PWR Advanced Cooling Technology has ordered two universal batch CAB furnaces and a CAB continuous line. The furnaces will be used for brazing aluminum heat exchangers. The 3 solutions will go to 2 continents – Australia and North America.
PWR Advanced Cooling Technology specializes in the production of modern and efficient heat exchangers and has used SECO/WARWICK Group furnaces in the past. Two furnaces, the continuous CAB line and Universal Batch CAB Furnace, will be delivered to production plants in Australia. The second chamber furnace will be delivered at the same time to the American branch of PWR, C&R Racing Inc.
Andi Scott, general manager - advanced technology, PWR Australia Source: PWR Australia
The universal batch CAB furnace meets the requirements for protective atmosphere aluminum brazing technology (Nocolok®) and allows users to braze products in a horizontal or vertical position. The continuous CAB line performs brazing in a protective atmosphere for mass production of various heat exchangers.
“We have already ordered the company’s furnaces twice, and the current contract, although more than 25 years have passed since the first order, is the best proof that we are satisfied with the product quality, cooperation, and after-sales service.” said Andi Scott from PWR Advanced Cooling Technology.
“The current contract is special because we will deliver different solutions simultaneously to two continents but to the same customer,” commented Sławomir Woźniak, CEO of the SECO/WARWICK Group.
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Nordic Traction Group, a manufacturer of traction chains and tracks for forestry and agricultural machinery, recently upgraded their heat treatment operations by installing a new endothermic gas generator system.
Daniel Panny Head of Sales UPC-Marathon in Germany Source: LinkedIn
To carburize its traction chains, Nordic Traction Group, with manufacturing locations in Finland and Scotland, added the EndoFlex™ S system. The system, from UPC-Marathon, a Nitrex company with North American locations, replaces an outdated generator. The new system improves process reliability and product quality and requires less preventative maintenance.
“Since the EndoFlex™ S produces only the amount of gas required by the carburizing furnace, there is zero waste in endogas production. This also allows Nordic Traction to save big by maximizing energy usage and gas consumption,” said DanielPanny, Head of Sales at UPC-Marathon.
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Vacuum furnaces are widely used in the aerospace and automotive industries. These furnaces are used for multiple processes including brazing, aging, and solution heat treating for countless materials. Typically, vacuum furnaces are utilized to ensure a lack of oxidation/contamination during heat treatment. This article will talk about the origins, theory, and main parts of vacuum technology and how it is used in both aerospace and automotive industries.
This Technical Tuesday feature was written by Jason Schulze, director of technical services at Conrad Kacsik Instrument Systems, Inc., and was first published in Heat Treat Today's December 2022 print edition.
A Brief History
Vacuum furnaces began to be used in the 1930s for annealing and melting titanium sponge materials. Early vacuum furnaces were hot wall vacuum furnaces, not cold wall vacuum furnaces like we use today. Additionally, most early vacuum furnaces did not utilize diffusion pumps.
Vacuum Heat Treat Theory
Vacuum technology includes vacuum pumping systems which enable the vessel to be pulled down to different stages through the process. Degrees of vacuum level are expressed opposite of pressure levels: high vacuum means low pressure. In common usage, the levels shown below in Figure 1 correspond to the recommendations of the American Vacuum Society Standards Committee.
Vacuum level will modify vapor pressure in a given material. The vapor pressure of a material is that pressure exerted at a given temperature when a material is in equilibrium with its own vapor. Vapor pressure is a function of both the material and the temperature. Chromium, at 760 torr, has a vapor pressure of ~4,031°F. At 10¯5, the vapor pressure is ~2,201°F. This may cause potential process challenges when processing certain materials in the furnace. As an example, consider a 4-point temperature uniformity survey processed at 1000°F, 1500°F, 1800°F, and 2250°F. This type of TUS will typically take 6-8 hours and, as the furnace heats up through the test temperatures, vacuum readings will most likely increase to a greater vacuum level. If expendable Type K thermocouples are used, there is a fair chance that, at high readings, you may begin to have test thermocouple failure due to vapor pressure.
Figure 1. Vacuum levels corresponding to the recommendations of the American Vacuum Society Standards Committee
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
Vacuum Furnace Pumping System
Vacuum heat treating is designed to eliminate contact between the product being heat treated and oxidizing elements. This is achieved through the elimination of an atmosphere as the vacuum pumps engage and pulls a vacuum on the vessel. Vacuum furnaces have several stages to the pumping system that must work in sequence to achieve the desired vacuum level. In this section we will examine those states as well as potential troubleshooting methods to identify when one or more of those stages contributes to failure in the system.
