NGC Gears, a manufacturer of wind power gearboxes, has completed the installation of two additional Endothermic generators from a manufacturer with North American locations.
UPC-Marathon, a Nitrex company, installed the Endo generators at NGC Gears‘ its new facility in Jinhu, China. This acquisition brings the total of generator sets to five since 2022, collectively generating an impressive 800 m³/h (22,252 ft3/h) capacity of Endothermic gas supplied to carburizing and hardening furnaces used for processing various gear components. The latest installations in February and March of 2024 support the heat treating operations of the company’s wind energy gearbox production.
NGC’s decision to expand capacity is in response to the growing demand for wind power solutions in China and globally. The new Endothermic gas generating systems will significantly enhance the company’s production capabilities, enabling NGC to meet increasing market needs with greater efficiency and reliability.
EndoFlex generators from UPC-Marathon (Source: Nitrex)
EndoFlex offers precise control of production media to the carburizing and hardening environments, leading to higher quality gear production with improved longevity and performance. The result is improved carburizing and hardening processes, higher-quality hardened gears, reduced operating costs, and increased efficiency, as well as immediate cost savings through reduced electricity and gas consumption and minimized waste.
Johnny Xu, general manager at UPC-Marathon China, shared, “The latest EndoFlex investments align with NGC’s development of low-consumption, high-efficiency gearbox products for large-scale onshore and offshore wind turbines.”
This press release is available in its original form here.
Kuźnia Jawor, a company specializing in the production of hot forged and CNC machined components for the automotive, machinery, mining, and piping industries, has enhanced its manufacturing capabilities through the addition of an oil-hardening furnace and two nitriding furnaces from a supplier based in North America.
Kuźnia Jawor replaced their production line with an oil-hardening furnace and two outdated nitriding furnaces from Nitrex. The decision to upgrade was prompted by the need to eliminate outdated technology and address controls issues. The current production line has been designed using a Nitrex nitriding system and a vacuum hardening furnace.
Kuźnia Jawor leverages its in-house capabilities to design and manufacture forging tools, a crucial element of the production process. This is necessary for obtaining repeatable strength parameters in steel and ensuring their resistance to geometric changes or abrasive wear, factors that are addressed through heat treatment. The new equipment enables them to actively reduce CO emissions, decrease energy consumption, and more.
Nitrex furnace
The company’s forging and CNC processes are marked by meticulous precision, with dies initially undergoing treatment in the vacuum furnace before proceeding to the nitriding phase. This multi-step approach is essential for achieving a zero-white layer, effectively preventing surface cracking in the H11, H13, and WNL hot work steel dies subjected to high-pressure hammer forging. A crucial part of this initiative was the installation of a Nitrex horizontal-loading system, featuring the furnace model NXH-9912, a custom solution designed to facilitate the seamless automatic transfers of loads between operations.
The turnkey system is equipped with Nitreg® nitriding technology, which enhances the wear and corrosion resistance of treated tooling. This technology improves efficiency gains, leading to savings in process time and resources, including electricity and process gases. Furthermore, the system adheres to industry standard 2759/10 controlled nitriding, ensuring the highest quality and precision in the heat treating process.
Interestingly, Kuźnia Jawor is also engaged in an ongoing collaborative research and development project with a local university, exploring hybrid coatings that combine Nitreg® nitriding technology with PVD and CVD processes, with the aim of further enhancing tool performance.
Located in the southwestern region of Poland, Kuźnia Jawor is a provider of forged and CNC automotive parts within Poland and mining parts in international markets such as Czechia and Türkiye.
Marcin Stokłosa, Nitrex Technical Sales Manager, NITREX Poland (Source:LinkedIn.com)
Marcin Stoklosa, manager of Technical Sales at Nitrex, who oversaw this endeavor, sums it up, “Kuźnia Jawor’s choice to partner with Nitrex was driven by the need to replace outdated equipment, modernize, and expand their production facility. The result? Improved quality, enhanced performance, and a stronger position in the forging industry.”
