PROPER AGITATION DICTATES QUENCH SUCCESS Part 1 Take a look at the improvements in quench agitator design, and learn how to select one that does a thorough job. By GE. Totton result in unacceptable amounts of | phase, occurs when the quenchant KS. Lally pearlite formation. Substantial re- | temperature at the interface of the ductions in the duration of A-phase | cooling metal is less than the boiling cooling times are usually obtained | point of the liquid. Cooling occurs ‘This is the frst ofa two part series on | by corresponding increases in agita- | by convective and conductive pro- quench tank agitation tion rates since agitation facilitates | cesses. As with A-and B-phase coo! the rupture of the vapor blanket | ing, heat transfer rates in the C-phase around the hot metal region are increased with increasing uenchingisacritically impor- | _ Thesecond phase of cooling is des- | agitation. tant process in the develop- | ignated as B-phase cooling and is | Figure 2 displays the impact of ment of desired metallurgical | characterized by nucleate boiling. | agitation on the cooling rates of oil properties in the heat treatment of | Heat transfer rates of B-phase cool- | and polymer quenchants and water. many steel and aluminum alloys. | ing are the highest of the three re- | Allof hese quenchant media exhibit Proper agitation of the quench bath | gions. Further increases inheat trans- | increased heat transfer rates with {soften thesingle parameter that dic- | fer rates in this region can also be | increasing agitation. Of course, the tates the success of the quenching | achieved by increasing the agitation | magnitude of the increase in agita process itself. The classic reference | rate. tion rates is dependent on many fac- thatis till consulted for quench tank | — C-phase cooling, the third cooling | tors such as the turbulence of flow, agitator design recommendations ‘was originally published in 1954 by US. Steel." Because agitator design Figure technology has undergone dramatic Three-Phase Cooling improvements since that time, agita- Of Inconel 600 in Poly tor recommendations can be up- dated. ‘Atleast three different cooling, re- gimes occur when hot metal is im mersed into a vaporizable liquid medium? and each of these regimes is associated with @ uniquely differ- ent heat transfer process. Figure 1 shows these different cooling, re gimes for an aqueous polymer quenchant. Upon immersion into the quen- | chant medium, a vapor blanket is. | formed around the hot metal. Thisis | conventionally designated as the A- | phase cooling, and heat transfer rates are typically slowest in this region. The duration of A-phase cooling 5° 40 a 0a Ope am ap often dictates whether the desired wets) degree ofhardening will occur since | Cooling ngonel 600 na solution of polyalkylene giyeal under sll quench condiion in @ extended A-phase cooling timesmay | aI°G/I04°F bath sows the tre phases of he cooing process. ‘TewPERATURE CO) n EAT TREATING / SEPTEMBER 1092physical properties ofthe quenchant, presence of additives, etc Increasing agitation rates will re- sult in a corresponding increase in heat transfer rates in all three cool- ing phases during the quenching, process. However, is this always a desirable feature? For example, itis well known that martensite forma- tion is typically accompanied by a volumetric expansion. It is gener~ ally recognized that cooling rates should be minimized in the region of the M, temperature to minimize cracking and distortion due to ex- cessive rates of martensite formation. (On the basis of this point alone, it seems the agitation rate should al- ways be minimized to reduce any potential for cracking and distortion. However, the propensity for crack- ing and distortion decreases as the uniformity of heat transfer during, the quench increases. In fact, increas ing quench severity does not always result in increased cracking if itis accompanied by improved quench uniformity." ‘The necessity for uniform heat transfer to reduce surface thermal gradients can be understood from the quench process shown in Figure 2. Cooling rates are controlled dur- ing the quenching process by the formation of an insulating. film around the metal upon immersion. If the film formation is either discon~ tinuous or has an excessively vari able thickness, substantial variation in localized heat transfer rates may be produced, which may result in an increased propensity for cracking and distortion, However, agitation will produce a substantial improvement in film for- ‘mation by enhancing the uniformity of the heat transfer process, Further- ‘more, agitation