

No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise, without the written permission of the copyright owner.

First printing, September 2007

Great care is taken in the compilation and production of this book, but it should be made clear that NO WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE, ARE GIVEN IN CONNECTION WITH THIS PUBLICATION. Although
this information is believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained from the
use of this publication alone. This publication is intended for use by persons having technical skill, at their sole discretion and
risk. Since the conditions of product or material use are outside of ASM's control, ASM assumes no liability or obligation in
connection with any use of this information. No claim of any kind, whether as to products or information in this publication,
and whether or not based on negligence, shall be greater in amount than the purchase price of this product or publication in
respect of which damages are claimed. THE REMEDY HEREBY PROVIDED SHALL BE THE EXCLUSIVE AND SOLE
REMEDY OF BUYER, AND IN NO EVENT SHALL EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT OR
CONSEQUENTIAL DAMAGES WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEGLIGENCE OF
SUCH PARTY. As with any material, evaluation of the material under end-use conditions prior to specification is essential.
Therefore, specific testing under actual conditions is recommended.

Nothing contained in this book shall be construed as a grant of any right of manufacture, sale, use, or reproduction, in
connection with any method, process, apparatus, product, composition, or system, whether or not covered by letters patent,
copyright, or trademark, and nothing contained in this book shall be construed as a defense against any alleged infringement
of letters patent, copyright, or trademark, or as a defense against liability for such infringement.

Comments, criticisms, and suggestions are invited, and should be forwarded to ASM International.

ISBN-13: 978-0-87170-865-6

SAN: 204-7586

ASM International®
Materials Park, OH 44073-0002
www.asminternational.org

Printed in the United States of America

Multiple copy reprints of individual articles are available from Technical Department, ASM International.
Heat Treat 2007 Organizing Committee

William Bauer D. Scott MacKenzie Michael Thomas
Metal Improvement Company Houghton International Inc. Bodycote Thermal Processing
Cornelius, NC Valley Forge, PA Livonia, MI

Dennis Beauchesne David L. Milam Dale J. Weires
ECM USA Timken Company Boeing Philadelphia
Kenosha, WI N. Canton, OH Philadelphia, PA

Vytas Braziunas Joseph W. Newkirk George P. Welch
Automation Intelligence LLC University of Missouri-Rolla Ajax Tocco
Milwaukee, WI Rolla, MO Magnethermic Corporation
Warren, OH
B. Lynn Ferguson Robert T. Oesterreich
Deformation Control Air Liquide America Dale C. Wetzel
Technology, Inc. Houston, TX Daimler Chrysler Corporation
Cleveland, OH Troy, MI
Carmen A. Paponetti, Sr.
Gregory A. Fett Expert Brazing & Daniel J. Williams
Dana Corporation Automotive Heat Treating, Inc. Induction Heating Consultant
Systems Group Cleveland, OH Novi, MI
Toledo, OH
George D. Pfaffmann Stanley Zinn
Kiyoshi Funatani Ajax Tocco Ferrotherm, Inc.
IMST Instrument Magnethermic Corporation Rochester, NY
Aichi, Japan Madison Heights, MI

Robert C. Goldstein Thomas Philips
Fluxtrol, Inc. Air Products and Chemicals Inc.
Auburn Hills, MI Saline, MI

David A. Guisbert Dale A. Poteet
QA Metallurgical Services LLC Innovative Metallurgical Technology
Niles, MI Brookfield, WI

Daniel H. Herring Fred R. Specht
The HERRING GROUP, Inc. Ajax Tocco
Elmhurst, IL Magnethermic Corporation
Cicero, IL
Robert A. Hill
Solar Atmospheres Inc. William D. Stofey
Hermitage, PA American Ultra Specialties, Inc.
(ret.)
R. Scott Hyde Hudson, OH
The Timken Company
Canton, OH R. Stewart Stringer
Air Products and Chemicals, Inc.
Roger Jones Allentown, PA
Solar Atmospheres Inc.
Souderton, PA
Contents