Vacuum furnaces have several stages to the pumping system that must work in sequence to achieve the desired vacuum level. Each pump within the system has the capability to pull different vacuum levels. These pumps work in conjunction with each other (see Figure 2).
Figure 2. Vacuum pumps work in conjunction with one another
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
The mechanical pump is the initial stage of vacuum. This pump may pull from 105 to 10. At pressures below 20 torr the efficiency of a mechanical pump begins to decline. This is when the booster pump is initiated.
The booster pump has two double-lobe impellers mounted on parallel shafts which rotate in opposite directions (see Figure 3).
Figure 3. Booster pump positions
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
The diffusion pump (Figure 4) is activated into the pumping system between 10 and 1 microns. The diffusion pump allows the system to pump down to high vacuum and lower. The diffusion pump has no moving parts.
Figure 4. Diffusion Pump
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
The pump works based on the vaporization of the oil, condensation as it falls, and the trapping and extraction of gas molecules through the pumping system.
Image 1. Holding Pump
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
The holding pump (Image 1) creates greater pressure within the fore-line to ensure that, when the crossover valve between the mechanical and diffusion pump is activated, the oil within the diffusion pump will not escape into the vessel.
Vacuum Furnace Hot Zone Design
Image 2. Insulated
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.Image 3. Radiation
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
The hot zone within a vacuum furnace is where the heating takes place. The hot zone is simply an insulated chamber that is suspended away from the inner cold wall. Vacuum itself is a good insulator so the space between the cold wall and hot zone ensures the flow of heat from the inside to the outside of the furnace can be reduced. There are two types of vacuum furnace hot zones used: insulated (Image 2) and radiation style (Image 3).
The two most common heat shielding materials are molybdenum and graphite. Both have advantages and disadvantages. Below is a comparison (Tables 1 and 2).
Table 1
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.Table 2
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
Vacuum Furnace Quenching System
Quenching is defined as the rapid cooling of a metal to obtain desired properties. Different alloys may require different quenching rates to achieve the properties required. Vacuum furnaces use inert gas to quench when quenching is required. As the gas passes over the load, it absorbs the heat which then exits the chamber and travels through quenching piping which cools the gas. The cooled gas is then drawn back into the chamber to repeat the process (see Figure 5).
Figure 5.Diagram of gas quenching
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
Vacuum Furnace Trouble Shooting
In Table 3 are some helpful suggestions with regard to problems processors may have.
Table 3
Source: Jason Schulze, Conrad Kacsik Instrument Systems, Inc.
Summary
Vacuum furnaces are an essential piece of equipment when materials need to be kept free of contamination. However, there are times when this equipment may not be necessary, and is therefore considered cost prohibitive, although this is something each processor must research. This article is meant to merely touch on vacuum technology and its uses. For additional and more in-depth information regarding vacuum furnaces, I recommend a technical book called Steel Heat Treatment, edited by George E. Totten.
About the Author: Jason Schulze is the director of technical services at Conrad Kacsik Instrument Systems, Inc. As a metallurgical engineer with over 20 years in aerospace, he assists potential and existing Nadcap suppliers in conformance as well as metallurgical consulting. He is contracted by eQuaLearn to teach multiple PRI courses, including pyrometry, RCCA, and Checklists Review for heat treat.
Peter Zawistowski Managing Director SECO/VACUUM TECHNOLOGIES, USA Source: secowarwick.com
An electric vehicle manufacturer will move the heat treatment of their prototype gears in-house with a vacuum furnace. The company expects new product development to accelerate.
SECO/VACUUM, a SECO/WARWICK Group company, will deliver a CaseMaster Evolution (CMe) model with a working hot zone of 16”x16”x24” and a load capacity of 440 lb. The EV maker’s R&D lab will use furnace to low-pressure carburize and oil quench prototype gears. With this expansion, the manufacturer hopes to mitigate scheduling delays encountered when sending their prototype gears out to local commercial heat treatment shops.
“We have a strong partnership together," said Peter Zawistowski, managing director of SECO/VACUUM, "having commissioned a number of highly successful heat treat furnaces that provide a wide variety of processes in their plants across the world."
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Last Friday Stellantis announced it will indefinitely halt operations at an Illinois assembly plant in February, citing the rising costs of electric vehicle production.
