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UCON QuenchantsUser’s Manual

Table of Contents

Page Number

Introduction ................................................................................................................................................................. 4

Product Description ..................................................................................................................................................... 6

Products ...................................................................................................................................................................... 6

Advantages of UCON™ Quenchants ..........................................................................................................................7

Quenching Variables ................................................................................................................................................8-9

Quenchant Selection:

Steel .....................................................................................................................................................10-13

Aluminum .............................................................................................................................................14-17

Quenchant Conversions .......................................................................................................................................18-22

Maintenance ........................................................................................................................................................23-25

Case Histories:

Integral Quenching .................................................................................................................................... 26

Open Tank Quenching ..........................................................................................................................26-27

Aluminum Quenching ................................................................................................................................ 27

Induction Quenching ................................................................................................................................. 27

Controllable Delayed Quenching ..............................................................................................................28

Immersion Time Quenching Technology ..............................................................................................28-30

Ecological Fate Data ................................................................................................................................................. 30

Toxicological Properties ............................................................................................................................................ 31

Storage and Handling ............................................................................................................................................... 31

Product Safety ........................................................................................................................................................... 31

Additional Information:

Physical Properties – Graphs ...............................................................................................................32-35

Cooling Rate Data ................................................................................................................................36-38

Quenching Data ........................................................................................................................................ 39

Heat Transfer Coeffi cients ...................................................................................................................40-41

Emergency Service .................................................................................................................................................... 42

1

List of Figures

Figure 1 Illustration typical quenching processes by the superposition of quenching

time-temperature curves on the CCT curve for a quench-hardenable alloy .......................................... 4

Figure 2A Illustration of the wetting process for Water .........................................................................................5

Figure 2B Illustration of the wetting process for Oil ..............................................................................................5

Figure 2C Illustration of the wetting process typical of a UCON Quenchant ......................................................... 5

Figure 3 Cooling curves obtained at different positions in the center

and at the surface of a cylindrical probe ................................................................................................5

Figure 4 Illustration of a PAG cooling curve .........................................................................................................8

Figure 5 Illustration of the Grossman H-Factor for UCON Quenchant E .............................................................. 8

Figure 6 Illustration of Aluminum Parts Quenched in UCON Quenchant A ....................................................... 14

Figure 7 Stress Distribution vs. Percent Material Removed for A356 Aluminum Castings ............................... 15

Figure 8 Comparison of aluminum sheet distortion reduction achieved

with cold and hot water and UCON Quenchant A .............................................................................. 15

Figure 9 Illustration of draft tube impeller design .............................................................................................19

Figure 10 Examples of chute quench designs ......................................................................................................21

Figure 11 Illustration of the introduction of sample onto a refractometer prism ................................................ 23

Figure 12 Illustration of a Cannon-Fenske viscosity tube ....................................................................................24

Figure 13 Illustration of a portable conductivity meter ........................................................................................24

Figure 14 Illustration of the separation temperature effect for a PAG quenchant .............................................. 24

Figure 15 Illustration of a nitrite color test ..........................................................................................................25

Figure 16 Illustration of a “Dip Stick” test for biological activity ........................................................................ 25

Figure 17 Normal hardness distribution (1) after quenching in oil at 20°C without agitation;

inverse hardness distribution (2) after quenching in UCON Quenchant E

at 15% concentration, 40°C bath temperature and 0.8 m/s agitation ............................................... 28

Figure 18 Test results of specimens with normal and inverse hardness distribution ......................................... 28

Figure 19 Crankshaft hardness and distortion results .........................................................................................29

Figure 20 Hardness distribution for track links produced by the continuous ITQS process ................................ 30

Figure 21A Schematic illustration of the quench system used to quench the probes ........................................... 35

Figure 21B Schematic illustration of dimensions of probes used to collect time-temperature

cooling curve data tabulated in Tables 14 –16 .....................................................................................35

2

List of Tables

Table 1 Typical Physical Properties ..................................................................................................................6-7

Table 2 Factors Effecting Heat Transfer Rates ....................................................................................................8

Table 3 Typical Applications For UCON Quenchant A .......................................................................................11

Table 4 Typical Applications For UCON Quenchant E .......................................................................................12

Table 5 Typical Applications For UCON Quenchant HT .....................................................................................13

Table 6 Limits For Quenching In UCON Quenchant A Solutions ....................................................................... 16

Table 7 Calculation of Quench Factors and Yield Strength for 2024 Sheet

and 7075 Sheet and Bar Stock ............................................................................................................17

Table 8 Suggested Coatings for Use on Contact with UCON Quenchants ....................................................... 19

Table 9 Power Requirements for Impeller Agitation .........................................................................................20

Table 10 Size of Impeller Mixers .........................................................................................................................20

Table 11 Pressure and Orifi ce Size Recommendations for Indirect Spray Quench Systems .............................. 22

Table 12 Environmental Fate ...............................................................................................................................30

Table 13 Ecotoxicity ............................................................................................................................................. 30

Table 14 Cooling Rate Data – UCON Quenchant A ............................................................................................36

Table 15 Cooling Rate Data – UCON Quenchant E .............................................................................................37

Table 16 Cooling Rate Data – UCON Quenchant HT ..........................................................................................38

Table 17 Cooling Rate Data – Water and Selected Oils .....................................................................................38

Table 18 Quenching Data for AA 7075-T73 using a Type I Aqueous Polymer

UCON Quenchant A (Solution Temperature 870°F) .............................................................................. 39

Table 19 Heat Transfer Coeffi cients for 20% Water Solution of UCON Quenchant A vs.

Probe Diameter [Bath Temperature 43°C, Agitation V = 0 m/s (no agitation)] ................................... 40

Table 20 Heat Transfer Coeffi cients for 20% Water Solution of UCON Quenchant A vs.

Probe Diameter (Bath Temperature 60°C, Agitation V = 0.254 m/s) .................................................. 40

Table 21 Heat Transfer Coeffi cients for 30% Water Solution of UCON Quenchant A vs.

Sample Diameter (Bath Temperature 54.4°C, Agitation V = 0.1 m/s) ................................................ 41

Table 22 Heat Transfer Coeffi cients for 35% Water Solution of UCON Quenchant A vs.

Sample Diameter (Bath Temperature 43.3°C, Agitation V = 0.254 m/s) ............................................ 41

3

Figure 1 Illustration typical quenching processes

by the superposition of quenching time-temperature

curves on the CCT curve for a quench-hardenable

alloy. The solid quenchant cooling curve line will

permit the formation of maximum martensite.

However, if the cooling process is delayed

suffi ciently, undesirable microstructures will be

formed as illustrated by the dotted cooling curve line.

INTRODUCTION

UCON Quenchants

Quenching involves the controlled cooling of a metal

from a high temperature to a cooler temperature to

facilitate the formation of the desired microstructure

and physical properties. For example, steel is typically

heated to an austenitization temperature and cooled

at a rate suffi cient to minimize the formation of

undesirable microstructures such as pearlite, and

maximize the formation of martensite as shown in

Figure 1.

In addition to facilitating the formation of desirable

microstructures, another critically important function

of a quenchant is to maximize the uniformity of the

cooling process over the surface of the part during

the cooling process. A series of photographs taken

when a cylindrical probe was quenched in water, oil

and an aqueous PAG (polyalkylene glycol) quenchant,

such as a UCON Quenchant, are shown in

Figures 2A–C.

It is important to note that three different cooling

mechanisms, fi lm boiling (very slow cooling), nucleate

boiling (fastest cooling) and convective cooling (slow

cooling) occur simultaneously on the metal surface

throughout the quenching process. Since all three

cooling mechanisms exhibit different cooling rates,

the formation of signifi cant thermal gradients is

unavoidable. These thermal gradients will lead to

increased thermal and transformational stresses and

if suffi ciently high, they will produce increased

distortion and possibly even cracking.

Quenching in an aqueous solution of a UCON

Quenchant will produce much more uniform quenching

over the entire surface of the cooling metal surface

as shown in the series of photographs on page 5.

Also shown are cooling curves obtained at different

positions in the center and at the surface of a

cylindrical probe quenched in water and in a dilute

solution of a poly(alkylene glycol) quenchant (Figure 3).

The data shows that although the cooling curves are

similar in the center of the probe, the difference in

cooling along the surface from the bottom when

quenching in water is much greater than when

quenching in aqueous polymer solution. This explains

why the addition of small quantities of a UCON

Quenchant (5–8%) often results in a dramatic

reduction of distortion and cracking.

4

1400 Critical temperature

Tem

pera

ture

(°F)

High speed oil

Martensite

Time (sec.)

Hot (180°F) water

MS

Mf

1200

1000

800

600

400

200

0.5 1 10 102 103 104

1Source: H.M. Tensi, A. Stich, and G.E. Totten, “Fundamentals of Quenching”, Metal Heat Treating, 1995, Mar/Apr, p.20-28.

Figure 2A Illustration of the wetting

process for Water.1

Figure 2B Illustration of the wetting

process for Oil.1

Figure 2C Illustration of the wetting

process typical of a UCON Quenchant.1

Figure 3 Cooling curves obtained at

different positions in the center and at

the surface of a cylindrical probe.

5

1000

750

500

250

00

(a) (b)

12

3

3

2

1

1-3

c

10 20Time (sec.) Time (sec.)

Tem

pera

ture

(°C)

30 40 0 5 10 15 20

polymerwater

Table 1 Typical Physical Properties UCON Nitrite QuenchantsProperties Method(ASTM) A E HT RL

Weight per Gallon at 20°C, lbs. 9.13 8.94 9.18 8.97

Specifi c Gravity at 20/20°C D 891 1.092 1.074 1.102 1.077

Flash Point, °C D 93 & D 92 None None None None

Pour Point, °C D 97 -16 0 -20 0

pH Range E 70 9.0 - 11.0 9.0 - 11.0 9.0 - 11.0 9.0 - 11.0

Rust Inhibition D 665A Pass Pass Pass Pass

Viscosity at 100°F, SUS D 7042 2200 - 2800 1120 - 1375 2700 - 3300 1000 - 1250

Viscosity at 100°F, cSt D 7042 475 - 604 242 - 297 583 - 712 216 - 270

Product Description

UCON Quenchants are a series of non-fl ammable,

aqueous solutions of a liquid organic polymer and a

corrosion inhibitor. The organic polymer is completely

soluble in water and produces clear homogeneous

solutions at room temperature. However, at elevated

temperatures, the polymer separates from the water

as an insoluble phase. Upon cooling, the polymer

redissolves to reform a homogeneous, aqueous

solution. This process is completely reversible and

is commonly referred to as the “cloud point” effect.

The mechanism by which a UCON Quenchant

mediates the quenching process is dependent on the

“cloud point” effect exhibited by the particular UCON

Quenchant solution. For example, when hot metal is

quenched in a diluted solution of a UCON Quenchant,

a fi lm of the liquid polymer is deposited on the

surface of the hot metal. The rate at which the metal

is cooled is governed, in part, by the heat transfer

properties, or cooling rates, of the polymer-rich fi lm.

The particular heat transfer properties obtained

depend on the particular UCON Quenchant employed,

quenchant concentration, agitation rates, and

quenchant solution temperature. By adjusting these

parameters, a single UCON Quenchant may be used

in a wide variety of heat-treating processes and with

a range of metal alloys. Proper selection of these

variables permits quenching rate variations, ranging

from those achieved with brine solutions to those

achieved with medium-to-slow-quenching oils.

Products

UCON Quenchants A, HT, RL and E are the principal

members of the series. These products contain an

inorganic nitrite salt as the corrosion inhibitor.

However, non-nitrite -containing formulations are also

available, as UCON Quenchants A-XL, RL-XL and E-XL.

These quenchants contain a proprietary non-nitrite

corrosion inhibitor additive package. UCON

Quenchants designated as XL are completely

compatible with their nitrite-containing UCON

Quenchant analogs without nitrosamine formation.

Similar quenchant performance is obtained with

either quenchant product.

UCON Quenchant A and A-XL permit the fastest

quench rates and facilitate quench uniformity from

water to medium-speed quench oils. They can be

used to quench both ferrous and non-ferrous metals.

UCON Quenchants E and E-XL are useful where the

slowest quench rates are desirable. They provide

uniform heat transfer in typical oil quenching

applications. They are typically used in ferrous metal

heat-treating to replace medium- to slow-quenching

oils. In non-ferrous applications, these quenchants

provide superior distortion-reduction properties for

thin sheet products.

UCON Quenchants RL and RL-XL provide slower

quench rates than UCON A and A-XL. These products

are readily adapted to induction hardening but may be

used in other quenching systems as well.

UCON Quenchant HT is used in applications requiring

intermediate quench rates. UCON Quenchant HT

exhibits higher separation temperature than other

members of the series. This allows greater fl exibility

in the selection of initial bath temperatures and in

the permissible run-out temperature during the

quench cycle.

Although A, E, RL and HT and their XL analogs are

the products of choice for most quenching operations.

Other UCON Quenchants are also available for

specialty heat-treating operations.

6

Advantages Of UCON Quenchants

UCON Quenchants offer a high degree of versatility

and improved performance to the complex quenching

process.

Reduced Fire Hazards

UCON Quenchants exhibit signifi cant fi re safety,

biodegradability and health advantages over oil. They

have a National Fire Protection Association (NFPA)

rating of:

Health = 0

Flammability = 0

Reactivity = 0

UCON Quenchants meet the approval requirements

for the FM Approvals Standard 6930 Flammability

Classifi cation of Industrial Fluids. Products are

manufactured and labeled as FM Approved. This

provides an opportunity to reduce costs for protection

equipment and/or fi re insurance.

