S. Sahay, Tata Research Development and Design Centre, Pune, India

Summary: Integrated process models - based on the heat transfer, process characteristics and phase transformation – have been developed for various heat treatment processes, including annealing and carburizing operations. With the capability of predicting the spatial and temporal evolution of temperature, microstructure and properties within the components being processed, these process models have been used for analyzing and optimizing industrial heat treating operations. In addition, the process models are also used as soft sensors to monitor the process parameters, which are difficult or expensive for in situ measurements. In this presentation, the efficacy of this technique will be elaborated through industrial case studies, where 12-20% savings in terms overall cost reduction, productivity enhancement, energy reduction, quality improvement and variation reduction have been achieved. The difficulties in modeling the industrial operations and some of the successful simplifying methodologies will be discussed. Finally, the required advances for widespread industrial implementation of process models will be suggested.