The automaker, which employs about 1,350 workers at the Belvidere, Illinois plant that builds the Jeep Cherokee SUV, said the action will result in indefinite layoffs and added it may not resume operations as it considers other options. Stellantis said the industry "has been adversely affected by a multitude of factors like the ongoing COVID-19 pandemic and the global microchip shortage, but the most impactful challenge is the increasing cost related to the electrification of the automotive market." The company had said it will invest over 30 billion euros ($31.6 billion) through 2025 on electrifying its vehicle lineup, and also expected EVs to make up 100% of its sales in Europe and 50% in the United States by 2030.
The company shared it is working to identify other opportunities to repurpose the Belvidere facility and has no additional details to share at this time. Sam Fiorani, head of production at AutoForecast Solutions said the UAW and Stellantis could reach a deal in contract talks next year for a new vehicle for the plant "but any new product redirected its way will take investment and time to retool the plant, leaving Belvidere empty for a year or more."
Piotr Skarbiński Vice President of Aluminum and CAB Products Segment SECOWARWICK Source: LinkedIn
Two Chinese manufacturers choose EV/CAB lines to expand their heat exchanger production to better heat treat oversized battery cooler.
The furnace supplier, SECO/WARWICK, noted that this will be the fourteenth CAB line for one of the manufacturers in the China market.
“This year, CAB lines for brazing heat exchangers have been sold to several new customers on the Chinese market," said Piotr Skarbiński, vice president of the Aluminum and CAB Products at SECO/WARWICK. “The EV/CAB line . . . [has] temperature uniformity across the belt, suitable for the strict requirements of the automotive industry, as well as its reliability and quality."
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A heat treat supplier is scheduled to deliver two CAB lines and one universal chamber furnace for aluminum brazing to automotive manufacturer in China. The manufacturer of diesel engine components will be able to braze large-size coolers for vehicle batteries.
Liu Yedong managing director SECO/WARWICK Retech China
The universal chamber furnace brazes a variety of heat exchangers in horizontal or vertical positions. "The system’s [universal chamber furnace] advantages include a shorter loading time, higher efficiency, and relatively lower cost," summarized Liu Yedong, managing director at SECO/WARWICK China.
One of the CAB lines will incorporate a furnace equipped with a 2.3 meters wide conveyor belt for large-dimensions battery coolers. The second, narrower line, has a 1.5-meter conveyor belt width.
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Twice a month, Heat TreatToday publishes an episode of Heat TreatRadio, an industry-specific podcast that covers topics in the aerospace, automotive, medical, energy, and general manufacturing realms. Each episode provides industry knowledge straight from the experts.
Stay abreast of quenching tips, techniques, and training --- especially in the auto industry --- with this original content piece that draws from three video/audio episodes.
Heat Treat Radio: The Greenness and Goodness of Salt Quenching with Bill Disler
Bill Disler President, CEO AFC-Holcroft Source: AFC-Holcroft
Sure, salt quenching has been around for quite some time, but this method is coming more to the forefront when we consider some of the concerns and costs of oil quenching. In this Heat TreatRadioepisode, listen in to Bill Disler of AFC-Holcroft discuss the pros and cons of salt quenching. His brief overview and then salt versus other quench options will leave you ready to embrace quenching at your heat treat shop.
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"I’d say, in general, the most common thoughts with salt are to use it for bainitic quenching. If you’re quenching into a bainitic structure, salt has always been the only way to do this," comments Bill. "But what we’re seeing the growth into, and much more activity, is martensitic quench." As you listen, key into the point of salt quenching offering a "green-minded" solution due to recyclability.
Heat Treat Radio: Water in Your Quench with Greg Steiger, Idemitsu
Greg Steiger Senior Key Account Manager Idemitsu Lubricants America
Water in the quench tank? How much is too much? What do you do to get rid of it? Is it possible to prevent water from getting into the tank? Greg Steiger of Idemitsu answers these questions and more in this essential episode.
"Our research has shown that basically about 200-250 ppm water, you start to get uneven cooling," Greg Steiger cautions. "When you start getting up to large amounts of water, somewhere around 750 ppm to over 1000 ppm, it becomes a safety issue."
The entire episode gives answers to how to identify, prevent, and remove water in the quench.
Heat Treat Radio: All Things Auto Industry Quenching with Scott MacKenzie
D. Scott MacKenzie, Ph.D Senior Research -- Metallurgy Quaker Houghton, Inc.
This interview gets to some nitty gritty details regarding quenching and the shift to electric vehicles. What does the future of heat treating look like for electric vehicles (EVs)? Where is aluminum heat treat fitting in? Listen in to get industry insight on these answers. Scott MacKenzie of Quaker Houghton also explores simulation and modeling, the need for trained metallurgists in our industry, and more broad heat treat considerations.
