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TOP-FTEMP: Monitoring and Control of Forging Temperature

REV:03/22/14

SCOPE: This procedure covers the monitoring and control of furnace and billet temperatures. It does not cover manually-controlled preheat furnaces which operate well below hot forging temperatures.

STEP WHO WHEN INFO TO USE WHAT TO DO RESULTS
1 All production workers Constantly Personal observation Watch color and behavior of steel to be sure not overheated (not white, no sparks or bubbling in still air); if there is any reason to suspect that the induction heaters' pyrometers are not operating properly, immediately report to Forging Production Supervisor or Leadman; If need to make adjustments on furnace temp controls, report to Forging Production Supervisor or Leadman; IF OVERHEAT, STOP PRODUCTION AND REPORT IMMEDIATELY TO FORGING PRODUCTION SUPERVISOR OR LEADMAN TO INITIATE STEP 7. Constant visual observation
2 Forging Engineer Whenever changes are needed to Forging Material Reference List (Steel Info) in tooling program Customer purchase order; raw material supplier; Material Grade Report Enter new grade and forging temperature into tooling program; notify QA Assistant supplying forging temperature, temperature tolerance, and emissivity. Forging Material Reference List (Steel Info) kept updated
3 QA Assistant When receive notice of changes to Forging Material Reference List Forging temperature, temperature tolerance, and emissivity of new grade specified by Forging Engineer Make changes to Forging Material Reference List as required. Forging Material Reference List updated
*For steps 4 and 5, it is mandatory that anyone using a pyrometer must sign it out, and back in on the Sign Out Sheet for Pyrometers in the QC Supervisor's office
4 QC Specialist or QC Inspector As new jobs are started (or early each shift for continuing jobs) Own readings; forging temperature guidelines from Tooling Info; Jobs info (if includes forging temperature) With the emissivity set per Forging Material Reference List (if not noted the setting should be 0.85) use hand-held pyrometer* to measure temperature of forging billet between furnace and hammer; record reading per TOP-PROQC; if reading outside of forging temperature guidelines (or Jobs info), report immediately to Forging Production Supervisor (if not available, to Production Leadman, QC Supervisor or QA Manager). Regular review of temperatures
5 Maintenance Man Once a day and as requested by Forging Production Supervisor or Production Leadman Own readings For each hammer in operation: make sure reject gates are mechanically functional; use hand-held optical pyrometer* with the emissivity per Forging Material Reference List (if not noted the setting should be 0.85) to check the consistency of gas furnace hearth temperatures (at least 3 spots across hearth, all within 75° F of each other) and to check the accuracy of induction heater pyrometers (readings within 50°F of the hand-held pyrometer); record results on Furnace Temperature Log; if results fall outside these ranges, report immediately per TOP-BRKDN ; and to Forging Production Supervisor, QC Supervisor, and/or QA Manager; if have any reason to suspect the possibility of overheating, report immediately to Production Supervisor, QC Supervisor, and/or QA Manager. If adjustments need to be made to furnace temp controls, make adjustments and lock (possibly locked with passwords); forward Furnace Temperature Log to Maintenance Supervisor. Furnace controls monitored; Furnace Temperature Log to Maintenance Supervisor; furnace temp controls safeguarded from unauthorized
6 Maintenance Supervisor Each production day Furnace Temperature Log Review day's Furnace Temperature Log; if Furnace Temperature Log is not turned in, instruct Maintenance Man to proceed immediately per step 5 of this TOP and consider invokingTOP-ENFRC. Furnace Temperature Log to file; daily update of Temperature Log assured; compliance with TOP assured
7 Forging Production Supervisor or Leadman Randomly, or as requested

Personal observation; any observations or data from above steps; Forging Material Reference List (Steel Info) Review any measurements presented; visually check color and behavior of steel (not white, no sparks or bubbling in still air); Make sure pyrometer is properly aimed at the billet; report any malfunctioning induction heater pyrometers per TOP-BRKDN; and to QC Supervisor or QA Manager; IF need to make adjustment on Furnace temp controls, report to Maintenance Department; If quality forgings cannot be produced at recommended maximum forging temperature production calls: Manufacturing Manager or QC Supervisor, and a representative from the engineering department to determine the next step. Compare furnace pyrometer reading with the QC hand-held pyrometer. Proper settings on the hand-held pyrometer are verified (measuring distance & emissivity) IF OVERHEAT, STOP PRODUCTION, NOTIFY QC SUPERVISOR, SEPARATE OUT ANY FORGINGS WHICH MAY HAVE BEEN OVERHEATED, IDENTIFY THOSE WHICH ARE KNOWN OVERHEATS. Random review of temperatures; follow-up of reports of overheating; control of overheats; Maintenance informed of needed adjustments on Furnace temp controls
8 QA Manager If possible overheats reported Discussions; personal investigation Determine scope of problem and scrap all questionable parts if cost of testing not justified; if justified, have samples heat treated if required by Job Order, then send samples out for destructive testing to determine if internal damage (excessive grain growth or grain boundary precipitates) may have occurred; if so, scrap all questionable parts and submit findings as a Corrective Action Report (see TOP-CARRR); if testing results okay, return parts to normal process and notify Materials Manager with approval to use elevated temperatures on future orders. No parts suspected of possible overheat damage accepted without representative testing; any lab results to QC files; Materials Manager notified
9 Forging Engineer Upon notification that the forging temperature needs to be changed for a particular grade of material Notification Update Trinity Forge material information. Trinity Forge material information kept updated

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