News from 91´«Ă˝ – June-August 2012
Bob Hill, President of 91´«Ă˝ of Western PA will be speaking, next week, at the 6th International Quenching and Control of Distortion Conference presented by the ASM Heat Treating Society. This event provides a unique forum to discuss the ongoing activities on solving distortion issues within research institutes and industries worldwide.
Bob will discuss “Gas vs. Liquid Quenching – A Direct Comparison” Tuesday, September 11, 2012, 8:00 AM in the Atlantic D room of the Radisson Blu Aqua Hotel in Chicago.
It is a well-known fact within the heat treating community that high pressure gas quenching yields far less distortion than liquid (salt, water, polymer, and oil) quenching. Metallurgical science regarding cooling rates and hardenability has neglected HPGQ technology, until now.
Bob’s presentation will introduce revolutionary information for the metallurgical world – side by side comparisons of water vs. gas sprayed Jominy End Quench Tests for hardenability. The high velocity gas that will be sprayed at the end of the 1″ OD x 4″ long specimens will be typical of the gas velocities that parts would encounter in a newly designed 20 bar furnace. Hardness results and microstructure results will be directly compared on various alloys. Additionally, a new universal load size and test block to determine cooling rates will be introduced based on the North American Die Cast Association (NADCA) specification.
This new information will be proposed as a standard for all heat treating equipment- whenever there is a desire to compare critical cooling rates.
91´«Ă˝ of CA Increases Small Furnace Processing Capability
August, 31, 2012
To accommodate growing customer demand, 91´«Ă˝ of California recently added some new equipment. The two new furnaces and freezer will assist in processing small to medium lots of parts made from metals ranging from PH grade stainless to Titanium.
- 2 Bar Vacuum Furnace – working zone of 12”W x 12”H x 22”L, operating temperatures range from 900°F to 2200°F. Capable of 2 bar quenching with nitrogen, argon, and helium.
- Air Temper Furnace – working zone of 21”W x 23”H x 23”L, operating temperatures range from 900°F to 1200°F
- Cryogenic Treatment Freezer – working zone of 12”W x 9”H x 27”L, operating  temperatures range from -100°F to -300°F
President Derek Dennis explains, “More than ever, our customers are committed to streamlining their manufacturing processes through aggressive lean principle based programs. Since lead-time and delivery commitments are a very important part of eliminating waste, Solar plays a critical role in helping our customers achieve their goals. As a partner, rather than simply just another vendor in the approved supplier list, we have invested in this new processing equipment to speed turn-around, meet our customer’s evolving needs and contribute toward their success.”
New Equipment and Face-lift for Lab at 91´«Ă˝
August, 31, 2012
Solar’s Metallurgical laboratory work at the Souderton plant has increased considerably in support of our carburizing and nitriding customers. To keep up with production testing and R&D work, newlab equipment was recently added including a new cut-off saw, mounting press, polishing machine, and a microhardness tester. All of the new machines allow for custom or standard recipe control which is ideal for achieving consistent results time after time.The lab also received a face-lift with a new acid cabinet and ventedhood, an epoxy resin countertop, and a new floor. New electrical fixtures were also installed and the entire room was given anew coat of paint. The entire investment was about $135,000. In an effort to keep costs down, most of the work was performed by Solar employees. The investment is proving to be an excellent oneas the quality and quantity of the work produced in the lab are both exceptional.
20 Bar Furnace Expands SAWPA Capabilities
July, 25, 2012
91´«Ă˝ of Western PA recently commenced operation of a new custom-built horizontal 20 bar vacuum furnace (40” wide x 50” deep x 36” high, 3500 max load) at its Hermitage facility. Designed and built by sister company Solar Manufacturing, it is the fastest cooling furnace in the Solar fleet and one of only a few of its kind in the U.S.
The excessive pressure and high speed gas velocities of the 20 bar furnace simulates oil quenching. However, using inert gas as an alternative to oil minimizes distortion and provides a much cleaner and greener process. Solar can also better serve customers requiring vacuum carburizing by increasing core hardnesses of large cross-sections. This is a particular benefit to those in the gear industry. President Bob Hill states, “By adding these unique capabilities of the 20 bar quenching to our repertoire, we can now effectively process a wider range of materials and assist more customers than we could with our 10 bar furnaces.”
The unique cooling capability of this high-tech furnace was recently put to the test by processing a 2,000lb., 40” tall valve casing with a 3” maximum cross section. This 4140 fully- machined weldment was austenitized at 1575○F +/- 10○F. After the 20 bar nitrogen quench, the resultant hardness was HRC54 with a fully martensitic structure. The part was then tempered to specifications and delivered to the customer with minimal distortion.
