William (Bill) Jones Owner and CEO Solar Manufacturing
Recently, a North American heat treater acquired a used VFS HL50 external quench vacuum furnace at an auction in the Philadelphia area. The main objective of this purchase was to retrofit this older furnace with a newer hot zone and pumping technology that will help minimize and target the condensation of detrimental binders evaporating out of MIM injection molded parts.
Solar Atmospheres of Western PA's maintenance team was responsible for refurbishing the furnace to its current standard. Solar Manufacturing, led by owner and CEO William Jones, designed the technology and the apparatus needed to consolidate the binders into one central location, thus minimizing the cleaning downtime the staff was experiencing. This includes a completely new hot zone, a binder pumping port, and a second vacuum pump. The collaborative effort ensured both projects came together seamlessly.
By mid-October, the high production MIM sinter job will be fully transferred from current Solar vacuum furnaces to this dedicated and refurbished vacuum furnace. After multiple sintering runs, the company will then have the data to compare the downtime of a traditional vacuum furnace versus the newly designed debind/sinter furnace. Solar looks forward to providing the MIM world with this new, critical processing information.
Piotr Zawistowski Managing Director SECO/VACUUM TECHNOLOGIES, USA Source: secowarwick.com
An international manufacturer of cutting tools purchased a vacuum tempering furnace. This North American-made, horizontal, front-loading furnace is purpose-built to accommodate the client's needs with an all-metal hot zone for clean vacuum processing. As with the earlier furnaces from the same supplier, one of which was installed at a different facility, the new furnace includes a convection fan and a pressurized gas quench for quick cooling.
This is the fourth Vector furnace solution provided to the client. "There is no stronger statement," states Piotr Zawistowski, president of SECO/VACUUM, "[. . . ] than the customer who continues to order more of the same technology from us year after year as they expand. We are privileged to be a part of their growth."
Maciej Korecki Vice President of the Vacuum Furnace Segment SECO/WARWICK (source: SECO/WARWICK)
"This customer demands – and has come to expect from us – a complete range of benefits, including precision heat treat uniformity, consistency from one workload to the next, and fast processing speeds along with low energy consumption," noted Maciej Korecki, vice president of the Vacuum Furnace Segment at SECO/WARWICK Group.
This single-chamber vacuum heat treating furnace is a good solution for machine tool manufacturers and is available with curved graphite elements or an all-metal hot zone. Additionally, it can be used for most standard hardening, tempering, annealing, solution heat treating, brazing and sintering applications.
Vacuum furnace manufacturer announced it is building six furnaces for various applications in the precision processing of metals in heat treating, brazing, and annealing applications.
The product line from which these furnaces will come from, Centorr Vacuum Industries‘ Workhorse®, was introduced in the 1960’s and has been one of the company’s best-selling furnaces over the past six decades. Available in sizes from 1 cubic ft to over 100 cubic ft, this versatile furnace design has a refractory metal hot zone and high-vacuum pumping system for the processing of advanced materials requiring an extremely clean high-vacuum environment.
The furnace can also handle a variety of customer loads in either high-vacuum or partials pressures of inert gas, when necessary to protect the customer’s load.
Mercury Marine of Fond du Lac, Wisconsin, recently launched a plan to upgrade its heat-treating capabilities with a move to the low-pressure carburization and high-pressure gas quench system. The new plan incorporates completely automated vacuum heat treating systems.
In the partnership with ECM Technologies, the Nano vacuum heat treating system (pictured above) incorporates 20 bar nitrogen gas quenching along with low pressure carburizing (aka vacuum carburizing). The Nano will operate several different carburizing, hardening, and spheroidizing processes simultaneously.
This change marks a departure from Mercury’s traditional atmospheric carburization and oil quench system while benefiting from advantages that come with vacuum processing:
Applies vacuum heat treating in lieu of traditional atmosphere (elimination of intergranular oxidation & highly repeatable process with consistent results)
Employs preventive maintenance planning, remote system status access, and facility information systems integration
Relocates heat treat from a secondary location to the clean, controlled environment of the machining centers
Converts to small batch processing principles to maximize process efficiency
State-of-the-art growth with ECM’s advanced system automation and robot capability with load building and breakdown
Controls downstream operations by matching incoming dunnage with exiting workpieces
Takes advantage of vapor and vacuum-based pre-cleaning technology to remove multiple machining lubricants
Incorporates cryogenic and tempering processes within the automated system
The system uses all CFC workload fixtures and ECM’s advanced automation fixture tracking to maintain a precise cycle count to know fixture life. For Mercury, this significantly reduces energy consumption and process cost per piece. Additionally, the vacuum process takes their heat treatment to a near-zero emissions for drivetrain components processed within the system.
HTA Group (HTA) purchased two vacuum furnaces to augment its support for Australian defense capabilities. The equipment will provide heat treatment processes for HTA’s manufacturing customers in the region to meet defense customer and quality specifications. The project was developed in response to customer demand and market analysis identifying gaps in Australia’s advanced manufacturing industrial framework.