Environmental Safety

UCON Quenchants resist bacterial growth, are

biodegradable, and are essentially nontoxic to bluegill

sunfi sh. For more information on environmental

effects, see Ecological Fate Data.

Processing Safety

UCON Quenchants designated XL may be used safely

in processes where there is danger of contamination

with amines. The XL corrosion inhibitor system will

not promote nitrosamine formation. The heat treater

may add XL grades to nitrite-containing quenchants

in the bath without risk of nitrosamine formation and

without the need to dispose of the existing bath.

Flexibility

Optimum operating conditions may be attained

through concentration, bath temperature, and

agitation. By adjusting these parameters, a variety of

quenching severities, ranging from water to slow oil,

may be achieved in a single bath.

Reduced Process Costs

Scrap and off-spec processing costs are reduced by

the control of soft-spotting, distortion and cracking.

Losses from drag-out can be controlled by washing

quenched parts with water or quenchant solution.

Any residual quenchant will volatilize cleanly in

tempering operations above 644°F (340°C), leaving

the part free of undesired residues, such as lacquers,

varnishes, etc.

Lower Quenchant Costs

The major make-up requirement is water to replace

that lost by evaporation. Quench baths that have been

badly contaminated from various sources (hydraulic oil

leakage, salt, etc.) may be restored by such techniques

as decantation, heat, or membrane separation.

Easier Maintenance and Housekeeping

Equipment maintenance and plant cleanliness are

easier to achieve with water-soluble quenchants.

Cooling coils and quench tanks remain free of oil-

derived sludges or deposits. The smoke, soot, and

residues typical of oil quenching are completely

eliminated.

7

Table 1 Typical Physical Properties cont. UCON XL Quenchants

Properties Method(ASTM) A-XL E-XL RL-XL

Weight per Gallon at 20°C, lbs. 9.06 8.89 8.90

Specifi c Gravity at 20/20°C D 891 1.087 1.068 1.069

Flash Point, °C D 93 & D 92 None None None

Pour Point, °C D 97 -25 -7 -7

pH Range E 70 7.5 - 9.0 7.5 - 9.0 7.5 - 9.0

Rust Inhibition D 665A Pass Pass Pass

Viscosity at 100°F, SUS D 7042 2376 - 2900 1112 - 1371 1061 - 1297

Viscosity at 100°F, cSt D 7042 513 - 626 240 - 296 229 - 280

Figure 4 Illustration of a PAG cooling curve Figure 5 Illustration of the Grossman H-Factor for

UCON Quenchant E

Table 2 Factors Effecting Heat Transfer Rates

Properties Of The Fluid Heat Transfer Coeffi cient

Type Of Quenchant ��

Concentration � �

Rate Of Agitation � �

Bath Temperature � �

Properties Of The Sample Heat Transfer Coeffi cient

Thermal Diffusivity � �

Sample Diameter � �

Surface Roughness � �

Surface Oxidation � �

Increasing �

Decreasing �

Quenching Variables

There are many factors that affect heat transfer rates

during quenching and thus also affect cooling curve

shape. The most important of these factors and their

effect on heat transfer rates are summarized in Table 2.

Of these factors, the most important are: polymer

concentration, agitation and bath temperature. This is

illustrated in the cooling curve fi gure (Figure 4 lower

left) and the contour chart of Grossman H-Factors

(Figure 5 lower right).

8

15

1.0

0.8

1.0

Circ. Rate - 75Circ. Rate - 50 Circ. Rate - 100

0.80.6

0.80.5

0.4

0.60.4

100

105

Bath

Tem

pera

ture

Polymer Concentration

110

115

120

125

130

135

140

16 17 18 19 20 21 22 23 24 25

Polymer Concentration

Heat transfer rates are affected by the thickness of

the insulating polymer fi lm surrounding the hot metal

surface during cooling. Increasing the quenchant

concentration will result in a thicker fi lm and thus

slower cooling rates (< H-factor). Conversely,

decreasing the concentration of the quenchant will

produce a thinner insulating fi lm and faster cooling

rates (> H-factor).

Agitation

It is important to understand why optimization of the

uniformity of the fl ow rate around the cooling surface

is critical to reduce undesirable thermal gradients

during quenching. Agitation is particularly important

since it may have a dramatic effect both on the timing

of the rupture and redissolution and thickness of the

insulating fi lm. Agitation can also affect the uniformity

of fi lm formation and breakage around the cooling

surface. Increasing agitation will cause faster rupture

and redissolution of the polymer fi lm (> H-factor).

Decreasing agitation rates will exhibit the opposite

effect.

Bath Temperature

Control of bath temperature, or temperature rise, is

also important for quench process control. Increasing

bath temperature will decrease cooling rates (< H-

factor). Conversely, decreasing bath temperature will

increase cooling rates (> H-factor).

By adjusting and control of these process variables,

a single UCON Quenchant may be used in a wide

variety of heat treat processes with a wide range of

alloys. Proper selection of these variables permits

quenching rate variations, ranging from those of brine

solutions to those achieved with medium- to slow-

quenching oils.

9

Stee

lQuenchant Selection—Steel

Applications

UCON Quenchants A and A-XL

These quenchants are readily adapted to induction

and fl ame hardening, both spray quench and

immersion, for such items as gears, crankshafts,

camshafts, and other pieces of intricate geometry

and diffi cult metallurgy.

Their use may follow heating in either oxidizing or

protective atmosphere furnaces of batch or continuous

design. They may also be used for continuous cast

quenching and for general hardening of cast irons and

forged and cast steels.

UCON Quenchants E and E-XL

These quenchants are useful for quenching high-

carbon and most alloy grades of steel associated with

typical oil quenching. UCON Quenchants E and E-NN

are adaptable to induction and fl ame hardening, both

spray and immersion quenching, for high alloy steels

with intricate geometry, including nodular, malleable,

and cast irons.

They are used following treatment in oxidizing, neutral

and protective atmosphere furnaces of shaker, rotary,

batch, or continuous design. They are also suitable for

direct quenching from the forge, for continuous cast

quenching, and for general hardening of cast irons and

forged or cast steels.

UCON Quenchant HT

The broader temperature range for UCON Quenchant

HT makes it adaptable to batch-type integral quench

furnaces. Because of variations in equipment design,

each installation requires individual attention to

provide satisfactory performance.

This quenchant may also be readily applied to spray

quench and immersion induction hardening for gears,

camshafts, crankshafts, and other items that have

complex geometry and diffi cult metallurgy.

Its use can follow heating in either oxidizing or

protective furnaces of shaker, rotary, or continuous

design, as well as for direct quenching from the forge,

continuous cast quenching, and general hardening of

forged and cast steels and cast iron.

UCON Quenchants RL and RL-XL

UCON Quenchants RL and RL-XL are used for

quenching of medium- to high-carbon steel and alloy

steels of most grades including 300 and 400 series

stainless steels. UCON Quenchants RL and RL-XL are

readily adapted to induction hardening, both spray

and immersion quenching, for such items as spline

shafts, gears, crankshafts, camshafts, and other

pieces of intricate geometry and different metallurgy.

UCON Quenchants RL and RL-XL may follow oxidizing,

neutral, or protective atmosphere furnaces of shaker,

rotary, bath or continuous design. These quenchants

may be used for direct quenching from the forge; for

continuous cast quenching; and for general hardening

of forged and cast steels, and cast irons.

Typical Industrial Applications

The following tables provide a convenient summary

of the application areas in which UCON Quenchants

have proven useful, as well as the quenching media

they replace. It should be noted that there is some

overlap in product uses and also that there are other

UCON Quenchants available for special applications.

10

Table 3 Typical Applications For UCON Quenchant A

Item Alloy Heating Quenchant Fluid Prior As-Quenched Method1 Concentration, % Temp., °F Quench Hardness, Rc

Ferrous 1045 I 10 100 None 40-45

Ball Bearing Plates Meehanite F 15 Ambient — 40-45

Cam Follower Studs 1070 I 15 100 Brine 60

Camshafts Gray Iron I 20 110-120 Water —

Caster Horns 1012 C 8 80 Oil —

1020 C 8 80 Oil —

Cast Iron Saddles Cast Iron FL 6 85 — 56-60

Crankshafts 1050 I 10-12 100 Oil 56+

5046 I 10-12 100 Oil —

1048 I 11-14 115-120 Water 48

1046 I 10-11 110 PVA 56+

Drive Shafts Carbon I 10-12 90-120 — —

Forged Joints 1045 F 18-19 130-140 Oil 350-500(BHN)

1141 F 18-19 130-140 Oil 350-500(BHN)

Gears 4140 I 10-15 80-100 — 50-60

4150 I 10-15 90-120 — 50-60

1040 I 10-12 60-100 — 52-56

Pins 1045 I 8-10 70 Water 59-60

Roller Cutters 4870 F 18 100+ Oil 59-60

Screws 1022 CN 10 95 Oil 83(Rn)

Splined Shafts 1046 I 20 100+ Oil 56-58

1041 I 10 80-110 Water 49-55

1141 I 10 80-110 Water 49-55

410 SS I 14-16 100-120 Oil 38-42

8645 I 14-16 100-120 Oil 58-62

8650 I 14-16 100-120 Oil 58-62

8655 I 14-16 100-120 Oil 58-62

1050 I 14-16 100-120 Oil 58-62

8620 C 14-16 100-120 Oil 58-62

Track Links 5135 F 5 80-110 Oil 52-57

1 C = Carburizing

CN = Carbonitriding

PF = Pit Furnace

F = Furnace

FL = Flame

I = Induction

11

Table 4 Typical Applications For UCON Quenchant E

Item Alloy Heating Quenchant Fluid Prior As-Quenched Method1 Concentration, % Temp., °F Quench Hardness, Rc

Gear Blanks 4140 DFQ 24-26 120-130 Oil 55-62

4150 DFQ 24-26 120-130 Oil 55-62

Gears 4140 FB 24-26 100-120 Oil 54-62

4150 FB 24-26 100-120 Oil 54-62

Oil Field Components 4140 PF 22-26 120-130 Oil 55-64

4150 PF 22-26 120-130 Oil 55-64

4340 PF 22-26 120-130 Oil 55-64

Shafts 4140 PF 20-25 120-130 Oil 55-64

4150 PF 20-25 120-130 Oil 55-64

5200 PF 20-25 120-130 Oil 55-64

9Cr, 1Mo PF 20-25 120-130 Oil 55-64

8260 PCF 18-24 90-100 Oil 60+ (Surf.)

Shoe Shanks 1060 CF 18-22 90-110 Oil 60+

1065 CF 18-22 90-110 Oil 60+

Spindles 4140 FB 22-26 120-130 Oil 51-55

Sprocket Gears PM2 I 23-27 120-130 Water 59-62

1.0C, 2.0Cu I 23-27 120-130 Oil 59-62

Agricultural Tools 1080 DFQ 22-26 130 Oil 60-62

1085 DFQ 22-26 130 Oil 60-62

Hard Faced (Brazed) Disk 1085 F 22-25 140 Oil 59-62

Large Carburized Gears (30,000 lb.) 4320 F 22 120 Oil 59-63

Die for Engine Valves H13 F 23.5 90 Oil 53-55

Crankshaft 1043 F 15 86 Oil 95-99HB

4140H F 10 100 Oil 105-109HB

Track Links 15B37 F 10-12 95-104 Oil 38-40

1 CF = Continuous Furnace

DFQ = Direct Forge Quench

FB = Fluidized Bed

I = Induction

PCF = Pit Carburizing Furnace

ITQS = Immersion Time Quenching System

F = Furnace

PF = Pit Furnace

2 Powdered Metallurgical Parts

12

Table 5 Typical Applications For UCON Quenchant HT

Item Alloy Heating Quenchant Fluid Prior As-Quenched Method1 Concentration, % Temp., °F Quench Hardness, Rc

Crankshafts 1050 F 18-22 90-120 Water 56-62

Die Blocks 4140 F 23-25 110-130 Oil 55-62

4340(Mod) F 23-25 110-130 Oil 55-62

Forged Roll Rings “Waspaloy” F 18-22 80-120 Water/Oil Varies

“Inconel” F 18-22 80-120 Water/Oil Varies

Ti-6Al-4V F 18-22 80-120 Water/Oil Varies

Al-6061 F 18-22 80-120 Water/Oil Varies

Gears 4140 IQF 20-24 120-130 Oil 53-58

High-Pressure Cylinders 4130 F 18-20 90-120 Oil 46-55

4140 F 18-20 90-120 Oil 46-55

Leaf Springs 5160 DFQ 30-34 130-160 Oil 59, min

Oil Tools 8620 ICF 28-32 90-120 Oil 50-60

4320 ICF 28-32 90-120 Oil 50-60

4820 ICF 28-32 90-120 Oil 50-60

Powdered

Metallurgical Parts 0.54 C, 1.65 Cu F 12-16 100-120 Oil 40-50

Shafts 4140 F 22-26 120-130 Oil 55-60

4150 F 22-26 120-130 Oil 55-60

Large Rings 4340 F 20-24 120 New Installation 50-55

(22 ft. dia., 62,000 lb.) 4140 F 20-24 120 New Installation 50-55

4150 F 20-24 120 New Installation 50-55

1 DFQ = Direct Forge Quench

F = Furnace

ICF = Integral Carburizing Furnace

IQF = Integral Quench Furnace

13

14

Alu

min

umFigure 6 Illustration of Aluminum Parts Quenched in UCON Quenchant A.

Bore Area (sq. in.)

