November 2022 Volume 4

Official Publication of the Forging Industry Association

HEATING TECHNOLOGY FOR FORGING

November 2022 forging.org

Decarbonization andSustainability in theMetals Industries pg. 38

Industrial Heating TechnologyTips pg. 8

Five Industrial ChallengesSolvedwith InductionHeating pg. 14 Feeling theHeat to ReduceYour Carbon Footprint pg. 16

AMachineRepairman’sGuide to Resolving theLabor Crisis pg. 82

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PRESIDENT'S NOTE

President's Note

Good news from the recent FIA-FIERF board meetings includes two important new standing committees: Women in Forging, and the NextGen Group (<35). What does this mean? Each group will now have a formal committee structure (Chair, Vice Chair) and expectation to develop training and programs for the membership. We’ve had good response from both groups as staff has developed some initial events to test the waters. More good news on the Government Affairs front: additional focus on ourMilitary supply chains, whichwe believe will raise all member boats, whether military forgings are in your mix or not. How you ask? The funding is used for research and equipment at universities and trade schools which benefits all members, andmembers can also apply for funds for equipment investment. FIA has been approached by our nation’s armed services to work cooperatively with Congress to secure funding for a forging program. In response to this request, the FIA Board has approved technical-focused appropriations lobby firm (SMI Inc.) to assist us lobbying Congress for specific appropriations to be managed by the Army Research Lab (ARL) and another with the Industrial Base Analysis & Sustainment (IBAS). This recent activity was driven in part by the President’s Supply Chain Analysis executive order study order that highlighted several industries and segments – including forgings and castings. Focus here is on FY-2024 funding period so a year long effort in front of us in 2023 which begins at FIA’s February Lobby Day program. We will keep members apprised of the journey. We're Moving! Join us at our Open House in Independence, Ohio (just south of Cleveland) on Monday, December 12th to see why we're so excited to share FIA’s new home office and world-class training room with our members. (For more details turn to pg. 69.) Best regards, James R. Warren President and CEO

Meetings Are Back Nearing the end of 2022…time for reflection! First: is it me or did this year go by at warp-speed x infinity? With a full year with Covid mostly under control, the activity ‘floodgates’ opened wide and broad! From an FIA staff perspective,

adding three new conferences in 2022 (plus our regular load) and seeing them all with great event features, plant tours and content AND great attendance really was a thrill, and I could not be prouder of the FIA staff and committees (Safety, Lightweight, ForjaMex). Probably earned myself a sizeable bullseye on the back for pushing everyone so hard, but in the end, I believe the staff and committees who worked on these events were proud of their effort and happy with the results. I’m referring to our new Forging Lightweight Alloys Conference (February), Safety Conference (March), and ForjaMex (September). More memories of the year: FIA launching its first ever Government Affairs department, securing a new lobby firm (The Franklin Partnership) and the board committing to the Fall Meeting of Members in Washington D.C., of which we are just back from. Literally, it has been a firehose blast of activity – beginning with a manufacturing-industry wide effort to keep the 301 trade tariffs on China at the 25% tariff rate. We succeeded!! Thank you to Trenton Forging for testifying at the USITC hearing and thank you to all members who filed comments on the USTR website. Our work here is not done. Starting November 15th tariff proponents (FIA, FIA members) can file additional comments and those against the 301 tariffs have their chance to comment (unlike the summer hearing – limited to tariff supporter comments only). We will be communicating with you more on this, and please see articles in this issue from our Government Affairs Manager (pg.4) and our FIA lobbyist (pg.6). The Coming Year Lots going on! It is a Forge Fair year, andwe’re off to a great start. The show floor is filling up quickly with exhibitors. We expect another record pace of industry events and have every reason to believe this economy will hold together so members are comfortable getting to the upcoming training and conferences.

Forging Industry Association

PUBLISHER James R. Warren jwarren@forging.org MANAGING EDITOR Angela Gibian angela@forging.org Editorial Staff

Board of Directors

Antonio Alvarez Perry Bennett Peter Campbell

Mark Derry JimKravec Mike Morgus Scott Naar James Romeo

ASSOCIATE EDITOR Amanda Dureiko amanda@forging.org DESIGN Lorean Crowder lorean@forging.org

CHAIRMAN Dan Ulven VICE CHAIRMAN Chelsea Lantto

Mark Candy John Coward

FIA MAGAZINE | NOVEMBER 2022 1

CONTENTS

NOVEMBER 2022 | VOLUME 4

OPERATIONS & MANAGEMENT 46 A New Rule for Independent Contractor Status? 48 Leadership and Management FAQ 51 Understanding First Article Inspection (FAI) 54 Scared by Today’s Energy Prices? Know Your Options! 56 Employee Relations: Maintaining and Strengthening Your Workforce 58 Buying Forgings & FIA’s RFQ Program 60 Addressing Cognitive Distortions in the Workplace 62 Be a Leader Worth Following 64 Workforce Development in the Forging Industry 66 Exploring the Impact of a Potential Recession INDUSTRY NEWS 68 FIA’s First Ever Mexico Conference – ForjaMex – A Great Success 69 FIA Headquarters Moves to Independence 70 FIERF Professors Summit Brings Together Educators and Industry 72 Welcome New Members 73 FIA Member Spotlight: The Crosby Group 74 FIA Upcoming Events 76 Advanced TitaniumMaterials for the Aerospace Industry FORGING RESEARCH 77 FIERF Donor Spotlight: Onex, Inc. 78 Artificial Neural Network (ANN) and Multiple Input Multiple Output (MIMO) Systems to Monitor & Predict Forged Part Attributes – Part I: Bust MEMBERS SPEAK 82 A Machine Repairman’s Guide to Resolving the Labor Crisis AD INDEX 84 November Advertiser Index