These results were made possible through many innovative furnace features that improve gas velocities by a factor of three. The newly designed fan and improved gas-flow system minimizes pressure drops and increased gas velocities to nearly 200 MPH. State-of-the-art technology is incorporated throughout the furnace including an interactive touch screen SolarVac™ 4000 interface and a compact design. The furnace will be commissioned to process to stringent pyrometry specifications for aerospace customers including Boeing.
91´«Ă˝ Climbs Aboard Boeing’s 787 Dreamliner – Private Tour Reveals The Future of Air Travel
July, 05, 2012
The first, all-new airliner of the 21st century, the Boeing 787 Dreamliner, landed at Philadelphia International Airport on June 27th for its first visit to the city.  As a major supplier to this “game changing” new aircraft, 91´«Ă˝ received a personal invitation from Boeing for a private tour.
Solar provided vacuum heat treating of flight critical components, mostly made of titanium. With the majority of the aircraft’s weight made up of titanium and graphite composites, the Boeing 787 Dreamliner is the first midsize airplane capable of flying long range with a 20% increase in fuel efficiency. The 787 will allow airlines to open new, non-stop routes preferred by the traveling public. This airplane can leave PHL and fly non-stop to most any other airport in the world -up to 8,200 to 8,500 nautical miles!
Your first impression of the aircraft is how large and majestic it is. While
climbing the boarding stairs, the sweeping and extremely thin all-composite wing was most impressive along with the massive 100,000 pound thrust dual Rolls Royce engines.
As soon as you enter the plane, it is obvious that you are someplace special. The spacious, cathedral-style entrance is akin to the welcoming lobby of a hotel- not just a tube and turn right. The soft tone LED lighting combines for a fantastic flying environment. The overhead luggage bins are huge (4 roller boards can fit in one bin). The seats in both business class and coach are more comfortable and offer more legroom. The lavatories in coach offer more room than any other aircraft. The windows are substantially larger thereby offering outstanding views even when sitting in the center of the two aisle configuration. The electronic dimmer controls within the glass of the windows eliminates the clunky shades. There are rest quarters (the captain called them tree houses) located in the front for the pilots and in the aft for the flight attendants.
The most thrilling part of the tour was to actually sit in the cockpit. Here you can see Bob Hill, President of 91´«Ă˝ of Western Pennsylvania sitting in the captain’s chair. Note- the HUD (heads up display) which is the bracket holding the transparent glass. This device  provides the pilot with critical information without looking at his instrument panel.
What a momentous day for 91´«Ă˝ and the heat treating world!
A Breath of Fresh Air
June, 13, 2012
A new air furnace at 91´«Ă˝ of Western PA is speeding delivery time and providing more vacuum processing capacity for our customers. This large, electric re-circulating air furnace works in conjunction with our vacuum furnaces to improve customer service.
Bob Hill, President of 91´«Ă˝ of Western PA explains, “Many times, our customers’ parts that are aged, stress relieved, or tempered at low temperatures require additional machining after they are heat treated. In these cases, where surface oxidation is not detrimental to the part, the job is completed in the air furnace which frees up space for jobs requiring vacuum heat treating. Not only does this increase our delivery times to our customers, but it will also increase our existing vacuum capacity by 15%.”
The working area of the hot zone has a 50″ W x 50″ H x 144″ overall length which will be calibrated in accordance with AMS 2750 D and BAC 5621 at ± 10°F. The maximum operating temperature is 1400°F and maximum load capacity is 10,000 pounds. Next time you are in Hermitage, please stop in to see our latest addition.
California Plant Celebrates a Year of Serving the West Coast
June, 13, 2012
On March 1st, 2012, 91´«Ă˝ of CA (SCA) celebrated its first anniversary of operations. During the year, SCA achieved many milestones on the road to establishing themselves as the premium vacuum heat treating and brazing facility on the west coast.
Quality Manager Mike Moffit was very successful in providing a rapid response to customer quality requirements. Within the first few months of operation, SCA obtained Nadcap Accreditation and ISO9001:2008/AS9100 Rev. C Certification which was quickly followed by many prime approvals including Boeing, Northrop Grumman, and Parker Aerospace.
The Sales Department, spearheaded by Director of Sales Mike Drakeley, and supported by Outside Sales Manager John Levensky has established a highly diversified customer base servicing the aerospace, medical, power generation, defense, and automotive industries. Sales increased by 10%-15% monthly in the first 12 months. For 2012, SCA is projecting sales between $4.5M-$5.0M – a 200% increase over the first year.
SCA continues to work diligently on equipment enhancements in order to best serve our customer’s unique requirements. Facilities Engineer Chuck Miller has been successful in all equipment and support system installation, as well as developing an effective preventative maintenance program. A continual focus on improving energy efficiency resulted in an award from Southern California Edison.
As part of the commitment to operational excellence, SCA continues to train employees on new processes and exceed customer expectations. Operations under the direction of Dan Barszcz, Production Manager, have established a well-trained and confident workforce.