75%

UQA40%

UQA30%

UQA20%

UQA10%Water

Oil

0 10 20 30 40 50 60 70 80

Stra

in (1

0-4 in

./in.

)

600

500

400

300

200

100

Figure 7 Stress Distribution vs. Percent Material

Removed for A356 Aluminum Castings

Figure 8 Comparison of aluminum sheet distortion reduction

achieved with cold and hot water and UCON Quenchant A

Quenchant Selection—Aluminum

Severe distortion and residual stresses are often encountered when aluminum

is quenched in water. However, when an aqueous solution of a UCON

Quenchant, such as UCON Quenchant A, is used as the quenching medium, a

dramatic reduction in both residual stresses (Figure 7 lower left) and distortion

(Figure 8 lower right) is typically achieved.

UCON Quenchants A and A-XL are proven quenching agents for wrought, cast,

dip-brazed and forged aluminum alloys. Their superiority to water quenching in

reducing residual stresses in aluminum alloys results in extensive straightening

cost savings and improved uniformity of mechanical results. (See Figure 6).

UCON Quenchant A is an AMEC approved Type 1 Polymer Quenchant according

to AMS 3025B.

Water – 85°FAgitation Rate – 25 FPMTotal Distortion – 1.55 in.

Water – 160°FAgitation Rate – 25 FPMTotal Distortion – 1.385 in.

UCON Quenchant A 20%Agitation Rate – 25 FPMTotal Distortion – 0.12 in.

15

Table 6 Limits For Quenching In UCON Quenchant A1 Solutions

Maximum Thickness 3 Polymer 4,5

Alloy Form Inches Millimeters Concentration % Notes

2024 Sheet, Extrusions 0.040 1.02 34 max. 2

2024 Sheet, Extrusions 0.063 1.60 28 max. 2

2024 Sheet, Extrusions 0.071 1.80 22 max. 2

2024 Sheet, Extrusions 0.080 2.03 16 max. 2

2219 Sheet, Extrusions 0.073 1.85 22 max. 2

6061 Sheet, Plate, Bar 0.250 6.35 40 max.

6061 Sheet, Plate, Bar 0.375 9.52 32 max.

6061 Sheet, Plate, Bar 1.000 25.40 22 max.

7049 Sheet, Plate, Bar 0.080 2.03 40 max.

7049 Sheet, Plate, Bar 0.250 6.35 34 max.

7050 Sheet, Plate, Bar 0.375 9.52 28 max.

7075 Sheet, Plate, Bar 0.500 12.70 22 max.

7175 Sheet, Plate, Bar 1.000 25.40 16 max.

6061 Forgings 1.000 25.40 20-22

7075 Forgings 2.000 50.80 13-15 6

7175 Forgings 2.500 63.50 10-12 6

7049 Forgings 1.000 25.40 20-22

7049 Forgings 2.000 50.80 13-15

7149 Forgings 3.000 76.20 10-12

7050 Forgings 1.000 25.40 28-32

7050 Forgings 2.000 50.80 26-28

7050 Forgings 3.000 76.20 20-22

7050 Forgings 4.000 101.50 15-17

7049 Extrusions 0.250 6.35 28 max.

7050 Extrusions 0.250 6.35 28 max.

7075 Extrusions 0.375 9.52 22 max.

7175 Extrusions 0.375 9.52 22 max.

1. UCON Quenchant A is an AMEC approved Type 1 Polymer Quenchant according to AMS 3025B.

2. Applicable when fi nal temper is T4 or T42. When fi nal temper is T6 or T62, sheet and plate up to 0.250 inch (6.35mm), inclusive, may

be quenched in UCON Quenchant A to a maximum concentration of 22%.

3. Thickness is the minimum distortion of the heaviest section at the time of heat treatment.

4. Where only maximum concentration is shown, any concentration equal to or below the maximum concentration shall be controlled

within ±2% of that selected. When concentration is specifi ed on a drawing or purchase order without tolerance or range, the

tolerance shall be ±2%.

5. Concentration shall be checked according to ASTM D445 weekly and whenever concentration is changed.

6. Prohibited for 7075 alloy when fi nal temper is T6.

16

Table 7 Calculation of Quench Factors and Yield Strength for 2024 Sheet and 7075 Sheet and Bar Stock

A. 2024-T851 Sheet Data (0.063 in.)

Q = -0.552 + 0.225 · C

� ± 0.74, R2 = 90.2

YS = 66.78 - 0.0738 · C

� 0.2421, R2 = 90.3

B. 7075-T73 Sheet Data (0.125 in.)

Q = 0.399 + 0.004554 · CR + 0.03754 · C + 7.491 · ST - 0.08374 · CR · ST + 0.2765 · C · ST

� ± 0.2007, R2 = 97.6

YS = 69.19 - 0.00153 · CR - 0.00866 · C - 1.999 · ST + 0.02638 · CR · ST - 0.07747 · C · ST

� ± 0.06109, R2 = 96.8

C. Type I 7075-T73 Bar Data (0.5 - 2.0 in.)

Q = -39.96 + 2.345 · C + 4.483 · D + 0.4557 · T + 0.1876 · C · D - 0.02703 · C · T

� ± 0.5003, R2 = 98.5

YS = 69.41 - 0.00833 · C - 1.17 · D - 0.0525 · C · D

� ± 0.1304, R2 = 98.7

T = Temperature (°F) C = Concentration (%)

ST = Sheet Thickness (inch) Q = Quench Factor

D = Bar Diameter (inch) YS = Yield Strength (ksi)

CR = Agitation Rate (ft./min.) · = Multiply

17

Quenchant Conversions

In any conversion of a quench facility from an oil to

an aqueous UCON Quenchant, there are a number of

factors to consider prior to fi lling with the UCON

Quenchant. These include:

1. Cleaning—Prior to the addition of the UCON

Quenchant, all of the residual oil and especially any

sludge and metal oxide debris that may have

accumulated in the tank must be removed. After oil

and solid debris removal, the tank should be thoroughly

cleaned. Although steam cleaning is preferred, it may

be unavailable. In such cases, an alkaline detergent

such as Oakite 443 (Chemetall Oakite, 800-526-4473,

www.oakite.com) or equivalent (used according to the

manufacturer’s recommendations) may be used with

agitation suffi cient to facilitate a thorough cleaning

process. Since residual detergent solution may lead

to deleterious foaming when the UCON Quenchant is

added, thorough rinsing is essential. Since residual

oil and sludge may potentially lead to undesirable,

non-uniform heat transfer or act as nutrients

subsequently leading biological degradation, it is

important to be sure that not only the tank is cleaned,

but also piping, traps, and heat transfer equipment

also be thoroughly cleaned at the same time.

2. Compatibility

• Tank Materials—Commonly available carbon

steel tanks are also suitable for aqueous UCON

Quenchants. However, epoxy coatings listed in

Table 8 may be used if added protection is desired.

Galvanized tanks should not be used with UCON

Quenchants.

• Basket and Fixture Materials—Although

aqueous UCON quenchants contain corrosion

inhibitors all basket and fi xture materials that

come into contact with the quenchant solution

are subject to potential corrosion and reduced

lifetimes.

In view of these potential corrosion problems,

optimal lifetimes of baskets and fi xtures will be

obtained if they are constructed from corrosion

resistant materials. Examples of materials that

have been successfully used in the past include:

• HK • 309 Stainless Steel

• HH • 310 Stainless Steel

• HX • 330 Stainless Steel

• HW • RA333

• HU • INCONEL® 600

• HT • INCONEL® 601

However, it is recommended that specifi c material

selection be made in conjunction with the basket

and fi xture suppliers.

• Filters and Screens—Quenchants may contain

various types of contaminants, such as metal scale,

sludge and carbon, which may promote non-uniform

heat transfer if they are not removed. In addition

solid contaminants may cause excessive wear of

pumps, and seals and also heat exchanger fouling.

Solid contaminants may be removed by fi ltration.

However, care must be taken in the selection of the

fi lter media. For example, cellulosic “paper” fi lters

are not compatible with the aqueous UCON

Quenchant media. It is recommended that the fi lter

supplier be consulted for selection of compatible

fi lters and for proper sizing.

• Seals—Selection of compatible seal materials is

important when converting from water, oil or other

quenching media, The use of leather or cork based

products is never recommended. Generally

acceptable seal materials include: Dupont Viton

available from Parker (all Viton materials are not

equally compatible), neoprene, EPDM and BUNA N.

However, these are only generic suggestions and

the seal manufacturer should be consulted before

fi nal material selection.

18

Impellerinsertion0.5 D D

30° Entrance flare

0.5 DCoverage

Radial clearance

Notch

Limit ring orsteady bearing

Flow straighteningvanes

Direction offluid flow

UCON Quenchants exhibit solvency characteristics

different from petroleum oils. Thus, in industrial

applications many paints and surface coatings may be

softened and/or lifted by UCON Quenchants. Paints

removed from exterior machine surfaces can be

replaced by one of the coatings given in Table 8.

Catalyzed epoxy, epoxy-phonolic, and modifi ed

phenolic coatings have performed well in contact

with UCON Quenchants. Alkyd and vinyl coatings are

unsatisfactory. These coatings are not recommended

for service at temperatures above 60°C (140°F). In

terms of temperature resistance we fi nd modifi ed

phenolic to be best, followed by epoxy-phenolic, with

epoxy coatings being last.

Table 8 Suggested Coatings for Use on Contact with UCON Quenchants

Coating Manufacturer Type

Phenoline 373 Carboline Company Modifi ed Phenolic

350 Hanley Industrial Ct.

St. Louis, MO 63144

314-644-1000

www.carboline.com

Plasite 7122 Carboline – Green Bay Epoxy-phenolic

P.O. Box 8147

Green Bay, WI 54308-8147

800-848-4645

www.carboline.com

Intergard Tank Coating International Protective Coatings Epoxy

6100 Antoine Dr.

Houston, TX 77091

713-684-1254

151 U Hempel Coatings Epoxy

600 Conroe Park North Dr.

Conroe, TX 77303

800-678-6641

www.hempel.com

PittGuard 97-145 Porter Paint Epoxy

400 South 13th Street

Louisville, KY 40203

800-332-6270

www.porterpaint.com

3. Tanks

• Tank Sizing—As a fi rst approximation, the total

quench load per gallon should not exceed 1 lb/gal,

including fi xtures. It is preferred that the tempera-

ture rise not exceed 10°F (5°C) during the quench.

Larger temperature rises may be acceptable if the

separation temperature of the quenchant solution

is not exceeded and the desired metallurgical

properties are obtained.

• Baffl es—Tank baffl es should be used to eliminate

vortexing and to convert swirling motion to

productive top-to-bottom fl uid motion. In rectangu-

lar tanks with properly placed multiple mixers, the

combined effects of tank corners, and interference

between mixer fl ow patterns generally eliminate

the need for baffl es. However, vertical cylindrical

tanks with top-entering mixers do require baffl es.

Draft-tubes require internal baffl es or fl ow

straightening vanes, (See Figure 9).

Figure 9 Illustration of draft tube impeller design

19

4. Agitation—Agitation of many oil quench systems

is limited to the what is available from the recircula-

tion system of the heat exchanger. However, this is

inadequate for aqueous UCON Quenchants. Although

various forms of agitation may be employed such

as spray and impeller, usually the most commonly

encountered and least expensive is impeller agitation.

Impeller mixer horsepower requirements and size is

determined after the total tank size is determined

based on the total load being quenched, including

fi xtures. This can be estimated from Table 9 for a

marine impeller operating at 420 rpm with a pitch

ratio of 1.0. It should be noted however that substan-

Table 9 Power Requirements for Impeller Agitation

Tank volume Power required

Gallons Liters hp/gal kW/L

50-800 2000-3200 0.005 0.0010

800-2000 3200-8000 0.006 0.0012

2000-3000 8000-12,000 0.006 0.0012

>3000 >12,000 0.007 0.0014

aAgitation at 420 rpm. Marine propeller with 1.0 pitch ratio.

tial reductions in horsepower can often be achieved

with the use of newer impeller designs and operational

speed. This information is readily available from your

equipment supplier.

If multiple agitators are being used, the power

requirement/agitator is determined from:

Power per mixer = total power / number of mixers

The sizing of the impeller diameter is dependent on

the power requirement of the mixer. Impeller diameter

as a function of the power requirement is summarized

in Table 10.

Table 10 Size of Impeller Mixers

Motor a,b Impeller Size c,d

hp kW in. cm.

0.25 0.19 13 33.0

0.33 0.25 14 35.6

0.50 0.37 15 38.1

0.75 0.56 16 40.6

1.0 0.75 17 43.2

2.0 1.49 20 50.8

3.0 2.34 22 55.9

5.0 3.73 24 61.0

7.5 5.59 26 66.0

10.0 7.46 28 71.1

15.0 11.19 30 76.2

20.0 14.92 32 81.3

25.0 18.65 33 83.8

aThe power requirements were calculated assuming 280 rpm,

specifi c gravity 1.0, and airfoil impeller with Np 0.33. (airfoil and

marine propeller power numbers are nearly identical.)

bThe shaft horsepower (hps is equal to 80% of the motor

horsepower (hpm) (0.8xhpm - hps).

cThese are the power requirements for an open impeller operating

at 280 rpm.

dWhen used in a draft tube, the impeller size should be reduced

by 3%. Axial fl ow impellers are used in draft tubes to more closely

control the direction of the fl ow pattern. Draft tube circulators

have a higher resistance head that the impeller must pump

against, which is due to the fl uid friction losses in the draft tube.

The higher head conditions require a slightly different impeller for

optimum pumping performance.