p. 27

p. 30

PRESIDENT'S NOTE 1 President's Note

WASHINGTON UPDATE 4 FIA Washington Update 6 Engaging FIA Members on Tariffs EQUIPMENT & TECHNOLOGY 8 Industrial Heating Technology Tips: Five Best Practices for Non-Contact Temperature Measurement 14 Five Industrial Challenges Solved with Induction Heating 16 Feeling the Heat to Reduce Your Carbon Footprint 18 Decarbonization Techniques for Gas Fired Forge and Heat Treat Thermal Processes 22 Maximizing Energy Efficiency of Induction Systems for Forging Applications 27 Q&A With Xena Workwear Founder & CEO Anastasia Kraft MAINTENANCE 30 Optimizing Plant Operations and Profitability Through Enhanced Maintenance Management 32 Forging Lubrication Troubleshooting & FAQ AUTOMATION 34 Forging Roundtable with FIA’s JimWarren and Bonney Forge Corporation’s Drew Hunsinger MATERIALS 38 Decarbonization and Sustainability in the Metals Industries 44 Heat Treat Corner

DEPARTMENTS 1 President's Note 4 Washington Update 8 Equipment & Technology 30 Maintenance 34 Automation 38 Materials 46 Operations & Management 68 Industry News

77 Forging Research 82 Members Speak 84 Ad Index

Images courtesy of Ajax TOCCO

For advertising contact info@forging.org

FIA Magazine (ISSN 2643-1254 (print) and ISSN 2643-1262 (online)) is published 4 times annually, May, August, November and February by the Forging Industry Association, 6363 Oak Tree Blvd., Independence, Ohio 44131. Telephone: (216) 781-6260. Only (1) copy of the print version distributed at no charge only to members of the Forging Industry Association. Digital version distributed at no charge to qualified individuals. Subscription requests available at www. forging.org. Printed in the U.S.A. Periodicals postage paid in Independence, OH and additional mailing offices. POSTMASTER: Send address changes to Forging Industry Association, 6363 Oak Tree Blvd., Independence, Ohio 44131. Copyright © 2022 by the Forging Industry Association in both printed and electronic formats. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the publisher. The publisher is not responsible for product claims and representations or for any statement made or opinion expressed herein. Data and information presented by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

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WASHINGTON UPDATE

FIAWashington Update By Megha Patel

United States International Trade Commission (USITC) hearing on the economic impact of Section 232 and 301 tariffs in late July. Jim Warren, FIA President & CEO, and Chelsea Lantto, Trenton Forging President, testified on July 20th to express the positive effect the tariffs have had on domestic forging companies and the necessity to leave them intact. FIA continues to stay at the forefront of all Section 301 tariffs issues and will keep the members informed on the latest development in the coming months. For the past fewmonths, FIA has been actively engaged in grassroots advocacy. FIA staff and the Public Policy Committee put together a Letter to the Editor highlighting the need for Section 301 tariffs and the economic pressure they put on China. On July 31st, Crain’s Cleveland published the piece digitally and in print, which brought excellent exposure to the domestic forging industry. We have also been pouring a great deal of time and effort into conducting plant

tours with lawmakers to educate them on the importance of manufacturing in the United States. In early October, Campbell Press Repair graciously hosted their district’s United States House Representative, Elissa Slotkin. The following week, Michigan State Senator TomBarrett visitedMichigan Forge and Campbell Press Repair. Both elected officials were in awe of the forging industry’s capability and capacity, especially their ability to ensure national security. FIA will continue to host key government leaders at our member companies’ facilities to educate and develop substantive relationships.

What a wonderful whirlwind the last few months have been! Policymakers in Washington D.C. have been anything but idle. From the USTR review on Section 301 tariffs to the USTIC hearing, there has not been a single, dull moment in the government affairs realm. Not to mention our own grassroots advocacy efforts have been full speed ahead. I know the most important topic on our minds is the Section 301 tariffs. So where do we stand on the continuation of the much needed relief? Well, much has still yet to be determined. What I can tell you is here at FIA, in partnership with our lobby firm The Franklin Partnership, we are very much engaged in the process and are doing all in our power to ensure the Section 301 tariffs remain in effect for our industry. At the beginning of June, we sent out a Call to Action asking members to submit a comment to the United States Trade Representative (USTR) regarding the necessity of the tariffs. Over twenty member companies filed a request for continuation and FIA entered its own remark on behalf of the forging industry. There was overwhelming support across numerous industries that USTR could not ignore the need for the next steps in the four-year review. On October 12th, USTR announced they would open a portal for comments once again, but this round will focus on the economic impact rather than just a simple request for continuation. The comment period begins November 15th and will end January 17th of next year. FIA will be sending out a Call to Action once again and this time around the stakes are incredibly greater. If the requests for eliminating the tariffs outnumber the ones for continuation, the Section 301 tariffs will cease to exist. Therefore, we truly need the help of all our members to file a submission. Every single employee is eligible to request a continuation, not just the company, so please be sure to spread the word. In conjunction with our USTR efforts, FIA and a member company participated in the

