11

High Performance, Low Emission Carburizing Furnace Atmosphere

Generation & Control Using Rapid Laser-Based Gas Analysis

October 11, 2000

High Performance, Low Emission Carburizing Furnace Atmosphere

Generation & Control Using Rapid Laser-Based Gas Analysis

October 11, 2000

Ronald R. RichRonald R. Rich

Atmosphere Recovery, Inc.Atmosphere Recovery, Inc.andand

Ralph W. LarsonRalph W. Larson

Dana CorporationDana Corporation

22

Topics PresentedTopics Presented

• Carburizing Atmosphere Technology & IssuesCarburizing Atmosphere Technology & Issues• Atmosphere Gas Monitoring Needs & MethodsAtmosphere Gas Monitoring Needs & Methods• ARI Laser Gas Analyzer (LGA)/Controller System ARI Laser Gas Analyzer (LGA)/Controller System • Improved Process Development HistoryImproved Process Development History• New Approaches to Gas Carburizing with LGANew Approaches to Gas Carburizing with LGA• Metallurgical Findings & Technology StatusMetallurgical Findings & Technology Status

33

Carburizing Use & PurposeCarburizing Use & Purpose

• Improves Steel Wear Resistance on Part Surfaces (Adds Carbon)Improves Steel Wear Resistance on Part Surfaces (Adds Carbon)• Maintains Steel “Toughness” at Part Depth (Lower Carbon)Maintains Steel “Toughness” at Part Depth (Lower Carbon)• Parts to Heated to High Temperatures in a Gas “Atmosphere” Parts to Heated to High Temperatures in a Gas “Atmosphere” • Atmosphere Provides Reactive Chemistry Containing Carbon in Gas Atmosphere Provides Reactive Chemistry Containing Carbon in Gas

Form in a Reducing EnvironmentForm in a Reducing Environment

Typical Parts (Gears)Typical Parts (Gears) Typical Furnace (Batch)Typical Furnace (Batch)

44

Traditional Carburizing Atmosphere

EndogasEndogas

AirAir

Natural Natural GasGas

Composition: CO~20%, Composition: CO~20%, NN22~39%, H~39%, H22~39%, 1% CH~39%, 1% CH44, ,

Balance: COBalance: CO22, H, H22O, OO, O22

At Metal Surface:At Metal Surface:2H2H22+2CO+3Fe +2CO+3Fe Fe Fe33C+2HC+2H22O+COO+CO2 2

3Fe + CH3Fe + CH44 Fe Fe33C + 2HC + 2H22

Exhaust StackExhaust Stack

55

Typical Carburizing OperationTypical Carburizing Operation

Air

EndothermicAtmosphereGeneratorSystem

Continuousor Batch Furnace

AtmosphereFlare

BypassFlare

Pressure& BypassControl

Indirect-Fired Burners

Carburizing Chamber(s)

Endo GasCooler

Flare Exhaust(High CO) Burner Exhaust

(Low CO)

FixedFlowRate

Indi

rect

-Fir

ed B

urne

rs

Air/GasRegulation

CatalyticReactionVessel(s)

Air/GasRegulation

Air/GasRegulation

Burner Exhaust(Low CO)

Flare Exhaust(High CO)

Vari-ableFlow

AirAir

Natural Gas Supply

Doorand SealLeaks

(ExtremelyHigh CO)

AirAirNat.

Gas

Nat.Gas

Vari-ableFlow

Air

Furnace Atmosphere Supply

FurnaceDoor(s)

66

Major Concerns Related to Atmosphere Carburizing

Major Concerns Related to Atmosphere Carburizing

• Process Control Problems with Existing TechnologiesProcess Control Problems with Existing Technologies– Variable Production Part Parameters (Case Depth, %Carbon)Variable Production Part Parameters (Case Depth, %Carbon)– Many Atmosphere Constituents InferredMany Atmosphere Constituents Inferred– Inefficient Control Algorithms to Employed to Reduce Sooting Inefficient Control Algorithms to Employed to Reduce Sooting – Limited Warning of Equipment MaintenanceLimited Warning of Equipment Maintenance