20

Fume Eductor

Jacketed CoolerWith Cascade

Submerged Sprays

Perforated PlateFor Quenchant RemovalFrom Chute Area

Sprays To MeshPickup Belt

5. Draft-Tube

• Agitation—Fluid fl ow may be directed by using an

impeller mixer in conjunction with a draft-tube such

as that illustrated in Figure 9. A horsepower

requirement for impeller mixers used in conjunction

with a draft-tube is 0.006 hp/gal (0.0012 kW/L).

A properly designed draft-tube should have the

following characteristics:

1. A down-pumping operation is used to take advan-

tage of the tank bottom as a fl ow-directing device.

2. A 30° entrance fl ow on the draft-tube minimizes

the entrance head losses and ensures a uniform

velocity profi le at the inlet.

3. Liquid depth over the draft-tube should be at least

one-half of the tube diameter to avoid fl ow loss due

to disruption of the impeller inlet velocity profi le.

4. Internal fl ow straightening vanes are used to

prevent swirl.

5. The impeller should be inserted into the draft-

tube to a distance equal to at least one-half of

the tube diameter.

6. A steady bearing or limit ring is used to protect

the impeller from occasional high defl ection. A

steady bearing is the lower cost alternative but

requires maintenance.

7. The impeller requires 1–2 in. (25–50 mm) of radial

clearance between the blade tips and the draft-tube

inner wall. When the draft-tube must be minimized,

an external notch can be used to reduce the draft-

tube dimensions by 2–3 in. (50–75 mm).

6. Chute-Quench Systems—For optimal quench

uniformity, both vigorous and uniform agitation and

adequate quenchant turnover in the chute zone of

a continuous furnace is necessary. Although there

are numerous chute designs that may be used, two

illustrative examples that have been successfully

utilized are shown in Figure 10.

A properly designed chute-quench system should

incorporate the following features:

1. Suffi cient agitation and turnover in the chute zone

to provide adequate and uniform heat transfer.

2. A cooling jacket for the chute above the quench

zone to prevent water vapor from entering the

furnace vestibule. Cooling can be achieved by

routing the quenchant returning from the heat

exchanger through the chute zone cooling jacket.

3. A fume eductor located in the chute zone above

the cooling jacket to prevent vapor contamination

of the furnace atmosphere.

4. A perforated or screened opening in the chute

area to allow heated quenchant to escape during

the quench. Solid chutes should never be used.

5. A mesh belt of suffi cient porosity and length to

permit quenchant agitation around the part to

facilitate completion of the quench.

Figure 10 Examples of chute quench designs

21

Fume Eductor

Jacketed CoolerWith Cascade

PerforatedPlate ForQuenchantRemoval FromChute Area

Flow

7. Integral Quench

• Furnace Applications—Although integral

quench furnaces have been traditionally used with

oil quench systems, recent furnace design

improvements have permitted the use of UCON

Quenchants, if the following precautions are taken:

1. The workload (including weight of fi xtures) should

not exceed 1 lb/gal of quenchant. The temperature

rise must not exceed 10°C (18°F).

2. Axial quenchant fl ow through the quench load is

recommended. Proper racking of the parts must

be used to assure proper fl ow.

3. There should be a tight inner door seal to prevent

water vapor from entering the furnace vestibule.

It is recommended that a slight increase in gas

fl ow (positive pressure) in the furnace vestibule

be provided during the transfer of the load into

the quench chamber and during the quench.

4. The agitators must always be on when the inner

door is opened to minimize build-up of water

vapor in the vapor spaces of the quench chamber.

8. Induction Quenching—Induction quenching

systems utilizing UCON Quenchants may be open or

submerged sprays or immersion quenching may be

used. For submerged quenching, it is important that

the reservoir be suffi ciently large to allow the foam

head to dissipate before the quenchant is pumped

back into the system. Therefore, the reservoir volume

should be at least 5–8 times the volume rate of fl ow.

For example, if the fl ow rate is 10 gal/min, then the

reservoir capacity should be 50–80 gal. These systems

also require the use of heat exchangers and fi lters.

One of the most common problems with immersion

quenching with induction systems is that the reservoir

is undersized. If the reservoir is too small, a mixture

of the quenchant and foam will be used to quench the

part. This will often lead to increased distortion and

cracking.

In the case of open and submerged spay systems, a

common problem is the use of excessive pressures,

often those used previously for water. However, when

excessive pressures are used, the effect is to blow the

polymer coating off the part thus losing the desired

effect of heat transfer mediation and enhancement of

the uniformity. Some general recommendations for

pressure and orifi ce sizes are provided in Table 11.

These may vary with the system design but the

concerns remain the same.

Table 11 Pressure and Orifi ce Size

Recommendations for Indirect Spray Quench Systems

Type of spray Pressure (psig) Orifi ce size in. mm

Open < 20 1⁄8 3.18

Submerged > 40 1⁄4 6.35

22

Maintenance

Determination of Quenchant concentration and

troubleshooting of quenchant systems can be readily

performed with a few simple tests: appearance,

refractive index, viscosity, conductance, separation

temperature, corrosion inhibitor, foaming and

biological attack.

Appearance

There are various water-insoluble contaminants that

may lead to visible spotting, increased distortion and

cracking. These include: residual oil sludge from the

previous quenchant, hydraulic oil, forging lubricants,

metalworking lubricants and others. These contami-

nants will cause non-uniform heat transfer and may

be identifi ed by visual inspection of the quenching

solution. If insolubles are observed, they typically

may be removed by skimming or fi ltration.

Refractive Index

The use of a temperature-compensated, hand-held

refractomer, like that shown in Figure 11, is the most

convenient means of daily monitoring of quenchant

concentration. The most common models provide

arbitrary refractive index readings in Brix units over

a 0–30° or 0–15° range. Typically, a drop of the

quenchant solution is placed on the prism and the

value of the refractive index in Brix units is obtained

by looking through the eye piece. The quenchant

concentration is determined with the aid of Brix

concentration charts.

Refractive index is relatively insensitive to polymer

degradation and is affected by the presence of

contaminants such as salt. Therefore, confi rmation

of quenchant concentration using an alternative

procedure such as viscosity must be performed

periodically.

Figure 11 Illustration of the introduction of sample onto a

refractometer prism

23

Viscosity

Quenchant viscosity depends on concentration and is readily determined using

a Cannon-Fenske tube (Figure 12), stopwatch and constant temperature bath.

This is an excellent method for measuring polymer concentration, since it is only

slightly affected by contamination, but is strongly affected by degradation.

Comparison of Concentration by Refractive Index and Viscosity

To determine if signifi cant polymer degradation or contamination has occurred, it

is useful to compare the difference (delta) in the quenchant concentration values

obtained by the refractive index (CR) and viscosity (C

V).

� = CR - C

V

Differences in � of greater than 6–8 are signifi cant and steps should be taken to

minimize this difference.

Conductance

Although it is recommended that distilled or reverse osmosis purifi ed water be

used for quenchant dilution and water make-up, sometimes tap water is used.

When the water evaporates there is a gradual concentration of metal ions which

may lead to faster cooling rates and possibly cracking. Another common source

of metal ion contamination is from drag-out of salt from salt pot furnaces prior

to quenching.

Variations in metal ion content may be easily determined with an electrical

conductance meter such as that shown in Figure 13.

Separation Temperature

The poly(alkylene glycol) polymers used to formulate UCON Quenchants exhibit a

characteristic reversible and reproducible separation from solution when heated

to a temperature in excess of the separation temperature as shown in Figure 14.

Although salts may signifi cantly affect separation temperature, polymer degrada-

tion is the most common cause. Degradation causes the separation temperature

to rise, and an increase of 2 to 4°C (4–7°F) over the life of the bath is not

unusual. A larger increase or a sudden change in separation temperature is a

cause for concern.

Figure 13 Illustration of a portable

conductivity meter

Figure 14 Illustration of the separation temperature effect for a PAG quenchant

Figure 12 Illustration of a

Cannon-Fenske viscosity tube

24

Initial 20% solution(with agitation)

Solution immediatelyafter separation(with agitation)

Solution after layer formation (no agitation)

(lower layer is concentrated polymer)

Corrosion Inhibitor1

Because UCON Quenchants are water based, they must be

formulated with a corrosion inhibitor. Most of the UCON

Quenchants being used throughout the world contain

sodium nitrite as the corrosion inhibitor. The nitrite

concentration can be readily determined by a simple color

test. A tablet, furnished with a test kit, is dissolved in a

specifi c volume of the solution, and the color is compared

to the colors of known concentrations of sodium nitrite as

shown in Figure 15.

A test kit is also available for determining additive levels

in the UCON XL Quenchants. This kit utilizes reagents and

UV light to initiate a color change, which is related to

additive level using a color disc.

Biological Contamination2

The presence of biological contamination and its type

and concentration is usually determined using a microbial

dip-slide test as illustrated in Figure 16. If the contamina-

tion is severe, the addition of a biocide may be required.

UCONEX™ glutaraldehyde biocide may be used for UCON

Quenchant. Note: The potential for biological growth is

dramatically reduced by assuring daily agitation of the

quenchant for at least 20 minutes. Never leave the

quench tank unagitated for greater than 48 hours.

Foaming

Although every quench tank exhibits some foaming in

use, in some cases the quench tank may become

contaminated and either excessive foaming and/or more

stable foam may result. In such cases, increased

distortion or cracking may be observed. To determine if

this situation exists may require a foam test. There are

various possible foam tests, but one of the best is to use

a Waring blender and determine the time required for the

foam head to break after stirring in the blender for a fi xed

time such as 5 minutes. (ASTM D3519) Note: if it is determined that a foam problem exists, 100 ppm of UCON Foam Control Agent 200 or UCON Lubricant 50HB 5100 may be added as an antifoam.

Periodic Analysis

Preferably these analyses will be conducted periodically.

The frequency of analysis is typically every 4 or 6

months. The variation in the bath properties should be

monitored using a form. When the delta value of the

quenchant is in excess of 8, consideration should be given

to replacement of the bath. If there is a sudden change in

delta, more than 1–2 units, the physical property data

may need to be complemented with comparative cooling

curve analysis, as recommended by your distributor.

Figure 15 Illustration of a nitrite color test

Figure 16 Illustration of a “Dip Stick” test for biological activity

25

1Test kits available from Hach Corporation, www.hach.com. Nitrite

test kit, Model NI-6. Triazole test kit, Model TZ-1 (for XL Quenchants).

2Test kits available from Orion Diagnostica, Distributed in the United

States by Chemicals & Equipment Co., Inc. Lake Placid, NY; Easicult

Combi.

103 104 105 106 107

103 104 105 106

Easicult-TTC(colorless agar)

Easicult Combi(colorless agar side)

Easicult-M(yellow-brown agar)

Easicult Combi(rose bengal side)

Determination of total aerobic bacteria

Concentration of yeasts and fungiYeast Fungi

Infection

Slight Moderate Heavy

26

Case Histories

UCON Quenchants have proven their versatility and

value to heat treaters of ferrous and non-ferrous

metals for a broad range of end-use applications. The

following brief case histories have been selected to

illustrate how UCON Quenchants can solve a variety

of problems associated with other quenching media.

Integral Quench

Case History #1

Problem: An oil tool manufacturer with an integral

quench furnace wanted to convert from oil to eliminate

fi re potential and increase core hardness of parts.

Solution: Charge the furnace quench tank with

UCON Quenchant HT after minor modifi cations to

ensure a good, tight-fi tting furnace door and good

quenchant circulation.

Results: Carburizing and neutral hardening yielded

parts with acceptable hardness and microstructure.

There was a defi nite increase in core hardness

compared to oil quenching. In many cases, results

exceeded what could be achieved with oil. Based on

this performance, two more integral quench furnaces

were added over the next 18 months, and they also

employed UCON Quenchant HT.

Case History #2

Problem: A major auto parts producer wanted to

avoid potential fi re hazards of an oil quenchant and to

increase the as-quenched hardness of carbonitrided

rocker arms and other automotive parts in his two

integral quench furnaces.

Solution: Make limited modifi cations of the furnaces

and install UCON Quenchant A.

Results: Short-cycle carbonitriding showed no

atmosphere upsets and excellent metallurgical

properties with this water-based quenchant. Depth

of case and level of hardness were improved over

previous oil-quenched parts, and the fi re hazard was

eliminated.

Open Tank Quenching

Case History #3

Problem: A large forging company wanted to install

a 50,000-gallon quench system to heat treat both low

and high hardenability materials, without the hazards

associated with oil quenching.

Solution: Develop new heating processes that provided

for bath temperature and agitation rate changes, and

charge the quench system with UCON Quenchant HT.

Results: The company was able to run a broad range of

material chemistries in a single quench bath, without

sacrifi cing metallurgical properties. The wide variety

of low-to-high hardenability materials could not have

been heat treated properly in one oil quench system.

Case History #4

Problem: Large steel rings, weighing up to 62,000 lbs.

were forged from AISI 4340, 4140 and 4150 up to a

maximum diameter of 22 feet. This was a new process

and the fi re and environmental pollution problems

potentially encountered with quench oil presented an

unacceptable risk.

Solution: A 50,000 gallon tank of UCON Quenchant

HT (20–24%, 120°F) with a minimal temperature rise

was used.

Results: The expected physical properties with no

distortion and cracking problems were achieved.

Furthermore, no environmental pollution problems or

fi res were encountered with the use of UCON

Quenchant HT.

Case History #5

Problem: Carburized pinion gears weighing up to

30,000 lbs. and manufactured from AISI 4320 were

quenched in oil. However, local environmental regula-

tions would not allow the construction of another

production line because of unacceptable air pollution

problems.