Applied Energy
How to Improve Inductor Life, Part 2 ............................................................................................. 1
W.I. Stuehr, D. Lynch, Induction Tooling, Inc., North Royalton, OH, USA
Optimizing Axle Scan Hardening Inductors ................................................................................. 5
R. Goldstein, V. Nemkov, R. Madeira, Fluxtrol, Inc., Auburn Hills, MI, USA
Processing of Multi-Layer Materials by Induction Heating Gradient Effect ............................... 10
E. Baake1, H. Schülbe1, A. Nikanorov1, R. Mergen2, A. Eberhard2,
(1) Leibniz University of Hannover, Hannover, Germany;
(2) Miba Bearing Group, Laakirchen, Austria
Increasing Inductor Lifetime by Predicting Coil Copper Temperatures ..................................... 16
R. Goldstein, V. Nemkov, Fluxtrol, Inc., Auburn Hills, MI, USA
Heat Transfer Characteristics of Laminar Methane/Air Flame Impinging on a Flat Surface ....... 23
S. Chander1, A. Ray2, (1) National Institute of Technology, Punjab, India;
(2) Indian Institute of Technology, New Delhi, India
Controlling Induction Heating Magnetic Fields with Flux Field Concentrators ......................... 33
T. Learman, Alpha 1 Induction Service Center, Columbus, OH, USA
Thermodynamic and Kinetic Aspects of Endothermic Carburizing Atmospheres with
Natural Gas Enrichment ................................................................................................................. 40
O. Karabelchtchikova1, S.A. Johnston2, H.F.M. DaCosta2, R.D. Sisson, Jr.1,
(1) Worcester Polytechnic Institute, Worcester, MA, USA;
(2) Caterpillar, Inc., Mossville, IL, USA
Emerging Technology
New Applications of EPM in Metal, Oxide and Semiconductor Processing .............................. 45
B. Nacke, Leibniz University of Hannover, Hannover, Germany
An Attractive Materials Process: Exploring High Magnetic Field Processing for
Developing Customized Microstructures with Enhanced Performance .................................... 52
G. Mackiewicz-Ludtka, G.M. Ludtka, R.A. Jaramillo, J.B. Wilgen, R.A. Kisner
Oak Ridge National Laboratory, Oak Ridge, TN, USA
Heat Treating Atmosphere Activation ......................................................................................... 62
Z. Zurecki, Air Products and Chemicals, Inc., Allentown, PA, USA
Microwave Processing and Heat Treating of Metals .................................................................. 69
E.B. Ripley, R.L. Hallman, Jr., J.A. Oberhaus, B.C. Warren,
Y-12 National Security Complex, Oak Ridge, TN, USA
Fluidized Bed: An Energy Efficient Heat Treating Technology for Cast Al Alloys .................. 77
S.K. Chaudhury, D. Apelian, Worcester Polytechnic Institute, Worcester, MA, USA
Integrated Heat Treatment – System for Precise Die Hardening in Automotive Industries ... 87
S. Bonss, J. Hannweber, U. Karsunke, M. Seifert, B. Brenner, E. Beyer,
Fraunhofer IWS Dresden, Dresden, Germany
Effect of Post-Spray Heat Treatment on Mechanical Properties of Ni-TiC
Composite Coatings Produced by Cold Gas Dynamic Spray ................................................... 94
K.Y. Sastry, M. Lubrick, V. Leshchynsky, R.Gr. Maev, University of Windsor,
Windsor, ON, Canada
Dr. George E. Totten International Symposium on Quenching & Cooling
Microstructure and Property Predictions by Using a Heat-Treatment
Planning System, CHT-q/t ............................................................................................................ 100
L. Zhang1, Y.M. Rong1, R. Purushothaman1, J.W. Kang2,
(1) Worcester Polytechnic Institute, Worcester, MA, USA;
(2) Tsinghua University, Beijing, China
Modeling of Microstructure Evolution during the Rapid Heating of Hypoeutectoid Steels ... 108
B.J. Yang, W. Li, A. Hattiangadi, G. Zhou, N. Singh, M.L. Johnson, Caterpillar, Inc, Peoria, IL, USA
Assessing Heat Treatment Distortion Sensitivity ...................................................................... 115
A.M. Freborg, Z. Li, B.L. Ferguson, Deformation Control Technology, Inc., Cleveland, OH, USA
Optimal Spray Characteristics in the Air-Assisted Water Spray Cooling of a
Downward-Facing Heated Surface .............................................................................................. 126
R.J. Issa, West Texas A&M University, Canyon, TX, USA
Some New Approaches in the Field of Quenching Fundamentals ........................................... 134
N. Kobasko, IQ Technologies, Inc., USA, Intensive Technologies, Ltd., Ukraine
Intensive Quenching to Reduce the Carburizing Cycle for Automotive Cross Production ... 141
L.C.F. Canale1, E. Merheb1, J.C. Vendramim2, G.E. Totten3, N.I. Kobasko4, M.A. Aronov4,
J.A. Powell4, (1) University of São Paulo, São Carlos, Brazil; (2) Isoflama Ind. E Com. Eq. Ltda.,
Indaiatuba, Brazil; (3) Portland State University, Portland, OR, USA; (4) IQ Technologies, Inc.,
Akron, OH, USA
Applying CFD to Characterize Gear Response during Intensive Quenching Process ........... 147
A. Banka1, J. Franklin1, Z. Li2, B.L. Ferguson2, M. Aronov3,
(1) Airflow Sciences Corporation, Livonia, MI, USA ; (2) Deformation Control Technology, Inc.,
Cleveland, OH, USA ; (3) IQ Technologies, Inc., Akron, OH, USA
Improving Gear Performance by Intensive Quench ................................................................... 156
B.L. Ferguson, A.M. Freborg, Z. Li, Deformation Control Technology, Inc., Cleveland, OH, USA
Historical Review of Residual Stress in Quenched Fe-Ni Alloy Cylinders and