Thank you to all our members who have made the advocacy efforts possible. Without your tremendous support, none of this would be possible. FIA will continue to progress our advocacy goals and spare no effort to ensure a robust North American forging industry. Megha M. Patel

Government Affairs Manager Forging Industry Association Phone: 216-781-6260 Email: megha@forging.org

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e FIA Next Gen Committee is comprised of individuals (approximate age 20-35) who are young business and manufacturing employees working in the forging industry. e Next Gen Committee will provide an opportunity to collaborate with peers, share experiences, and discuss the challenges facing the forging industry.

Our mission is to increase awareness and attractiveness of the industry, as well as help to create the next wave of leadership. Members have the opportunity to enjoy plant tours, receive continuing education and training hours through the e-learning ForgingUniversity Platform, network, and attend meetings and events to stay up to date with ideas and issues fromall over the industry.

Getting involved is a great way to meet young professionals in the eld, explore career opportunities, nd mentors, and get the skills and knowledge you need for advancement. is is also a great way to advance professional relationships and stay informed as a younger employee.

Interested in learning more about the FIA Next Gen Committee? Please contact Amanda Dureiko at amanda@forging.org or call 216-781-6260.

www.FIERF.org / www.Forging.org

WASHINGTON UPDATE

Engaging FIA Members on Tariffs By Omar S. Nashashibi

TheForging IndustryAssociation (FIA) is undertaking amembership mobilization campaign to convince the Biden administration to keep the 25 percent tariffs on Chinese forgings in place. The Biden administration announced that it will accept public input from supporters and opponents of the tariffs on Chinese imports, through an online portal open fromNovember 15-January 17. This is a prime opportunity to have the voices of American forgings heard in Washington, D.C., and FIA members will receive a notice in November and December to take action and tell the Biden administration to keep the tariffs on China. On October 12, 2022, the Office of the U.S. Trade Representative (USTR) announced it will start a new docket to accept public input about the effectiveness and impact of the Section 301 tariffs on Chinese imports and the U.S. economy. The Biden administration continues to debate internally on how to approach China and the tariffs imposed by former President Trump. The law requires the federal government to conduct a four-year review of the 25 percent tariffs on roughly 6,800 imports from China and 7.5 percent on approximately 3,200 Chinese products. USTR is seeking public comments to consider the effectiveness of the actions in achieving the objectives of the Section 301 action, which sought to counter China’s intellectual property theft and forced technology transfer. They are also asking the public what other actions “would be more effective in obtaining the elimination” of China’s actions and the effects of the action on small businesses. In addition, trade officials want to knowabout the effects of the tariffs on U.S. supply chain resilience and on domestic manufacturing, including in terms of capital investments, domestic capacity and production levels, industry concentrations, and profits.

The pressure is intensifying in Washington, D.C. from those opposing the tariffs and pushing the Biden administration to lift or suspend the Section 301 action on Chinese imports. Government officials began debating this summer whether to lift some of the tariffs, restart an exclusion process suspending the action on some imports, or continue as is with all tariffs in place. While few believe the White House would lift all 10,000 tariffs on China, President Biden himself approved of an exclusion process this summer that USTR has yet to restart. The FIA succeeded in convincing the Biden administration to maintain the tariffs on imports, including forgings, while USTR conducts a full review. This summer, roughly a dozen FIA member companies filed formal comments with government officials at the request of the association in an effort to convince the USTR to maintain the tariffs long-term. FIA is now calling on its members to increase those efforts from this summer and file as many public comments as possible with the USTR to support the continuation of the Section 301 tariffs on imported Chinese forgings. FIA needs government officials to hear directly from manufacturers in addition to the lobbying effort and stakeholder comments the association will file on behalf of the industry. The more forgers that file comments, the clearer it becomes to decision-makers that the industry has the domestic capacity, technical ability, and willingness to fill orders and bring manufacturing to the U.S. At the recent FIA conference inWashington, D.C., a member asked, who would ever think it is a good idea to increase manufacturing imports to the U.S. by lifting tariffs on China? Unfortunately, the response is thousands of OEMs and Tier I businesses, in addition to retailers and others who believe lifting tariffs will lower inflation. One of the questions posed to stakeholders is whether the tariff action has achieved its stated goal, in this case, China ceasing its intellectual property theft and forced technology transfer. Most agree Beijing continues business as usual, however, recent data shows that imports from China of goods subject to the 25 percent tariff are 22 percent lower than in June 2018, when the previous administration imposed the Section 301 action. Those goods with a 7.5 percent tariff are only 3 percent below their pre-tariff levels, all this is according to data compiled by the Peterson Institute for International Economics. This not only validates the need to keep a higher tariff rate on imported forgings from China. In July, an FIA member testified along with FIA President Jim Warren before the U.S. International Trade Commission in support of continuing the tariffs and stated an increased rate to 50 percent would better protect the domestic industry.

