Discussion on the Roadmap for the Development of Heat Treatment Technology in the United States——Xu Yueming's Speech at the 2008 Director General of the China Society of Mechanical Engineering
In 2004, the American Society of Metals Heat Treatment Society announced the “Heat Treatment Technology Development Roadmap-2004 Revisionâ€. Mr. Fan Dongli, Honorary Chairman of the Association, published two articles in the "Metal Heat Treatment" (Beijing) and "Heat Treatment" (Shanghai), "Overview of the US Heat Treatment Technology Development Roadmap" and "United States Heat Treatment Technology Development Roadmap in Action" The main contents of the road map were introduced at relevant meetings of the National Association and Association.
We believe that this is a major event in the international heat treatment industry and should be taken seriously. Like the United States, the world's number one industrial power, from politics, mass organizations, to private enterprises, it is so important to treat heat treatment. It took several years to form such a clear goal, vision, technology, comprehensive content, measures, and comprehensive actions. The long-term planning is really rare. This roadmap has a lot of things to learn from, and it is necessary to conduct serious research and discussion in the industry. Therefore, the Society Secretariat held a seminar on the road map in March 2007. After the meeting, some written materials were organized and organized in the "Metal Heat Treatment", "China Heat Treatment Technology Newsletter" and the Society's website. This activity has had a wide-ranging impact in the heat treatment industry. In combination with China's “Eleventh and Five†plans, we will identify gaps, make up for shortcomings and defects, accelerate the progress of China's heat treatment production technology, and catch up with the international advanced level as soon as possible. The role.
First, the background
The US Department of Energy's Industrial Technology Agency (DOE-OIT) introduced a program called "Future Industries" in the 1990s to improve the global competitiveness of US infrastructure manufacturing while reducing energy consumption and waste emissions. . The plan mainly includes three aspects: (1) “Vision Statement†– the technical requirements and vision blueprint for the future industry; (2) “Technology Roadmap†– the technical roadmap for realizing the vision blueprint, and the necessary R&D Project; (iii) “Implementation†– measures to ensure the achievement of objectives and implementation of the R&D plan.
The plans originally included in the Department of Energy were mainly in the industries of steel, non-ferrous metals, chemicals, etc. These industries consumed about 80% of the energy produced by the manufacturing industry and produced about 90% of industrial waste. When recognizing that heat treatment is an important integrated part of metal production, heat treatment is required as long as there is metal. At the same time, heat treatment production also uses a large amount of energy, and produces considerable waste quality in the production, and later the heat treatment industry is also included in the future industrial development plan. The US Department of Energy and the Heat Treatment Society (HTS) have signed an Allied Partner agreement to participate in future industrial programs.
In February 1996, the US Department of Energy, the Heat Treatment Society, and the Metal Treating Institute convened 20 heat-treated captive and commercial processing companies, manufacturing and sales leaders to discuss the US 2020 vision for heat treatment. aims.
In February 1997, a panel of 17 experts from the Heat Treatment Society discussed and proposed the first draft of the Heat Treating Technology Roadmap, and proposed dozens of fields in terms of equipment and hardware, process and materials, energy and environment. Project development project. In 1999, the American Heat Treatment Society released the “1999 R&D Planâ€, which supplemented and refined the technical development roadmap proposed in 1997. In September 1999, the Center for Heat Treating Excellence (CHTE) was established at the Metal Processing Institute of the Worcester Polytechnic Institute (WPI). Subsequently, the "Thermal Processing Technology Center" (TPTC) was established at the Illinois Institute of Technology. The mission of the two centers is to undertake and organize industry-wide enterprises to participate in R&D, achieve the 2020 goal of the roadmap, and complete the proposed R&D projects.
In July 2002, the R&D committee of the Heat Treatment Society discussed, modified and supplemented the roadmap at the Illinois Institute of Technology.
From January to August 2004, the Heat Treating Technology Roadmap-2004 HTS Revision was published.
Second, the status quo of the US heat treatment industry
The US heat treatment industry has an annual output value of 15 billion US dollars. About 80% of the heat-treated parts are steel products, including steel rods and steel pipes, castings, forgings, welded parts, machined parts, rolled parts, stamping parts, and drawing. Pieces or extrusions, etc.