An electric box furnace, currently headed to a Midwest equipment provider, will ultimately be installed at a Snap-on production facility that services tool and die support within the company’s production line.
The model QDD29 economical dual-chamber heat treating and tempering oven from L&L Special Furnace has a compact over/under design that saves floor space and provides reliable heat treating in-house.
QDD29 economical dual-chamber furnace (Source: L&L Special Furnace)
The top chamber is primarily deployed for heat treating tool steels at temperatures up to 2200°F; the tempering chamber is suited to temperatures up to 1250°F and has a recirculation baffle that makes it suitable for small aluminum work as well. The hardening and tempering chambers have interior dimensions of 12” wide by 8” high by 24” deep, with total external dimensions of 55” wide by 70” tall by 56” deep.
The QDD29 is controlled with digital single setpoint controls along with overtemperature protection. Solid-state relays drive the heating elements in a control circuit.
This press release is available in its original form upon request.
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Vacuum heat treat operations expand for ZDT Glimag, an entity providing services in the field of vacuum heat treatment, laboratory tests, and production of parts for mining machines.
The addition of this Vector® vacuum furnace will be the third vacuum furnace from SECO/WARWICK. The current design has an operating space of 600 x 600 x 900 mm and will be equipped with numerous options to allow a wide range of heat treatment processes for various steel grades. Main processes will include vacuum brazing, FineCarb® vacuum carburizing, and high-pressure hardening. The design of the chamber size will enable efficient heat treatment of large packages of test and research elements.
The efficiency of processes is also influenced by the ability to cool at 15 bar (which, unlike the old furnaces, eliminates the need to wash the parts after the process). In combination with inverter control, the system also helps reduce power consumption peaks, which are so problematic today. Another big advantage is low heat losses and appropriate temperature uniformity in the heating chamber, which is resistant to rapid wear and is easy to use and service.
Beata Kowalewska President of the Management Board – Financial Director of ZDT Glimag Source: LinkedIn
Beata Kowalewska, president of the Management Board – Financial Director of ZDT Glimag, comments: “Since the 1960s, we have been designing prototypes, conducting research and technological tests, and implementing new technologies for mining. We are currently in the process of materializing the project titled ‘Implementation of an innovative product resulting from research and development work: a brake pad with a composite friction layer with increased abrasion resistance,’ implemented under the European Funds for a Modern Economy (FENG) 2021-2027 Program. FENG is a program supporting entrepreneurs in the area of broadly understood innovation. It places great emphasis on R&D activities.”
He continues, “The new SECO/WARWICK furnace fits perfectly into the policy of broadly understood modernity implemented in this project. It will streamline and expand the scope of heat treatment processes and improve their economics, taking into account energy savings and the graphite chamber efficiency. It will also ensure the process cleanliness and velocity. With the FineCarb® vacuum carburizing option, the technology also increases our flexibility and research capabilities. Additionally, this technology will allow us to perform more difficult processes requiring extremely low contamination levels, thanks to the ability to obtain the appropriate vacuum needed for these processes.”
Maciej Korecki VP of the Vacuum Furnace Segment SECO/WARWICK Source: SECO/WARWICK
Maciej Korecki, VP of the Vacuum Furnace Segment in the SECO/WARWICK Group, comments on ZDT Glimag saying, “It is a center very well oriented in the metal heat treatment industry, constantly testing new, innovative solutions that in turn make the mining industry more efficient. The new Vector will introduce revolutionary changes in the hardening plant, introducing innovation and a very wide range of precise processes.”
The Vector® line vacuum furnaces can be used in most standard vacuum carburizing, hardening, tempering, annealing, supersaturation, and brazing processes. At the same time, the solution can be adapted to the recipient’s individual requirements, and therefore to a specific industry, an attribute necessary for research centers that test innovative solutions for external customers.
The solution‘s characteristic features are convection heating, i.e., a system improving the heat transfer efficiency when heating at lower temperatures, and directional cooling, which allows complex, flimsy, and long elements to be cooled in various ways, minimizing their deformations. An additional advantage is the vacuum carburizing option, which allows users to carry out precise processes to increase the steel surface hardness (carburizing) during the entire thermal process.