The two new Vector® single chamber high-pressure quench vacuum furnaces from SECO/VACUUM will go to HTA's Melbourne and Sydney commercial heat treatment facilities to provide expanded processing capabilities to support the Australian defense industry.
"HTA is the only Australian Nadcap-approved thermal processor and has had ongoing success with commercial and aerospace operations to date," commented Dr. Karen Stanton, director of Corporate and Strategy at HTA (pictured in the headline image above). "Increasing the footprint of heat treatment assets through the establishment of this capability in Melbourne and Sydney will increase the ability of defense component manufacturers to deliver projects faster and allow them direct access to a qualified local supply chain."
Norm Tucker Director of Operations HTA Group
"SECO/WARWICK Group has the most advanced and user-friendly vacuum furnaces on the market," added Norm Tucker, director of Operations at HTA. "But equally important to me is the way we can collaborate with their team to determine the best furnace features and capabilities to do the job. These two new Vector furnaces will be the first of their capability in Sydney and Melbourne and will be used to heat treat high strength components such as landing gear or brazing engine parts and opening up advanced processing capabilities to our new and current customers."
Piotr Zawistowski Managing Director SECO/VACUUM TECHNOLOGIES, USA Source: secowarwick.com
"HTA has been very smart about how they approach their growth, measuring business opportunities through research and thoughtfulness and looking carefully at the potential upside of their investments," noted Piotr Zawistowski, managing director at SECO/VACUUM. "We are proud to be an integral partner in their planning and execution."
The addition of Vector® vacuum furnaces to HTA’s processing capabilities follows 7 other installations of SECO/WARWICK products in Brisbane and Los Angeles CA, including high-pressure gas quench vacuum furnaces, vacuum aluminum brazing furnaces, and tempering/stress relieving furnaces.
Watervliet Arsenal will receive a new ion nitriding thermal processing furnace system with full controls. It will be fully installed and commissioned in a horizontal configuration.
Ben Bernard Vice President of Marketing Surface Combustion
This is the second ion nitriding furnace supplied from Surface® Combustion, to Watervliet Arsenal; the first was originally over 40 years ago. They awarded a contract to Surface so they could again bring their processing capability in-house. Adding control to the supply chain for product was one of the many reasons they acquired an ion nitriding thermal processing furnace system for their plant. This configuration best suits the facility and Watervliet Arsenal's processing needs, and will also include process development.
Surface has always placed a high value on customer relationships and believes that an equipment purchase is the beginning of something much more than a finite transaction. In fact, they have been working with the Watervliet Arsenal location for over 40 years.
"It is always great to see customers coming back to Surface," said Ben Bernard, vice president of Marketing at Surface, "because they appreciate our incredible product lines as well as our engineering capabilities and long standing relationships."
An international electric vehicle (EV) automaker has ordered high-pressure gas quenching (HPGQ), tempering, and nitriding furnaces for heat treatment of large high-pressure casting dies, which will be used in the production of aluminum underbody components for electric vehicles.
The tool & die market serving traditional and EV automotive markets use vacuum heat treating technology extensively to produce bright, high-quality parts. SECO/VACUUM Technologies, a SECO/WARWICK Group company, will provide two furnaces and auxiliaries with working zones that can accommodate loads with dimensions up to 1000mm x 1000mm x 2400mm (40″ x 40″ x 96″) and up to 7.5 metric tons of weight.
“[We] have built a reputation with [this client’s] engineering team,” explained Piotr Zawistowski, managing director of SECO/VACUUM, “[and so] we are capable of achieving the required quenching rates within such a large envelope, which will be accomplished with a powerful 500kW quenching system. The [client] also appreciated the custom engineering that we put into handling such a heavy workload.”
The Vector® vacuum hardening furnace is equipped with a convection heating system to improve heat transfer at lower temperatures, thus reducing internal stresses; the cooling system can quench with nitrogen at pressures up to 25 bar. The furnace will exceed NADCA 207 requirements for the quenching process and Class 2 temperature uniformity requirements per AMS2750F.
The nitriding furnace is a pit-type configuration, with working dimensions to match the hardening furnace. The patented ZeroFlow® nitriding process uses uniform high convection heating, precision nitriding potential, and ammonia control, along with vacuum purging to reduce operating costs.
Michael Johnson Sales Manager Solar Atmospheres of Western PA
Solar Atmospheres of Western PA successfully vacuum heat treated what is reported to be the largest and longest load of nickel alloy tubing ever in a commercial vacuum furnace. The mission was to preserve the crucial elements of brightness and cleanliness of the 45-foot-long seamless tubing while meeting extremely stringent mechanical properties.
“We spent countless hours reviewing critical systems such as triplicate pumping systems and redundant hot zone controls for any unforeseeable event that might arise during the 100+ hour run,” stated Michael Johnson, sales director at Solar Atmospheres of Western PA. “We are also fortunate that we can rely on our furnace manufacturing division, Solar Manufacturing, for guidance should any issue arise. This successful run will ignite a production campaign for the next 5 years, once again boosting confidence that this 48 foot vacuum furnace will surpass our customers’ expectations.”