Solution: The solution was to quench the pinion gears

into a well-agitated 35,000-gallon quench tank con-

taining a 22% solution of UCON Quenchant E at 120°F.

Results: The use of UCON Quenchant E to quench the

very large pinion gears produced physical properties

favorably comparable to those obtained previously

with no cracking or distortion while at the same time

eliminating the air and water pollution problems

encountered with quench oil.

27

Case History #6

Problem: A well-known oil tool manufacturer had

been using a polymer quenchant for over eight years,

but with only fair results. Cracking occurred with

certain steels, such as 9Cr, lMo and 410 and 416

stainless. When marquench salt was used as an

alternative, there was no cracking, but physical

properties were diminished. The company wanted

to fi nd a polymer quenchant for these materials that

would eliminate cracking and increase physicals.

Solution: Convert one of their pit quenching systems

to UCON Quenchant E.

Results: Materials such as 4140, 4142, and 4340

were run very successfully with no strict temperature

control. The 9Cr, lMo and 410 and 416 stainless steels

were quenched with a bath temperature of 125–135°F.

In all cases, there were no cracks and a defi nite

improvement in physical properties.

Case History #7

Problem: The same oil tool company as in Case

History #4 found that with their polymer quenchant

too many parts from the steel mill developed cracks

unless surface imperfections were removed prior

to quenching. They wanted to avoid the extensive

machining step.

Solution: Replace their old polymer quenchant with

UCON Quenchant E.

Results: Cracking was greatly reduced, and scrap costs,

which had been as high as $13,285 in fi ve months of

operation, dropped to $1,509 for a 12-month period.

Aluminum Quenching

Case History #8

Problem: A major airframe manufacturer wanted

to reduce the distortion caused by water-quenching

various thin-gauge aluminum aircraft parts.

Solution: Replace the water with UCON Quenchant A

to provide more uniform cooling.

Results: Quenched parts showed substantial

reductions in distortion, with improvements ranging

from 55 to 97 percent. Tensile and corrosion proper-

ties were maintained. Because hand straightening of

the sheet metal parts was virtually eliminated, the

company realized labor savings of $739,000 per year.

Case History #9

Problem: Aluminum pistons manufactured from

aluminum casting alloy 332 were solution heated in

a continuous furnace at 896°F (480°C). 1000 lb. load

(800 lbs. + 200 lbs. fi xtures) was quenched every 20

minutes in a 1100 gallon quench tank containing a

polymer quenchant not available in the USA. After

quenching the pistons were aged to a T6 condition.

Solution: An 18–22% of UCON Quenchant A was

used at a bath temperature of 90°C with good

impeller agitation.

Results: Excellent results were obtained with no

distortion or cracking, while meeting the manufacturer’s

recommended physical properties.

Induction Quenching

Case History #10

Problem: A customer wanted their vendor to induction-

harden low hardenability parts to a greater depth than

could be obtained with water or other quenchants.

Solution: Convert the submerged spray system to

UCON Quenchant A to produce faster cooling rates

and provide greater depth of hardening.

Results: Parts quenched with UCON Quenchant A

showed a great improvement in the depth of hardening,

as well as the level of hardness achieved.

28

Controllable Delayed Quenching

Case History #11

Problem: Many times quenching of medium alloy

steels such as AISI 4140 in oil does not produce the

desired uniformity of hardness or there is an excessive

hardness gradient from surface to core.

Solution: Research results have shown that

quenching of 2 inch AISI 4140 bars in 15% and higher

concentrations of UCON Quenchant E provided an

unusual but reproducible inverse hardening effect as

shown in Figure 17.

Results: Quenching of AISI 4140 in 20% UCON

Quenchant E at 40°C and 0.8 m/s agitation produced

signifi cantly greater bending fatigue after tempering

at 480°C for two hours than achievable with oil

quenching as shown in Figure 18.

Controllable delayed quenching (CDQ) conducted in

this way using UCON Quenchant E provides greater

depth of hardening, more uniform microstructure and

about 7 times greater bending fatigue strength.

Immersion Time Quenching Technology

Case History #12

Problem: Engine valves are produced using a die

manufactured from AISI H13 in direct forging process.

The dies were time quenched in a mineral oil quenchant

followed by air cooling. Typically, after forging and

quenching, the neck of the die is badly damaged from

wrinkling after production of approximately 1000 valves.

The die is repaired by removal of 0.6–0.7 mm of the die

neck. This process may be performed 15–16 times at

which point the die must be discarded. With 5 hot-

forging presses operating 24 hours a day, this is a

costly and wasteful process.

Solution: The oil quenchant was replaced by a 23.5%

aqueous solution of UCON Quenchant E at 33°C using

a batch Immersion Time Quenching System (ITQS).

Results: Although the oil quenched dies had undergone

a 0.05–0.07 mm reduction in diameter of the inner-hole,

no dimensional change was observed for the dies

produced using UCON Quenchant E. Furthermore, more

uniform hardness was observed (Rc=55-56) with the

dies quenched in UCON Quenchant E than with oil

quenching (Rc=53-55). The overall results showed that

no wrinkling was observed with the dies quenched

in UCON Quenchant E. The oil quenched dies had

to be discarded after the production of only 15,000

valves. The dies quenched in UCON Quenchant E could

be reused for the production of 150,000 valves, an

improvement of 100 times over the original process!

Figure 18 Test results of specimens with normal

and inverse hardness distribution

Figure 17 Normal hardness distribution (1) after

quenching in oil at 20°C without agitation; inverse

hardness distribution (2) after quenching in UCON

Quenchant E at 15% concentration, 40°C bath

temperature and 0.8 m/s agitation

AISI-4140Batch No. 73456

HRC HRC

55

50

1

R R

2

45

3/4R 1/2R 1/4R 1/4R 1/2R 3/4R050 mm Dia.

55

50

45

Number of cycles (N)

Nom

inal

Stre

ss [M

Pa]

No cracks

Fa

Test parameters:

S-N Curve

Fa = const.

500

400

300

200

1001e4 1e5 1e6 1e7

R = Fmin/Fmax = 0

Material: 42CrMo4 (AISI-4140)Kt = 1, 65

F

t

Stress Ratio R = �min / = 0�max

NormalInverse

29

Case History #13

Problem: AISI 1043 crankshafts, 17.8 and 18.4

kg, were heated to 850°C in a continuous furnace,

quenched in mineral oil, then tempered at 580°C and

610°C for the 17.8 and 18.4 kg crankshafts, respec-

tively. The challenge was to improve the quench

uniformity and reduce the distortion obtained using

this process.

Solution: The oil quench process was replaced by a

batch ITQS process using UCON Quenchant E under

the conditions shown in Figure 19.

Results: The data in Figure 19 shows that quenching

in UCON Quenchant E and a batch ITQS process will

produce more uniform hardness and less distortion

than achievable with a mineral oil quenchant.

93.59494.59595.59696.59797.59898.59999.5100

100.5HRB

SURFACE CORE SURFACE

Note: Improvementin hardness uniformityrelative to oil quench

Hardness check point (at intervals of 2mm)1

1

2

3

4

5 10 15 20 25 30

TestNumber

Conc. ( )

1. Total Quenching Time is 4 Minutes2. Total Bending Distortion Limit is 1.2 mm

4 Poly(alkylene glycol) 15 44 0.55 m/sec-20 sec-0.12 m/sec 0.5

3 Poly(alkylene glycol) 15.75 30 0.73 m/sec-20 sec-0.12 m/sec 0.5

Poly(alkylene glycol) 102 43 0.73 m/sec-110 sec-0.12 m/sec 0.95

Temp. (C) Agitation Bending(mm)

Oil Quench1 70 0.4 m/sec-Full-0.4 m/sec 0.6

0 0/

Figure 19 Crankshaft hardness and distortion results

Case History #14

Problem: Track (AISI 15B37) were produced in a direct

forge condition using a continuous ITQS process. The

problem was to identify conditions that would yield

uniform microstructure and cost reduction relative to

the conventional forge, quench and temper process.

Solution: The solution was to use UCON Quenchant E

at 35-40°C and an initial maximum agitation rate time

of 10 seconds.

Results: Excellent hardness uniformity (as shown in

Figure 20) was achieved. In addition to reduced crack-

ing, more uniform microstructure and substantial cost

reduction was achieved with the direct forge process

by quenching in UCON Quenchant E.

30

39.5

39.0

38.5

39.0

40.0

40.0

39.5 39.5

40.0

39.0

38.5

39.5

39.0

39.0

40.0

40.0

40.0

39.0

39.0

40.0

38.0

39.0

39.5

39.0

39.0

1

55

839.5 39.5

39.5

38.5

39.0

39.5

39.5

39.5

39.5

39.0

39.0

39.0

40.0

40.5

40.0

38.5

39.5

39.5

40.5

39.5

39.0

39.0

38.5

39.5

+

+

+

+40.0

40.5+

+

+

+

+

+

+39.5+

39.5+

39.5+

+40.5

+38.0

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

40.0

38.5

39.5

39.5

23

45

6

7

89

10

11

1213

1415

1617

1819

A B

20

10 10mm

C

Figure 20 Hardness distribution for track links

produced by the continuous ITQS process

Ecological Information

Table 12 Environmental Fate

Chemical Oxygen Biochemical Oxygen Demand (BOD) Test1, Demand (COD), % Bio-oxidation

Product mg O2/mg cpd Day 5 Day 10 Day 20

UCON Quenchant A 0.95 3 15 23

UCON Quenchant E 0.73 7 10 31

UCON Quenchant HT 0.92 2 18 18

UCON Quenchant RL 0.73 1 12 24

Ethylene Glycol Standard 1.30 72 96 94

Glucose/Glutamic Acid, Std. Soln. 300 mg/L 62 83 93

1 Bio-oxidation values, measures of biodegradability, are derived from the percentage ratio of Biochemical Oxygen Demand (BOD) and

Chemical Oxygen Demand (COD), according to procedures published in Standard Methods for the Examination of Water and Wastewater,

16th edition, Am. Public Health Assoc., Washington, D.C. (1985).

Table 13 Ecotoxicity Bacterial Inhibition, 48-hr LC50, Daphnia

Product IC50, mg/L magna, mg/L1

UCON Quenchant A >1000 4289

UCON Quenchant E >5000 9502

UCON Quenchant HT >1000 4287

UCON Quenchant RL >1000 5148

1 Measured by ASTM/EPA procedures for Daphnia magna toxicity tests. Reported LC50

calculated

by Spearman-Karber.

Similar results will be obtained with the XL quenchants.

31

Product SafetyWhen considering the use of UCON Quenchants for

an application, you should review our latest Material

Safety Data Sheets and ensure that the use you intend

can be accomplished safely. For Material Safety Data

Sheets and other product safety information, contact

your UCON Quenchants representative.

Toxicological InformationUCON Quenchants are water solutions of polyalkylene

glycols. In animal studies, these materials show a low

order of acute toxicity by swallowing or skin absorption.

They are not irritating to the skin or eyes. The poly-

alkylene glycols have very low vapor pressures and

are not inhalation hazards at room temperature.

Adequate workplace ventilation should be provided to

prevent irritation and accumulation of vapors; this may

require the use of a special, local ventilation system

in the immediate area where vapors are released. If

the quenchant is burned under conditions of relatively

complete combustion, the major products are carbon

dioxide and water vapor. If it is subjected to over-

heating (thermal degradation) but does not burn, the

degradation products can be such things as organic

acids (formic, acetic acids), aldehydes, esters, ketones,

etc. The vapors or fumes can be highly irritating to

the eyes, nose and throat. Special ventilation may be

needed. In normal use, no respiratory protective equip-

ment should be needed, but self-contained breathing

apparatus should be available for use in emergencies.

Small amounts of organic vapors can be formed by

oxidation of quenchants. These vapors can be irritating

or toxic if released in a poorly ventilated area; do not

allow vapors to accumulate. Good ventilation should

be maintained around quench tanks.

Dow recommends quenchant users read the latest

Material Safety Data Sheet for the specifi c product

toxicological properties.

Storage and HandlingUCON Quenchants are normally shipped, stored, and

handled in steel containers and equipment. They freeze

near 0°C and become highly viscous at temperatures

below about 20°C. Storage at room temperature is

suggested.

A centrifugal pump will be satisfactory for handling

viscosities up to 500 cSt. For higher viscosities, a

positive displacement pump is suggested. The pump

motor and recirculated diameter must be sized

adequately for the maximum viscosity expected to be

handled. For on-off service, full-bore ball valves will

minimize pressure drop in the piping system.

Since UCON Quenchants are comparatively safe to

store and handle, bulk storage tanks may be located

inside a building. If outside storage is planned, a

heated and insulated tank should be provided. The

storage tank can be vented directly to the atmosphere.

In prolonged and quiescent storage, evaporation and

condensation of moisture may cause a “lean” layer of

solution to form on the liquid surface. Thus, samples

should be taken from the bulk of the stored liquid and

not from the surface, or the liquid should be circulated

prior to sampling to assure uniformity.

