CaseMaster Evolution Spare Your Time, Save Your money when carburizing within state of the art furnace

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Carmel Clark
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1 CaseMaster Evlutin Spare Yur Time, Save Yur mney when carburizing within state f the art furnace

PRESENT GENERATION OF SEALED QUENCH FURNACES ecnmic generatin f sealed quench furnaces Aviatin Autmtive

Technlgies High-temperature carburizing by Lw pressure carburizing by FineCarb Bright hardening Oxidatin in the

Pwer Type Size W [mm] H [mm] L [mm] [kg] [kw] 4 300 300 80 40 6 250 70 9 150 12 800 1200 1200 240 15 0 0 1500

heating system available as an ptin pictrial view.

Prfessinal Service & Advice ent Cmmitment Reliable & Prven Slutins 2 Stable Market Psitin T Triple chamber fr

2 PRESENT GENERATION OF SEALED QUENCH FURNACES ecnmic generatin f sealed quench furnaces Aviatin Autmtive Machine-building Bearing Cmmercial Heat Treating Industry thrugh Evlutin t the Perfectin in carburizing Aplicable Technlgies High-temperature carburizing by Lw pressure carburizing by FineCarb Bright hardening Oxidatin in the preheating chamber Annealing Tempering CaseMaster Evlutin MAIN TECHNICAL DATA FOR STANDARD APPLICATIONS Weight Pwer Type Size W [mm] H [mm] L [mm] [kg] [kw] Custmized versin can be prduced t the furnace chamber dimensins requested by custmer There is gaz heating system available as an ptin pictrial view. Knw-Hw w Versins Available Custmer Satisfactin 4/7 Service 24/7 rience Lng Experience Why Sec/Warwick? Prfessinal Service & Advice ent Cmmitment Reliable & Prven Slutins 2 Stable Market Psitin T Triple chamber fr cntinuus wrk flw with additinal chamber dedicated separately fr: Pre-heating, pre-xidatin, Pre-heating with pre-nitriding acc. t technlgy, High Pressure Gas Quenching D Duble chamber fr batch (In &Out) wrk prcessing, 3

special steels High-speed & ecnmic prcess

mediums Nminal temperature up t 1320 C +

Quench allw fr: Shrter carburizing cycle

int the wrklad & high dissciatin rate in

emissin, n exhaust hds, lack f atmsphere t

idling perids, quick start up & shut ff f

safety imprvement due t lack f flammable

meets AMS2750D, AMS 2759, BAC 5621, PN-EN

3 Main Advantages f CaseMaster Evlutin furnaces Unifrmity and high quality f parts fllwing heat treatment High temperature carburizing fr the typical & special steels High-speed & ecnmic prcess perfrmance Very lw cnsumptin f prcessing mediums Nminal temperature up t 1320 C + FineCarb as an equipment f furnaces type CaseMaster Evlutin in cmparisn t cntrlled-atmsphere furnaces type Sealed Quench allw fr: Shrter carburizing cycle time because f very high carbn transitin int the wrklad & high dissciatin rate in the pertinent temperature ranges f up t 1050 C Greater repeatability results in terms f parts and wrklads N CO/CO 2 emissin, n exhaust hds, lack f atmsphere t utilize N Endthermic generatrs N furnace idling perids, quick start up & shut ff f the furnace, Prcess flexibility Wrkplace safety imprvement due t lack f flammable prcess gases Clean, nn-txic wrk envirnment Easy & intuitive prcess cntrl Oil r Gas quench features Reductin f distrtin and their repeatability Prcess simulatrs & fully autmated prcessing Flexibility, n furnace idling perids, quick start up & shut dwn f the furnaceing The furnace meets AMS2750D, AMS 2759, BAC 5621, PN-EN 98/37, PN-EN Very shrt wrklad transprt time within the furnace, fast pening & clsing f internal dr Cmpact and mdular design New design f an il circulatin system enabling maximum unifrmity and rate f cling 4 5

FineCarb lw pressure carburizing technlgy SimVac carburizing and quenching simulatr Lw pressure carburizing is characterized by an extrardinarily high cefficient f carbn transfer.

This means that, in the case f thin carburizatin layers, the prcess is cnsiderably faster than the gas carburizing prcess. The advantage is smaller in the case f thick layers that exceed fr example,.

The lw pressure carburizing prcess may easily be carried ut even at temperatures f up t 1050 C (1 F), within the natural temperature range f a vacuum furnace.

3 60 Jamasc steel /Case depth t 0.3%C [mm] 0.5 0.7 0.9 Case depth t 0.3%C [mm] 2.0 1.6 1.3 1.

perate within a temperature range f 880-930 C (1-1700 F). Operating at higher temperatures results in shrter carburizing cycles due t the cnsiderable increase f the diffusin cefficient (DC).

