Flash Bainite

8/3/2019 Flash Bainite

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Rapid Heating & Water QuenchingLow, Medium, & High Carbon Steel

80ms Bainite Transformation


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My name is Gary M. Cola, Jr.

BSME, Lawrence Institute of Technology in Southfield,Michigan in 1988

The next 4 years, I developed Monte Carlo 3-

Dimensional tolerance analysis software.

As a consultant, I reviewed manufacturing concerns onprojects such as the FEAD belt alignment of the firstViper engines at JTE, Ford engine imbalanceharmonics, GM tire clearance modeling through thesuspension and body, and the ink alignment of Xeroxsfirst successful prototype color copier.

I started Master CNC, a machine shop, in 1993 to servethe Metro Detroit Tooling Industry.


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Flash BainiteFlash Bainite SFP W or k s, LLCSFP W or k s, LLChas developed an evolutionary,has developed an evolutionary,

new Maximum Strength Steel microstructurenew Maximum Strength Steel microstructurewithwith never be fo r e seen neve r be fo r e seen m echan i ca l p rope r t i es m echan i ca l p rope r t i es ..

Flash Bain i t e Flash Bain i t e combines the most desiredcombines the most desiredmechanical properties of todaymechanical properties of todays bests best

commercial martensitic and bainitic highcommercial martensitic and bainitic highstrength steelsstrength steels an dan d develops some of its own.develops some of its own.

Flash Ba in i t e Pr ocess ingFlash Ba in i t e Pr ocess ing challenges 75 years ofchallenges 75 years ofmetallurgical know ledge to create themetallurgical know ledge to create the s t r o n g e s t ,s t r o n g e s t ,m ost du ct i le , r ead i l y w e ldab le,m ost du ct i le , r ead i l y w e ldab le, LEAST EXPENSIVELEAST EXPENSIVEMa x i m u m St re n g t h St eel ev e r ,Ma x i m u m St re n g t h St eel ev e r , in just 3 secondsin just 3 seconds

w/w/ little energylittle energy and minimal capital equipment.and minimal capital equipment.


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S i m p l e M u l t ii m p l e M u l t i -Pa t e n t Pe n d i n ga t e n t Pe n d i n gF l a s h P r o c e s s i n g A p p a r a t u sl a s h P r o c e s s i n g A p p a r a t u s

Sheet Feed RollersSheet Feed Rollers

Highly Energy EfficientHighly Energy EfficientOxy/Propane RapidOxy/Propane RapidAustenizing HeatersAustenizing Heaters

Environmentally FriendlyEnvironmentally FriendlyFlowing Water QuenchFlowing Water Quench

Sheet Draw RollersSheet Draw Rollers (I(I--Beam,Beam,Tubing, Wire, etc possible)Tubing, Wire, etc possible)

Already Recognized by worldAlready Recognized by worlds leadings leadingResearchers, Universities, and IndustryResearchers, Universities, and Industry


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The time betweenThe time betweenthe Bainite Start (Bs)the Bainite Start (Bs)and Finish (Bf)and Finish (Bf)temperatures istemperatures is

interpreted to be 80interpreted to be 80milliseconds.milliseconds.

Neither isothermalNeither isothermal

holding (TTT) norholding (TTT) nortraditional continuoustraditional continuouscooling (CCT) occurscooling (CCT) occursduring this bainiticduring this bainitic

transformation.transformation.

Flash Bainite has been created in common steels withFlash Bainite has been created in common steels withcarbon contents ranging from 0.04% to 0.74%wt.carbon contents ranging from 0.04% to 0.74%wt.

Sixteen vastly different low, medium, and high carbonSixteen vastly different low, medium, and high carbonsteels have an almost identical instantaneoussteels have an almost identical instantaneoustransformation curve.transformation curve.


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AISI8620 Flash Bainite (left) compared to austemperedAISI8620 Flash Bainite (left) compared to austempered

86208620 alloy walloy w/ 1.7%wt/ 1.7%wt cobaltcobalt & 0.6%wt& 0.6%wt aluminum (right).aluminum (right).