• Process Improvement Potential (Over 60 Years Old)Process Improvement Potential (Over 60 Years Old)– Improved Part Quality & PerformanceImproved Part Quality & Performance– Reduced Atmosphere Consumption Reduced Atmosphere Consumption – Furnace Cycle Time ReductionsFurnace Cycle Time Reductions– Higher Performing Surface Treatment OptionsHigher Performing Surface Treatment Options

• High Levels of Carbon Monoxide Air EmissionsHigh Levels of Carbon Monoxide Air Emissions• Inefficient Use of Atmosphere Gas and EnergyInefficient Use of Atmosphere Gas and Energy

77

Most Industrial Furnace Atmosphere Gases SimilarMost Industrial Furnace

Atmosphere Gases Similar• Carburizing, Carbonitriding, & NitridingCarburizing, Carbonitriding, & Nitriding

– NN22, CO, H, CO, H22, CO, CO22, H, H22O, CHO, CH44, O, O22, NH, NH33, CH, CH33OHOH

• Atmosphere Tempering and AnnealingAtmosphere Tempering and Annealing – NN22, H, H22, CO, CO, CO, CO22, H, H22O, CHO, CH44, O, O22, NH, NH33, Ar , Ar

• Copper and Aluminum BrazingCopper and Aluminum Brazing– NN22, H, H22, CO, CO, CO, CO22, H, H22O, CHO, CH44, O, O22, NH, NH33, Ar, Ar

• Powdered Metal SinteringPowdered Metal Sintering– NN22, CO, H, CO, H22, CO, CO22, H, H22O, CO, CxxHHyy, O, O22

88

Typical Atmosphere Control Measures Only One Gas Species

Typical Atmosphere Control Measures Only One Gas Species

• TypesTypes– Zirconia Oxygen Probe – Measures OxygenZirconia Oxygen Probe – Measures Oxygen– Dew Point Meters – Measures Water VaporDew Point Meters – Measures Water Vapor– Electrochemical Cells – Low Range Single GasesElectrochemical Cells – Low Range Single Gases

• BenefitsBenefits– Lower Capital Cost Lower Capital Cost – Limited Calibration RequirementsLimited Calibration Requirements

• DisadvantagesDisadvantages– All Other Gas Constituents Not Measured or ControlledAll Other Gas Constituents Not Measured or Controlled– Many Assumptions About Other Gas Constituents NeededMany Assumptions About Other Gas Constituents Needed– Requires High Atmosphere Flows for Adequate ControlRequires High Atmosphere Flows for Adequate Control– Inaccurate Correction for Most Atmosphere VariancesInaccurate Correction for Most Atmosphere Variances– Limited Process Control Variation & Improvement OptionsLimited Process Control Variation & Improvement Options

99

Carburizing Atmosphere Monitoring Improved With Infrared Analyzers

Carburizing Atmosphere Monitoring Improved With Infrared Analyzers• Usually Measures Only Three More GasesUsually Measures Only Three More Gases

– Carbon MonoxideCarbon Monoxide– Carbon DioxideCarbon Dioxide– Methane Methane

• Does Not Measure Other Significant GasesDoes Not Measure Other Significant Gases– Oxygen (Additional Sensor Required)Oxygen (Additional Sensor Required)– Water Vapor (Theoretically Could)Water Vapor (Theoretically Could)– HydrogenHydrogen– Nitrogen and Inert GasesNitrogen and Inert Gases

• Non-Linear ResponseNon-Linear Response– Accurate Only Within Limited Concentration Range Accurate Only Within Limited Concentration Range – High/Low Constituent Concentration InterferenceHigh/Low Constituent Concentration Interference– Reference Cell Requires Frequent CalibrationReference Cell Requires Frequent Calibration

1010

Benefits of CompleteAtmosphere Gas Analysis

Benefits of CompleteAtmosphere Gas Analysis

• Improved Carbon & Nitriding Potential ControlImproved Carbon & Nitriding Potential Control• Improved Oxidation/Reduction Potential ControlImproved Oxidation/Reduction Potential Control• Reduction in Atmosphere ConsumptionReduction in Atmosphere Consumption• Allows Use of “Non-Standard” Atmosphere GasesAllows Use of “Non-Standard” Atmosphere Gases• Control of “Cleaner” Furnace AtmospheresControl of “Cleaner” Furnace Atmospheres

