[MikeK]

Chris,
Thank you for the additions. I do disagree with your statement #1. Although quenching is also done in case hardening treatments, the Ford process as stated does not, in any way produce any case as it does not specify any previous treatment to diffuse carbon or nitrogen into the matrix surface. No type of quench can do that. The caustic is specified simply because it has a heat transfer rate much greater than plain water. 10% caustic potash (KOH) has a 1.38 rate, 10% sodium hydroxide (NaOH) has a 2.06 rate. This is done to ensure through hardening with the relatively low alloy steel Ford used. The quench function is to rapidly form Martensitic structure from austenite before excess carbon has time to diffuse out and form cementite (Fe3C).