4 FineCarb lw pressure carburizing technlgy SimVac carburizing and quenching simulatr Lw pressure carburizing is characterized by an extrardinarily high cefficient f carbn transfer. In the initial phase f carburizing, fr example, at the temperature f 950 C (1740 F), the carbn stream directed at the charge surface reaches the rate f 250 g/m 2 h. This means that, in the case f thin carburizatin layers, the prcess is cnsiderably faster than the gas carburizing prcess. The advantage is smaller in the case f thick layers that exceed fr example, inches (0.8 mm), where the carbn transfer is much mre dependent n the diffusin cefficient (DC). The lw pressure carburizing prcess may easily be carried ut even at temperatures f up t 1050 C (1 F), within the natural temperature range f a vacuum furnace. The prcess temperature increases up t C ( F), where in cmparisn the traditinal gas carburizing prcesses typically FineCarb carburizing temp. [ O C] Jamasc steel /Case depth t 0.3%C [mm] Case depth t 0.3%C [mm] Time carburizing+diffusin [min] FineCarb - The methd f Carburizing Steel in an Oxygen Free Atmsphere Under Lw Pressure µ m INTERNAL OXIDATION NO INTERNAL OXYGEN perate within a temperature range f C ( F). Operating at higher temperatures results in shrter carburizing cycles due t the cnsiderable increase f the diffusin cefficient (DC). Bth the increased amunt f carbn in the carburizing atmsphere, and faster diffusin (Dc) are respnsible fr the increase f efficiency during vacuum carburizing when cmpared t the traditinal gas carburizing. Apprximate duratin f vacuum carburizing prcess fr 16MnCr5 steels, crrelated t the temperature and the required thickness f the A HT layer Purity f prcess because f multicmpnent carburizing gases mixture Excellent carbn penetratin when carburizing densely packed lads & cmplex shaped wrkpieces r blind hles parts Repeatable & high-speed prcessing Very lw cnsumptin f carburizing gases Better quality thanks t N grain bundary xidatin & precise case unifrmity Prcess-simulatin sftware package, SimVac (carburizing & gas quench simulatr), Simplicity f carburizing f Aircraft & Ally Steels i.e.: Pyrwear Ally 57, M-50 NIL, SAE 9310, Ferrium C61 ally etc. Cmpatible with NADCAP High carbn ptential f carburizing gas mixture (C 2 H 2, C 2 H 4, H 2 ) Green manufacturing prcess n CO 2 emissin This prcess simulatin sftware package enables t design and simulate the carburizing SimCarb and quenching prcesses SimHard, prir t running trials. Optimal design and checking f prcess parameters, will help t save the real prcess time and t avid having scrapped parts. Optimal segment planning f carburizing prcess, divided int: carburizing and diffusin stages Calculatins based n steel grade, size and shape f parts as well as cling prfile fr hardening Autmatic r manual simulatin mde f peratin Simulated carbn prfile cmparisn Intuitive graphical interface Cmpatible with SecVac furnace cntrl system GAS CARBURIZING 20 VACUUM CARBURIZING Cmparisn f carburizing prcesses 6 7