– Hydrogen/Nitrogen/Inert CombinationsHydrogen/Nitrogen/Inert Combinations– Carbon Dioxide/Hydrocarbon MixturesCarbon Dioxide/Hydrocarbon Mixtures– Novel Mixtures for Improved PerformanceNovel Mixtures for Improved Performance– Sooting Reduced or EliminatedSooting Reduced or Eliminated

• Early Warning of Some Furnace Maintenance IssuesEarly Warning of Some Furnace Maintenance Issues• Potential for Reduced Furnace Cycle TimesPotential for Reduced Furnace Cycle Times

1111

Additional Benefits if Complete Atmosphere Analysis is Rapid

(15 Seconds or Less)

Additional Benefits if Complete Atmosphere Analysis is Rapid

(15 Seconds or Less)• ““Real Time” Process Monitoring, Control and R&DReal Time” Process Monitoring, Control and R&D• Correlation with Existing Furnace SensorsCorrelation with Existing Furnace Sensors• ““Non-Equilibrium” Atmosphere OperationNon-Equilibrium” Atmosphere Operation• Accurate Carburizing Rate AssessmentAccurate Carburizing Rate Assessment• Greater Potential for Reduced Furnace Cycle TimesGreater Potential for Reduced Furnace Cycle Times• Drastic Reduction in Atmosphere ConsumptionDrastic Reduction in Atmosphere Consumption• Efficient Use of “Non-Standard” Atmosphere GasesEfficient Use of “Non-Standard” Atmosphere Gases• Early Warning of Many Furnace Maintenance IssuesEarly Warning of Many Furnace Maintenance Issues• Improved Furnace Performance and Safety MonitoringImproved Furnace Performance and Safety Monitoring

1212

Conventional Complete GasAnalysis Technologies

Conventional Complete GasAnalysis Technologies

• Gas Chromatography (GC)Gas Chromatography (GC)– Moderate Price ($15,000 - $60,000)Moderate Price ($15,000 - $60,000)– Slow (2 Minutes+)Slow (2 Minutes+)– Frequent Calibration and ServiceFrequent Calibration and Service– Carrier Gas NeededCarrier Gas Needed

• Mass Spectroscopy (MS) Mass Spectroscopy (MS) – Higher Price ($50,000 - $120,000)Higher Price ($50,000 - $120,000)– Fast if Vacuum Already Present (Can be Slow if Not)Fast if Vacuum Already Present (Can be Slow if Not)– Expensive to MaintainExpensive to Maintain– Equal Mass Gases Require Additional Analysis (GC)Equal Mass Gases Require Additional Analysis (GC)

1313

• Unique Frequency “Shift” for Each Type of Chemical BondUnique Frequency “Shift” for Each Type of Chemical Bond

• Measures Gases of All Types (Except Single Atoms)Measures Gases of All Types (Except Single Atoms)

• Rapid “Real Time” Response Rates PossibleRapid “Real Time” Response Rates Possible

• Signal Directly Proportional to Number of Gas Atoms Signal Directly Proportional to Number of Gas Atoms

• 0-100% Gas Concentrations Measured with One Detector0-100% Gas Concentrations Measured with One Detector

• Resolution and Accuracy Depends On:Resolution and Accuracy Depends On:– Laser Power and Optics Variation (Including Cleanliness)Laser Power and Optics Variation (Including Cleanliness)

– Gas Concentration and PressureGas Concentration and Pressure

– Molecular Bond TypeMolecular Bond Type

– Background and Scattered RadiationBackground and Scattered Radiation

– Optical and Electronic Detector Circuitry Optical and Electronic Detector Circuitry

Raman Gas Analysis PrincipalsRaman Gas Analysis Principals

1414

Raman Shift (cm-1)

1000 1500 2000 2500 3000 3500 4000 4500

Integrated Intensity (V

)

0

20

40

60

80

N2 H2

H2OCH4

CO

CO2

Some Atmosphere Raman Shift Spectra

Source:Source:NASANASA

SpeciesSpectral

Location (cm-1)

