INTRODUCTION
Heat treating is an old practice. It covers a wide range of processes and technologies. Two major areas are of importance: thermal processing equipment technology and thermal processing technology. The equipment may serve the purpose of heating, or heat treating processes. The heat treatment process may involve furnaces and ovens. Heat treatment processes are classified by temperature of treatment, furnace atmosphere, and pressure, Since all of the processes involve application of heat, it is imperative to use appropriate means of heat conservation by proper insulation wherever possible. Due to the recent development in electronics and computer technology, significant improvements have been made in energy input (heating elements, burners, etc.) and control mechanisms.
The heat treating industry is directly related to the metal producing and secondary processing industries. Materials handled by the heat treating industry are variety of products provided by manufacturers that are used by other manufacturers, to make consumable or usable products; some of the products end up directly with consumers. The major heat treating processes are for iron, steel, ferro-alloys, glass, and other nonferrous metals. Hence, this industry is directly related to the overall economy of the country. The industry was adversely affected during the significant slowdown of the steel industry during the mid-1980s. However, since then, the industry has become more efficient through cost cuts and effective use of resources. During the 80s and 90s the industry made long strides in quality and innovation and became globally competitive. During the second part of 1998, however, the whole industry was affected by high quantities of steel imports. It was also affected by the slowdown of the aircraft industry, which is dependent upon revenues from the Southeastern developing countries. However, since then, the industry has adjusted to the changing environment and has become more efficient and cost-conscious, with the use of computerized systems.
Reasons for the Study and Its Importance
The purpose of this study is to show the varieties of equipment and processes in the heat treating furnace industry, their individual functions, and their importance to the overall metal and nonmetal consumer and producer industries. The heat treating furnace industry plays an important role in making materials usable. Heat treatment is needed to cause desired changes in the metallurgical structure and hence the properties of metal parts. Properties of most metals and alloys can be affected by heat treatment. Ferro-alloys, particularly steels, undergo the most dramatic changes in properties. Generally, the most stable steel structures are produced when steel is heated to a high temperature and then slowly cooled. This is called annealing or normalizing. The process of heat treatment performs multiple functions as are needed for individual cases. In some cases, it releases stress, strain, and fatigue so that the material will work normally. In other cases, it alters the structure so that the material's properties will improve. As an example, parts made from glass and some ceramic cannot be used without proper annealing. They will simply shatter under residual stress. All of these functions are carried out in heat treating furnaces of various kinds, shapes, and sizes.
There are two components of the heat treating industry. One component of the industry involves the manufacture of the heat treating furnaces and the other the utilization o the furnaces for heat treating purposes. A number of furnace manufacturers also offer custom heat treating operations. Since the total heat treating industry is very large and broad (a total of 750 to 850 large, medium, and small companies), with a total turnover of about $15 billion, this report will deal only with heat treating furnace manufacturers who make the furnaces and sometimes offer customized heat treating services.
Objectives of Study and Its Contribution
There are several objectives of this study. The primary objective is to indicate why this industry is so important to the overall industry of various categories. This study will demonstrate the types of heat treating furnace industries prevalent in the market and their market shares. The study will discuss the varieties of heat treating furnaces and their different heating systems, slat baths, and ovens with varying atmospheres of treatment. It will show the development of the ancillary systems of heating by various methods and control systems that are affected by recent developments in electrical and electronic systems. It will also indicate the growth potential of the market through the next 5 years. The primary contribution of the study will be to provide comprehensive information about heat treating furnace industries, including the recent developments relating to designs, heating systems, and controls, and their current state and future potential.
Audience for Report
The report is meant for a variety of people who are interested in the heat treating of metals like iron, steel, and nonferrous metals, and of other materials like glass and ceramic parts. Heat treating furnace manufacturers who makes furnaces of various types will have detailed information about their industries. The heat treating industry has a major impact on ancillary industries such as those involving the manufacture of gas and oil heating systems, electrical resistance and induction heaters, and controls and switches for heating, furnace atmosphere, and the total process. Manufacturers of salt bath, ovens, and lehrs, etc. will also be interested in the report. Other people who are inclined to look at the potential of this industry will also benefit from this report. Investment-oriented people will be able to evaluate the potential of either the heat treating or the furnace manufacturing component of the business.
Scope and Content of Report
The scope of the report will be limited to heat treating furnaces for ferrous and nonferrous metals, and annealing furnaces for glass and ceramics. The report will provide a comprehensive report about the different types of furnaces with regard to their sizes, shapes, capacities, and price ranges. The report will include information on the heat insulating refractories for different types of furnaces. It will also discuss the different types of heating systems available along with the modern control systems.
The report includes information regarding the manufacturers—the leading companies, their locations, products, capabilities, asset values, and some of their officers. It also identifies the different types of furnaces and ovens that each individual company makes. The report presents the current market of the heat treating furnace business and indicates the future potential for the next 5 years. The report also discusses the domestic as well as world market for the heat treating furnace industry and indicates current conditions and future prospects.
Methodology and Information Sources
The report is presented in a systematic way by identifying the heat treating furnace manufacturers and their customers along with their current and future market potential. The information for the report has been derived from a variety of sources. The theoretical aspects of the heat treatment processes have been provided from books on fundamental principles on heat treatment. A major amount of information has been provided from the American Society of Metals and Industrial Heating. Actual information has been gathered mostly from dialogue with furnace manufacturers and users as well as makers of heating systems and controls. Other information has been provided by discussion with Lance Miller of the Metal Treating Institute (MTI) and the author's personal experiences in using heat treating furnaces and processes. Information in the section on environmental and safety issues has been obtained from Randy Junkins of Junkins Engineering Inc.
Analyst Credentials
The analyst has been associated with refractories that cater to the heat treating furnace industry as one of the major consumers for the past 25 years. A holder of a doctorate in material science from Sheffield University in England, (with a bachelor's and master of science degree in chemistry and chemical technology), Dr. Banerjee has a thorough understanding of materials and their thermal properties. The majority of the refractories currently used in heat treating furnaces are the products of the analyst's own invention. The analyst also has a wide range of experience in furnace construction, use, repair, and development for improved efficiency and productivity. With the basic knowledge of materials and metallurgical treatments, he is well conversant and suited for the study of heat treating furnaces. In addition, the analyst has published more than 60 papers, authored 26 patents internationally, and written/co-edited two books ("Microstructure and Properties of Refractories," published in Oct. 1993, and a monograph titled "Monolithic Refractories," published in Sept. 1998). At present, he is a refractory consultant serving clients in the U.S and in the international market.
View Cart