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WASHINGTON UPDATE

In several surveys this summer which served as the foundation of FIA’s testimony, member companies reported Chinese competitors quoting 30-60 percent lower than U.S. forgers. FIA is again surveying members to collect real-time information it can use in association comments to help support our arguments demonstrating the need to keep tariffs on forgings. Those in support of lifting the tariffs will weigh in with USTR using their own set of numbers and claims about the Section 301 action. The Center for Responsive Politics reports that in 2021, Chinese government and non-government entities spent $84.38 million trying to influence policy in Washington, D.C., and U.S. public opinion around the country. This shows how high the stakes are for Beijing, Chinese exporters, and yes, American companies importing goods from China. The stakes are also high for the forging industry as demonstrated by FIA’s most recent member survey conducted in June and August 2022, where 68 percent of respondents reported having “taken on new business fromChina after customer sought to have that product manufactured in the U.S. following imposition of tariffs on Chinese imports.” The benefits of the tariffs could disappear with the stroke of a pen, which is why FIAmembersmust file comments withUSTRbetween November 15 and January 17. If the decision-makers inWashington, D.C. do not hear from the industry, they will assume tariffs on

Chinese forgings lacks support. Now is the time for FIAmembers to speak up for themselves, support the FIA in Washington, D.C. and file comments supporting the continuation of the tariffs on forgings from China. Look out for a call to action from FIA and be sure to raise your voice for the forging industry.

Omar S. Nashashibi is a founding partner at The Franklin Partnership, LLC, a Washington-D.C. based lobbying firm representing the Forging Industry Association before the federal government. Phone: 202-715-1264 Email: omar@franklinpartnership.com www.franklinpartnership.com

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FIA MAGAZINE | NOVEMBER 2022 7

EQUIPMENT & TECHNOLOGY

Industrial Heating Technology Tips: Five Best Practices for Non-Contact Temperature Measurement By Josh Carney

Heating metal stock prior to forging is a main tenet of hot forging operations. The temperature to which the stock is heated depends on the base element plus any alloying elements. Controlling the temperature is critical to producing a quality forging, that is, one without surface defects, grain growth, or decarburization. In forging, several different methods of heating are employed. These include gas furnace, electric furnace, or induction heating. The choice usually depends on the material, process, and producer preferences. This variation in heating methods naturally leads to different means of measuring and controlling the temperature of forging stock. Two of the most popular instruments for temperature measurement are the contact thermocouple and the non-contact infrared (IR) thermometer. An IR thermometer, also known as a pyrometer, enables fast response measurement of high temperature objects. It also can make measurements at a distance in conditions that would be unsuitable or even unsafe for human operators. This article discusses the use of IR pyrometers in forging and presents several ‘best practices’ for using andmaintaining pyrometer accuracy. I. Heating and Process Control When viewed as a process, material heating for forging has two key components. The first is material heating- the act of adding thermal energy to the forge stock. There are several modes of heating for forging including: • Direct heating by electromagnetic induction • Direct heating by combustion of fossil fuels • Indirect heating by combustion of fossil fuels • Indirect heating by resistive heating elements i.e., glow bars

Figure 1: The four typical modes of heating in forging The second component of material heating is temperature control. Heating forging stock to the required temperature is critical to producing high quality forgings. The action of measuring temperature and adjusting heating controls is termed process control. For every heating mode, there exists at least one kind of process control.

Figure 2: Typical process control loop diagram In the process control loop diagram shown in figure two, the set point (SP) represents the desired temperature of the forge stock. The process variable (PV) is the feedback from the temperature measurement apparatus. If the SP is incorrect, this results in an incorrect output (temperature). If the PV is incorrect or inaccurate,

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EQUIPMENT & TECHNOLOGY

this also results in an incorrect output. The process control loop is, for example, what burner controls use to maintain furnace temperature. In the case of an induction furnace, the control loop is what dictates induction coil power. II. The Need for Accurate Temperature Measurement In hot forging applications, the stock is heated to a predetermined temperature prior to forging. The temperature is selected based on the metal type and composition. A temperature too low will affect the dimensions of the forging. Having a temperature too high or holding it for too long will cause surface chemistry of the metal to change and/or alter the forging grain structure [1]. Surface decarburization from overheating is prevalent with induction heating when a temperature control loop is not present. Forging materials at temperatures other than ideal also leads to equipment problems. A forge press can be damaged due to increased force required to form under-heated stock. Overheated carbon steel stock tends to develop heavy oxide scale which accelerates die wear [1]. III. Temperature Measuring Instruments For a process control loop to work it needs a signal from the process variable. In temperature control applications this signal is provided by the temperaturemeasurement apparatus.Measuring temperature takes place by direct contact and non-contact methods. A. Direct Contact Measurement Measurement by direct contact is accomplished by bringing a probe or sensor in contact with the surface or medium. The most popular device for temperatures above 1000°F is the thermocouple. Thermocouples are typically used to measure heating furnace atmosphere temperatures, where, for example, in a box furnace application, the thermocouple is situated in a location where it senses the same temperature as the stock that is heating. In this application, contact measurement does not measure the stock temperature but accurately measures the temperature of the environment which is heating the stock. Thermocouples are ideally suited for furnace and oven temperature measurement, and the measurement of gaseous and liquid-phase fluids.