The heat treatment industry employs 140,000 people, 90% of which are in the heat treatment plant of the main engine factory and 10% in the professional heat treatment plant.
There are about 700 heat treatment professional factories. In 1995, the industrial output value reached 1.5 billion US dollars, and the annual return was 25%. The output of professional heat treatment plants increased year by year.
In various processes used in professional heat treatment plants, the carburizing/carbonitriding process accounts for about 20% of the total heat treatment, quenching in the neutral atmosphere accounts for about 20%, vacuum quenching accounts for about 15%, and annealing/stress recovery is about 10%, other processes (induction heat treatment, nitriding, salt bath heat treatment, non-ferrous metal heat treatment, etc.) account for about 35%.
Heat treatment consumes a lot of energy and consumes about 500 trillion BTU per year, accounting for about 20% of the total cost of heat treatment. Heat treatment uses hazardous chemicals and gases and must comply with strict environmental and safety regulations.
The exhaust gas and waste liquid generated by the quenching medium are the main pollution sources of heat treatment, and the use of quenching medium for water, oil, gas and polymer aqueous solution accounts for about 90%.
Third, the 2020 US heat treatment technology development vision, industrial blueprint
1. Vision goal ï¬ Reduce energy consumption by 80%
ï¬ Shorten the process cycle by 50%
ï¬ Reduce production costs by 75%
ï¬ Achieve zero distortion of heat-treated parts ï¬ Achieve zero dispersion of heat-treated parts (relative to standard)
ï¬ Increase the life of the heat treatment furnace by 10 times ï¬ Reduce the price of the heat treatment furnace by 50%
ï¬ Achieve zero discharge from heat treatment production
2. Vision Blueprint By 2020, the heat treatment industry will still face many technical challenges like the current one. Materials and processes will be more deeply understood and understood, process and heat treatment quality will be more strictly controlled, and all heat treatment processes will be environmentally friendly. Computer control and robotics will enable white-collar workers and blue-collar workers to work in a clean, safe and comfortable environment. The workers are loaded and unloaded on the air-conditioned loading and unloading truck. The technicians control the process through a computer in an air-conditioned environment close to the heat treatment furnace. The engineers use a powerful material and process database and terminal computer-aided design to formulate the process. All heat treatment workers are proud of the industry because they recognize that heat treatment is a key process in the manufacturing industry for vehicles, electronics, and machinery. In order to operate and maintain a variety of advanced equipment, workers will be well trained and highly skilled.
Fourth, the challenges facing the heat treatment industry
The challenges facing the heat treatment industry come from technology, government, customers, revenue, structure, and manpower.
In terms of technology, the most urgent research includes the development of more efficient heat treatment furnaces, longer service life materials, more sophisticated process control, and improved quenching media. At present, less than half of the energy consumption of the heat treatment furnace is used to heat the workpiece, and the rest is used to heat the furnace body, the furnace atmosphere, the tray and other furnace internal components. Despite great efforts in heat recovery, there is still a need to find further ways to reduce heat emissions. Pay attention to the study of the influence of the original material on the heat treatment quality (shape and mechanical properties), and establish a database for material design and precision process simulation to achieve heat treatment without distortion, stable quality and predictable performance. To achieve these goals requires cooperation between industry, academia and research.
In terms of human resources, industrial development must motivate workers to learn and become highly skilled employees through training. In this regard, heat treatment companies should work with institutes, associations, universities, and colleges that train engineering and technical personnel. Heat treatment should be a technical area that is challenging for aspiring engineers.
In terms of revenue, it is necessary to increase the heat treatment industry income to attract investment, so that more R&D funds are invested, and then technological progress is promoted.
In terms of customer relationships, partnerships must be established at the design stage of the customer's product to become a product design partner to help customers optimize materials and processes.
In terms of international competition, heat treatment in North America will face low-cost competition in other third world countries. In addition, when castings, forgings and other parts are transferred to other countries for production, the corresponding heat treatment will also be transferred.
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