Note theNote the complete transformation of Flash Bainite.complete transformation of Flash Bainite.

A

ISI86

20

8

620CO

ALflash austemper

The 8620 alloy, even with Co and Al added to accelerateThe 8620 alloy, even with Co and Al added to acceleratenucleation, still yields an incomplete transformationnucleation, still yields an incomplete transformation

matrix with weak retained austenite.matrix with weak retained austenite.

d h b


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Vehicles 100s of pounds lighter AND safer.Vehicles 100s of pounds lighter AND safer.

May07 Automotive Eng Int printed that by MY2012, 56%of vehicle steel will be


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AustemperingAustemperingvsvsFlash ProcessingFlash Processing Typically 30 minutes toTypically 30 minutes to

commercially process partscommercially process parts

Costly thermal energy toCostly thermal energy to

heat 15 minutes@1600heat 15 minutes@1600FF 650650F molten salt quenchF molten salt quench

consumes yet more energyconsumes yet more energy

Limited to small parts dueLimited to small parts dueto oven/salt bath sizeto oven/salt bath size

Incomplete transformationIncomplete transformation

creates weak retainedcreates weak retainedausteniteaustenite

Typical successfullyTypical successfully

austempered mediumaustempered mediumcarbon steels weld poorlycarbon steels weld poorly

Just a few secondsJust a few seconds Minimal thermal energy toMinimal thermal energy to

instantly heat 1800instantly heat 1800--23502350FF

Water quench isWater quench isenvironmentally friendlyenvironmentally friendly

Very wide parts of almostVery wide parts of almost

infinite length possibleinfinite length possible Complete transformationComplete transformation

increases hardnessincreases hardness

Low, medium, and highLow, medium, and highcarbon steels readilycarbon steels readily

convert toconvert to Flash BainiteFlash Bainite

Low carbon steels areLow carbon steels arereadily weldablereadily weldable


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Variable Thickness Blanks w ithVariable Thickness Blanks w ith

Patterns of M icrostructurePatterns of Microstructure

Highly austenized steelHighly austenized steel

stretches easily. With drawstretches easily. With draw

control, multiple thicknessescontrol, multiple thicknesseswith abrupt or taperedwith abrupt or tapered

changes can be created.changes can be created.

By controlling localized heatBy controlling localized heatintensity, multiple differingintensity, multiple differing

microstructures can result.microstructures can result.

Unheated areas leave millUnheated areas leave mill

spec properties unchanged.spec properties unchanged.

Both techniques can beBoth techniques can beapplied in combination.applied in combination.


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Flash Proc essed Bain i t ic AISI8620has a t t a ined 2 4 5 .7 K S I (1 8 0 0 M Pa )

w hile m a in t a in ing 7 . 3 % e longat ion .AND ret a ins 65% o f i t s s t rengt h a f t e r

m u l t ip le t herm al c yc les t o 1000F.Knowing how parts arepressure formed, think

what can be done witha 0.20%wt carbonBainitic Steel that is

still >150KSI after beingfully tempered at thesteel mill and then

Warm Formed.Note: AISI8620 is not even a steeldesigned to re-harden upon air cooling.


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Die QuenchingDie QuenchingvsvsWarm FormingWarm Forming

5 minute heat to 18005 minute heat to 1800FF

Deep vertical sectionsDeep vertical sections

do not quench properlydo not quench properlydue to poor die contactdue to poor die contact

Quality control for safetyQuality control for safety

critical parts is done bycritical parts is done bychecking Rockwell Cchecking Rockwell C

UntemperedUntempered martensitemartensite

The cost/availability ofThe cost/availability ofBoron steels and dieBoron steels and diequenching is?quenching is?

Much lower formingMuch lower formingtemperaturestemperatures

Microstructural qualityMicrostructural qualitycontrol at steel millcontrol at steel mill

Fully tempered bainiteFully tempered bainite

Secondary operations forSecondary operations formultiple hits,multiple hits, restrikesrestrikes,,flanging, and hemmingflanging, and hemming

AgainAgain, any low, medium,, any low, medium,or high carbon steelor high carbon steelreadily transforms toreadily transforms toFlash BainiteFlash Bainite


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AISI4130 Flash Bainite with Tensile Strength ofAISI4130 Flash Bainite with Tensile Strength of

268.5KSI(1850MPa) @ 6.3% Elongation, taken268.5KSI(1850MPa) @ 6.3% Elongation, taken

midmid--section from an 8mm thick bar.section from an 8mm thick bar.