Editor’s Note:
We suspected that this is a significant heat treating accomplishment, so we asked industry consultant and expert Dan Herring for perspective. Here are the questions and his responses. The following is provided by Heat Treat Today and not Solar Atmospheres of Western PA.
HTT: In what industries might these tubes be used?
DH: Typical examples would include steam generator tubing in nuclear power plants, high temperature aircraft systems, the oil and gas extraction industry, and anywhere applications call for corrosion/pressure/temperature resistant tubes/pipe.
HTT: Is there anything special about processing nickel alloy tubing?
DH: Yes. In order to maximize corrosion resistance, one must keep the surfaces of the tubes as oxide-free as possible. Hence, the use of vacuum. Also, the long lengths of the pipe means fewer welded joints (fewer joints means a stronger pipe, and likely more resistant to corrosion).
HTT: Is this release noteworthy?
DH: It is absolutely noteworthy. This demonstrates size capability available in only a handful (if that many) heat treat shops IN THE WORLD.
A hydroplane racing team located in Cinnaminson, NJ had three propeller blades heat treated to ensure parts were free of scale and keep the blades from shearing apart. The propellers will now withstand the RPM and torque conditions of racing without failing. Also, the hardening will protect the blades from impact with potential debris in the water.
This case study/press release from the heat treater, Metlab, goes into detail to describe the propellers and how heat treatment changed the material.
A modern unlimited hydroplane is the world’s fastest racing boat, capable of speeds greater than 200 mph. These boats represent the product of over 100 years of evolution in race boat design and materials with the most powerful engines, most advanced construction techniques, and the best safety systems available in boat racing today. A typical unlimited hydroplane can weigh a minimum of 6,750 pounds.
All unlimited hydroplanes are a “three-point” design, meaning they are designed only to touch the water at three points when racing – at the rear of the two front sponsons (the projections of the hull in front of the driver cockpit) and the propeller at the rear of the boat. Most of the unlimited class boats are powered by Chinook helicopter Lycoming T55 L7 turboprop engines, generating up to 3,000 HP.
Metlab, which is known for offering a wide variety of thermal processing solutions, had the opportunity to heat treat a series of propellers for a hydroplane racing team located in Cinnaminson, NJ.
The propellers must meet strict design criteria imposed by the Union Internationale Motonautique (or “UIM,” headquartered in Europe), not only for propellers but for the entire boat design. The propellers are typically 16″ in diameter and have three blades. Different pitch propellers are chosen for use based on course length, conditions, and starting position. It is not uncommon for a racing propeller to cost more than $15,000.
Propeller: Mercury Racing – T.E. Clever model
The propeller creates the distinctive “rooster tail” behind the boat, raising literally tons of water into the air for up to 300 feet behind the boat. They are made from several different materials, but the steel of choice is 17-4 PH stainless steel chosen for its mechanical properties and corrosion resistance. The propeller must support a significant portion of the boat’s weight while rotating up to 14,000 RPM.
Three propeller blades were heat treated for the client to the H-900 condition (900°F/ hours at heat). They were age hardened in a vacuum furnace to ensure parts were free of scale. The high tensile strength (200 KSI) produced by the heat treatment keeps the blades from shearing apart; the excellent ductility associated with the heat-treated material allows the propellers to withstand the RPM and torque conditions without failing. And a hardness of HRC 40 protects the blades from impact with potential debris in the water. 17-4 PH stainless steel properly heat treated also benefits from increasing torsional fatigue strength, a common cause of propeller failure.
Metlab provides heat treating solutions for highly technical parts and components. Consult with a metallurgical specialist at Metlab about your specifications and heat treating requirements.
Michael Lister Director of Sales - North America Consarc Corporation
The Doncasters Group recently ordered a vacuum furnace for their Doncasters Southern Tool facility in Oxford, Alabama. The order includes startup and installation with delivery scheduled before the end of 2021.
The new 300-pound Consarc vacuum precision investment casting (VPIC) furnace is equipped with high vacuum capabilities, controls, and increased automation with Teach Pour and other features that will give this furnace exceptionally high productivity for Doncasters Group.
The company is an international manufacturer of high-precision engineering components, designed to operate in the most demanding conditions. They serve the world’s leading OEMs in the aerospace, industrial gas turbine, and specialist automotive markets.
This order represents the 16th VPIC ordered from Consarc for delivery in North America in the last 24 months. Globally, the supplier has received 30 orders for this type of equipment in the same time frame.
"The recent strength in obtaining new orders for this product line is a testament to a customer centric philosophy we have at Consarc," said Michael Lister, director of Sales – North America at Consarc Corporation. "Our clients are sophisticated process owners who are well versed in the equipment and have demanding specifications placed on them by their own customers. Our collaborative approach in design, both before and after the order, is why customers trust [us] with these high value projects. We are able to understand their current problems and engineer long term solutions to mitigate those issues."
Recently, a North American heat treater acquired a used VFS HL50 external quench vacuum furnace at an auction in the Philadelphia area. The main objective of this purchase was to retrofit this older furnace with a newer hot zone and pumping technology that will help minimize and target the condensation of detrimental binders evaporating out of MIM injection molded parts.