Intensity

Relative to N2

Relative % of endothermic gas

Absolute % based on calibration

1284 1.59 1.611.21 2.101.58

1373 2.05 1.841.17 2.411.31

CO 2117 1.1 21.393.79 27.974.96

N2 2316 1 43.684.01 57.125.24

CH4 2905 7.47 0.590.44 0.770.57

H2O 3648 3.4 2.221.89 2.912.48

H2 4148 1.69 30.393.37 39.744.41

CO2

1515

Laser Raman Analysis TechnologiesLaser Raman Analysis Technologies• External Cavity Raman Lasers (Under Development)External Cavity Raman Lasers (Under Development)

– Remote Fiber Optic Sensor HeadsRemote Fiber Optic Sensor Heads– Higher Price Because of High Laser Power ($75,000 - $300,000)Higher Price Because of High Laser Power ($75,000 - $300,000)– Fast Only if Laser Power HighFast Only if Laser Power High– Expensive to Operate (Power, Cooling, Probe Tip?)Expensive to Operate (Power, Cooling, Probe Tip?)– Laser Beam DangerousLaser Beam Dangerous– Less AccurateLess Accurate

• Internal Cavity Raman Laser (ARI’s “LGA” Design) Internal Cavity Raman Laser (ARI’s “LGA” Design) – Gas Sample Flows Through InstrumentGas Sample Flows Through Instrument– Moderate Price ($25,000 - $60,000)Moderate Price ($25,000 - $60,000)– Fast if Detectors SelectiveFast if Detectors Selective– Low Cost OperationLow Cost Operation– Safe Low Power Laser BeamSafe Low Power Laser Beam

1616

Multiple Port ARI LGA SystemMultiple Port ARI LGA System

Furnace Gas 1 In

Plasma Cell

Mirror Polarizer Prism & Mirror

Laser BeamGas Sample Tube

Sample Pump & Pressure Control

Individual Gas Detectors

Gas Outlet

Filter

Individual Gas Detectors

Furnace Gas 2 In

Filter Furnace Gas 3 In

Filter Generator Gas InFilter

Valve

Assem

bly

1717

ARI LGA Detector Features ARI LGA Detector Features • Gas Analysis CapabilitiesGas Analysis Capabilities

– 8 Gas Species Detected Simultaneously 8 Gas Species Detected Simultaneously – Fast Detector Response (50 milliseconds)Fast Detector Response (50 milliseconds)– 50 Parts per Million to 100% Concentration Range50 Parts per Million to 100% Concentration Range– More Accurate than NIST Calibration Gas MixturesMore Accurate than NIST Calibration Gas Mixtures– No Zero and Span Gas Requirement (Optional)No Zero and Span Gas Requirement (Optional)– Design Allows Customized Selection of Gas SpeciesDesign Allows Customized Selection of Gas Species

• Lifetime and ServicingLifetime and Servicing – Two to Five Year Component LifetimesTwo to Five Year Component Lifetimes– Ten Minute Detector ExchangeTen Minute Detector Exchange– Individual Components Can Be Serviced and CleanedIndividual Components Can Be Serviced and Cleaned

1818

Additional LGA System FeaturesAdditional LGA System Features• Integrated Sample Flow Control & MonitoringIntegrated Sample Flow Control & Monitoring

– Specialized Long Life Sample Filters (One Year +)Specialized Long Life Sample Filters (One Year +)

– Internal Sample Pump and Calibration ValvesInternal Sample Pump and Calibration Valves– Low Volume Sample Gas Flows (200 ml/minute) Low Volume Sample Gas Flows (200 ml/minute) – Electronic Flow and Pressure MonitoringElectronic Flow and Pressure Monitoring– Optics and Enclosure Inerting (Standard for Atmosphere Analysis)Optics and Enclosure Inerting (Standard for Atmosphere Analysis)

– Multiple Sample Ports (16 + Optional)Multiple Sample Ports (16 + Optional)– Sample Line Purge and Back-flush (Optional)Sample Line Purge and Back-flush (Optional)– High Dew Point Atmosphere Operation (Optional)High Dew Point Atmosphere Operation (Optional)