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Pieces of steel can be weldedtogether and then Flash Processed.

Both the joined components and the

Weld Seam become Flash Bainite.Flash Bainitehas fullynucleated in the weldseams from 1mm to 8mmthick thus far.

Matching chemistry, weldseam strength maintains93% of that of adjacent

mill spec steel withNO Heat Affected Zone.


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AISI4130 Flash BainiteAISI4130 Flash Bainite Weld SeamWeld Seam with Strengthwith Strength

of 249KSI(1717MPa) @ 3.4% Elongation, takenof 249KSI(1717MPa) @ 3.4% Elongation, taken

midmid--section from an 8mm thick bar.section from an 8mm thick bar.

A bli f H d d


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Assemblies of HardenedSteel are currently

constructed of many smallerpanels

Many thick contoured soft pieces can now bewelded together andtransformed into a Single Panelof Strong,

DuctileFlash Bainitewith NO Heat Affected Zones

Rivets, Bolts, & Welding are justa few of the ways

45% Stronger than Current Steel Armor


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TARDEC, OEMS, & AUTOSTEEL have seen usTARDEC, OEMS, & AUTOSTEEL have seen usGreat Interest & Testin is UnderwaGreat Interest & Testin is Underwa

Armor P late, Slat Armor, Ax les, Frame Rails,

Drive Shafts, Springs, Tubular Spaceframes,Cables, Perimeter Fences, Guard Shacks,

45% Stronger than Current Steel Armor


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VehiclesVehiclessometimessometimescarry acarry a

much heavier burden thanmuch heavier burden thanthey were initially designed for.they were initially designed for.

Sheet, plate, bar, and hollowSheet, plate, bar, and hollow

tubing have been transformedtubing have been transformed

intointo Flash Bainite.Flash Bainite.

Preformed 60Preformed 60--80KSI frame rails80KSI frame railscould becould be Flash ProcessedFlash Processed intointo

160 to 270KSI, and stil l retain160 to 270KSI, and stil l retain

7.5% Reserve Elongation.7.5% Reserve Elongation. OxyOxy--propane flames are justpropane flames are just

one way to rapidly heat steel.one way to rapidly heat steel.

Heat/ Quench from only oneHeat/ Quench from only oneside, including w ater spray.side, including w ater spray.


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Current/ Future CapabilitiesCurrent/ Future Capabilities

Soon We WillSoon We Will

0.25mm to 25mm thick?0.25mm to 25mm thick?

3/ 43/ 4diameter tubingdiameter tubing

Width to match machineWidth to match machinesize and heating methodsize and heating method

w ith unlimited lengthw ith unlimited length

Induction heatInduction heat Replace Laser WeldedReplace Laser Welded

blanks on componentsblanks on components

Components w ithComponents w ithmicrostructurallymicrostructurally

patterned crumple zonespatterned crumple zones

Thick Welded AssembliesThick Welded Assembliesw ithout weak HAZsw ithout weak HAZs

Now We CanNow We Can

Flash Process 1mmFlash Process 1mm--2.5mm2.5mm

thick by 75mm w ide by thethick by 75mm w ide by the

length of the coillength of the coil

OR 8mm thick by 33mmOR 8mm thick by 33mm

wide by length of the barw ide by length of the bar

Continuously vary the FlashContinuously vary the Flash

Processed steelProcessed steel s gauges gauge

Create patterns of differentCreate patterns of different

steel microstructures bysteel microstructures by

varying heat intensityvarying heat intensity

BUT prototype throughBUT prototype through--putput

is limited by a two stageis l imited by a two stage

oxyoxy--propane regulatorpropane regulator

Ho m ch in o r World is made of Steel?How much in our World is made of Steel?


