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. 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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