• Integrated Electronics & SoftwareIntegrated Electronics & Software– ““Open Hardware” Pentium/Pentium III PCOpen Hardware” Pentium/Pentium III PC– ““Open Software” Windows NT 4.0/Win2000 BasedOpen Software” Windows NT 4.0/Win2000 Based– Many Local and Remote Displays and Data Storage OptionsMany Local and Remote Displays and Data Storage Options– Available Analog and Digital I/O OptionsAvailable Analog and Digital I/O Options– Multiple Configurable Process and PLC Interface OptionsMultiple Configurable Process and PLC Interface Options

1919

Interior View of SubsystemsInterior View of Subsystems

Pentium PC BasedPentium PC BasedMonitor/ControllerMonitor/Controller

Win NT or DOS OSWin NT or DOS OS& 4.3 GB Hard Disk& 4.3 GB Hard Disk

Optional I/OOptional I/OCard SlotsCard Slots

Laser & Gas SensorLaser & Gas SensorAssemblyAssembly

Display, Keyboard,Display, Keyboard,Serial & Network PortsSerial & Network Ports

Gas Flow ControlGas Flow ControlAssemblyAssembly

Gas Sample PumpGas Sample Pump

Multi-PortMulti-PortControl OptionsControl Options

2020

Exterior View NEMA 4/12 UnitExterior View NEMA 4/12 Unit

CoolingCoolingUnitUnit

Sample, Calibration &Sample, Calibration &Inerting Gas InputsInerting Gas Inputs

Model 4EN Furnace Atmosphere Analyzer

Electrical &Electrical &CommunicationCommunication

(131oF Maximum)

2121

Interior View NEMA 12 UnitInterior View NEMA 12 Unit

LGA UnitLGA UnitSub-AssemblySub-Assembly

Power & NetworkPower & NetworkConnectionsConnections

IntegratedIntegratedSample FiltersSample Filters

IntegratedIntegratedMulti-portMulti-port

ValvesValves

Calibration &Calibration &Purge GasPurge GasRegulators Regulators

2222

Sample Software Control Screens

Main Control ScreenMain Control Screen Atmosphere Analysis ValuesAtmosphere Analysis Values

2323

LGA Carburizing ApplicationsLGA Carburizing Applications• External Atmosphere Generator Monitoring & ControlExternal Atmosphere Generator Monitoring & Control• Complete Furnace Atmosphere Control Including:Complete Furnace Atmosphere Control Including:

– Communications with PLC-Based Furnace ControllerCommunications with PLC-Based Furnace Controller

– Real-Time Carbon Potential Correction of Oxygen Sensor Real-Time Carbon Potential Correction of Oxygen Sensor

– Reduced Atmosphere Gas Usage & In-Situ Generation Reduced Atmosphere Gas Usage & In-Situ Generation

• Stand-Alone PC Based Control System Integrating:Stand-Alone PC Based Control System Integrating:– Complete Furnace Atmosphere ControlComplete Furnace Atmosphere Control

– Improved Safety MonitoringImproved Safety Monitoring

– Burner & Over Temperature ModulesBurner & Over Temperature Modules

– Oxygen Probes & Quench Tank MonitoringOxygen Probes & Quench Tank Monitoring

– Part Load and Tray TrackingPart Load and Tray Tracking

– Interface with Plant SCADA and SPC SystemsInterface with Plant SCADA and SPC Systems

2424

Use for Rapid Generator MonitoringUse for Rapid Generator MonitoringGENERATOR GAS ANALYSES: 01/22/2000

Statistic \ Gas CO H2O NH3 O2 N2 CO2 H2 CxHy Number of Samples 607 607 607 607 607 607 607 607 Minimum, % volume 19.890 0.010 0.000 0.000 38.520 0.330 39.980 0.010 Maximum, % volume 20.090 0.010 0.000 0.020 38.830 0.450 41.190 0.140 Average, % volume 19.984 0.010 0.000 0.008 38.675 0.360 40.341 0.029 Standard Deviation 0.054 0.000 0.000 0.006 0.109 0.038 0.356 0.040 95% Confidence Interval 0.004 0.000 0.000 0.001 0.009 0.003 0.028 0.003

0

5

10

15

20

25

30

35

40

45

50

0 2 4 6 8 10 12 14 16 18 20 22 24

Hour of Day

Con

cen

trati

on

, %

CO H2O NH3 O2 N2 CO2 H2 CxHy

37

42

7 9

Expanded View Showing Rapid VariationsExpanded View Showing Rapid Variations

2525

New Approaches to Carburizing Demonstrated at Dana Corp.

