Frank Masyada invents new process

Thermal Cycling

Our facility located in Clearwater, Florida is recognized as the world’s leader in the practice and development of the Thermal Cycling Process. Developed by Frank Masyada in 1996 this advancement of the standard cryogenic process proved more consistent, more reliable and more effective on a wider variety of parts than the ‘Deep Cryogenic Process’.

Having used the deep cryogenic process for considerable time while working in engineering for a variety of fortune 500 companies I found to be very effective on specific expendable tooling components but also somewhat inconsistent. I would have a specific type of high quality end mill treated and it would show up to two to three times life increase one time and the next time I had the same, but new tools treated doing the same work the results would not be as good as the first treated tools. This characteristic was also evident when the cryogenic process was used as a stress relief process.

Doing considerable research (technical data available upon request) I discovered that the reasons for the inconsistent results were as much a fault of the process parameters as the inconsistencies in the metallurgical make-up of the products used for the working of the components (tools) and the components being worked (parts being machined, or parts under usage -engine components, guns, etc.).

The Deep Cryogenic Process as practiced today involves bringing the temperature of the cryogenic chamber to temperatures as low as negative 318 degrees F. The chamber may be brought down to this low temperature at from 1 to 3 degrees per minute, the parts will then be subjected to a prolonged ‘soak’ at the negative 318 F, the temperature will then be brought up to room temperature at 1 to 3 degrees per minute and in some cases subjected to a 300 degree F heat cycle.
The above is the standard deep cryogenic process as practiced today throughout industry. There may be some variation due to mass of load, material, etc., and these variations may bring the temperature down slower, or faster, maintain the soak longer or shorter, and the newest gimmick practiced by a number of companies is the “triple temper”.

I discovered a number of years ago that the inconsistencies in the cryogenic process were as a result of its consistency. That is the same rates of decent, the same degrees of soak were all used for a wide, and in some cases dramatically different type of materials, with an as diverse range of application and performance specifications.

Years ago the reason for treating components at cryogenic temperatures was the conversion of austenite to martinsite, years ago that argument was sound to a point but if a component had a greater than 10% retained austenite the cryogenic process could not convert that amount to a martisitec form. So the part still had some austenitic retention. Today most high quality tools have very little austenitic retention as a result of advances in heat treat. Parts may have 1% to 2 % austenite, which may have no effect on the performance or life.
Life and performance improvements in tools, engine parts, weapons, carbide, PCD’s and certain polymers are improved as a result of changes in yield, tensile, induced compressive stresses, reduced natural frequencies, improved bonding strength and greater adhesion of coatings to metals.

In developing the Thermal Cycling Process I discovered that bringing the temperature of materials to the temperatures that standard cryogenics soaks the parts at has no, or little positive effects on the factors and material restructuring at the molecular or nuclear level that will positively effect the performance of the part. As a matter of science the temper that is normally used, plus 300 degrees F has absolutely no effect to the component, and the ‘triple’ temper that is used by some dealers has three times less effect and is a serious waste of time and effort. I would ask that you take a high quality machine tool and subject it to a temperature of plus 300 for a couple of days. You will find that the only change you made to that tool is that it is hot when you take it out and no metallurgical change has taken place.

Each family of materials has a specific series of temperatures ranges that cause the greatest amount of restructuring at the molecular and atomic level. When materials are put through these temperature swings (Thermal Cycling) stresses are induced or reduced, tensile and yield increase, natural frequencies can be changed and surface bonding is increased. In developing the Thermal Cycling process I determined that by soaking a part in the standard deep cryogenic process in effect you were simply making a frozen part colder, at some level during the temperature decent to soak all restructuring activity ceased.

“Thermal Technology Services” has discovered the ranges for materials that continually causes the structural activity to be at its maximum movement, until the entire component has the benefits of the process. This is obvious and can be demonstrated by a simple comparison of subjecting the same type parts to both processes and creating a test to determine the most effective process.