will facilitate the redissolution of the film-forming material at the conclusion of the quench. Similar analogies can be drawn for water and quench oil. Ifthe quench process is to be opti mized, itis necessary to both mini- mize the thermal gradients occur- ring over the surface of the part dur- ing the quench as well as through- ut the bulk quenchant in the tank itself since quench severity usually decreases as the temperature of the . Aqueous Polymer (35°C) Probe = 1/2 x4 in. Inconel 600 Heat transfer rates increase with the increase in agitation of ol (a) and polymer ‘quenchants (c) and of wate (b) On Cooling Rates = Oath emperare HOF = Soe eo Cooling rate, C/sec. 2. Convention at probes 14, ASI ype 304 stainless see! Cooling rate, *C/sec. som 19 Myce 00) 1600, ae 1400, 100 2 1200 g 69 3 § 100 £ § z B sco! 00 = eco ea a0 109 200 3 0 5a as bo aos a8 Time, se. b, Water (55°C) probe = 1x4 in, AIS! type 304 stainless steel go , 3 ~ Poder 209m 5 Pode ipa Cooling rate, “Cisec.The impeller mixer is the most common and cost effective agitation method. quenchant increases. This is done by optimizing, although not necessar~ ily maximizifig, the agitation pro- vided by each individual quench system. Agitation Selection ‘Quench tank agitation can be pro vided by various methods including, recirculation pumps, submerged spray, air or nitrogen sparge, impel- ler stirrer, ultrasonics, actual movi ‘ment of the part itself, ora combina- tion of two or more of these meth- ‘dis. While an air or nitrogen sparge can be used for quench tank agita- tion, either one increases air contact, Figue3 Typical Impellers In Quench Tanks 2. High efficiency aro-ype impeller (Cigtnin 4310 tito impoter Marne propeller (1.0 pitch ratio) € Side-enty mixer impeller (Uightnin A312 fugit impeter) Suc: tn oUt Gow Sr ‘An axia-low, or marine, impeller (a) is ‘commonly used for open systems; 2 high efficiency artoltype impeller (4) ks most often used for toprentering mixers, both vertical and angled; the special design of the impeller blades for sie-entry mixers (e)halances the mecanical forces acting nthe impelier inthis mode. figure 4 Impeller Arrangements, . Flow Patterns topview (A R ist Qs FR 4 fi. ee ven ATR NS NS ea Top-entering mixer Angled ‘Side-entering mixer top-entering miner ‘Axial-low impellers can eifier be top-enteing, sie-entering or angled top-enterng Taher Power Requirements for Propeller Agitation‘ Standard Quench ou Tank Volume Water or Brine Gallons Liters Hpiual. WA __Hnfgal. RWI 50-00 2000-3200, 0.005 0.001 0.004 0.0008 00-2000 3200-8000 0.006 = o.oor2 0004 ©» 0.0008, 2000-3000 8000-12,000 0.006.012 0008.00 33000 312,000 0007 = ours = 0008.00 1 These power requirements were takan from the orginal US. Stel reference which assumes the impellers rotating at 420 rpm." ‘The mixer power requirements for a marine impeller operating 420 rpm vary abzarding to tank volume and quenchant Tabet Equivalent Quench Tank Mixer Size Standard Quench ou Water or Year Note p/gal.—KWA Koval 1954 Marin impeter 0.007 000s 0005 0.001 at 480 rom? 1970 Matin impeter 0.004 0.0008 0.008 0.0006, at 280 rom? 1990 Airfoil impeler 0.003 0.0006 0.002 0.0004 at 280 rpm? 1. This table s based ona 3000 gallon tank wth an open-impeller mixer providing “violent” circulation. The recommended power requirements for an airtol impeller used in 2 drt tube application is 0,006 Hp/gal fora quench ol and 0.0048 fp/gal for water or brine. 2. The power levels fr other output speeds are adjusted using Equation | The requited power eve! ks proportional to mer speed by Equation 1: Pa. N® when P= power and N= impeller spood. Continuing advances in impeller and system design have permitted a reduction in mixer Dower requirements, resuling insubstantial energy savings EAT TREATING /GEPTEMBER 1992with the quenchant, facilitating the normal ongoing oxidation process, thus reducing the normal lifetime of the quenchant. Therefore, this method of agitation is not generally recommended, Ultrasonic agitation is effective, but typically the relatively expensive manual movement of the part itself does not assure uniformity. Agita- tion using recirculation pumps also will not provide quench uniformity throughout the tank. In these cases, submerged sprays are often used; however, recirculation pumps, as a rule, require approximately ten times the power to provide the same amount of linear flow rate as an impeller mixer. Therefore, the most common and cost-effective method of providing agitation is an impeller mixer. Mixer Impeller Types A mixer is used to provide fluid motion and shear. Flow-controlled mixing is