SCHOOL OF MANUFACTURING ENGINEERING

TITLE ASSIGNMENT 2

SENSOR FOR PROCESS

MONITORING : HEAT
TREATMENT

EPT 361 INSTRUMENTATION AND CONTROL

MATRIX NO.
SUBJECT CODE SYSTEM

1. GUN YONG CHEE 141053601

NAME
2. NOOR AMIRA KHASANAH BINTI ROSLI 141050809

3. NUR ATHIRAH BT MD KAMIL 141050823

4. MOHD ZAHIRI BIN MOHD AMIN 121051038

5. ADIBAH NURINA BINTI HASHIM 141050755

SUBMISSION DATE 21 APRIL 2017 SESSION/SEMESTER 2017/6

LECTURER/PLV DR SAZLI BIN SAAD

 TABLE OF CONTENT

TITLE PAGE
INTRODUCTION 1-7
 LIST OF SENSORS 8-10
FUNCTION OF SENSORS
PRINCIPLE OF SENSOR 11-13
OPERATIONS
SENSOR WIRING 14-15
DIAGRAM
TROUBLESHOOTING 16
METHOD
CONCLUSION 17
REFERENCES 17-18

INTRODUCTION
Heat treatment is characterized as a mix of heating and cooling operations
connected to a metal or alloy as it has fancy characteristic and properties. Its widely
recognized application is metallurgical however heat treatment can likewise be
utilized as a part of fabricate of glass, aluminium, steel and numerous more
materials. Heat treatment is to soften metals before, and amid hot and chilly handling
operations, or to change their microstructure as to accomplish the coveted
mechanical properties.

Heat treatment of metallic alloys are additionally used to modify the surface science
of a material. This is accomplished by diffusing Carbon, Nitrogen and different
gaseous or strong material into the surface of the part. These procedures are used
to give characterized hardened surface and to enhance wear, erosion and weariness
resistance.

The parameters and procedures that can impact the creation and material
properties of metal segments incorporate the accompanying: Alloy sort - Heating -
Cooling - Work input - Time - Atmosphere - Surface plating - Surface dissemination.
To guarantee that any metal segment is appropriate and satisfactory for the
composed reason, it might should be presented to a chosen scope of molding and
finishing treatment. The treatments are led in such a way to guarantee that the
required blend of these parameters are carefully controlled to accomplish the
coveted completed segment.

The heat treatment of metals includes raising the temperature of an alloy, regularly
through an endorsed warm profile, to a characterized temperature. The material is
then held at this temperature for a timeframe before being cooled either at an
endorsed rate or under fast extinguishing conditions to a settled temperature. These
treatments are completed in furnace and ovens where, notwithstanding the
adjustments in temperature, gasses are utilized to control the atmosphere in the
process. Controlled climates are choose to be use to decrease the impacts of
oxidization or to give an enhancing air to surface science impacts, on the part of
segment to be being dealt with.

Heat treatment is the warming and cooling of metals to change their physical and
mechanical properties, without giving it a chance to change its shape. Warm
treatment could be said to be a technique for fortifying materials however could
likewise be utilized to adjust some mechanical properties, for example, enhancing
formability, machining, and so on.. The procedure of warmth treatment includes the
utilization of warming or cooling, more often than not to outrageous temperatures to
accomplish the needed outcome. It is critical assembling forms that can help
fabricating process as well as enhance item, its execution, and its qualities .

There are 6 types of heat treatments that industries usually used :

Hardening

Hardening includes wheating of steel, keeping it at a fitting temperature until all

pearlite is changed into austenite, and afterward extinguishing it quickly in water or
oil. The temperature are quickly happens relies on the carbon content in the steel
utilized. The heating time ought to be expanded guaranteeing that the center will
likewise be completely changed into austenite. Steel part of ferrite,martensite or
cementite microstructure will be solidified.
 Tempering

Tempering is a process which includes heating steel that has beenextinguished and
solidified for satisfactory purpose. The hardness and quality acquired rely on the
temperature at which heat treating is done. Higher temperatures will lead into high
flexibility, however low quality and hardness. Low treating temperatures will create
low pliability, however high in quality and hardness. Practically speaking, fitting
hardening temperatures are chosen that will deliver the coveted level of hardness
and quality. This operation is performed on all carbon steels that have been
solidified, keeping in mind the end goal to decrease their fragility, with the goal that
they can be utilized successfully in craved applications.
 Annealing

Annealing treatment includes treating steel to a high temperature, and afterward

cooling it gradually to room temperature, so that the subsequent microstructure will
have high in pliability and in durability, however low in hardness. Toughening is
performed by warming a segment to the fitting temperature, drenching it at that
temperature, and after that stopping the heater while the piece is in it. Steel is
strengthened before being prepared by chilly shaping, to decrease the necessities of
load and vitality, and to empower the metal to experience vast strains without
disappointment.
 Normalizing