New Approaches to Carburizing Demonstrated at Dana Corp.

Spicer Off-Highway ComponentsSpicer Off-Highway ComponentsPlymouth, MNPlymouth, MN

2626

Plant Products and ProcessesPlant Products and Processes

• ProductsProducts– Primarily Large Off-Road Axles and GearsetsPrimarily Large Off-Road Axles and Gearsets

– Some Interdivisional Component CarburizingSome Interdivisional Component Carburizing

• Atmosphere Heat Treat ProcessesAtmosphere Heat Treat Processes– Five “Carburizing” FurnacesFive “Carburizing” Furnaces

– Three “Endothermic” GeneratorsThree “Endothermic” Generators

2727

Improvements Initiated Becauseof New Air Emission Concerns

Improvements Initiated Becauseof New Air Emission Concerns

• Previously Recognized Air EmissionsPreviously Recognized Air Emissions– Smoke from QuenchingSmoke from Quenching

– Burner Combustion GasesBurner Combustion Gases

• Unrecognized Air Emissions IssuesUnrecognized Air Emissions Issues– Carbon Monoxide (CO) from Atmosphere UseCarbon Monoxide (CO) from Atmosphere Use

– Comes from Atmosphere Generation, LeakageComes from Atmosphere Generation, Leakage

and Flaring - 10,000 to 200,000 ppmand Flaring - 10,000 to 200,000 ppm

– Original “Potential to Emit” Estimate - 231 Tons Original “Potential to Emit” Estimate - 231 Tons Per Year (TPY)Per Year (TPY)

2828

Rapid Gas Analysis Process DevelopmentRapid Gas Analysis Process Development• 1993-1994 Environmental & Air Quality Monitoring1993-1994 Environmental & Air Quality Monitoring

– Furnace Gas and Emission TestingFurnace Gas and Emission Testing– Options for Industrial Furnace Process Modification IdentifiedOptions for Industrial Furnace Process Modification Identified

• 1994 - Atmosphere Recovery, Inc. Founded 1994 - Atmosphere Recovery, Inc. Founded – Carburizing Heat Treat Furnace Atmosphere Recovery ResearchCarburizing Heat Treat Furnace Atmosphere Recovery Research– Dana & USDOE Sponsored Research ProgramDana & USDOE Sponsored Research Program– Intent to Produce SystemsIntent to Produce Systems

• 1995-1999 - Constructed and Tested Prototype Systems1995-1999 - Constructed and Tested Prototype Systems– Numerous Papers and PresentationsNumerous Papers and Presentations– Plant and Process Energy and Environmental AwardsPlant and Process Energy and Environmental Awards

• 1999-2000 – Laser Gas Analyzer Product Demonstrations1999-2000 – Laser Gas Analyzer Product Demonstrations– Endothermic and Exothermic ApplicationsEndothermic and Exothermic Applications– Tests with “Non-Standard” AtmospheresTests with “Non-Standard” Atmospheres

2929

Batch Furnace ModificationsBatch Furnace Modifications

• Side Pipe Waste Gas Exit with CapSide Pipe Waste Gas Exit with Cap• Backup Safety Pressure Control Box and DialsBackup Safety Pressure Control Box and Dials• Electronic Endothermic Gas ControlElectronic Endothermic Gas Control• Communication with Existing ControlsCommunication with Existing Controls• Finding - Minimal Modifications NeededFinding - Minimal Modifications Needed

3030

Typical Test Load2,000 lbs. Driveshaft “Crosses”

Side ViewSide View Top ViewTop View

3131

Initial Demonstration - Atmosphere Recovery Process

Initial Demonstration - Atmosphere Recovery Process

Air

AtmosphereRecoverySystem Continuous

or Batch Furnace

Indirect-Fired Burners

Carburizing Chamber(s)

Endo GasCooler

4% or LessFlare Exhaust

(Low CO) Burner Exhaust(Low CO)