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How much in our World is made of Steel?How much in our World is made of Steel?

Sheet, plate, bar, and tubing have beenSheet, plate, bar, and tubing have been

transformed totransformed to Flash Bainite.Flash Bainite.

Angles and IAngles and I--beams are simple. The Blue Water Bridgebeams are simple. The Blue Water Bridge

shows the strength of old steel (back)shows the strength of old steel (back) vsvs current steelcurrent steel

(fore).(fore). Flash BainiteFlash Bainiteis far stronger than both,is far stronger than both, withwithductility!ductility!


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Flash Proc esses havepat ent s pending inm ore t han 95% o f t he

indus t r ia l w or ld.The basic technology is

already globally knownandready to be applied for veryreasonable terms, far lessthan the total savings that

will be realized.


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What is Next?What is Next?

Vehicles could be made many hundredsVehicles could be made many hundredsof pounds lighter, saving hundreds ofof pounds lighter, saving hundreds of

dollars in steel costs alone.dollars in steel costs alone.

The technology has now gone far beyondThe technology has now gone far beyondProof of Principle. Parts must be made.Proof of Principle. Parts must be made.

Vehicles must be tested.Vehicles must be tested.

Flash Bainite is the very product that theFlash Bainite is the very product that theUS Automotive and Steel Industries haveUS Automotive and Steel Industries havesought for the last 20 years.sought for the last 20 years.

Strength Ductility & Benefits ofStrength Ductility & Benefits of


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Strength, Ductility, & Benefits ofStrength, Ductility, & Benefits of

Titanium at the Cost of SteelTitanium at the Cost of Steel TitaniumTitanium--38644 density38644 density

is 61% that of Steelis 61% that of Steel

Widely used TitaniumWidely used TitaniumAlloys have 150Alloys have 150--180KSI180KSITensile Strength.Tensile Strength.

High Strength TitaniumHigh Strength TitaniumAlloys maintain 6 to 8%Alloys maintain 6 to 8%elongation (stretch).elongation (stretch).

BUTBUT 20x the cost of Steel20x the cost of Steel

29% of available reserve29% of available reserve

isis under Russian Control.under Russian Control. White Glove WeldingWhite Glove Welding

Low CarbonLow Carbon Flash BainiteFlash Bainitehas attained 245has attained 245--270KSI270KSITensile Strength withTensile Strength with6.3 to 7.3% elongation.6.3 to 7.3% elongation.

270KSI x 61% density ratio270KSI x 61% density ratio

= 165,000 pound load= 165,000 pound load

At the same mass and onlyAt the same mass and only61% part volume, the61% part volume, the

strength and ductility ofstrength and ductility ofFlash BainiteFlash Bainitematchesmatchesthat of High Strengththat of High StrengthTitanium Alloys at aTitanium Alloys at afraction of the cost and thefraction of the cost and thefamiliarity offamiliarity ofSTEEL.STEEL.


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There are a great many

ways to prevent carbondioxide emissions.

Some are just easier,and far less costly, toimplement than others.


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Flash Bainite is the Strongest, Most

Ductile, yet Inexpensive Steel ever.Flash Bainite is made w / l itt le energyfrom low grade steel in just 3 seconds.Flash Bainite is as strong and ductileas Titanium Alloys at 20x less cost.Armor can be made much stronger,Combat Systems w il l weigh far less,

and soldiers w ill be better protected.Vehicles 100s of Lbs Lighter

Generate Far Less CO2

Using Less Foreign Oil.

CongressionalCongressionalFundingFundingis Neededis Needed

MichiganMichigans owns ownIndependentIndependentSFP Works LLCSFP Works LLCneneedsedsAllies toAllies to

helphelpDetroit Jobs,Detroit Jobs, thetheUS,US, & the World.& the World.


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Low Grade Steel into Strongest EVER

3 Second Process, Very Eco-FriendlyGary M. Cola, [email protected]

Cell: (586) 453-4090Fax: (586) 752-7161

11825 29 Mile RoadWashington Twp,__

Michigan 48095

Steel as Strong as Titanium

Flash Bainite

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