The original press release from SECO/WARWICK Group is available here.
Nucor-Yamato Steel Company beam mill in Blytheville, AR, will expand their in-house heat treat with 180-shtph walking-beam furnace, as well as ancillary upstream & downstream material handling equipment.
The reheating furnace from Danieli Centro Combustion will deliver thermal efficiency and minimum environmental impact through low carbon footprint and NOx emissions.
The solution includes a material handling layout to be executed in phases, which will allow Nucor-Yamato to maintain production using the existing furnace without any major interruptions. This will mean minimal changes to the existing layout, enabling the use and retention of most of the existing equipment until the new equipment is installed.
The furnace has patented Hydro-Mab burners capable of firing up to 100% H2 for potential “Zero CO2” emissions and is expected to be operational by the Spring of 2025.
A technology research institute has chosen a heat treat vacuum furnace which will support research and development in the fields of materials engineering and machine construction and operation.
SECO/WARWICK will supply a Vector® vacuum furnace with high-pressure gas hardening and will include options for vacuum carburizing, pre-nitriding for carburizing technology, low-pressure nitriding (LPN), and low-pressure carbonitriding (LPCN).
This configuration provides precision performance in vacuum, ensuring steel detail surfaces are protected, and the ability to carry out hardening processes through the use of high cooling gas pressures (15 bar).
The small vacuum furnace will have a working space of 400x400x600 mm. With a round heating chamber, the furnace, despite its small size, can be used to test and perform research on many sizes of parts including work with large dimensions.
Says Sławomir Woźniak, CEO of the SECO/WARWICK Group, "We cooperate with scientific institutions all over the world because we are aware that industry development depends on their work. Many groundbreaking discoveries have already been made, but I am sure that many more are yet to come."
The R&D institute deals with methods of refining metal products by increasing their corrosion resistance and increasing mechanical properties, especially fatigue strength and resistance to wear in friction processes. The technological institute strives to disseminate and apply in practice the results of scientific research and development work, develops new technologies, and conducts service activities.
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Marle Group, a global manufacturer of orthopedic prostheses, has expanded its heat treating potential with the acquisition of a new furnace. The furnace on order will be used for the heat treatment of cobalt implants.
This Vector® vacuum furnace, supplied by SECO/WARWICK, will provide the high temperatures, pure environment, temperature uniformity, and quick cooling necessary for the Cobalt alloy hardening process.
Antoine Escbach
Factory Director
Marle Group
LinkedIn
In the words of Antoine Eschbach of Marle Group, “The furnace we ordered solves the challenges faced by anyone who has to heat treat cobalt alloys in a production process. . . . Knee implantology is a field that is developing rapidly especially in developed countries, such as United States of America and in many European countries. Our mission is to create the highest quality implants which raise the living standard of people around the world, and the Vector furnace will help us to achieve this goal."
In order for cobalt alloys to be used in implantology, they must be deprived of their ferromagnetic properties. This shiny, hard metal loses this property only when it reaches a temperature higher than 1131°C/2067.8°F. Such a high temperature makes it necessary to use a vacuum furnace in the implant production process.
The solution on order uses two gases - nitrogen for cobalt hardening and argon to achieve purity of the process during heating. It is also equipped with a dew point sensor for each of the gases, thanks to which the phenomenon of water vapor condensation and, consequently, the possibility of the processed load’s surface oxidation is eliminated.
Also significant for the cobalt treatment process is also a quick cooling system based on a gas blower ensuring a maximum hardening pressure of 15 bar abs.
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Nitrex and Linde announced they have renewed and expanded their heat-treating focused joint marketing agreement. What started as a local agreement 13 years ago, between Nitrex and Linde, formerly known as UPC-Marathon and Praxair, respectively, has evolved into an international marketing agreement and now covers Europe and North America.
To date, Nitrex and Linde have worked together on over 30 projects. By using their complementary offerings, they have upgraded essential equipment and have helped customers achieve quality results. Nitrex provides Linde customers with equipment and analyses to control first-rate gas atmospheres, thanks to its competence in the heat treatment and electrical fields, technical solutions, support, and world-class gas panels.
“Our competencies complement each other,” says Roman Grosman, National Director of Business Development for Linde in the U.S. “In the event that Linde’s heat treatment clients require equipment that we do not offer, Nitrex can meet this need.”
“This continues to be a win-win relationship,” says Paul Oleszkiewicz, President, CPO & CSO of UPC-Marathon, a Nitrex company. “We can supply Linde gas customers with process controls, and in turn, Linde offers a reliable gas supply network. We are both aiming for the highest quality, efficiency, performance, and a greener tomorrow and providing optimal service for our customers.”
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A European subcontractor for the automotive and racing industries as well as a partner for teams participating in Formula 1 races has acquired a second vacuum furnace.
The order from SECO/WARWICK includes a Vector® vacuum furnace with 15 bar abs high pressure gas quenching, and high vacuum (HV). The furnace will process engine and gear components for vehicles racing large-scale motorsport competitions.
This partner provides carburizing, and various heat treatment services for titanium, aluminum and precipitation hardening of alloys. These services must be of aviation quality within the demanding timeframes required by European F1 teams.
In the new SECO/WARWICK furnace, the customer will execute vacuum heat treatment of titanium and its alloys and will perform vacuum carburizing processes for steel elements. Titanium alloys are very strong materials, but at the same time soft and plastic, which makes them difficult to machine. Low thermal conductivity and density creates an environment where the cutting material is subject to a strong thermal load and tends to harden.
The FIA regulations for Formula 1 racing specify in detail what material a part must consist of and how it must be manufactured. Titanium or titanium alloys are used for many engine parts and suspensions because they have high toughness, strength, and ductility, and are corrosion resistant. Formula 1 car components must be manufactured precisely and safely in both prototype and small series production.
The purpose of this particular model of Vector furnace will be unique, as carburizing and hardening of parts such as gears for engines and transmissions for high-performance F1 sports cars are not the typical processes for which SECO/WARWICK supplies its furnaces.
Commenting on this order, Maciej Korecki, vice president of the Vacuum Segment at SECO/WARWICK, explained, "The vacuum furnace system which will be delivered to England has numerous options such as cryogenic processing, convection, FineCarb® vacuum carburizing, pre-nitriding for PreNitLPC® carburizing technology or low-pressure carbonitriding LPCN."
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Siemens Energy, a recognized manufacturer of gas turbines and other energy technologies, has selected an eco-friendly vacuum furnace with high-pressure gas hardening (6 bar abs.) and high vacuum for one of its production facilities.
The vacuum furnace from SECO/WARWICK, known as Vector®, will execute efficient and ecologically clean processes in a high vacuum range. Consisting of a dry pump, a Root’s pump, and five Oerlikon/Leybold turbomolecular pumps, the furnace will meet the manufacturer's restrictive requirements.
Maciej Korecki
Vice President of Business of the Vacuum Furnace Segment
SECO/WARWICK
(Source: SECO/WARWICK)
The Vector also contains a metal heating chamber, which prevents direct heat loss to the vacuum chamber’s wall and ensures high process purity. The efficiency is also influenced by the ability to conduct the heating and cooling process at 6 bars with two gases (nitrogen or argon).
Maciej Korecki, vice president of the Vacuum Segment at the SECO/WARWICK Group, states, “This is our first order from a Siemens Energy production facility, but in the past, we have supplied equipment to gas turbine manufacturers."
Commenting on the future of clean energy for the power industry, Korecki further notes, "Gas turbines can run on a variety of gases, including hydrogen. Green hydrogen, as an energy carrier without a carbon footprint, will gradually increase its market share not only in the energy industry, but also in other economic sectors, contributing to gradual decarbonization of the atmosphere."
