Product Range. Fire Resistant Hydraulic Fluids. Heat Treatment Drawing Rolling Hot Products. Forging. Cutting Coolants. Die-Casting.

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1 Enhancing The Quenchant Performance By P.K.Deval Hardcastle Petrofer Pvt. Ltd

2 Contents About Hardcastle Petrofer Quenchant Performance - Criteria Restoration/Repair of Degraded Quenchant Up gradation of Quenchant Performance Methodology Case Studies

3 ABOUT HARDCASTLE PETROFER Joint Venture with Petrofer, Germany Manufacturing f t i Facilities at Gujarat and J & K ISO 9001 and ISO certified company Wide Product Range

4 Product Range Fire Resistant Hydraulic Fluids Heat Treatment Drawing Rolling Hot Products Compounds Oils Forging Cutting Coolants Cleaners Rust Preventives Die-Casting Products

5 Our Focus.. To provide Quality Solutions to the Customers through our Products and Services

6 Our Services Selection of the Right Product Development of customized products In-situ modification of quenchants Technical support on system related aspects Application support Condition monitoring of our products Design support for quench systems Filtration of used oil

7 Types Of Quenchants Water Water Quenching Additives Quenching Oil Polymer Quenchants Molten Salt Baths Molten Metal Baths Gases

8 Quenchant Performance Criteria Achievement of desired properties Metallurgical and Dimensional Achievement of desired finish Longer service life Less drag-out or consumption costs Consistency of quenched results Absence of quench cracks Reduced rework or rejection costs Optimum cycle time

9 Performance Enhancement Restoration / Repair of Degraded Quenchant Up gradation Of Quenchant Performance

10 Quenching Oil Degradation Indicators Sludge Formation Contamination by scales, water, soot Increase in acid value / saponification value Depletion of additives Increase/ decrease in viscosity / Flash Point

11 Quenching Oil Degradation Effects Poor Finish Loss of Quench Severity Inconsistent Results Distortion and Cracking Poor Cleanability High Drag Out

12 Quenching Oil Degradation Remedies Settling Filtration / Centrifuging Oil Refining Addition of additives

13 Quenching Oil Degradation Corrective / Preventive Actions On-line filtration / centrifuging Periodic cleaning of heat exchanger Periodic cleaning of tanks Control of Oil Temperature

14 Polymer Quenchant Indicators Foul Smell Reduced ph Change of colour Degradation Increase in Solution Hardness Increase in electrical conductivity Change in refractometer factor Increased tramp oil content

15 Effects Polymer Quenchant Degradation Increased Quench Severity Inconsistent Results Corrosion of tank / quenched parts Stickiness Distortion and cracking

16 Remedies Polymer Quenchant Degradation Tank Cleaning / Sanitisation Addition of additives Correction factor for refractometer Maintain higher concentration Change the bath

17 Polymer Quenchant Degradation Corrective / Preventive Actions On-line filtration Installation of oil skimmer Periodic cleaning of tanks Control of water quality Agitation when not in use Regular monitoring of bath

18 Upgradation of Performance To Improve. Quench Severity Surface Appearance Distortion Control Metallurgical Properties

19 Methodology Lab Analysis of Tank Sample Review & Analysis of Data Development Work Production Trials Formulation For Top-ups Control & Monitoring

20 Case Studies

21 In-situ Upgradation Of Quenchant

22 Customer : Background Manufacturer & 100% Exporter of Gears for Trucks and Tractors. Process : Carburising i in Sealed Quench Furnace Quenchant : Medium speed Quench Oil HQ M

23 Problems Faced Low Core Hardness & Surface Bainite In case of some Heavy Sectioned Gears

24 Root Cause Analysis Data Collected From Production Log Books Inspection Reports Microstructure Study Cooling Curve Analysis of Quenching Oil

25 Development Work Additive Package Designed Cooling Curve Analysis Before & After

26 Results Additive Package Added In-situ Additive Addition Under Supervision Quench Results Satisfactory t Special Product developed for Top-ups Satisfied Customer

27 Case Study I Bright Quenching Of Marquenched Parts Case Study

28 Customer Background Reputed Automobile Manufacturer using HIQUENCH MT 650 satisfactorily since 94. Process Carburised in SQF and CGC Furnaces Quenching in HIQUENCH MT 650 Oil Temp. 120 in CGC, in SQF

29 Problem Faced Dark appearance of quenched components High dirt count of the components Manual cleaning / buffing required The problem was more severe in CGC furnace.

30 Analysis Process Approach Study of the process Study of system parameters Discussions with customer

31 Factors Identified System Related Quenchant Related

32 System Improvements On-line 20 Micron filter installed Pre-cleaning started with our HICLEAN L2 Post Quench Cleaner changed to HICLEAN L2 Furnace soot blowing frequency and procedure improved Furnace Controls improved Shifted to better quality LPG

33 Product Upgradation Additive package designed d Simulated lab trials taken Additive added in quench tank

34 Result Significant improvement in the surface appearance achieved Millipore value improved from 8-10 mg to 4-6 6mg Satisfied Customer New product developed HIQUENCH MT 640 BQ

35 Conclusion It is possible to Enhance Quenchant Performance With Systematic Approach & User Supplier Collaboration

36 QUERIES ARE WELCOME

37 Thank You!

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