1、Designation: A1100 16Standard Guide forQualification and Control of Induction Heat Treating1This standard is issued under the fixed designation A1100; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of last revision. A num
2、ber in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.1. Scope1.1 This guide covers the process control and productproperties verification of continuous heat treating of materialusing a quench and temper
3、induction process (surfacehardening, surface heat treating, and batch heat-treated prod-ucts using induction are not considered in this guide). Ex-amples of products covered by this guide may include productscovered by API Specifications 20E, 5L, and 5CT.1.2 This guide indicates some features of ind
4、uction heattreating compared to furnace heat treating. Induction heattreating processes typically operate at higher temperaturescompared to furnace processes.1.3 This guide addresses the features and requirementsnecessary for induction heating and ancillary equipment.However, induction equipment may
5、 be used in combinationwith convection heating equipment (for example, gas orelectric furnaces).1.4 UnitsThe values stated in SI units are to be regardedas the standard. No other units of measurement are included inthis standard.1.5 This standard does not purport to address all of thesafety concerns
6、, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2. Referenced Documents2.1 ASTM Standards:2A255 Test Methods for Determining Hardenabi
7、lity of SteelA751 Test Methods, Practices, and Terminology for Chemi-cal Analysis of Steel ProductsA941 Terminology Relating to Steel, Stainless Steel, RelatedAlloys, and FerroalloysA1058 Test Methods for Mechanical Testing of SteelProductsMetricE7 Terminology Relating to MetallographyE10 Test Metho
8、d for Brinell Hardness of Metallic MaterialsE18 Test Methods for Rockwell Hardness of Metallic Ma-terialsE112 Test Methods for Determining Average Grain SizeE384 Test Method for Microindentation Hardness of Mate-rials2.2 ASM Standards:3ASM Handbook Volume 4C Induction Heating and HeatTreatment2.3 AP
9、I Specifications420E Alloy and Carbon Steel Bolting for Use in the Petro-leum and Natural Gas Industries5CT Specification for Casing and Tubing5L Specification for Line Pipe2.4 ANSI Standard:5ANSI/NCSL Z540.3 Requirements for the Calibration ofMeasuring and Test Equipment3. Terminology3.1 For defini
10、tions of terms used in this guide, refer toTerminologies A941 and E7.3.2 Definitions of Terms Specific to This Standard:3.2.1 induction heat treating, vprocess by which an elec-tromagnetic field is used to induce a voltage in an electricallyconductive material thereby causing current flow and heat i
11、sgenerated in the electrically conductive material through theJoule heating effect. (See ASM Handbook 4C, p. 18.)3.2.2 major rebuild, nany rebuild or repair that could alterthe temperature uniformity characteristics of an induction heattreat line.3.2.3 product, nset of similar materials to be heated
12、 bypassing through induction coils under the same conditions asdefined in 6.3 process variables. (Including as examples bar,rod, tube, pipe.)1This guide is under the jurisdiction of ASTM Committee A01 on Steel,Stainless Steel and Related Alloys and is the direct responsibility of SubcommitteeA01.22
13、on Steel Forgings and Wrought Fittings for Piping Applications and BoltingMaterials for Piping and Special Purpose Applications.Current edition approved Nov. 1, 2016. Published December 2016. DOI:10.1520/A1100-16.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Cu
14、stomer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.3Available from American Society for Metals (ASM International), 9639Kinsman Rd., Materials Park, OH 44073-0002, http:/www.asminternational.org.4Ava
15、ilable from American Petroleum Institute (API), 1220 L. St., NW,Washington, DC 20005-4070, http:/www.api.org.5Available from American National Standards Institute (ANSI), 25 W. 43rd St.,4th Floor, New York, NY 10036, http:/www.ansi.org.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700
16、, West Conshohocken, PA 19428-2959. United States13.2.4 quench media, ncoolant used to quench out the workpiece.3.2.4.1 DiscussionTypically, it contains water or waterand a polymer-based quench media.3.2.5 refractometer, ndevice used to measure the concen-tration of quench media that is mixed with w