1. Thermocouple Probe How a thermocouple probe works

When two wires of dissimilar metals (i.e., nickel and nickel/ chromium alloy) are joined together to create a junction at one end then heated, a temperature dependent potential voltage is generated between the wires. The generation of this voltage is termed the thermoelectric effect. When the thermoelectrically produced voltage is fed into a transducing device, it can be converted into a temperature reading or temperature-dependent output signal. This is how a thermocouple creates a temperature measurement. Why thermocouples are not ideal unless necessary In a hot forging application, the forging stock is almost always in motion. If not in motion as is the case with ‘pigeonhole’ style induction coils, it has limited access. In these two cases, the use of a contact thermocouple to measure the forge material stock is presented with numerous challenges. The foremost is how to bring the thermocouple in contact with the stock for long enough time to acquire an accurate measurement. Pausing for too long slows down production and results in temperature loss. B. Non-Contact Measurement: The Pyrometer The non-contact method of temperature measurement, through the use of pyrometers, has become the preferred way to determine forge stock temperature prior to forging. What is a pyrometer? How does a pyrometer measure temperature? All matter with a temperature above 0 Kelvin/-273 degrees Celsius (absolute zero) radiates electromagnetic energy in the form of infrared (IR) radiation. How efficiently the surface a body radiates energy is a property called emissivity and is defined as “a ratio of the total energy radiated by a given surface at a given temperature to the total energy radiated by a blackbody at the same temperature” [2].

Figure 4: Electromagnetic energy spectrum The amount of IR energy a body will radiate at a given temperature is affected by its composition and surface characteristics. Materials like metals characteristically have a low emissivity. Many non metals with smooth/polished surfaces also exhibit low emissivity values. Conversely, non-metals and materials with rough surfaces typically have a high emissivity [3].

Figure 3: Basic thermocouple probe and symbol

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EQUIPMENT & TECHNOLOGY

Figure 6: Basic pyrometer functional diagram

• Single wavelength A very common pyrometer is the single wavelength or ‘single color’ type. The detectors are available in short, mid and longwave variations and among the most economically priced because of the simplicity of design. A single wavelength To improve upon a good thing, what are termed two-color pyrometers or ratio pyrometers are available. The principal difference is, instead of a single detector sensitive at one wavelength, the two-color design incorporates two discrete detectors, each sensitive at a different wavelength, for dual wavelength temperature measurements. In this configuration, IR energy upon passing through the focusing optics is directed at the two internal detectors. From here the signal value output from one detector is then divided by the signal value of the other detector resulting in a value that is a ratio of the two detectors. This ratio is converted by the pyrometer processor into a temperature dependent signal. The two-color pyrometer has several advantages of the single color pyrometer, namely that it can maintain a high level of temperature accuracy despite obstructions resulting from smoke and lens fouling. It is also able to more accurately measure the temperature of low-emissivity materials such as aluminum, stainless steel, and copper alloys. pyrometer is the commonly used in forging. • Dual wavelength (Two-Color infrared)

Figure 5: Table of common materials and their emissivity Understanding now that materials radiate IR, what is a pyrometer? A pyrometer is an optical device with a focusing lens to direct infrared radiation emitted by a target (e.g., a hot billet) onto an internal thermal detector which absorbs the IR radiation. The detector then converts the absorbed radiation into an electrical signal which is amplified and converted into a temperature-dependent output signal [4]. Pyrometers have the advantage over contact measuring devices as they accurately measure object temperatures at distances more than 80 inches [2]. They can also measure very high temperatures, exceeding 3500°F, which is greater than most thermocouples. Another advantage is rapid temperature measurement. The acquisition time for pyrometer is very low, 10-15 milliseconds. This means a pyrometer can make between 60 and 100 temperature measurements per-second. [5] Pyrometer types When selecting a pyrometer for forging applications there are several parameters which must be specified when ordering, the foremost of these is wavelength. The term wavelength applied to IR pyrometer specification refers to the particular of wavelength or frequency at which the detector is sensitive at. Just as the visible light portion of the electromagnetic radiation is a spectrum with colors ranging from red to violet (long wavelength to short), the IR portion is also spectral with an IR ‘colors’ range from long IR (8-14um) to short IR (0.6-3um) [6]. Of course, IR radiation is invisible to the naked eye and does not have ‘color’ as we are familiar with. However, specifying the detector wavelength is important and depends on application temperature and material characteristics.

