To: XXXXXXXX From: Rod Duncan, Casteel Technical Service Subject: SHORT CYCLE HEAT-TREATMENT OF XXXXX CASTINGS During

my 30 year career as a consultant in this industry, I have established heat-treat cycles at a least half-dozen steel foundries. I have always used the short cycle austenitizing system, and have never seen a failure due to insufficient austenitizing heat-treatment. In fact there are a number of advantages of short cycle, which I will explain herein. The basis for short cycle came from a research project by SFSA in the 70s, a copy of which I have distributed to you. Since that report, there have been several other more recent studies sponsored and published by SFSA, and conducted by university research teams. All studies have supported the conclusion of the original research. Basically, the studies show that at 1700F the carbon diffusion (homogenization) and the solution of carbides takes a matter of a few minutes. Further holding times are counter productive. The current XXXXX austenitizing cycle times have been established using an old and largely discredited rule of thumb one hour per inch of thickness. Although I have often heard this rule quoted, I have yet to see any collaborating research to support it. I think that it came from a long ago time when furnace burners were poorly designed, furnace insulation and equipment were poorly maintained, and furnace heat input was much lower than modern furnaces The disadvantages of the current practice are as follows: Holding times at high temperature are 2 to 4 hours too long, causing excessive grain boundary oxidation damage, and hence reduced fatigue resistance (based on research by CAT). The long cycle times cause increased heat-teat costs and energy inefficiency. Long cycles result in grain growth and hence lower charpy toughness. Heat treat oven thru-put is decreased The advantages of short-cycle are as follows: Double the throughput of your new heat treat facility Reduce the energy cost per pound of product by 50% Better surface quality and perhaps reduced grain-boundry craze cracking Possibly higher charpy values due to finer grain size

ESTABLISHING CYCLE TIMES: The short cycle times are established using the following guidelines: The casting loading condition is such that the conduction heat is optimized Casting heating times are initially established using thermocouples attached to the surface of the heaviest section in the load. Ovens are set initially at a temperature that is 100F higher than the desired austenitizing temperature, then the oven is cycled down to the austenitizing temperature at the time the castings reach that temperature. Holding times from that time are 1 hour, which is actually providing a large safety factor, since the actual time required at temperature is only a few minutes. Normalizing temperature is 1750F, quench cycle temperature is 1600F (this will increase the quench rate) Note that this only applies to austenitizing cycle times. Tempering cycles are time dependant, requiring a minimum of 3 hours at temperature.