Explanation of Its Origin Using Computer Simulation ............................................................... 163
K. Arimoto1, K. Funatani2, (1) Arimotech, Ltd., Osaka, Japan, (2) IMST Inst., Nagoya, Japan
Effect of Quenching on the Dimensional Stability of SAE 52100
Make Bearing Components .......................................................................................................... 173
S. Bhattacharya, M.B.N. Raju, Tata Steel, Jamshedpur, India
George E. Totten, Ph.D., FASM: A Biographical Overview of His Life and a Brief
Overview of His Impact on Global Quenching Technology ...................................................... 183
L.C.F. Canale, A.C. Canale, University of São Paulo, São Carlos, Brazil
The Contribution of Dr. George E. Totten to Unitize World Heat Treatment R&D, and
Update State of the Quenching and Control of Distortion ........................................................ 191
K. Funatani, IMST Institute, Nagoya, Japan
History of Quenching ................................................................................................................... 196
D.S. MacKenzie, Houghton International, Inc., Valley Forge, PA, USA
Effective Design of Heat Treat Processes Using Computer Simulations ................................ 205
Z. Li, A.M. Freborg, B.L. Ferguson, Deformation Control Technology, Inc., Cleveland, OH, USA
Using Wave Technology for Heat Treatment .............................................................................. 214
A. Sverdlin1, A. Ness1, R. Ganiev2, (1) Bradley University, Peoria, IL, USA;
(2) Research Scientific Center, Moscow, Russia
The Analysis of Gas Flow in the Wind Tunnel of High Pressure Gas Quenching Furnace .... 220
Y. Luo1, J. Kang1, B. Liu1, Y. Rong2, (1) Tsinghua University, Beijing, China;
(2) Worcester Polytechnic Institute, Worcester, MA, USA
Fluidized Bed Quenching Performance and Its Application for Heat Treating
Aluminum Alloys ........................................................................................................................... 225
J. Keist1, S. Chaudhury2, D. Apelian2, (1) Arizotah, LLC, Plymouth, MN, USA;
(2) Metals Processing Institute, Worcester, MA, USA
Mathematical Model of the Microstructural Response of a Medium-Carbon,
Low-Alloy Steel Quenched in a Fluidized Bed ........................................................................... 231
J.B. Hernández-Morales1, A.M. Dueñas-Pérez2, M. Díaz-Cruz2, R. Yates3,
(1) Universidad Nacional Autónoma de México, México; (2) ESIQIE-Instituto Politécnico
Nacional, México; (3) Alternativas en Computación, México
Processes & Applications
The Nitrocarburizing of Plain Carbon Steel Automotive Components ..................................... 239
V. Campagna1, R. Bowers1, D.O. Northwood1, X. Sun2, P. Bauerle2,
(1) University of Windsor, Windsor, ON, Canada;
(2) DaimlerChrysler Corporation, Auburn Hills, MI, USA
Optimization of Oxygen-Free Heat Treating ............................................................................... 245
K. Connery, S. Ho, Praxair, Inc., Burr Ridge, IL, USA
Statistical Process Control and Process Validation in Gas Carburizing of Gears .................. 249
C.R. Kinser, TRW Automotive, LLC, Lebanon, TN, USA
Case Histories Involving Embrittlement of Steel ....................................................................... 254
S. Suess, Stork Technimet, Inc., New Berlin, WI, USA
A Probabilistic Modeling Approach for Industrial Carburizing Operation ............................... 261
S.S. Sahay, Tata Research Development and Design Centre, Pune, India
Heat Treatment of Cr-Mo Powder Metallurgy Steels for High Performance Applications ...... 265
A. Klekovkin, N. Nandivada, D. Milligan, North American Höganäs, Hollsopple, PA, USA
Fatigue Studies and Characterization of Induction Tempered Welded Steel Tubes ............... 275
P. Shanmugam, M. Preethi, R. Natarajan, Tube Investments of India, Avadi, Channai, India
Non-Contact Ultrasonic Treatment of Metals in a Magnetic Field ............................................ 281
G.M. Ludtka, J.B. Wilgen, R.A. Kisner, R.A. Jaramillo, G. Mackiewicz-Ludtka,
Oak Ridge National Laboratory, Oak Ridge, TN, USA
Evaluation of Aging Response of Al-Cu-Mg-Si Based Cast Aluminum Alloy and
Its Effect on Tensile Property ...................................................................................................... 288
M. Maniruzzaman, E. Wallhagen, R.D. Sisson, Jr., Worcester Polytechnic Institute,
Worcester, MA, USA
The Aging Behavior of AA7136 Wrought Aluminum Alloy ........................................................ 294
C. Nowill1, M. Maniruzzaman1, R.D. Sisson, Jr. 1, D.S. MacKenzie2
(1) Worcester Polytechnic Institute, Worcester, MA, USA;
(2) Houghton International, Inc., Valley Forge, PA, USA
Special Heat Treatment Practices for Aerospace Aluminum Alloys ........................................ 299
P. Dungore, A. Agnihotri, Jawaharlal Nehru Aluminum Research Development and
Design Centre, India
The Effect of Aluminum on Isothermal Oxidation Resistance of
Austenitic Heat Resistant Steels ................................................................................................. 303
M.O. Aminian1, J. Hedjazi2, Y.Kharazi2, (1) Delta Advanced Ceramics Co., Tehran, Iran;
(2) Iran University of Science and Technology, Tehran, Iran
Effects of Quenching Variables on the Impact Resistance of 0.3C Hypo-Eutectoid