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EQUIPMENT & TECHNOLOGY

IV. Errors Prevalent in Pyrometer Temperature Measurement and How to AvoidThem In view of the previous discussion, maintaining strict temperature control is fundamental to producing a high-quality forging. When a pyrometer is used for temperature measurement and control, there are several ‘best practices’ which if observed will reduce problems associated with inaccurate temperature control. No. 1: Avoid Inaccuracy Caused by Poor Focus or FouledOptics Cause of inaccuracy: Poor optical focus and lens fouling diminish irradiance on the detector. Best practice: Check the focus, avoid obstructions, clean the lens, or use a two-color pyrometer. Because pyrometers are optical devices, they require certain maintenance and upkeep. Improper focus causes the target (the heated stock) to be smaller than the measurement area. In this condition the temperature measurement is lower than what the target temperature actually is. Similarly, lens fouling from smoke or die lubricant will reduce the irradiance on the detector which also causes temperature measurement error. One distinct advantage of the two-color pyrometer is that the two detectors averaging scheme eliminates the error. There are of course limitations to the extent to which error is eliminated and is detailed in the product literature. No. 2: Avoid High Angles with Surface Cause of inaccuracy: As pyrometer to target angle decreases from 90 degrees, the apparent emissivity will also decrease. Best practice: Locate pyrometer so that the target surface is close to a 90-degree angle. One challenge of locating a pyrometer on the forging line is placement relative to the measurement target. The tendency is to locate it in the most convenient place without much regard for what the pyrometer needs. If pyrometer to target angle approaches 50-degree θ it will alter the apparent emissivity. Ensuring that the angle to target surface is near a 90-degree angle will minimize temperature error.

No. 3: Specify the Correct Emissivity or Signal Ratio Cause of inaccuracy: Emissivity programmed into the pyrometer does not match the target emissivity. Best practice: Measure and compensate for emissivity using the standard test method in ASTME1933-99a. Having the emissivity parameter set too high or too lowwill result in significant measurement errors. The best way to avoid this is to carry out the procedure(s) given in the ASTM publication E1993-99a. Materials such as brass and aluminum have a very low emissivity compared to oxidized steel which has a very high emissivity. Although emissivity tables are available, they cannot account for every situation. The best way is to determine the emissivity in-situ. No. 4: Calibrate the Pyrometer and Controls Annually, As A System, With NIST Traceable Standard Cause of inaccuracy: Pyrometer calibration can drift over time. Control devices in process loop can change temperature readout Best practice: Calibrate the pyrometer and controls annually, or as often as required by applicable quality standards. Regular (annual) calibration is due diligence in maintaining a quality system. Calibration should include any control devices associated with the pyrometer (control loops, logic controllers, temperature displays etc.). A documented history of calibration creates confidence in accurate pyrometer measurements. As a bonus, many quality assurance auditors love the smell of a freshly printed calibration certificate. No. 5: Training for TeamLeaders on Best Practice andMaterial Temperature Controls Cause of inaccuracy: People. Lack of knowledge leads to uniformed decisions, inappropriate corrective actions. Best practice: Provide team leaders with high level training on pyrometer operation and sources of errors. In terms of character and tenacity, the forging industry has some of the best people I know. Unfortunately, I also have seen more eye-pyrometers (human eye, which is) than in any other industry. A lot can be said about the ability of the human eye to read color temperature, but it is no substitute for an accurate pyrometer. A good practice is to train leaders on pyrometer theory and maintenance to avoid defective forgings and other temperature problems. V. Conclusion: Producing quality forgings depend on accurate temperature controls. Pyrometers have several advantages over thermocouples including:

• non-contact • fast readings • measurement at a distance • durability

Figure 7: Low target angles affect temperature measurement

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EQUIPMENT & TECHNOLOGY

Disadvantages are primarily failure in application, including: • Poor focus or lens fouling • Bad location in reference to measurement target • Incorrect emissivity • Calibration drift or incorrect signal scaling by logic or process loop controls • Human error: misunderstanding the operation of temperature and process control equipment leads to uniformed decision making Applying best practices to pyrometer setup and maintenance can help avoid the many problems caused by poor temperature control. References 1. American Society for Metals, Metals Handbook Vol. 5 Forging and Casting, vol. Five, Metals Park: American Society for Metals, 1970. 2. Williamson Corporation, Williamson Pro Series Pyrometer Installation and Operation Manual, Concord: Williamson Corporation. 3. G. C. Holst, Common Sense Approach to Thermal Imaging, Winter Park, Florida: JCD Publishing and SPIE Optical Engineering Press, 2000.

4. V. I. C. R. Lappe, "Using Infrared Thermometer to Control Temperature During Induction Heating," ASM Handbook, Volume 4C, Induction Heating and Heat Treatment, vol. 4c, pp. 730-741, 2014. 5. AMETEK Land, Spot AL & AL LT User Guide, Pittsburg: AMETEK Land, 2021. 6. American Society for Nondestructive Testing, Infrared and Thermal Testing, vol. Three, Columbus, Ohio: American Society for Nondestructive Testing, 2001. Josh Carney is certified Level 2 infrared thermographer in accordance with (ASNT) SNT-TC-1A Josh Carney Technical Director Integral Power Technologies, LLC Phone: 440-701-6022 Email: jcarney@integralpowertechnologies.com

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The Original Modular Billet Heater

Setting the Industry Standard Once Again ... The Inductoforge ® Modular Billet Heating System disrupted the induction forging industry nearly 15 years ago, as the first to offer independently controlled power modules and use them to precisely control billet temperatures. Today, the Inductoforge ® continues to redefine the forging industry by offering the latest advancements such as, true “stopped line” stand-by function, automated billet push-out systems, and next-generation forging coil design. The Inductoforge ® gives our customers exactly what they want.... more reliability, more efficiency, and more control over their production.