strongly dependent on the bulk turnover produced by the im- peller. Therefore, common mixing, processes that occur in quenching. Practice, fluid blending and heat transfer are strongly related to im- peller flow. Mixing impellers used for quench- ing operations are either open-im- peller or draft-tube systems. Open- impeller mixers do not have a flow- directing surface encasing the im- peller but rely on the impeller itself, or a baffle, to direct flow into the quenching region of the tank. ‘A.common impeller used for open systems is an axial-flow impeller such as the marine propeller shown in Figure 3a An axial-flow impel- ler directs fluid flow parallel to the impeller shaft. Axial-flow impellers can either be top-entering, side-en- tering or angled top-entering as shown in Figure 4 "Three-blade marine impeller mix ers have been traditionally installed for quench tank agitation. These impellers are used with either sice- entering or top-entering mixers, ce- pending on the tank configuration and mixer size. The mixer power requirements for a marine impeller with a LO-pitch ratio operating at 420 rpm are summarized in Table l! HEAT TREATING / SEPTEMBER 1002 i Recommended Quench Tank Mixer Sizes Woter or brine el per-impeer mbes 003 0005 op ent orsde entry aici impel t 280 rpm raf ube mixer 006 oor os 0008 sifu peter at 280 rpm (ench tank miner sizes canbe determined trom this table. Ta Sizing of Impeller Mixers Motor? Impeller Size bw inch em 033 025 4 355 080 as7 18 384 075 058 6 408 10 ars "7 432 20 148 20 508 30 234 2 559 50 373 24 610 75 559 26 860 100, 148 28 m4 150 1119 30 782 200 1492 32 813 250 1865 3 833 1. The power requirements were clcultd rom Equation V assuming 280 rpm, the speci gravity tobe 1.000 and an ail impeer wih = 0.33. (Aol and marine propel power numbers are neat identical) 2. The shat horsepower (sHp) sequal to 80% of the motor horsepower (rip), (08 x p= sp. 3. These are the power requirements for an open impel operating et 280 rom. 4 When used in a rat-ubo, the impel size shoud be reduced by 8 percent. Axal-ow impeters are used in raft tes to more closely contol he crecton othe low pate Drt-tue ccultrs nave a higher resistance head ta the impeller must pump against whichis duet the fi friction loses inthe drat-ube pipe. Vetocty head losses also occur tthe entrance, ext and any angles that may be present inthe da-ube. The higher head conditions requ a sigh diferent mpele or optimum pumping performance ‘The sizing ofthe impeller diameter is based on mixer power. ‘The impeller most often recom- | gallon tank with an open-impeller mended at the present time for | mixer providing “violent” citcula- angled top-entringand vertical top- | tion Te econmended power require entering mixersisthe highefficiency | ments for an airfoil impeller are airfoil-type illustrated in Figure 3b. | shown in Table II ‘A.40 percent greater flow efficiency | ‘The power levels for other output is achieved with this type of impel- | speeds are adjusted using Equation ler versus the traditional marine | 1. The required power level is pro- impeller operating at thesame peed. | portional to mixer speed: Continuing advances in impeller and Equation 1 system design have permitted sub- PaN® stantial reductions in mixer power | P = power N = impeller speed requirements resulting in substan- | The impeller blades used for side- tial energy savings. These are illus- | entry mixers (Figure 3c) have a dif- trated in TablelIlisbased on a3,000- | ferentshape from those used for top-Draft-tube agitation provides directional fluid flow around the part. entry mixers (Figure 3b), which bal- | draft tubes to more closely control_| primary flow is quite small, a plug- ances the mechanical forces acting | the direction of the flow pattern. | flow through the tank results. Fort, fon the impeller in a side-entering | Draft-tube circulators have a higher | et. al,, calculated the streamlined mode. This is primarily due to the | resistance head that the impeller } pattern in the volume located above higher operating speeds thataretypi- | must pump against due to the fluid | an open, high-speed impeller in a cally required in the side-entering | friction losses in the drafttube pipe. | baffled vessel as shown in Figure design. An advantage of this impel” | Velocity head losses also occur at | 6a‘ The use of a draft tube in the ler over conventional marine impel- | theentrance, exit and any anglesthat | same system (Figure 6b) results in a lersis the bolted blades permiteasier | maybepresentin thedrafttube. The | significant improvement in the spa- installation, higher head conditions require a | cial uniformity of flow, especially The sizing of the impeller diam- | slightly different impeller for opti- | close to the surface. eter based on mixer power isshown | mum pumping performance. A fluid velocity profile for an op: in Table IV. The required power is erating draft-tube circulator was ddotermined from Table I! Drat-Tube Miner Design | measured experimentally using = ‘Axial-flow impellers are used in | Draft-tube agitation is often used | laser Doppler velocimeter (LDV) and in quenching applications'o provide | is shown in Figure 7.’ The fluid ve- directional fluid flow around thepart | locity vectors in the upper region of being quenched. For example, when | the tank are reasonably close to the an open impeller is used with some | streamlines presented in Figure 6b. tank designs, theremayberelatively | Note that the stagnant zone beneath {quiescent or stagnant mixing zones | the impeller has been eliminated (Figure 5) near the tank bottom di- | whenadratt-tube is used. However, rectly beneath theimpeller. Thismay | the up-flow in the lower portion of ‘occur when the ratio of liquid depth | the annulus is still not completely to vessel diameter or side length is_| uniform. A small recirculation zone greater than 1.0. The use of down- | is also present, as evidenced by the + fanatusrual draft tube and reduce the tendency | used for smaller draft-tube systems for solids deposition. i pumping drafi-tube circulators will | down-flow at the outer wall of the { produce a strong flow pattem that | draft-tube. A will sweep the fluid away from the | Marine impellers are normall P P ly E + $s] | “With a draft tube itis theoretically Radius Rin. possible to approach the condition Figure? When an operimpellerisused win some | where the path length of mostofthe | | Draft-Tube Circulator tank designs, there may be relatively fluid particles is the same. However, Fluid Velocity Vectors: ‘quiescent o stagnant mixing zones tear | when the ratio of induced flow to the tan batom, beneath th impli «0 rT Figure 6 pad Fluid Flow Patterns: Open, Draft-Tube Systems © 4a. Open-impeller system b. Draft-tube system {streamlined pattern inthe volume is located above an open, high-speed impeller in {ated vessel in 7a The use of drat tabs in the same sytem (7) results ina signicant | Improvement inthe spatial uniformity of low, especially close tothe surface. | presented in Figure 7b ‘6 HEAT TREATING / SEPTEMBER 1992RS IS SSS SS SEES (Figure 3a). However, the lower | are used to prevent fluid swirl. ‘weight of the airfoil impeller makes it a lower-cost alternative when im peller diameters larger than 24 inches are required. In a draft-tube system, the airfoil-type impeller will be de- signed with a lower tip chord angle than that which is used on a side- centering mixer in order to avoid stall- ing under conditions of high head resistance, ‘A draft tube should possess cer- tain characteristics 1. A down-pumping operation is used to take advantage of the tank bottom as a flow-directing device. 2. A 30-degree entrance flare on the draft tube minimizes the entrance head losses and assures a uniform velocity profile at the inlet 3, Liquid coverage over the draft tube should be at least one-half of the tube diameter to avoid flaw loss due to disruption of the impeller in- let velocity profile 4.Intemal flow-straightening vanes 5. The impeller shouldbe ingerted into the draft tube a distance equal toat leat one half ofthe tube dam. ter Inet velo profes dcatthis dimension, vA stendy-baring or limitzing, is used to protec the impele from ccasional high deflection Use of @ Steady bearing ia lower cost alter native but requires periodic mainte hance. Although higher in cost, the Timing doesnot require periodic mainienance, The miner manta turer shouldbe consulted fr recom- mendations for the safely and de- Sign dimensions foreach aterative 7:The impeller requis one totwo inches of tadial clearance between the blade ps and the draft tube Where the drattube size must be minimized an external notch canbe ted to rede the drafttube dam: ster by 23 inches, Look forthe final article ofthis two pat setts in Heat Treating’ October issue, Part 2 addresses basic ‘mixing principles, multiple mixers, and computer assisted agitation sys- tem design. [HT] KS. Lally is the research and develop- ‘ment manager of Lightnin, a unit of Gen ‘eral Signal,inRochester,N.Y.G.E. Totten is a research scientist for Union Carbide Chemicals and Piastics Co, Inc. in Tary- town, NY. 1, Utes See sha Ba ord Queen a ‘Delt pepe Aptana PATE SE cng. wera an 8 Pts, Cor tense neta ekteh Bowne