Separationand

BlendingUnit

Air/GasRegulation

Air/GasRegulation

Natural Gas Supply

80%+ReducedQuantity

Doorand SealLeaks(Still

High CO)

Furnace Atmosphere Supply

FurnaceDoor(s)

Air

Furnace Atmosphere Return

ByproductFlare

AirNat.Gas

IR-GCLater LGA

Part of System

3232

Prototype SystemPrototype System

• Prototype Development, Assembly and TestingPrototype Development, Assembly and Testing

• First Full Scale Operation - Aug. 6, 1997First Full Scale Operation - Aug. 6, 1997

• Finding - Process Worked and Increased Furnace ProductivityFinding - Process Worked and Increased Furnace Productivity

IR-GC (Later Replaced by LGA)

3333

Inter-Cavity Raman & GC Comparison on ARI Trial

Inter-Cavity Raman & GC Comparison on ARI Trial

ARI FURNACE TEST 980918Comparison of Gas Analyses: Raman Laser and GC

0

10

20

30

40

50

60

70

-2.5 -2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0Program Time, hours (0.0 = time at initial 1750 deg F)

%CO - Regap %N2 - Regap %CO2 - Regap %H2 - Regap %CH4 - Regap %CO - GC %N2 - GC %CO2 - GC %H2 - GC %CH4 - GC

3434

System Location in PlantSystem Location in Plant

““Explosion Resistant” Test AreaExplosion Resistant” Test Area

3535

Later Demonstrations -Integral Atmosphere Generation

Later Demonstrations -Integral Atmosphere Generation

Air

AtmosphereGas Supply

System Continuousor Batch Furnace

Indirect-Fired Burners

Carburizing Chamber(s)

Endo GasCooler

Burner Exhaust(Low CO)

Gas Monitoringand

Blending Unit

Air/GasRegulation

Natural Gas Supply

80%+ReducedQuantity

Doorand Seal

Leaks(Still

High CO)

Furnace Atmosphere Supply

FurnaceDoor(s)

Furnace Atmosphere Sample Line

GasC

GasA

GasB

LGA isIntegral

Part of System

3636

ARI Test #980918 - ARI Modified Furnace Atmosphere - Laser Gas AnalysesTest Identification Data Timed Event Description Hours Standard % Save Hardness Sample See Test Pin

Heat Code DP217 Program Start to Program End 5.65 10.42 45.78 Surface Hardness, RC Sample NA# of Gears on Load 4/156* Initial 1750 deg F to Program End 4.45 8.92 50.11 50 RC Case Depth, in Hardness Depth, inMarathon Program 160 Initial 1750 deg F to Final 1750 deg F 3.50 7.92 55.81 Tooth RC, 1/8 Top Table N/ATest Date 9/18/98 Tooth RC, Pitch NA Carbon BarProgram Start Time 10:58 Tooth RC, Root NA % C at 0.003"Program End Time 16:37 Tooth RC, 1/8 Core NA N/A

Comments: * Four gears part # R30GS101: Surface hardness spec: 58-63 RC; 50 RC Case depth spec: 0.025"-0.040" Gear Status* 156 crosses: Surface hardness spec: 58-63 RC; 50 RC Case depth spec: 0.051"-0.055" N/A

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

-2.5 -2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0Program Time, hours (0.0 = time at initial 1750 deg F)

0

7

14

21

28

35

42

49

56

63

70

Step (0-20) Deg F (0-2000) Carbon Pot (0-2%) % CO (0-70) % N2 (0-70) % CO2 (0-70) % H2 (0-70) % CH4 (0-70) Dew Point (0-70)

Example Results for Rapid CarburizingExample Results for Rapid Carburizing

3737

Parts Testing – Typical LoadParts Testing – Typical Load• Two Test Pins Two Test Pins

– One by PlantOne by Plant– One by Heavy Axle Division (HAD)One by Heavy Axle Division (HAD)

• 3 or 6 “Standard Heat Code” 8620 Planet Gears Per Load3 or 6 “Standard Heat Code” 8620 Planet Gears Per Load– Tested by PlantTested by Plant– Standard Load LocationsStandard Load Locations– Three As TemperedThree As Tempered– Sometimes Three as QuenchedSometimes Three as Quenched