To learn more about the Inductoforge ® , please visit our website at www.inductoheat.com

Inductoheat, Inc. • 32251 North Avis Dr. Madison Heights, MI 48071 • (800) 624-6297 • www.inductoheat.com

EQUIPMENT & TECHNOLOGY

Five Industrial Challenges Solved with Induction Heating By Jeff Weinacker

Inductionheatinghas been around ever sinceNicolaTesla discovered and harnessed the phenomena. His industrial applications made much of the modern world we know today possible. So, what exactly is induction heating? For most applications it is the use of an alternating magnetic field on an electrically conductive part. The magnetic field pushes and pulls electrons within the material. The energy used to do this is dissipated as heat within the part. When properly controlled through coil design and current control, this can produce precise, repeatable, and predictable results. This can be seen in modern induction stoves in many kitchens around the world. These stoves require a special pot with a bottom that can accept the magnetic field. Precise current control through an engineered coil provides even controllable heat with a nearly infinite temperature control. In the forging world we typically utilize this technology as a solution to heat billets, or Peter Campbell at Campbell Press may use a potable induction heater to loosen large bolts while disassembling a large press; but did you know that induction heating has solved many other industrial challenges as well?

over time and must be replaced. Within an industrial application these headers my be 3” or thicker and 48” in diameter with 1000’s of 2” diameter holes where the tubes are inserted and then rolled and expanded into the holes. In the past, skilled technicians used cutting torches to slice the tube and then beat it out with chisels. Many times this resulted in damage to the tube sheet that required welding and machining prior to fitting and rolling in new tubes. The solution: Use a specially designed portable induction machine with a specially designed internal coil. This heats the tube rapidly where it is rolled into the tube sheet. The tube reaches 2500F (Approximately 1370C) within 30-90 seconds. This rapid heating causes the tube to attempt to expand but, since it is constrained by the tube sheet and is heated to a malleable temperature, the tube shrinks. At the same time a hydraulic puller can be used to pull the hot tube out while it is still hot. #2 High Temperature Testing/Thermal Cycling The issue: High temperature testing can be difficult as normal resistance heating methods are limited by the melting point of the heater elements. The higher the temperature the more difficult this is to achieve. The solution: Induction, when engineered correctly, does not have any top temperature limit. One example where an induction machine and an engineered coil, test cycles can easily be run to 4000F (2204C) where the only limitation is the support of the part

or material being subjected to these high temperatures. These tests were done to evaluate high emissivity coatings and catalysts that normally run at excessively high temperatures.

#1 Removal of Worn-Out Boiler Tubes From a Tube Sheet The issue: In large industrial boilers as found in many power plants, water is fed in to a large header then up through small tubes to another header where the heater water or steam is gathered and sent to be used other places in the power plant. These tubes degrade

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EQUIPMENT & TECHNOLOGY

#3 High Speed Curing of Coatings The issue: Protective coatings can take time to dry or must bemelted on to provide an adequate coating bonded to the substrate. Coating Rebar, Angles, bars and much more was done using industrial gas fired ovens moving material through these ovens at speeds up to 300 feet per minute. The solution: Custom built induction machines were used along with engineered coils to provide heat to the parts prior to coating them. For powder coated parts these bars pass through the powder booth shortly after the induction heating. This adds enough heat to melt the powder and adhere to the parts consistently and evenly and since the heat is so fast, its only on the outer surface causing a rapid cooling after the coating adheres. This greatly reduces the production line length. The same can be done for painted on products, force curing the paint shortening the overall line length and removing a source of heat and CO2 within assembly plants.

Induction Bolt Heating. Photo courtesy of ESC Induction.

Heating of a generators retaining ring. Photo courtesy of ESC Induction.

#5 Disassembly of Rusted Nuts and Bolts The issue: In many industrial places bolted flanges are common.

These flanges are outside and exposed to the weather and may become corroded or rusted to the point where they cannot be removed by simple torquing methods.

#4Thermal Expansion The issue: Large heavy shrunk on parts of a turbine or generator ro tor need to be removed to repair or replace the part or components underneath. In the past, electrical resistance heating or flame rings were used to heat and thermally expand large components for re moval. Electric resistance has limitations in its total heat input and flame rings can severely affect the metal or burn adjacent compo nents and combustion byproducts are poisonous to humans.

The solution: Induction coils can be wrapped around these rusted and frozen nuts. Then, when the heat is applied, two things happen.The rapid expansion helps to break the bond formed by the iron oxide and the second is the further degradation of the rust into finer particles. These smaller particles no longer lock the nut to the threads allowing for the mechanical turning and removal of the nuts.

The solution: Custom designed portable induction heating equipment and flexible coils are used to apply the magnetic fields and heat in the appropriate places to thermally expand these com ponents for removal. This is not limited to the power generation industry. Applications can be found in Steel Mills, Paper Mills and Sugar Plantations to name just a few.

Note: These are just a fewofmany industrial applications for portable or stationary induction heating machines. New applications are found every day. Article Written By: Jeff Weinacker / President Mobile Induction Solutions @ThermESC Intl. For Help with Field Heating most any application Jeff is always happy to share his knowledge, give him a call at 973-970-9500. https://Thermointernational.com

Destack of turbine rotor. Photo courtesy of ESC Induction.

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EQUIPMENT & TECHNOLOGY

Feeling the Heat to Reduce Your Carbon Footprint By Mark Rhoa Jr.

Whether it is the government, management, or simply general public pressure, it seems like everyone in our industry is being asked to reduce our carbon footprint. No matter where you stand on the issue of “Going Green,” it is a reality that we are going to have to live with in the future. This then begs the question: How the heck do we reduce our carbon footprint? In the refractory and high temperature insulation world, I like to break this down into three areas: 1. Big Picture Capital Investments: For the sake of this article, we will focus on switching to electric heating. 2. Improved Material Performance: New developments in the ceramic fiber industry allow for the ability to better insulate furnace linings. 3. RoutineMaintenance Items: Plants can save money and reduce gas usage by keeping an eye on a few key parts of their furnace. Capital Investments Electrically heated furnaces seem to be growing in popularity, as they present an easy way to point to not directly using fossil fuels. While that may be considered “kicking the can down the road” since the electricity to heat them has to come from somewhere, it is still a viable piece in the green movement. In the forging industry, electrically heated furnaces would typically be seen in smaller forge furnaces and downstream heat treating processes. One of the options for electrically heating a furnace is the “Rod Over Bent” or ELE system. If you look at Figure 1, you’ll see that the electric elements are hung on the ceramic fiber modules utilizing ceramic tubes and S hooks. This design minimizes any additional support you may need on the shell. Additionally, since this element system utilizes ceramic fiber modules, it maximizes the thermal efficiency and can even be used with new age higher insulating fibers that will be discussed later. ELE systems also allow for differing zone temperatures through element layout. Finally, electrically heated furnaces typically require less permitting.

Figure 1: ELEModules. Image courtesy of Chiz Bros.

Improved Furnace Linings Back in the early 2000’s when the price of natural gas was above 10 MMBtu, there was a large push to look at various ways to make furnaces more efficient. The fracking revolution quickly reduced the price of natural gas in the U.S., and subsequently decreased the urgency to make furnaces more gas efficient. With the new advent of reducing one’s carbon footprint, that push has returned. One of the easiest ways to achieve this is by making the furnace linings more thermally efficient. Forging furnaces typically have a ceramic fiber lining on the roof and upper walls. While ceramic fiber is a great insulator in its most basic form, a new product developed by Unifrax now allows for traditional ceramic fiber linings to be up to 20%more thermally efficient. This is achieved by manufacturing it in a proprietary process that creates a fiber blanket with less shot. Figure 2 shows the difference between a standard fiber blanket and the new LT blanket.

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EQUIPMENT & TECHNOLOGY

Another key spot that can often lead to increased heat loss is the burner area.There are plenty of old furnaces with old burner systems out there. When burner blocks begin to show signs of wear, they are also likely becoming less efficient. This would typically be due to leaks in any of the cracks and any reduction in the block thickness leading to a reduction in insulating value. Just as important as the burner block itself, is ensuring that there is a proper seal between the block and furnace lining. High temperature mat (low density stuffing material) or a pumpable fibrous material are two typical solutions for the issue.

Figure 2: Lining Thickness While these fancy numbers are nice, the real question is, what does this mean to me from an energy savings standpoint? At 1900 degrees Fahrenheit an 8# density lining will yield a cold face temperature of 169 degrees utilizing traditional ceramic fiber blanket. With the new LT blanket in the same conditions, the lining causes a cold face temperature of 156 degrees. This translates to a reduction in the loss of BTU/Ft2HR of 34. This reduction can vary based on temperature, linings thickness and density, but with these conditions you get a 17% energy savings. Outside of reducing the carbon footprint, this will save money on the gas bill and increase the life of the furnace lining. Routine Maintenance Items While going green can sound great, we all know the realities of budget constraints. This can be especially burdensome on old furnaces that have been around for ages. Thankfully, there are some simple steps and best practices that furnace operators can implement to run their furnace more efficiently. The area that typically loses the most heat on furnace is around the door. The mechanical abuse along with the constant thermal shock of opening and closing lead to increased degradation of the insulation lining. Below are a few quick tips: 1. Furnace Door Design: Design your furnace doors with a module perimeter that can be easily removed and replaced. This prevents the additional cost of relining the whole furnace due to wear and tear on the sealing surface. 2. Fill in Hot Spots Immediately: The longer a hot spot lingers, the bigger the problemwill become, and BTU loss will increase exponentially. 3. Test Out Fiber Lintels and Jambs: While they are not the ideal solution for every type of forge furnace, a well-designed fiber lentil and jamb can help with increasing thermal efficiency and reducing the wear and tear of thermal shock.

Figure 3: Thermal Conductivity The biggest challenge I hear with going green is the fear of increased cost or loss of operational efficiency. These are valid concerns, as it doesn’t do a company any good to go green and then have to close its doors in two years. The reducing of one’s carbon footprint should be seen as a long-term goal, with benchmarks along the way. Proper communication to the entire team along with tangible numbers and benefits, go a long way to ensuring employees buy into the program. After all, sometimes simply complaining about “The Feds” is a great way to get everyone on board with the plan! Mark Rhoa, Jr. Chiz Bros Email: mrhoajr@chizbros.com Phone: 412-384-5220

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