32

Physical Properties

Polymer Concentration, % by Vol.0 5 10 15 20 25 30 35 40 45 50

Visc

osity

at 1

00 °F

, cSt

50

45

40

35

30

25

20

15

10

5

0

Viscosity / Concentration Relationshipfor UCON Quenchant A at 100°F

Temperature °F60 70 80 90 100 110 120 130 140

Spec

ific

Grav

ity, t

°F/6

0°F

1.04

1.03

1.02

1.01

1.00

.99

.98

Specific Gravities For Aqueous Solutions ofUCON Quenchant A

40%

30%

20%

10%

0%

UCON Quenchant A

Concentration Volume Percent*

*Concentration as determined by10440 refractometer, using 2.0 factor

Temperature °F60 70 80 90 100 110 120 130 140

Spec

ific

Heat

, BTU

/lb °F

1.00

.98

.96

.94

.92

.90

Specific Heats For Aqueous Solutions ofUCON Quenchant A

40%

30%

20%

10%

0%

UCON Quenchant A

Concentration Volume Percent*

*Concentration as determined by10440 refractometer, using 2.0 factor

Temperature °F60 70 80 90 100 110 120 130 140

Ther

mal

Con

duct

ivity

, BTU

/hr.

ft2 °F/

ft

.38

.36

.34

.32

.30

.28

Thermal Conductivities forAqueous Solutions of UCON Quenchant A

40%

30%

20%

10%

0%

UCON Quenchant A

Concentration Volume Percent*

*Concentration as determined by10440 refractometer, using 2.0 factor

33

Polymer Concentration, % by Vol.0 5 10 15 20 25 30 35 40 45 50

Visc

osity

at 1

00 °F

, cSt

50

45

40

35

30

25

20

15

10

5

0

Viscosity / Concentration Relationshipfor UCON Quenchant E at 100°F

Temperature °F60 70 80 90 100 110 120 130 140

Spec

ific

Grav

ity, t

°F/6

0°F

1.04

1.03

1.02

1.01

1.00

.99

.98

Specific Gravities For Aqueous Solutions ofUCON Quenchant E

40%

30%

20%

10%

0%

UCON Quenchant E

Concentration Volume Percent*

*Concentration as determined by10440 refractometer, using 2.5 factor

Temperature °F60 70 80 90 100 110 120 130 140

Spec

ific

Heat

, BTU

/lb °F

1.00

.98

.96

.94

.92

.90

Specific Heats For Aqueous Solutions ofUCON Quenchant E

40%

30%

20%

10%

0%

UCON Quenchant E

Concentration Volume Percent*

*Concentration as determined by10440 refractometer, using 2.5 factor

Temperature °F60 70 80 90 100 110 120 130 140

Ther

mal

Con

duct

ivity

, BTU

/hr.

ft2 °F/

ft

.38

.36

.34

.32

.30

.28

Thermal Conductivities forAqueous Solutions of UCON Quenchant E

40%

30%

20%

10%

0%

UCON Quenchant E

Concentration Volume Percent*

*Concentration as determined by10440 refractometer, using 2.5 factor

34

Polymer Concentration, % by Vol.0 5 10 15 20 25 30 35 40 45 50

Visc

osity

at 1

00 °F

, cSt

60

55

50

45

40

35

30

25

20

15

10

5

0

Viscosity / Concentration Relationshipfor UCON Quenchant HT at 100°F

Temperature °F60 70 80 90 100 110 120 130 140

Spec

ific

Grav

ity, t

°F/6

0°F

1.04

1.03

1.02

1.01

1.00

.99

.98

Specific Gravities For Aqueous Solutions ofUCON Quenchant HT

40%

30%

20%

10%

0%

UCON Quenchant HT

Concentration Volume Percent*

*Concentration as determined by10440 refractometer, using 2.0 factor

Temperature °F60 70 80 90 100 110 120 130 140

Spec

ific

Heat

, BTU

/lb °F

1.00

.98

.96

.94

.92

.90

Specific Heats For Aqueous Solutions ofUCON Quenchant HT

40%

30%

20%

10%

0%

UCON Quenchant HT

Concentration Volume Percent*

*Concentration as determined by10440 refractometer, using 2.0 factor

Temperature °F60 70 80 90 100 110 120 130 140

Ther

mal

Con

duct

ivity

, BTU

/hr.

ft2 °F/

ft

.38

.36

.34

.32

.30

.28

Thermal Conductivities forAqueous Solutions of UCON Quenchant HT

40%

30%

20%

10%

0%

UCON Quenchant HT

Concentration Volume Percent*

*Concentration as determined by10440 refractometer, using 2.0 factor

35

D

Insert handle full depthweld water tight

2D4D

Variable speed pump Drain

Resistance heater

Screen

Sleeve

Quench tankand equipment

Probe

Cooling coils

Figures 21 A Schematic illustration

of the quench system used to quench

the probes

Figures 21 B Schematic illustration of

dimensions of probes used to collect time-

temperature cooling curve data tabulated in

Tables 14–16

36

3. The hardnesses were calculated by Quench Factor Analysis as described in described the paper written by Bates, C.E. and Totten, G.E., entitled “Quench Severity Effects on the As-Quenched Hardness of Selected Alloy Steels”, Heat Treatment of Metals, 1992, 2, p 45-48.

Table 14 Cooling Rate Data—UCON Quenchant A

Circulation Polymer Probe Maximum Temp. at Max. Time from Cooling Rate at Cooling Rate at Cooling Rate at Film Rockwell Rockwell Rate1 Conc. Bath Temp. Diameter2 Cooling Rate Cooling Rate 1350°F–500°F 1300°F (704°C) 650°F (343°C) 450°F (232°C) Coeffi cient Hardness Hardness (732°C – 260°C) for 4140 for 1045

(ft/min) (%) (°F) (°C) (in.) (°F/sec) (°C/sec) (°F) (°C) (sec.) (°F/sec) (°C/sec) (°F/sec) (°C/sec) (°F/sec) (°C/sec) Steel3 Steel 3

50 5 110 43.3 0.5 376.50 209.17 1151.0 621.7 3.20 345.80 192.11 191.10 106.17 102.30 56.83 1380.40 58 59

50 5 110 43.3 1.0 117.10 65.06 1242.0 672.2 11.00 114.20 63.44 57.20 31.78 31.80 17.67 1359.20 57 47

50 5 110 43.3 1.5 55.50 30.83 1262.0 683.3 23.60 54.90 30.50 25.75 14.31 14.35 7.97 1191.70 56 34

50 5 110 43.3 2.0 32.30 17.94 1290.0 698.9 41.60 32.10 17.83 14.50 8.06 8.15 4.53 1054.40 55 23

20 10 90 32.2 0.5 322.20 179.00 1220.5 660.3 3.95 314.40 174.67 152.70 84.83 77.85 43.25 1185.10 58 58

80 10 90 32.2 0.5 355.90 197.72 1243.0 672.8 3.75 348.20 193.44 157.60 87.56 79.10 43.94 1378.30 58 58

20 10 130 54.4 0.5 215.40 119.67 946.0 507.8 6.20 60.40 33.56 138.10 76.72 70.50 39.17 130.20 58 53

80 10 130 54.4 0.5 316.40 175.78 1215.0 657.2 3.90 305.10 169.50 161.00 89.44 80.30 44.61 1054.40 58 58

20 10 90 32.2 1.0 107.60 59.78 1137.5 614.2 12.70 104.60 58.11 48.90 27.17 21.90 12.17 1108.10 57 46

80 10 90 32.2 1.0 145.10 80.61 1206.5 652.5 12.20 109.50 60.83 47.70 26.50 27.00 15.00 1244.40 57 47

20 10 130 54.4 1.0 96.30 53.50 940.5 504.7 15.45 28.80 16.00 49.45 27.47 22.20 12.33 121.70 57 39

80 10 130 54.4 1.0 102.65 57.03 1188.0 642.2 12.80 99.50 55.28 48.75 27.08 23.30 12.94 965.00 57 44

20 10 90 32.2 1.5 50.60 28.11 1286.5 696.9 26.80 50.00 27.78 22.75 12.64 10.60 5.89 883.20 56 32

50 20 110 43.3 1.0 98.20 54.56 1293.0 700.6 14.40 97.10 53.94 41.95 23.31 18.30 10.17 882.85 57 44

100 20 110 43.3 1.0 101.10 56.17 1252.0 677.8 14.20 99.65 55.36 42.05 23.36 20.80 11.56 961.20 57 44

50 20 110 43.3 1.0 55.20 30.67 822.0 438.9 26.30 15.05 8.36 39.55 21.97 16.60 9.22 70.30 56 27

50 20 80 26.7 1.5 47.75 26.53 1273.0 689.4 29.60 47.40 26.33 20.35 11.31 9.15 5.08 748.00 57 30

0 20 110 43.3 1.5 28.90 16.06 916.0 491.1 50.20 9.10 5.06 21.15 11.75 10.60 5.89 65.70 54 16

50 20 110 43.3 1.5 30.35 16.86 957.5 514.2 43.20 12.15 6.75 19.75 10.97 9.20 5.11 92.50 55 19

100 20 110 43.3 1.5 49.15 27.31 1297.5 703.1 30.00 48.80 27.11 19.25 10.69 10.35 5.75 815.90 56 30

50 20 140 60.0 1.5 26.00 14.44 870.5 465.8 57.20 9.70 5.39 18.90 10.50 8.55 4.75 69.85 53 14

50 20 80 26.7 2.0 28.75 15.97 1285.0 696.1 51.60 28.45 15.81 11.30 6.28 5.45 3.03 663.75 55 20

0 20 110 43.3 2.0 18.75 10.42 969.5 520.8 79.20 6.20 3.44 11.75 6.53 5.45 3.03 61.25 52 12

50 20 110 43.3 2.0 19.30 10.72 981.5 527.5 65.20 8.05 4.47 12.95 7.19 6.60 3.67 87.60 53 14

100 20 110 43.3 2.0 28.70 15.94 1303.0 706.1 52.80 28.45 15.81 10.80 6.00 5.75 3.19 661.20 55 19

50 20 140 60.0 2.0 17.10 9.50 909.0 487.2 88.40 6.65 3.69 10.95 6.08 4.75 2.64 66.10 51 11

80 10 90 32.2 1.5 52.20 29.00 1279.0 692.8 26.20 51.50 28.61 22.65 12.58 13.10 7.28 968.90 58 32

20 10 130 54.4 1.5 32.70 18.17 953.0 511.7 39.60 12.10 6.72 22.70 12.61 10.35 5.75 94.85 58 21

80 10 130 54.4 1.5 48.15 26.75 1256.0 680.0 27.80 47.25 26.25 21.60 12.00 11.30 6.28 738.60 58 31

20 10 90 32.2 2.0 27.30 15.17 1183.5 639.7 48.40 25.00 13.89 12.45 6.92 5.95 3.31 437.90 58 20

80 10 90 32.2 2.0 31.20 17.33 1292.0 700.0 45.80 30.70 17.06 12.80 7.11 7.80 4.33 875.00 57 21

20 10 130 54.4 2.0 22.25 12.36 1036.0 557.8 61.20 7.40 4.11 12.95 7.19 5.90 3.28 82.30 57 15

80 10 130 54.4 2.0 27.60 15.33 1253.0 678.3 49.00 26.10 14.50 12.20 6.78 6.90 3.83 522.25 57 20

50 20 80 26.7 0.5 227.10 126.17 1211.0 655.0 5.10 215.00 119.44 124.30 69.06 67.70 37.61 583.80 58 56

0 20 110 43.3 0.5 159.75 88.75 991.5 533.1 7.70 52.95 29.42 118.10 65.61 64.90 36.06 108.50 58 50

50 20 110 43.3 0.5 183.15 101.75 1050.5 565.8 5.75 149.50 83.06 122.30 67.94 56.90 31.61 345.05 58 54

100 20 110 43.3 0.5 288.60 160.33 1276.5 691.4 4.65 280.40 155.78 129.35 71.86 62.15 34.53 934.05 58 57

50 20 140 60.0 0.5 142.15 78.97 818.5 436.9 9.80 370.05 205.58 110.90 61.61 54.70 30.39 83.85 57 46

50 20 80 26.7 1.0 115.15 63.97 1145.5 618.6 12.10 108.20 60.11 49.30 27.39 26.20 14.56 1184.20 57 46

0 20 110 43.3 1.0 63.75 35.42 1055.0 568.3 18.20 31.65 17.58 40.90 22.72 20.95 11.64 137.05 57 37

20 30 90 32.2 0.5 117.20 65.11 746.5 396.9 12.00 30.10 16.72 102.80 57.11 53.45 29.69 67.00 57 42

80 30 90 32.2 0.5 266.60 148.11 1307.0 708.3 6.00 259.65 144.25 106.45 59.14 54.65 30.36 822.70 58 54

20 30 130 54.4 0.5 94.60 52.56 709.5 376.4 17.60 26.55 14.75 86.95 48.31 40.20 22.33 57.90 56 33

80 30 130 54.4 0.5 231.60 128.67 1212.0 655.6 7.00 207.65 115.36 89.10 49.50 40.85 22.69 549.60 58 53

20 30 90 32.2 1.0 43.45 24.14 794.9 423.8 26.05 23.65 13.14 34.70 19.28 16.60 9.22 115.95 56 28

80 30 90 32.2 1.0 54.30 30.17 1245.0 673.9 18.80 50.10 27.83 38.95 21.64 23.55 13.08 273.70 57 36

20 30 130 54.4 1.0 30.20 16.78 595.5 313.1 39.80 12.25 6.81 31.30 17.39 14.25 7.92 55.50 54 18

80 30 130 54.4 1.0 56.60 31.44 1414.0 767.8 23.85 49.45 27.47 30.55 16.97 17.75 9.86 178.35 56 31

20 30 90 32.2 1.5 23.30 12.94 837.0 447.2 66.00 8.70 4.83 18.50 10.28 11.15 6.19 61.95 52 12

80 30 90 32.2 1.5 43.65 24.25 122.5 50.3 32.45 42.70 23.72 18.40 10.22 9.35 5.19 555.10 56 28

20 30 130 54.4 1.5 23.30 12.94 812.5 433.6 83.20 8.00 4.44 15.70 8.72 7.85 4.36 56.10 50 11

80 30 130 54.4 1.5 19.90 11.06 813.0 433.9 61.20 10.95 6.08 16.40 9.11 9.65 5.36 80.60 53 13

20 30 90 32.2 2.0 17.90 9.94 923.0 495.0 89.60 6.85 3.81 10.85 6.03 4.90 2.72 70.10 50 11

80 30 90 32.2 2.0 24.05 13.36 1166.0 630.0 50.60 23.55 13.08 12.50 6.94 7.15 3.97 407.45 54 19

20 30 130 54.4 2.0 14.05 7.81 843.5 450.8 113.60 6.05 3.36 9.90 5.50 5.00 2.78 59.20 48 10

80 30 130 54.4 2.0 14.30 7.94 851.5 455.3 96.40 7.65 4.25 10.25 5.69 4.75 2.64 80.85 50 11

50 30 110 43.3 0.5 79.80 44.33 904.0 484.4 14.00 44.65 24.81 72.25 40.14 67.25 37.36 99.65 57 40

50 30 110 43.3 1.0 32.65 18.14 729.0 387.2 35.80 16.50 9.17 29.35 16.31 14.75 8.19 76.00 55 21

50 30 110 43.3 1.5 19.80 11.00 1142.0 616.7 71.20 10.45 5.81 14.62 8.12 8.55 4.75 78.60 52 12

50 30 110 43.3 2.0 14.55 8.08 1117.0 602.8 77.60 10.25 5.69 13.00 7.22 7.40 4.11 117.00 51 1

Note: The probes were austenitized at 1550°F (843.3°C) and quenched.