• Three 8620/25/30 Test Pinions (Production Parts)Three 8620/25/30 Test Pinions (Production Parts)– Standard Load LocationsStandard Load Locations– All As TemperedAll As Tempered– One Tested by PlantOne Tested by Plant– Two Tested by HADTwo Tested by HAD

• Two Carbon Profiles (Bar by HAD, Rod by Plant)Two Carbon Profiles (Bar by HAD, Rod by Plant)

3838

Case Depth and Profile of PartsCase Depth and Profile of Parts

• RCRC5050 Value Case Depth Always Obtained Faster Value Case Depth Always Obtained Faster

• Improvement Percentages Depends Primarily on Desired Improvement Percentages Depends Primarily on Desired Final Case Depth (Shallower is Faster)Final Case Depth (Shallower is Faster)

• Less Case Depth Variation in LoadLess Case Depth Variation in Load

• Hardness and Carbon Profile ConsistentHardness and Carbon Profile Consistent

• Profiles Consistent with Higher Surface Carbon Profiles Consistent with Higher Surface Carbon PotentialsPotentials

• Surface Hardness Also AcceptableSurface Hardness Also Acceptable

• Surface Cleanliness not Significant (8620/8625/8630)Surface Cleanliness not Significant (8620/8625/8630)

3939

Retained Austenite/Carbides in PartsRetained Austenite/Carbides in Parts

• ““ARI Process Better (Lower Levels)”ARI Process Better (Lower Levels)”

• Levels Can Be Adjusted to Suit Desired ResultLevels Can Be Adjusted to Suit Desired Result

• Controllable Even with Wide Atmosphere Fluctuations Controllable Even with Wide Atmosphere Fluctuations

BaselineBaseline ARI AcceleratedARI Accelerated

4040

Grain Boundary Oxidation in PartsGrain Boundary Oxidation in Parts

• ““ARI Process Better (Lower Levels)”ARI Process Better (Lower Levels)”

• Levels Can Be Adjusted to Suit Desired ResultLevels Can Be Adjusted to Suit Desired Result

• Controllable Even with Wide Atmosphere Fluctuations Controllable Even with Wide Atmosphere Fluctuations

BaselineBaseline ARI AcceleratedARI Accelerated

4141

Metallurgical Findings SummaryMetallurgical Findings Summary

• Batch Cycle Times Faster (Load to Unload)Batch Cycle Times Faster (Load to Unload)– Same Process Temperature (Typically 1750 Deg. F.)Same Process Temperature (Typically 1750 Deg. F.)– Case Depth of .040” – 35% to 50% FasterCase Depth of .040” – 35% to 50% Faster– Case Depth of .065 – 20-30% FasterCase Depth of .065 – 20-30% Faster

• Less Case Depth Variation Though the Load Less Case Depth Variation Though the Load • Controllable Carbon Content/Hardness ProfileControllable Carbon Content/Hardness Profile• Controllable Retained Austenite LevelsControllable Retained Austenite Levels• Controllable Iron Carbide LevelsControllable Iron Carbide Levels• Wide Variation in Atmosphere Constituents ToleratedWide Variation in Atmosphere Constituents Tolerated• Advanced Soot Control Algorithms Do Not Affect PartsAdvanced Soot Control Algorithms Do Not Affect Parts• All Parts Released for ProductionAll Parts Released for Production

4242

ARI Technology StatusARI Technology Status• Laser Gas Analyzer/Controller Systems Sales & ServiceLaser Gas Analyzer/Controller Systems Sales & Service

– Carburizing (Current Sales)Carburizing (Current Sales)

– Annealing (Current Sales)Annealing (Current Sales)

– Nitriding (Future Sales)Nitriding (Future Sales)

– Brazing (Future Sales)Brazing (Future Sales)

– Powdered Metal Sintering (Future Sales)Powdered Metal Sintering (Future Sales)

– Casting/Drawing (Future Sales)Casting/Drawing (Future Sales)

• Integral Atmosphere Production Units Ready for OrderIntegral Atmosphere Production Units Ready for Order

• Improved Atmosphere Recovery Prototype Ready for TrialImproved Atmosphere Recovery Prototype Ready for Trial

• Corporate Demonstration Sites WantedCorporate Demonstration Sites Wanted