Amy Blanes, Office Manager, leads the administrative effort, working diligently with customers to provide an open line of communication and responsive service.
“I’m very proud of the team we have been able to establish. All department managers strive daily to manage their respective departments efficiently and effectively. SCA focuses on providing a quality service, on-time, in a safe, friendly and environmentally responsible workplace,” states Derek Dennis, President.
According to William R. Jones, Solar Corporate CEO, “With their hard work and determination, SCA began their second year of operation in a profitable position and projections indicate growing sales and profitability to 2012 year end. This can be attributed to diligence from the entire SCA team and particularly by Derek Dennis, SCA President. Considering that SCA is a green field start-up 3,000 miles away from corporate headquarters, it is quite an accomplishment.”
The SCA team thanks our customers for their support and looks forward to continuing to provide you with outstanding vacuum heat treating and brazing services.
91´«Ă˝ Schools Young Executives from 2012 MTI Class
June, 13, 2012
91´«Ă˝ was honored to host The Metal Treating Institute’s (M.T.I.) 2012 Young Executive Series Management Training Program (Y.E.S.) class participants for a plant tour in May.
For over twenty years, the Y.E.S. program run by M.T.I. has taught leadership, systems management, strategic thinking and people skills to owners, executives and managers working in heat treating fields.
The Y.E.S. class consists of four one-and-a-half day events that include classroom teaching, a two-hour plant tour, and thirteen hours of online classes. The tour segment is especially valuable as participants can see first-hand how other companies in their line of work run their businesses.
For their plant tour, the (23) attending members of the class of 2012 traveled to Solar headquarters in Souderton, PA from as far away as California and as close as a few steps. Participants from 91´«Ă˝ in the M.T.I. Y.E.S. program are Bob Sandora, Gordon Porterfield, and Tim Steber. Former Solar graduates include: Dan Barszcz, Mike Drakeley, Robert Hill, Jamie Jones, Roger Jones, Trevor Jones, Mike Moffit, and Mike Moyer.
The tour kicked off with a luncheon and introduction by Roger Jones, President of 91´«Ă˝. Next, Roger Jones, Gordon Porterfield and Tim Steber from the 91´«Ă˝ guided students to the Metallurgical lab where they examined the recent renovations including the addition of new Struers precision cutting, mounting and polishing equipment as well as new cabinetry.
During the plant tour, students saw a variety of vacuum furnaces in operation and received an overview of the capabilities of each furnace. They received an explanation of how each service is performed, and a review of how parts are shipped in and out of the facilities.
Across the road at Solar Manufacturing, the class experienced what it was like to build a vacuum furnace from the ground up. Solar employees demonstrated and described how each part of the furnace is assembled according to the customer’s specifications.
Solar thanks M.T.I. and the Y.E.S. students for a great day of learning. You don’t need to be a Y.E.S. student to enjoy a tour, simply contact your sales representative to set a date.
Solar Receives an International Visit and Local Awards from ASM
June, 13, 2012
The Solar companies were recently honored to host Professor Christopher Berndt, International President of ASM for a plant tour. He enjoyed learning more about vacuum heat treating, nitriding, and carburizing services. Of special interest was the metallurgical lab where he observed preparation and thorough examination of micro hardness mounts containing materials from thin sections of 17-7 PH to vacuum carburizing samples. Professor Berndt marveled at the variety of materials and configurations in various stages of vacuum heat treating at 91´«Ă˝ and vacuum furnace assembly and systems integration at Solar Manufacturing.
Three Past Chairmen of the ASM Philadelphia Liberty Bell Chapter led the tour: Roger Jones, President, Don Jordan, VP Technology / Corporate Metallurgist and Tim Steber, Regional Sales Manager. On behalf of ASM, Professor Berndt expressed his gratitude for their volunteer service to the association.
A few months later, Trevor Jones, Principal Engineer at 91´«Ă˝ was inducted as the new Chapter Chair of the ASM Philadelphia Liberty Bell Chapter. Trevor previously served as Vice-Chair following years of volunteer service to ASM. The event also honored members for their devotion of time and energy to chapter initiatives.
Several 91´«Ă˝ employees were acknowledged including:
- Roger Jones, Corporate President was presented the Meritorious Service Award to an ASM member for meritorious service and dedication in supporting the chapter and for their knowledge of and commitment to ASM.
- Donald Jordan Vice President/Corporate Metallurgist was presented the Albert Sauveur Award recognizing pioneering materials science and engineering achievements and basic advances of knowledge in materials science and engineering.
- Jamie Jones, Production/Plant Manager was presented the Young Members Award for a young member who has made significant contributions to the Chapter.
- Tim Steber, Regional Sales Manager was presented the President’s Award as the one person the Chapter Chairman felt had contributed the most for the good of the Chapter in promoting the goals and objectives of the society.