1. Circulation rate refers to axial fl ow through the tank illustrated in Figure 24A.

2. The probe used for this work was constructed from Type 304 stainless steel with a Type K thermocouple inserted into the geometric center. The probes were constructed with dimensions of an “infi nite cylinder” where the length is 4 times the diameter as illustrated in Figure 24B.

37

3. The hardnesses were calculated by Quench Factor Analysis as described in described the paper written by Bates, C.E. and Totten, G.E., entitled “Quench Severity Effects on the As-Quenched Hardness of Selected Alloy Steels”, Heat Treatment of Metals, 1992, 2, p 45-48.

Table 15 Cooling Rate Data —UCON Quenchant E

Circulation Polymer Probe Maximum Temp. at Max. Time from Cooling Rate at Cooling Rate at Cooling Rate at Film Rockwell Rockwell Rate1 Conc. Bath Temp. Diameter2 Cooling Rate Cooling Rate 1350°F–500°F 1300°F (704°C) 650°F (343°C) 450°F (232°C) Coeffi cient Hardness Hardness (732°C – 260°C) for 4140 for 1045 (ft/min) (%) (°F) (°C) (in.) (°F/sec) (°C/sec) (°F) (°C) (sec.) (°F/sec) (°C/sec) (°F/sec) (°C/sec) (°F/sec) (°C/sec) Steel3 Steel 3

50 5 110 43.3 0.5 300.00 166.67 1151.0 621.7 4.20 245.25 136.25 147.95 82.19 71.80 39.89 850.25 58 57

50 5 110 43.3 1.0 86.15 47.86 1137.0 613.9 14.00 64.45 35.81 50.55 28.08 22.25 12.36 372.20 57 43

50 5 110 43.3 1.5 46.70 25.94 1222.0 661.1 29.20 44.15 24.53 20.75 11.53 11.05 6.14 645.00 56 30

50 5 110 43.3 2.0 29.15 16.19 1290.0 698.9 49.60 20.15 11.19 11.65 6.47 6.55 3.64 708.80 55 20

20 10 90 32.2 0.5 262.20 145.67 1288.5 698.1 5.85 259.10 143.94 100.05 55.58 35.30 19.61 793.40 58 55

80 10 90 32.2 0.5 337.05 187.25 1253.5 678.6 4.95 333.95 185.53 112.80 62.67 51.95 28.86 1309.90 58 57

20 10 130 54.4 0.5 165.50 91.94 969.0 520.6 8.90 45.90 25.50 87.50 48.61 28.85 16.03 99.60 58 50

80 10 130 54.4 0.5 271.05 150.58 1290.0 698.9 6.00 268.20 149.00 97.50 54.17 41.95 23.31 853.90 58 55

20 10 90 32.2 1.0 85.50 47.50 1051.5 566.4 17.70 76.80 42.67 31.85 17.69 12.30 6.83 525.60 57 41

80 10 90 32.2 1.0 100.35 55.75 1293.0 700.6 15.60 99.30 55.17 35.85 19.92 19.45 10.81 959.40 47 43

20 10 130 54.4 1.0 63.75 35.42 1065.5 574.2 23.00 24.40 13.56 31.20 17.33 10.75 5.97 114.30 57 35

20 10 130 54.4 1.0 108.40 60.22 839.5 448.6 17.40 95.00 52.78 32.25 17.92 19.70 10.94 857.90 57 42

20 10 90 32.2 1.5 34.30 19.06 1084.7 584.8 42.60 19.95 11.08 14.65 8.14 6.35 3.53 149.65 55 *

80 10 90 32.2 1.5 47.10 26.17 1308.5 709.2 33.80 46.75 25.97 16.55 9.19 16.00 8.89 732.30 56 *

20 10 130 54.4 1.5 28.15 15.64 973.0 522.8 58.20 9.75 5.42 13.60 7.56 5.70 3.17 71.55 54 *

80 10 130 54.4 1.5 30.45 16.92 1051.0 566.1 42.00 21.15 11.75 15.00 8.33 8.25 4.58 180.30 55 *

20 10 90 32.2 2.0 22.60 12.56 1172.5 633.6 65.60 18.85 10.47 8.80 4.89 3.85 2.14 234.10 54 *

80 10 90 32.2 2.0 27.05 15.03 1301.0 705.0 58.20 26.70 14.83 9.60 5.33 6.00 3.33 551.60 54 *

20 10 130 54.4 2.0 18.10 10.06 1048.5 564.7 81.20 7.45 4.14 8.30 4.61 3.55 1.97 82.25 52 *

80 10 130 54.4 2.0 19.80 11.00 1148.5 620.3 66.40 16.00 8.89 9.05 5.03 5.15 2.86 197.70 53 *

50 20 80 26.7 0.5 234.85 130.47 1283.0 695.0 8.40 * * * * * * 915.50 58 52

0 20 110 43.3 0.5 98.90 54.94 726.5 385.8 16.35 28.50 15.83 85.95 47.75 28.50 15.83 62.70 57 35

50 20 110 43.3 0.5 169.30 94.06 1317.0 713.9 9.10 159.45 88.58 81.20 45.11 21.30 11.83 409.00 58 50

100 20 110 43.3 0.5 238.95 132.75 1210.0 654.4 7.90 213.25 118.47 88.90 49.39 38.40 21.33 695.05 58 54

50 20 140 60.0 0.5 80.70 44.83 717.5 380.8 15.30 38.10 21.17 69.15 38.42 20.10 11.17 84.20 57 38

50 20 80 26.7 1.0 71.80 39.89 1314.0 712.2 20.70 70.45 39.14 29.15 16.19 12.35 6.86 470.05 57 38

0 20 110 43.3 1.0 40.05 22.25 828.0 442.2 43.50 13.55 7.53 29.75 16.53 10.45 5.81 60.90 54 16

50 20 110 43.3 1.0 71.40 39.67 1368.5 742.5 24.60 67.45 37.47 27.15 15.08 9.60 5.33 498.55 57 35

100 20 110 43.3 1.0 49.90 27.72 1074.0 578.9 22.00 38.90 21.61 30.50 16.94 21.90 12.17 185.45 56 34

50 20 110 43.3 1.0 33.00 18.33 786.0 418.9 45.60 14.85 8.25 27.15 15.08 13.15 7.31 68.00 54 16

50 20 80 26.7 1.5 36.05 20.03 1143.0 617.2 42.50 30.60 17.00 14.00 7.78 6.55 3.64 426.40 55 *

0 20 110 43.3 1.5 23.45 13.03 841.0 449.4 68.40 8.70 4.83 20.20 11.22 12.85 7.14 61.45 51 *

50 20 110 43.3 1.5 36.00 20.00 1378.0 747.8 45.60 34.00 18.89 13.65 7.58 5.15 2.86 422.80 55 *

100 20 110 43.3 1.5 46.65 25.92 1306.0 707.8 39.20 46.15 25.64 13.75 7.64 6.55 3.64 711.60 56 *

50 20 140 60.0 1.5 23.15 12.86 716.0 380.0 69.20 9.25 5.14 22.20 12.33 13.50 7.50 66.00 51 *

50 20 80 26.7 2.0 24.30 13.50 1267.5 686.4 67.50 23.90 13.28 8.20 4.56 3.95 2.19 426.45 54 *

0 20 110 43.3 2.0 14.60 8.11 902.0 483.3 101.60 6.10 3.39 9.55 5.31 6.15 3.42 59.75 49 *

50 20 110 43.3 2.0 16.10 8.94 986.5 530.3 84.10 9.90 5.50 8.10 4.50 3.45 1.92 110.45 52 *

100 20 110 43.3 2.0 23.15 12.86 1189.0 642.8 61.80 22.40 12.44 9.90 5.50 6.20 3.44 393.80 54 *

50 20 140 60.0 2.0 14.55 8.08 1121.5 605.3 105.00 7.20 4.00 11.00 6.11 5.35 2.97 74.10 49 *

20 30 90 32.2 0.5 66.95 37.19 689.0 365.0 26.55 27.40 15.22 64.05 35.58 18.90 10.50 60.60 55 24

80 30 90 32.2 0.5 247.35 137.42 1255.5 679.7 9.60 232.85 129.36 62.60 34.78 34.40 19.11 668.00 58 50

20 30 130 54.4 0.5 59.10 32.83 533.0 278.3 33.60 24.65 13.69 51.60 28.67 45.25 25.14 54.70 54 *

80 30 130 54.4 0.5 110.45 61.36 1095.5 590.8 12.25 52.35 29.08 59.50 33.06 52.25 29.03 126.50 57 *

20 30 90 32.2 1.0 79.00 43.89 659.0 348.3 44.00 12.85 7.14 26.80 14.89 13.80 7.67 58.75 54 *

80 30 90 32.2 1.0 77.70 43.17 1392.0 755.6 25.65 75.50 41.94 23.30 12.94 21.05 11.69 536.75 56 *

20 30 130 54.4 1.0 32.00 17.78 997.5 536.4 63.60 12.30 6.83 24.25 13.47 24.75 13.75 55.90 52 *

80 30 130 54.4 1.0 66.90 37.17 1217.0 658.3 25.65 63.10 35.06 23.10 12.83 21.80 12.11 392.00 56 *

20 30 90 32.2 1.5 22.25 12.36 665.0 351.7 83.60 8.20 4.56 21.95 12.19 13.45 7.47 57.90 50 *

80 30 90 32.2 1.5 43.25 24.03 1305.0 707.2 36.60 42.05 23.36 17.90 9.94 13.50 7.50 550.20 55 *

20 30 130 54.4 1.5 19.60 10.89 618.0 325.6 96.40 7.75 4.31 19.25 10.69 13.25 7.36 54.25 49 *

80 30 130 54.4 1.5 18.95 10.53 664.5 351.4 64.00 9.75 5.42 18.80 10.44 12.85 7.14 70.45 52 *

20 30 90 32.2 2.0 15.40 8.56 759.5 404.2 108.00 7.15 3.97 13.65 7.58 7.55 4.19 74.10 48 *

80 30 90 32.2 2.0 17.25 9.58 1435.5 779.7 67.20 13.90 7.72 12.75 7.08 7.30 4.06 170.05 52 *

20 30 130 54.4 2.0 13.25 7.36 1062.5 572.5 127.20 7.00 3.89 12.65 7.03 7.55 4.19 70.50 46 *

80 30 130 54.4 2.0 14.10 7.83 1102.0 594.4 107.60 7.20 4.00 11.75 6.53 6.85 3.81 73.90 48 *

50 35 110 43.3 0.5 72.50 40.28 1006.9 541.6 20.20 32.25 17.92 46.15 25.64 28.75 15.97 73.95 56 34

50 35 110 43.3 1.0 28.50 15.83 1022.0 550.0 45.40 14.00 7.78 20.70 11.50 20.15 11.19 64.00 54 17

50 35 110 43.3 1.5 18.40 10.22 604.9 318.3 74.00 8.85 4.92 17.70 9.83 12.85 7.14 63.05 51 12

50 35 110 43.3 2.0 13.05 7.25 695.0 368.3 118.10 6.10 3.39 12.55 6.97 7.20 4.00 59.30 47 10

Note: The probes were austenitized at 1550°F (843.3°C) and quenched.

1. Circulation rate refers to axial fl ow through the tank illustrated in Figure 24A.

2. The probe used for this work was constructed from Type 304 stainless steel with a Type K thermocouple inserted into the geometric center. The probes were constructed with dimensions of an “infi nite cylinder” where the length is 4 times the diameter as illustrated in Figure 24B.