17、ater.3.2.5.1 DiscussionTypical units are in degrees Brix andare approximately equivalent to half the volume concentration.3.2.6 sensors, nneed to identify the type of sensors as theyare already in some standards.3.2.7 skin depth, nalso called depth of current penetration;the depth to which an altern
18、ating current will flow in aconductor. (See Appendix X3.)4. Significance and Use4.1 This guide helps purchasers assess induction processesincluding the critical parameters that can affect product quality.It guides the evaluation of heat-treating vendor performanceand capabilities to ensure higher an
19、d more consistent productquality.4.2 Refer to Appendix X1 for a flow chart for the use of thisguide.5. Equipment5.1 Equipment CapabilitiesEquipment used to producethe desired heat-treated product shall be capable of achievingtarget heat-treat parameters. Parameters shall be documentedas per Section
20、6, and Section 7 shall be used to verify that themanufacturing procedure has been well developed, properparameter tolerances have been selected, and equipment iscapable of achieving all parameter settings. Documented pro-cedures for the verification of equipment capabilities,calibration, and mainten
21、ance shall be maintained. These docu-mented procedures shall address all critical equipment for theinduction heat treatment line including, at minimum, thefollowing:5.1.1 All power supply units including relevantcomponents,5.1.2 All induction coils,5.1.3 Quench system and components,5.1.4 Pyrometers
22、 and other temperature-sensing devices,5.1.5 Material handling as it pertains to line speed control,and5.1.6 Controls.5.2 The documented procedures shall address verification,calibration, and maintenance of the equipment as described inthe following.5.3 Verification and Calibration of EquipmentEquip
23、mentfor the heat-treating line shall be verified and calibrated at alevel necessary to achieve the tolerances determined in Section6. It is recommended that calibration of test equipment followthe guidelines in ANSI/NCSL Z540.3. Equipment capabilitiesare related to the product chemistry, product dim
24、ensions, andproduction rate. It is possible that different products mayrequire different tolerance ranges for parameter settings. Thesetolerance ranges shall be documented as part of the manufac-turing procedures (Section 6). Classification and characteriza-tion of a heat-treat line based on equipme
25、nt accuracy rangesand equipment capabilities may be conducted using the methoddescribed in Appendix X4. It is recommended that verificationof equipment performance be conducted with heated product.Cold tests (for example, testing material handling, sensors, andcontrols) are useful, but equipment on
26、an induction heattreating line may behave differently with heated product.5.3.1 Power Supply Units:5.3.1.1 The power supply units shall be capable of achiev-ing the rated power and nominal frequency designated for theequipment by the manufacturer. Heating capabilities to achievetarget temperatures s
27、hould be verified at the point of installa-tion of new power equipment, including ancillary equipmentand devices such as connecting power cables and inductioncoils, and records of these capabilities should be kept (see 9.1).NOTE 1The output power is a function of the voltage and current ofthe electr
28、ical system. If voltage or current is limited (because of highinductance, for example), the maximum power will be limited. For thisreason, it is important to ensure that the power supply is evaluated with theinduction coil and desired product so that accurate power capabilities aredetermined.5.3.1.2
29、 The power level for any given manufactured productmay be selected at the heat treaters discretion to achieve thenecessary target manufacturing procedure parameters. Theoutput power stability should be monitored at regular intervalsto ensure sufficient power stability to achieve the tolerancelevels
30、documented in Section 6. Incoming power to the plantcan affect output power stability; therefore, incoming powermay be monitored to ensure consistent output power capabili-ties. Various power quality measuring devices are available formonitoring incoming plant power and output power duringoperation.