5 high Speed and ecnmic vacuum carburizing Pre-nitriding fr lw pressure carburizing,, allws the expansin f the applicatins f FineCarb family f Vacuum Carburizing Technlgy tward higher carburizing temperatures and wider range f steel grades. is a mdern, fast and ecnmic alternative f lw pressure carburizing, which allws t significant intensify this prcess. Thrugh dsing f the nitrgen carrier during cntrlled heat up ramp, the furnace can run at higher temperatures (0 C and abve), while maintaining a fine grain structure within the Technical Benefits TEMPERATURE [ C] PRENITRIDING AMMONIA DOSING TIME HYDROCARBONS DOSING TIME 300 chart acc. t 200 technlgy. Efficiency increase depending n Effective Case case. The strength prperties are similar t wrk that has been cnventinally carburized at lwer temperatures. This technlgy saves prcess csts by reducing the carburiz- BOOST DIFFUSION TIME BOOST DIFFUSION ing cycle time and reducing the cnsumptin f prcess gases (C 2 H 2, C 2 H 4, H 2, NH 3 ) as measured in liters and nt, as in the case f cnventinal technlgies, in cubic meters per hur. QUENCHING Ecnmical Benefits is a unique prcess ffering ttal value in bth cst f peratin and prcess efficiency: Reduce Carburizing Cycle Time Lwer Prcess Cst N intergrannular xidatin Excellent Unifrmity Optimum carbn penetratin N CO 2 emissins Envirnmentally-friendly Fr every prcesses (i.e. fr 0,6mm ECD) accrding t traditinal carburizing methds, technlgy can ffer yu up t 40% in increased prcess efficiency. Optimum carbn penetratin allws efficient heat treatment f cmplex shapes and the densely packed lads with superir case unifrmity. This technlgy is adaptable t bth new and existing furnaces equipped with FineCarb technlgy and may be equipped with either an il r gas quench. NUMBER OF PROCESSES [%] effective case depth & applied technlgy (Cnventinal, ) Utility cst (electricity, carburizing g Prcess time Cnventinal 920[ C] Cnventinal 920[ C] [ C] Prcess efficiency reductin [ C] Prcess flw 980[ C] 1030[ C] Depth The greater case depth, the greater prfits increase PROCESS DATA: 0 C, 1 h, 18CrNiM7-6 26,2 µm 1,26 mm GRAIN SIZE CASE DEPTH 13,1 µm finer grain 1,47 mm larger case depth RETAINED AUSTENITE PROCESS DATA: 1050 C, 18CrNiM % CARBIDES PROCESS DATA: 1050 C, 16MnCr5 15 % less retained austenite less carbides Prfits increase up t [%] Utility csts [%] reductin Cnventinal 920[ C] 980[ C] 1030[ C] evaluated n the time & utility cst reductin when precesses depending n applied technlgy carburizing acc. t Ttal prcess time reductin (Cnventinal, depending n the ) 8 9

SecVac autmatic cntrl systems Auxiliary equipment Aspects f maintenance and

management f emergency situatins Autmatical generatin f predefined reprts

f user access levels Custm setup f all data analysis charts and printuts Full

management Operatin time cunters, ability t plan peridic reviews Viability

cunter, with an ptin t be infrmed f the need t supplement Tw-stage warning

& Lw tempering furnaces Washing machines External Clsed Lp Water Cling System

expsed t the high temperatures, i.e. heating chamber casing, cnvectin fan mtr, pwer feedthrugh etc.

Advanced Prcess Management (Unlimited number f recipes) System resistance t the

cmpany management systems Data security - different levels f user s access

autmatin f the prductin Prgrammable by a calendar delayed start f the prcess

infrmatin Applicatin brwser prvides read nly access t data Advantages: Lack f

parameters (hardness, temperature) at a preset, cnstant level Extensin f the

6 SecVac autmatic cntrl systems Auxiliary equipment Aspects f maintenance and cntrl Functinal, simple t use, intuitive system Full visualizatin, cmprehensive management f emergency situatins Autmatical generatin f predefined reprts (graphical & numerical versins) and their exprt t external files The hierarchy f user access levels Custm setup f all data analysis charts and printuts Full integratin with SCADA sftware n need f extra sftware Aspects f peratin management Operatin time cunters, ability t plan peridic reviews Viability mnitring f the thermcuples Histry f peratin f the equipment Media cnsumptin cunter, with an ptin t be infrmed f the need t supplement Tw-stage warning alarm clr cding allws immediate identificatin f alerts Easy system backups High & Lw tempering furnaces Washing machines External Clsed Lp Water Cling System The CLWS is designed t cllect the heat frm all elements f the furnace which are expsed t the high temperatures, i.e. heating chamber casing, cnvectin fan mtr, pwer feedthrugh etc. The CLWS includes amng thers: clant tank, pump assembly, heat exchanger, instrumentatin, etc. Aspects f prductin technlgy A friendly prgramming f the machining prcess Advanced Prcess Management (Unlimited number f recipes) System resistance t the wrng technlgical prgrams Aspects f management Integratin with the superir cmpany management systems Data security - different levels f user s access Optimizatin f prductin n the basis f cllected infrmatin Wrk time saving by autmatin f the prductin Prgrammable by a calendar delayed start f the prcess with an ptin f GSM ntificatin Lng-term data lgging and remte access t archived infrmatin Applicatin brwser prvides read nly access t data Advantages: Lack f waste water, Stable temperature f the f ce skin Maintenance f cling medium parameters (hardness, temperature) at a preset, cnstant level Extensin f the life f the furnace equipment items which require cling Emergency water supply fr charge & furnace prtectin Mbile lading and unlading machines Lading trays Gas buffer tanks Others 10 11

Systems for Industrial Automation

Systems for Industrial Automation Systems fr Industrial Autmatin The industrial autmatin system is a cmbinatin f sftware, hardware and cmmunicatins infrastructure that allws real-time data acquisitin frm the prductin prcess and its management