Normalizing treatment also includes heating steel, and afterward keeping it at that
temperature for a timeframe, and after that cool in the open air surrounding. The
subsequent microstructure is a blend of ferrite and cementite which has higher
quality and hardness, however low in pliability. Normalizing is performed on
structures and auxiliary certain parts that will be subjected to machining, on the
grounds that it will enhances the machinability of carbon steels.
 carburization

Carburization is one of the heat treatment handle in which steel or iron is heated to a
certain temperature, underneath the liquefying point, within the sight of a fluid,
strong, or vaporous material which will breaks down in order to discharge carbon
when warmed to the temperature utilized. The external case or surface will have
higher carbon content than the essential material. At one point when the steel or
iron is drastically cooled by extinguishing, the higher carbon content on the external
surface turns out to be hard, while the center stays intense and delicate because of
the process.
 Surface hardening

In building applications, it is important to have the surface of the segment sufficiently

hard to oppose wear and disintegration, while keeping up pliability and durability
which to withstand effect and stun stacking. This can be accomplished by nearby
extinguishing, and dissemination of solidifying components like carbon or nitrogen
into the surface. Forms required for this intention are known as fire solidifying,
acceptance solidifying, nitriding and carbonitriding.
 LIST AND FUNCTION OF HEAT TREATMENT SENSORS

Sensors are planned and produced for estimation of air fixation in essentially steel
surface warmth treating, for example, hydrogen sensors for gas nitriding,
nitrocarburizing and oxinitriding, and Zirconia oxygen sensors for carburizing heat
treatment heater.There are few type of sensor that using for the Heat treatment for
doing the sensor monitoring.

Hydrogen Sensor

Figure 2.0.1 Hydrogen Sensor

STANGE SE-H2 is an In-Situ hydrogen sensor, which measures hydrogen
centralization of heater air through a convection pipe put in a precise position
speaking to gas piece. It was produced more than ten years back, from that
point forward it has been exceedingly presumed as a result of tough and
dependable execution went down by enormous establishments around the
globe, encounters and exceptional strength .
 Oxygen sensor

Figure 2.0.2 oxygen Sensor

STANGE SE-O2 is an In-Situ oxygen sensor for measuring oxygen content in
heaters utilizing a convection tube. On account of the exceptional plan, it
disposes of reference air supply, which permits the sensor to limit
upkeep. The sensor has grown fundamentally to nitriding and
Nitrocarburizing, Oxinitriding heaters. Since it has confirmation of vacuum,
SE-O2 can serve heaters with process phase of vacuum clearing to speed up
setting up heater generation condition and cooling adequately dependability .

Carbon Sensor

Figure 2.0.3 Carbon Sensor

The AP Test is appropriate for high temperature carburizing heat treating,

carbonitriding and endothermic gas generators. The AP Test is NOT
appropriate for nitriding applications. This AP Test comprises of % oxygen
sensor, thermocouple sensor, their insurance tube and the chilly end head.
Zirconia is a solid state electrolyte which conducts oxygen particles at
temperatures more than 760 Deg. Centigrade. The particle conduction brings
about a voltage between the two anodes. The size of the voltage is subject to
the temperature of the Zirconia and on the proportion of the oxygen incomplete
weight on the reference side of the electrolyte to the oxygen halfway weight on
the procedure side of the electrolyte. Two anodes reach the platinum covered
zirconium component at the tip of the sensor, one external terminal, one inward
cathode. The unique compound security tube is one channel for the oxygen test
flag, which dispenses with the need of a little flag wire typically presented to the
heater condition. The assurance tube has amazing imperviousness to
consumption and oxidation at high temperature, and has great mechanical
quality

Thermocouples

Figure 2.0.4 Thermocouple

The thermocouple measures the temperature in the warmth treatment heater

progressively. These qualities are the key parameters to exhibiting the quality
and legitimacy of the warming procedure.
PRINCIPLES OF HEAT TREATMENT