"The next thing you have to understand is the quenchant itself," Scott MacKenzie advises. "You have to understand the physical properties."
Are you a relatively new reader in automotive heat treat? Welcome. Enjoy this archive of articles from the automotive industry, which provides years of technical knowledge to fill any information gaps. Even the "OG" readers with Heat TreatTodaywill want to investigate this Technical Tuesday original content compilation that plumbs the depths of the archives.
1. What Heat Treatment To Use for Truck Gear Boxes?
This paper reveals the investigation and conclusions of distortion potentials for case hardening processes. Mainly, the focus was on how the SyncroTherm® concept method compared to conventional case-hardening processes for gears and sliding sleeves.
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Read about how the results effected the bottom line: reduced costs, quicker processes, and less distortion. Also, be sure to examine each of the charts and figures for further understanding of each test.
This article entered the Automotive Heat Treat archive in 2016, and was written by Andreas Schüler, Dr.-Ing. Jörg Kleff, Dr. Volker Heuer, Gunther Schmitt, and Dr. Thorsten Leist.
Problems in heat treating result in the loss of valuable time and money. Getting to the bottom of those problems also usually takes time and money to investigate what's happening and how to fix it. What is a heat treater to do?
In this article, we follow a case study from the automotive industry to understand how to pinpoint a heat treating problem. This article specifically looks at what was causing cracking in variable valve timing (VVT) plates.
3. Carburizing: The Importance of Temperature Monitoring and Surveying
Low pressure carburizing (LPC) furnaces play an important role in the automotive heat treating industry. During LPC, it is essential that processing temperature stays consistent and critical that the processing time frame is monitored.
This article discusses the importance of collecting temperature data and what to do with the data when it's been collected.
4. Vacuum Brazing --- Back to the (Automotive) Basics
Time to brush up on a vacuum brazing furnace, but automotive industry style. Review the terms, parts, function, and more that are involved in a successful vacuum braze for automotive parts.
This study covers a semi-automatic TAV vacuum brazing furnaces, details the makeup of the furnace, and gives an idea of what happens with a load from start to finish.
5. Saving Time --- Automation Versus Manual Hardness Tests
If you've ever heat treated automotive crank pins, you're probably familiar with at least one type of hardness test that case hardened crank pins are tested against. The big question is, which hardness testing method is better: automated or manual? This article compares these two methods to make and measure Vickers indentations.
Evaluate for yourself the comparisons between an experienced operator manually entering data to Wilson VH3100 series Vickers Microhardness Tester and a DiaMet software entry. Some additional findings show that the crank pins could be examined by the Wilson tester with far less manipulation in the vice as well as reduction in data recording mistakes.
Factorial Energy (Factorial), a developer of solid-state battery technology for electric vehicle applications, announced it will establish a new advanced manufacturing facility in the Boston suburb of Methuen, MA. The new facility will produce Factorial’s new solid-state battery cell technology for EVs.
Siyu Huang Founder and CEO Factorial Energy
The new production site at 501 Griffin Brook Drive in Methuen has an existing 67,000 square-foot building on the site that will undergo extensive buildout to house Factorial’s pilot production facility. The facility expects to begin operations in early 2023 and will bring 166 new jobs to the Methuen community.
Based in Woburn, MA, the company is currently working with automakers Hyundai Motor Company, Mercedes-Benz, and Stellantis to develop safer and higher performance solid-state EV battery cells for future passenger and commercial vehicles.
"We plan to continue building solid-state EV battery research and development facilities in New England and establish the region as a hub for electric mobility technology," commented said Siyu Huang, CEO of Factorial.
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Twice a month, 
This paper reveals the investigation and conclusions of distortion potentials for case hardening processes. Mainly, the focus was on how the SyncroTherm® concept method compared to conventional case-hardening processes for gears and sliding sleeves.
Problems in heat treating result in the loss of valuable time and money. Getting to the bottom of those problems also usually takes time and money to investigate what's happening and how to fix it. What is a heat treater to do?
Low pressure carburizing (LPC) furnaces play an important role in the automotive heat treating industry. During LPC, it is essential that processing temperature stays consistent and critical that the processing time frame is monitored.
Time to brush up on a vacuum brazing furnace, but automotive industry style. Review the terms, parts, function, and more that are involved in a successful vacuum braze for automotive parts.
If you've ever heat treated automotive crank pins, you're probably familiar with at least one type of hardness test that case hardened crank pins are tested against. The big question is, which hardness testing method is better: automated or manual? This article compares these two methods to make and measure Vickers indentations.