38

Table 16 Cooling Rate Data—UCON Quenchant HT

Concen- Bath Temp. Circulation Probe Maximum Temp. at Max. Time from Cooling Rate at Cooling Rate at Cooling Rate at

tration Rate1 Dia.2 Cooling Rate Cooling Rate 1350°F–500°F 1300°F (704°C) 650°F (343°C) 450°F (232°C)

(732°C–260°C)

(%) (°F) (°C) (ft/min) (in.) (°F/sec) (°C/sec) (°F) (°C) (sec.) (°F/sec) (°C/sec) (°F/sec) (°C/sec) (°F/sec) (°C/sec)

20 100 37.8 100 1 95.6 53.1 1279 692.8 13.75 93.16 51.8 45.34 25.2 29.24 16.2

20 120 48.9 100 1 90.2 50.1 1288 697.8 14.33 84.20 46.8 45.54 25.3 28.28 15.7

20 140 60.0 100 1 65.7 36.5 1155 623.9 17.39 58.61 32.6 38.36 21.3 23.86 13.3

25 100 37.8 100 1 74.8 41.6 1289 698.3 16.47 72.53 40.3 40.24 22.4 24.42 13.6

25 120 48.9 100 1 67.1 37.3 * * 17.42 63.31 35.2 38.35 21.3 23.63 13.1

25 140 60.0 100 1 59.2 32.9 1121 605.0 18.39 49.41 27.5 38.38 21.3 23.04 12.8

Note: The probes were austenitized at 1550°F (843.3°C) and quenched.

1. Circulation rate refers to axial fl ow through the tank illustrated in Figure 24A.

2. The probe used for this work was constructed from Type 304 stainless steel with a Type K

thermocouple inserted into the geometric center. The probes were constructed with dimensions

of an “infi nite cylinder” where the length is 4 times the diameter as illustrated in Figure 24B.

Table 17 Cooling Rate Data—Water and Selected Oils

Quen- Bath Temp. Circulation Probe Maximum Temp. at Max. Time from Cooling Rate at Cooling Rate at Cooling Rate at

chant Rate Dia. Cooling Rate Cooling Rate 1350°F–500°F 1300°F (704°C) 650°F (343°C) 450°F (232°C)

(732°C–260°C)

(°F) (°C) (ft/min) (in.) (°F/sec) (°C/sec) (°F) (°C) (sec.) (°F/sec) (°C/sec) (°F/sec) (°C/sec) (°F/sec) (°C/sec)

Water 80 26.7 0 1 108.0 60.0 1309 709.4 11.67 104.36 58.0 53.45 29.7 33.14 18.4

Water 100 37.8 0 1 104.6 58.1 1265 685.0 11.94 101.30 56.3 53.00 29.4 32.96 18.3

Water 120 48.9 0 1 102.0 56.7 1291 699.4 12.19 98.84 54.9 51.03 28.4 31.40 17.4

Water 140 60.0 0 1 92.3 51.3 1207 652.8 13.00 87.29 48.5 49.45 27.5 29.79 16.6

Fast Oil 150 65.6 100 1 73.6 40.9 1335 723.9 23.39 67.90 37.7 24.31 13.5 12.59 7.0

Conven-

tional Oil 150 65.6 100 1 60.8 33.8 1241 671.7 25.72 53.60 29.8 21.89 12.2 12.13 6.7

Martem-

pering Oil 300 148.9 100 1 63.4 35.2 1327 719.4 32.92 59.33 33.0 16.24 9.0 5.46 3.0

39

Table 18 Quenching Data for AA 7075-T73 using a Type I Aqueous Polymer

UCON Quenchant A (Solution Temperature 870°F)

Polymer Bar Bath Circulation Cooling Rate Film Quench Predicted

Concentration Diameter Temperature Rate Coeffi cient Factor Yield Strength

% (in) (°F) (ft/min) (°F/sec) (BTU/Hr.ft.°F) (KSI)

10 0.5 85 0 433.5 1210.0 2.56 68.5

10 0.5 85 50 458.1 1250.0 2.27 68.5

10 1 85 0 190.1 1232.5 5.81 67.6

10 1 85 50 195.2 1252.5 5.55 67.7

10 1.5 85 0 133.2 1275.0 8.90 66.8

10 1.5 85 50 129.7 1235.0 8.89 66.8

15 0.5 90 0 292.1 785.0 3.10 *

15 0.5 90 50 286.5 738.0 3.40 *

15 0.5 90 100 317.1 856.0 3.00 *

15 1 90 0 135.1 559.0 7.50 *

15 1 90 50 143.2 681.0 7.00 *

15 1 90 100 143.4 681.0 7.10 *

15 1.5 90 0 92.1 597.0 11.10 *

15 1.5 90 50 98.7 621.0 10.80 *

15 1.5 90 100 104.5 689.0 10.30 *

20 0.5 85 25 276.2 770.0 3.72 68.1

20 0.5 85 25 296.5 805.0 3.57 68.2

20 1 85 25 140.0 930.0 8.03 67.0

20 1.5 85 25 109.1 980.0 11.54 66.1

20 2 85 25 65.5 858.9 18.40 64.7

20 3 85 25 36.5 793.0 31.90 61.6

25 0.5 90 0 215.5 611.0 3.70 *

25 0.5 90 50 217.8 539.0 4.00 *

25 0.5 90 100 232.4 643.0 3.60 *

25 1 90 0 116.7 404.0 8.20 *

25 1 90 50 118.1 436.0 8.50 *

25 1 90 100 121.8 500.0 8.50 *

25 1.5 90 0 78.0 507.0 11.90 *

25 1.5 90 50 86.3 460.0 12.00 *

25 1.5 90 100 91.0 497.0 11.90 *

30 0.5 85 0 178.3 457.5 5.14 67.8

30 0.5 85 50 217.7 615.0 4.83 67.9

30 1 85 0 112.8 775.0 10.56 66.4

30 1 85 50 107.3 750.0 10.28 66.4

30 1.5 85 0 68.3 647.5 15.98 65.0

30 1.5 85 50 73.0 329.8 15.42 65.1

40

Table 19 Heat Transfer Coeffi cients for 20% Water Solution of UCON Quenchant A vs.

Probe Diameter [Bath Temperature 43°C., Agitation V = 0 m/s (no agitation)]

Probe Cooling Rate, (sec. -1)1 1300°F (704°C) 650°F (343°C) 400°F (204°C) �FB

Diameter 1300°F 650°F 400°F (in/m) (704°C) (343°C) (204°C) Kn Biv Kn Biv Kn Biv (W/m2K) 2

0.5 0.0432 0.230 0.166 0.0579 0.06 0.34 0.44 0.218 0.26 697

(.0127) 0.0379 0.210 0.157 0.051 0.052 0.31 0.206 0.24 604

1.0 0.0217 0.075 0.041 0.116 0.125 0.445 0.72 0.216 0.26 725

(.0254) 0.0252 0.077 0.044 0.135 0.15 0.457 0.23 0.28 870

1.5 0.081 0.039 0.027 0.098 0.11 0.52 0.93 0.32 0.43 426

(.0381) 0.0072 0.039 0.033 0.087 0.095 0.52 0.39 0.57 368

2.0 0.0053 0.0217 0.0135 0.114 0.124 0.515 0.90 0.28 0.36 360

(0.0508) 0.0051 0.0216 0.011 0.109 0.120 0.513 0.23 0.28 348

1. Cooling rate is the value “m” with units of sec-1 and is calculated from: m =

In(Ti – T

m) – In(T

2 – T

m)

where: T1 and T

2 are current temperatures, t

2 – t

1

Tm is the bath temperature and t is the time.

2. �FB

is in (W/m2K); FB = fi lm boiling.

Table 20 Heat Transfer Coeffi cients for 20% Water Solution of UCON Quenchant A vs.

Probe Diameter (Bath Temperature 60°C., Agitation V = 0.254 m/s)

Probe Cooling Rate, (sec. -1)1 1300°F (704°C) 650°F (343°C) 400°F (204°C) �FB

Diameter 1300°F 650°F 400°F (in/m) (704°C) (343°C) (204°C) Kn Biv Kn Biv Kn Biv (W/m2K) 2

0.5 0.032 0.218 0.1477 0.0428 0.043 0.323 0.44 0.23 0.28 499

(.0127) 0.033 0.222 0.136 0.044 0.045 0.328 0.21 0.21 500

1.0 0.014 0.08 0.049 0.075 0.08 0.475 0.76 0.306 0.40 464

(.0254) 0.0123 0.076 0.0385 0.066 0.07 0.451 0.24 0.30 406

1.5 0.0084 0.038 0.032 0.101 0.11 0.507 0.89 0.45 0.72 392

(.0381) 0.0084 0.038 0.023 0.101 0.11 0.507 0.89 0.32 0.43 392

2.0 0.0056 0.021 0.0134 0.120 0.125 0.498 0.86 0.33 0.44 363

(.0508) 0.0058 0.021 0.0127 0.124 0.13 0.498 0.86 0.317 0.42 365

1. Cooling rate is the value “m” with units of sec-1 and is calculated from: m =

In(Ti – T

m) – In(T

2 – T

m)

where: T1 and T

2 are current temperatures, t

2 – t

1

Tm is the bath temperature and t is the time.

2. �FB

is in (W/m2K); FB = fi lm boiling.

41

Table 21 Heat Transfer Coeffi cients for 30% Water Solution of UCON Quenchant A vs.

Sample Diameter (Bath Temperature 54.4°C., Agitation V = 0.1 m/s)

Probe Cooling Rate, (sec. -1)1 1300°F (704°C) 650°F (343°C) 400°F (204°C) �FB

Diameter 1300°F 650°F 400°F (in/m) (704°C) (343°C) (204°C) Kn Biv Kn Biv Kn Biv (W/m2K) 2

0.5 .0240 0.1890 0.1270 0.0316 0.032 0.249 0.30 0.167 0.19 372

(.0127) .0245 0.1960 0.1440 0.0322 0.034 0.258 0.32 0.189 0.22 395

1.0 .0114 0.0715 0.0521 0.060 0.063 0.376 0.54 0.274 0.348 366

(.0254) .0112 0.0696 0.0495 0.059 0.062 0.366 0.52 0.260 0.330 360

1.5 .0074 0.0352 0.0372 0.087 0.094 0.417 0.64 0.440 0.70 337

(.0381) .0074 0.0356 0.0335 0.088 0.095 0.422 0.65 0.347 0.59 341

2.0 .0055 0.0224 0.0229 0.116 0.125 0.472 0.78 0.480 0.80 363

(.0508) .0056 0.0224 0.0223 0.118 0.130 0.472 0.78 0.470 0.78 377

1. Cooling rate is the value “m” with units of sec-1 and is calculated from: m =

In(Ti – T

m) – In(T

2 – T

m)

where: T1 and T

2 are current temperatures, t

2 – t

1

Tm is the bath temperature and t is the time.

2. �FB

is in (W/m2K); FB = fi lm boiling.

Table 22 Heat Transfer Coeffi cients for 35% Water Solution of UCON Quenchant A vs.

Sample Diameter (Bath Temperature 43.3°C., Agitation V = 0.254 m/s)

Probe Cooling Rate, (sec. -1)1 1300°F (704°C) 650°F (343°C) 400°F (204°C) �FB

Diameter 1300°F 650°F 400°F (in/m) (704°C) (343°C) (204°C) Kn Biv Kn Biv Kn Biv (W/m2K) 2

0.5 0.034 0.133 0.0886 0.0456 0.048 0.197 0.23 0.138 0.15 557

(.0127) 0.040 0.128 0.0952 0.0536 0.055 0.189 0.22 0.146 0.16 638

1.0 0.0139 0.0556 0.0359 0.0745 0.08 0.33 0.45 0.224 0.27 464

(.0254) 0.0138 0.0524 0.0348 0.0740 0.08 0.311 0.40 0.217 0.26 464

1.5 0.0081 0.0272 0.0276 0.0978 0.105 0.363 0.52 0.388 0.56 406

(.0381) 0.0099 0.0272 0.0220 0.119 0.13 0.363 0.52 0.309 0.40 503

2.0 0.0073 0.023 0.0183 0.1566 0.18 0.546 1.05 0.457 0.74 522

(.0508) 0.01 0.0244 0.0196 0.214 0.26 0.579 1.15 0.489 0.82 621

1. Cooling rate is the value “m” with units of sec-1 and is calculated from: m =

In(Ti – T

m) – In(T

2 – T

m)

where: T1 and T

2 are current temperatures, t

2 – t

1

Tm is the bath temperature and t is the time.

2. �FB

is in (W/m2K); FB = fi lm boiling.

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fax 1-989-832-1465 call +32 3 450 2240 fax 60 3 7958 5598 fax 1-989-832-1465

fax +32 3 450 2815

www.ucon.comNOTICE: No freedom from any patent owned by Seller or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, Customer is responsible for determining whether products and the information in this document are appropriate for Customer’s use and for ensuring that Customer’s workplace and disposal practices are in compliance with applicable laws and other governmental enactments. Seller assumes no obligation or liability for the information in this document. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.

*Trademark of The Dow Chemical Company Form no. 118-01567-605AMS

*

Location Dow Products All Chemical Products (in case of emergency)

United States and Puerto Rico 800-DOW CHEM Phone CHEMTREC:

800-424-9300

Canada 519-339-3711 (collect) Phone CANUTEC:

613-996-6666 (collect)

Europe, Middle East, 49 41 469 12333 North and Central Africa

Latin America, Asia/Pacifi c, Phone United States:

South Africa, and any other 989-636-4400 (collect)

location worldwide

At sea, radio U.S. Coast Guard, who can directly contact:

Dow...800-DOW CHEM or CHEMTREC...800-424-9300.

DO NOT WAIT. Phone if in doubt. You will be referred to a specialist for advice.

Emergency Service

Dow maintains 24-hour emergency service for its products. The American Chemi-

cal Council (CHEMTREC), Transport Canada (CANUTEC), and the National Chemi-

cal Emergency Center maintain 24-hour emergency service: