(V) Optimizing Heat Treating Specifications for Economy and Durability

The world has seen a digital revolution (through Finite Element Analysis and Computational Materials Engineering) in optimization of the geometric design and processing (heat treating) of high technology components, such as jet engines and power generation turbine components. Economics has been the driving force for these very expensive products, which have associated high costs of failure. Increased operating temperatures due to targeted "tweaking" of materials manufacturing process parameters have allowed efficiency improvements in the range of 10 - 20% in some power generation applications. But the cost to perform the modeling is perceived to be too high for less critical industries. This paper will review the conceptual framework that allows medium technology industries, including machinery, automotive, and heavy equipment, to benefit from a rethinking of product design and materials selection methods.

The design of many products is based on a “Guess and Test” or “Tribal Knowledge” method. Products have been designed and manufactured based on the personal or company experience / history, or “feeling” of what has worked previously in similar applications. Often a supplier will be consulted for advice material selection. In some cases, where no durability test program is required, the field is the test lab, and the company never performs a full scientifically guided characterization of the strength, corrosion, or wear resistance of the components used in their products.

Some case studies of material specification optimization based on failure analysis will be presented.

Making use of our human capital in materials engineering knowledge will pay off in increased confidence in leaner designs, allowing, in some cases, use of lower cost, easier to manufacture materials, while making the case for more exotic or expensive materials, processes, or coatings when needed.