The outcomes that might be acquired by warmth treatment depend, as it were, on the
structure of the metal and the way in which the structure changes when the metal is
warmed and coded. An immaculate metal can't be solidified by warmth treatment on
the grounds that there is little change in its structure when warmed. Then again, most
compounds react to warmth treatment in light of the fact that their structures change
with warming and cooling. An amalgam might be as a strong arrangement, mechanical
blend, or a mix of a strong arrangement and a mechanical blend. At the point when a
combination is as a strong arrangement, the components and intensifies that frame
the composite are ingested, one into the other, similarly that salt is disintegrated in a
glass of water. The constituents can't be recognized even under a magnifying
instrument. Whenever at least two components or mixes are blended, yet can be
recognized by minuscule examination, a mechanical blend is shaped. A mechanical
blend may be contrasted with the blend of sand and rock in cement. The sand and
rock are both unmistakable. Similarly as the sand and rock are held together and kept
set up by the blend of bond, alternate constituents of a compound are inserted in the
blend framed by the base metal. A composite that is as a mechanical blend at common
temperatures may change to a strong arrangement when warmed. At the point when
cooled back to typical temperature, the combination may come back to its unique
structure. Then again, it might remain a strong arrangement or frame a mix of a strong
arrangement and mechanical blend. A compound that comprises of a blend of a strong
arrangement and mechanical blend at ordinary temperatures may change to a strong
arrangement when warmed. Whenever cooled, the composite may remain a strong
arrangement, come back to its unique structure, or frame an unpredictable
arrangement. Warm treatment includes a cycle of occasions. These occasions are
warming, for the most part done gradually to guarantee consistency; dousing, or
holding the metal at a given temperature for a predetermined timeframe; and cooling,
or giving back the metal to room temperature, once in a while quickly, in some cases
gradually. These occasions are talked about in the accompanying sections.

Heating

Uniform temperature is of essential significance in the warming cycle. In the event that
one segment of a section is warmed more quickly than another, the subsequent
uneven extension frequently causes contortion or breaking of the part. Uniform
warming is most almost acquired by moderate warming. The rate at which a section
possibly warmed relies on upon a few elements. One essential component is the
warmth conductivity of the metal. A metal that behaviors warm promptly might be
warmed at a speedier rate than one in which warmth is not consumed all through the
part as quickly. The state of the metal likewise influences the rate at which it might be
warmed. For instance, the warming rate for solidified apparatuses and parts ought to
be slower than for metals that are not in a focused on condition. At last, size and cross
area have an imperative impact on the rate of warming. Parts expansive in cross area
require a slower warming rate than thin segments. This slower warming rate is vital so
that the inside will be warmed to an indistinguishable temperature from the surface. It
is hard to consistently warm parts that are uneven in cross area, despite the fact that
the warming rate is moderate. In any case, such parts are less well-suited to be split
or too much twisted when the warming rate is moderate.

Soaking

The question of warmth treating is to realize changes in the properties of metal. To

achieve this, the metal must be warmed to the temperature at which basic changes
happen inside the metal. These progressions happen when the constituents of the
metal go into the arrangement. Once the metal is warmed to the best possible
temperature, it must be held at that temperature until the metal is warmed all through
and the progressions have sufficient energy to happen. This holding of the metal at
the correct temperature is called Drenching. The time allotment at that temperature is
known as the Drenching Time frame. The dousing time frame relies on upon the
substance examination of the metal and the mass of the part. At the point when steel
parts are uneven in cross area, the splashing time frame is dictated by the heaviest
section. In warming steels, the metal is at times raised from room temperature to the
last temperature in one operation. Rather, the steel is gradually warmed to a
temperature underneath the time when the strong arrangement starts, and it is then
held at that temperature until warmth is retained all through the metal. This procedure
is called PREHEATING. Taking after the preheating, the steel is immediately warmed
to the last temperature. Preheating help sin getting uniform temperature all through
the part being warmed, and, along these lines, decreases mutilation and breaking. At
the point when separated is of multifaceted plan, it might need to be preheated at more
than one temperature to counteract breaking and intemperate twisting. For instance,
accept that a multifaceted part is to be warmed to 1,500F (815C) for solidifying. This
part may be gradually warmed to 600F(315C), be splashed at this temperature, then
be warmed gradually to 1,200F (649C), and after that be drenched at that
temperature. Taking after the second preheat, the part would be warmed rapidly to the
solidifying temperature. Nonferrous metals are from time to time preheated in light of
the fact that they for the most part don't require it. Moreover, preheating tends to
expand the grain measure in these metals.

Cooling

In the wake of being warmed to the best possible temperature, the metal must be
come back to room temperature to finish the warmth treating process. The metal is
cooled by setting it in direct contact with a gas, fluid, or strong, or some blend of
these. The strong, fluid, or gas used to cool the metal is known as a "cooling
medium." The rate at which the metal ought to be cooled relies on upon both the
metal and the properties coveted. The rate of cooling additionally relies on upon the
medium; thusly, the decision of a cooling medium has a critical impact on the
properties acquired. Cooling metals quickly is called "extinguishing," and the oil,
water, saline solution, or different mediums utilized for fast cooling is known as an
"extinguishing medium." Since most metals must be cooled quickly amid the
solidifying procedure, extinguishing is by and large connected with solidifying.
Notwithstanding, extinguishing does not generally bring about an expansion in
hardness. For instance, copper is generally extinguished in water amid tempering.
Different metals, air-solidified steels for instance, might be cooled at a generally
moderate rate for solidifying. A few metals are effortlessly split or distorted amid
extinguishing. Different metals might be cooled at a fast rate with no evil impacts.
Along these lines, the extinguishing medium must be fit the metal. Brackish water
and water cool metals rapidly, and ought to be utilized just for metals that require a
fast rate of cooling. Oil cools at a slower rate and is more reasonable for metals that
are effortlessly harmed by quick cooling. For the most part, carbon steels are
considered water solidified and compound steels oil solidified. Nonferrous metals are
normally extinguished in water.
SENSOR WIRING DIAGRAM