Plain Carbon Steel ........................................................................................................................ 313
M.O.H. Amuda, B.U. Amaechi, D.E. Esezobor, G.I. Lawal, University of Lagos, Lagos, Nigeria
Effect of Heat Treatment Cycle on the Mechanical Properties of
Machinable Austempered Ductile Iron ........................................................................................ 323
M. TadayonSaidi1, N. Baghersaee2, N. Varahram3, M.H. Rao1, G.V.S.N. Rao1,
(1) National Institute of Technology, Warangal, India; (2) RWTUV Iran Joint Venture Co., Iran;
(3) Sharif University of Technology, Tehran, Iran
Tribology of Conformal Gears with Advanced Material Systems ............................................. 328
A.T. Wilder1, J.G. Wilder2, (1) University of Texas, Austin, TX, USA;
(2) Process Science, Inc., Leander, TX, USA
Effects of T6 Heat Treatment with Residual Heat of Casting on Microstructure and
Mechanical Properties of 319 Aluminum Alloy Castings .......................................................... 333
L. He1, J. Kang1, T. Huang1, Y. Rong2, (1) Tsinghua University, Beijing, China;
(2) Worcester Polytechnic Institute, Worcester, MA, USA
Plasma Nitriding of AISI H13 Tool Steel with Different Microstructures .................................. 338
L.C. Casteletti1, R.M.M. Riofano1, C.K.N. de Oliveira2, A.L. Neto1, G.E. Totten3,
(1) Escola Eng. São Carlos – USP, São Paulo, Brazil;
(2) Universidade Regional do Cariri, Ceará, Brazil;
(3) Portland State University, Portland, OR, USA
Three Point Bending Behavior of Orthodontic Thermo-Active Nitinol Wires .......................... 343
A.I. Filho1, C.A.R. Gouvêa2, A.L. Neto2, G.E. Totten3, L.C. Casteletti1,
(1) Departamento de Metalurgia do CEFET-ES, Vitória, ES;
(2) Escola Eng. São Carlos – USP, São Paulo, Brazil;
(3) Portland State University, Portland, OR, USA
Thermal Spray Coatings on an Aged 7475 Aluminum Alloy Substrate .................................... 346
D.T. de Macedo1, L.B. Cruvinel1, A.L. Neto1, G.E. Totten2, L.C. Casteletti1,
(1) Escola Eng. São Carlos – USP, São Paulo, Brazil;
(2) Portland State University, Portland, OR, USA
Electric Resistivity Evaluation of the Fe-31Mn-7.5Al-1-5Si-1.0C Alloy ..................................... 351
L.C. Casteletti1, A.L. Neto1, G.E. Totten2,
(1) Escola Eng. São Carlos – USP, São Paulo, Brazil;
(2) Portland State University, Portland, OR, USA
On the Influence of the Process of Carbonitriding in Smoldering Discharge on the
Properties of 25CrMnSiNiMo Steel .............................................................................................. 355
A.Z.I. Ziumbilev1, K. Nikolov2, (1) TU Sofia, Plovdiv, Bulgaria;
(2) DOC Dortmunder Oberflächencentrum GmbH, Dortmund, Germany
Effect of Nitriding on the Fatigue Properties of Continuously Cast Gray Irons ...................... 362
P.R. Gangasani, Dura Bar, Woodstock, IL, USA
Vacuum Technology
Hydrogen Pick-Up during Low Pressure Gas Carburizing Compared with
Traditional Gas Carburizing Processes ...................................................................................... 369
Ch. Laumen1, B. Clausen2, F. Hoffmann2, (1) The Linde Group, Unterschleissheim, Germany;
(2) Institut für Werkstofftechnik, Bremen, Germany
The Benefits of Using 3 Gas Mixture Low Pressure Carburizing (LPC) for
High Alloy Steels ........................................................................................................................... 376
R. Gorockiewicz1, A. Adamek2, M. Korecki2, (1) University of Zielona, Góra, Poland;
(2) Seco/Warwick S.A., Swiebodzin, Poland
Numerical Simulation of Gas Quenching Process of Workpieces ........................................... 385
Y. Luo1, J. Kang1, B. Liu1, Y. Rong2, (1) Tsinghua University, Beijing, China;
(2) Worcester Polytechnic Institute, Worcester, MA, USA
Fast Track
Demonstrations of Intensive Quenching Methods for Steel Parts ........................................... 390
M.A. Aronov1, N.I. Kobasko1, J.A. Powell1, J.H. Vanas1, P. Ghorpade2, D. Gopal2,
(1) IQ Technologies, Inc., Akron, OH, USA; (2) High Temp Furnaces Limited, Bangalore, India
Modern Gas Quenching Chambers Supported by SimVaCPlus Hardness Application ......... 398
P. Kula, R. Atraszkiewicz, E. Stańczyk-Wołowiec,
Institute of Materials and Engineering, Lodz, Poland
Curtains in Continuous Furnaces ............................................................................................... 403
M.S. Stanescu1, P.F. Stratton2, L. Druga3, (1) The Linde Group, Murray Hill, NJ, USA;
(2) The Linde Group, Huddersfield, UK; (3) UTTIS Indistries, Bucharest, Romania
How to Organize and Run a Low-Cost and Highly Effective Metallurgical/Processing
Lab for Small- and Medium-Size Heat Treatment Facilities ....................................................... 419
A. Khersonsky
The Role of Cleaning in the Heat Treatment Process ................................................................ 424
X. Wang, W. Liu, M. Maniruzzaman, K. Rong, R.D. Sisson, Jr.,
Worcester Polytechnic Institute, Worcester, MA, USA
Preface
Heat treating is a core competency and a vital part of the manufacturing community. Nowhere was this more evident than in the
gathering of heat treaters, engineers, scientists, managers, and industry leaders who attended the 24th ASM International Heat Treating
Conference and Exposition held at COBO Center in Detroit, Michigan, USA on September 17–19, 2007.

Heat treating is a vibrant and growth-oriented industry driven by the need of its users to satisfy the demand for increased product
performance, new technology developments and innovation. This event gave all those who participated a unique opportunity to
network, exchange ideas, and discuss critical issues so as to ensure that Heat Treating remains the most cost-effective technology.

The Heat Treating Society Conference was designed around a “Heat Treat University” theme, with sessions for beginners through
experts. The topics range from “fundamentals” through “leading edge research.” Special events included the Dr. George E. Totten
International Symposium on Quenching and Cooling — honoring Dr. Totten’s many years of experience in the heat treat industry.

This Conference is a joint effort and we wish to especially thank the members of the Heat Treating Society Board, the Heat Treating
Society Technology and Programming Committee, and the Exposition Committee for their inspiration, guidance and tireless efforts to
identify, solicit, and encourage industry experts to share their knowledge and expertise to create the finest program on heat treating in
the world. We as individuals and as an industry profit from the effort of these volunteers and the hundreds of hours they devote to
advancing the science of heat treating.

These papers represent the latest state-of-the-art in heat treating materials, processes, products, equipment, and methodology. The
topics cover the depth and breath of our industry and will be a valuable reference source for years to come.

The opportunity to co-chair this Conference and Exposition as well as to bring you this 2007 Heat Treating Proceedings on CD-Rom
has truly been our pleasure and privilege. Thank you for allowing us this opportunity.

Daniel H. Herring
The HERRING GROUP, Inc.

D. Scott Mackenzie
Houghton International

Daniel J. Williams
Induction Heating Consultant