31、5.3.1.3 The frequency at each induction coil should beverified and documented within each manufacturing procedureto ensure heating consistency. Periodic checks of the frequencyat the induction coils should be conducted.NOTE 2The frequency is affected by the power level and theinductance of the syste
32、m. Changes to the coil design, size of product,cooling media through the coil, current/voltage ratio, coil cableconnections, and other factors can affect the frequency at the output coil.Changes in the output frequency can affect the depth of the inducedcurrent in the work piece (skin depth) and, th
33、erefore, the thermal gradientwithin the work piece (see Appendix X3). Frequency can be measuredusing most standard multi-meters.5.3.1.4 It is not expected that power supply units willrequire calibration unless otherwise stipulated by the manufac-turer of the equipment. Calibration and verification s
34、hall followthe manufacturers recommended schedule or the scheduleoutlined in Table 1, whichever is more frequent.5.3.2 Induction CoilsInduction coils are an important partof the power supply units. The verified power output andvoltage/current match depend on the interconnection of coilsand power sup
35、ply units. For example, connecting coils in seriesor parallel to a power supply may significantly affect efficiency,inductance, and overall ability to heat the product. Verificationof equipment should include consideration of coil connectionsand interconnect wiring functionality. Reverification of o
36、utputpower capabilities should occur after any changes to the coildesigns or the interconnections. In the instance of multipleA1100 162induction coil designs on the same line, all coils will beproperly identified, and design/model number will be specifiedin the manufacturing procedure.5.3.3 Quench S
37、ystem:5.3.3.1 Quench media composition shall be documented forevery manufacturing procedure. Composition may includedocumentation of polymer chemistry, supplier, age, brineconcentration, water chemistry, and so forth as applicable.Verification of quench media composition, if applicable, shallbe cond
38、ucted at the interval specified in Table 1. Use of arefractometer is recommended, when applicable, to determinethe concentration at the start and during the operation. Notethat quench media compositions are also affected by wastematerial in the quench (that is, scale, rust, and so forth). It maybe n
39、ecessary to periodically discard and replace quench mediaas it becomes contaminated with minerals, oil, scale, rust, andother undesirable materials. The frequency of this refreshing ofthe quenchant depends on results from periodic monitoring ofquenchant chemistry.5.3.3.2 Quench flow rate shall be ve
40、rified periodicallyaccording to the schedule in Table 1 using a method suggestedby the equipment manufacturer or selected by the producer anddescribed in a documented procedure maintained by the heattreater.5.3.4 Pyrometers:5.3.4.1 Pyrometers shall be placed at positions along theheat treat line to
41、establish heating rates and soak timesaccurately, as appropriate for the application. Pyrometer posi-tion shall be consistent and recorded (see 9.1).5.3.4.2 Pyrometer calibration by the pyrometer manufac-turer typically entails calibration using a blackbody furnaceunder highly controlled conditions.
42、 The tolerance and accuracyof a pyrometer on a heat-treat mill can be significantly reducedcompared to measurement of a blackbody furnace in laboratoryconditions. The tolerance and accuracy for each pyrometershall be provided by the pyrometer manufacturer based on thetarget material composition and
43、temperature for the pyrometerapplication. In addition, it is recommended that pyrometeraccuracy be verified during production with the use of a“master” pyrometer. The master pyrometer may be a hand-heldor other unit in which the accuracy of the device has beenverified off-line using a target materia
44、l with similar surfacefinish, composition, temperature, and ambient conditions com-pared to the heated product. Temperature accuracy of themaster pyrometer is typically verified through the use ofthermocouples attached to the off-line target material. Com-parison to the master pyrometer should not b
45、e considered areplacement for regular calibration of the on-line pyrometers,which should be performed according to the manufacturersspecification. Records of pyrometer calibration and verificationshall be maintained (see 9.1). Calibration and verificationshould follow the manufacturers recommended s
46、chedule orthe schedule outline in Table 1.NOTE 3Proper selection of an appropriate pyrometer technology isessential to ensuring the accuracy. Single-wavelength pyrometers are mostcommon, but also least accurate. Higher accuracy can typically beachieved with shorter wavelength pyrometers, but pyromet
47、er accuracy isalso highly influenced by the emissivity setting.Additional information onTABLE 1 Verification and Calibration FrequencyParameters/Features to Verify Event Reverification FrequencyAPower Supply Power Stability Nominal frequency rangeAfter installation/commissioning ofnew power supply u
48、nitOnce per yearCreation of a new MPBAt time of new MP verificationAfter major rebuildCof equipment Once per yearInduction Coils Visual inspection of interconnectwiring and coil connectionsAfter installation/commissioning ofnew coilsOnce per yearAfter major rebuild of equipment Once per yearQuench C
49、ompositionInstallation/commissioning of newquench system or component;after flushing quench systemMonthlyMill startup After system remains dormant formore than 14 daysCreation of new MP At time of new MP verification FlowInstallation/commissioning of newquench system or componentOnce every 3 months for first year,annually thereafterCreation of new MP At time of new MP verificationPyrometers Temperature accuracyInstallation of new pyrometer Once every 3 months for first year,annually thereafterDPyrometer is sent out for repair Once every 3 months for firs