The qualities of a vacuum heater make the chamber temperature be 5 to 10

degrees more smoking than the work piece. This is known as a warm slope or Delta
Temperature (Delta T). Numerous metallurgists want to control their vacuum heaters
utilizing a thermocouple put by, or into, the heater work piece. This in any case can
bring about undesirable impacts, for example, unnecessary warmer temperatures
and overshoot of the coveted set point. Heater makers regularly utilize a chamber
thermocouple set close to the heater warmers with a specific end goal to get around
these issues. The perfect arrangement is to utilize a controller that has two separate
control circles, each with its own thermocouple input. One circle will utilize the
chamber thermocouple that is situated close to the radiators and the other circle will
utilize the work piece thermocouple. The control circle with the most minimal yield
request will be used to control the heater temperature. For this application
Eurotherm has executed a control system called abrogate control. Abrogate control
comprises of two control circles, each with it's own info and setpoint, however they
share a typical control yield. The least yield of the two circles is coordinated to the
normal yield circuit.

Figure 1 demonstrates a basic abrogate controller. The principle and abrogate

control yields are nourished to a low flag selector. The abrogate setpoint is set to an
esteem some place over the ordinary working setpoint, however beneath any
wellbeing interlocks or sudden qualities. There is one auto manual switch for both
circles. In manual mode the control yields of both circles track the genuine yield
along these lines guaranteeing bumpless exchange when auto is selected.Although
the 2604 is multi-circle controller it needs just a single control circle to actualize
supersede. Each circle is equipped for being set-up as a supersede control circle.
Two profiles can be utilized as a part of the setpoint software engineer, one to set
the chamber setpoint and the other to set the workpiece setpoint. In this way the
setpoints and their relationship to each other can change as the procedure is being
run. Then again, one of the profiles can set the workpiece setpoint and the other can
be utilized to set the Delta T between the workpiece and the chamber.
TROUBLESHOOTING METHOD

Sensors were designed to detect the reading of the measurements. Examples

of sensors for heat treatment are hydrogen sensor, oxygen sensor and carbon
sensor. If there is any problems had happen to the sensor, a few troubleshooting
methods must have taken to keep the sensor functioned.

For carbon sensor, there are some troubleshooting methods can be taken if
the sensor face some problems. Ensure the mV and t/c sensor between controler
are connected to each other and polarity is detected. Besides that, do a Leak test to
ensure that there is no leakage or any broken parts of the sensors. To determine the
electricity and realibility of the Golden Probe, the Probe Impedence resistance test is
one of the method for troubleshooting. We have to verify the reference air supply
whether it is connected to the reference air fitting because if the reference fitting is
connected to the burn off fitting, it will lead to low reading. Check whether the
reference air is flowing or not. Next, if any error is detected do not remove Golden
Probe from a hot furnace at rate less than 2 minutes. To avoid thermal shock, cool
the sensor on insulating medium.

The easiest way to detect whether there is an error occur or not by inserting it
to another location. This action is to ensure which part is broken and need to get fix.
After that change the different orientation for the sensor and transmitter. This
orientation may help prevent action that lead to a lost signal. If the green light does
not appear on the transmitter, try to disconnect wait a few seconds and reconnect. If
it does not working charge the transmitter

For temperature sensor, double check all the connection on wire. Observe
that no wires are touching towards each other and do not have isolation screw with
wires. Pull each wire to ensure that it is not loose. Uninstall temperature sensor by
setting function to None to apply. Next try sensor one by one and refresh device
manager. Check whether each sensor is detected and return to its value. A faulty
sensor can cause a too high current draw that messes up the bus. Swapping any
wire with V+ on the sensor fries it. The sensor will get hot and could cause instability
.Try them one by one because one sensor might mess up for the rest.
CONCLUSION

The main objective of the heat treatments is to get the desired mechanical properties
which are in terms of ductility, hardness and toughness by justifying the
microstructure. All properties have a close relationship with the materials
microstructure. To sum it all up, this sensor can be useful in various industries from
heavy industry to consumer products. This heat sensor is sensitive compare to all
models. Heat detectors have two main classifications of operation, "rate-of-rise" and
"fixed temperature." The Heat detector is used to help in the reduction of damaged
property. It is triggered when temperature increases.

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