North American commercial heat treater installs their sixth all-metal hot zone furnace at their Souderton plant in Eastern PA. This is Solar Atmospheres' sixth all-metal hot zone furnace installation, and the fourth for their climate-controlled room.
The furnace is a new Mentor model, built by sister company Solar Manufacturing, has a working zone of 12” x 12” x 18”, and is the first of its kind. The additional furnace increases the heat treater's capacity for processing sensitive materials such as PH stainless, nickel-based superalloys, titanium, and ferritic/austenitic stainless steels, yet focuses on smaller lots and one-off items. The furnace makes it possible to reap the benefits of an all-metal furnace while minimizing the overall cost.
Nine furnaces were shipped to six states in America, Canada, and the United Kingdom this past July from an international supplier of heat treat equipment. This same supplier will be providing five vacuum furnaces to four customers within the aerospace, defense, and commercial heat-treating industries. The products are all uniquely designed to meet the customers' specific heat treating requirements.
The ability for the international supplier, Ipsen USA, to deliver these products reinforces their transition into the Vacuum Center of Excellence within Ipsen.
Ipsen Vacuum Furnace (photo source: ipsenusa.com)
"Ipsen has worked with international operations teams for decades," said Patrick McKenna, president and CEO of Ipsen USA, "shipping equipment from the US to countries all over the world[...] With the identification of Ipsen USA as the Vacuum Center of Excellence, we can continue servicing those companies with the level of quality they expect and deserve."
Super IQ® Gas Carburizing furnace from SECO/WARWICK Group
REX Heat Treat, a commercial heat treater specializing in the aerospace market, has bought and installed a hybrid model -- conventional and vacuum -- furnace system from a European supplier. This technology will allow the company to improve their through-hardening and carburizing capabilities alongside their legacy harden and temper furnaces, while using their existing loader, baskets and washing system.
REX Heat Treat has become the first company to install and commission this hybrid model called Super IQ® Gas Carburizing furnace from SECO/WARWICK Group. Designed to eliminate endogas, the furnace allows clean processing and can even achieve higher temperature carburizing to speed cycles and improve yields in certain steels in a clean and cool manner.
Jonathan Rex, General Manager, Rex Heat Treat (photo source: LinkedIn)
“The technological advances," says Johnathan Rex, general manager at REX Heat Treat, "allow us to run at higher temperatures, vacuum carburize, and clean harden with no decarburizing effects. The fact that our existing systems fit perfectly with this new addition helps to minimize the overall investment and accelerate successful integration. We expect the Super IQ to reduce operating costs, improve safety, and enable more environmentally friendly processing."
A North American based aerospace manufacturer will receive a continuous vacuum (CV) furnace with 10 bar pressure quench capabilities. The 4 position, 4 zone furnace is rated to 2400°F, and will work well in processing medium to high volume parts.
The supplier, Gasbarre Thermal Processing, shares that the independent load and quench modules allow the heat module to hold temperature and vacuum, creating a pure environment. The extended heating element coverage is conducive for thorough temperature uniformity, and then only the workload is cooled in the isolated cooling chamber. Quick transference from the heat module to the cool module as well as fast quench capabilities will aid processing of medium to high volume parts.
Bob Hill, President, Solar Atmospheres of Western PA
Vacuum oil quenching (VOQ) is adopted at Solar Atmospheres of Western PA(SAWPA). The latest VOQ quench line, including a hardening furnace, tempers, washer, and charge car, will be installed and fully operational by the end of 2020. To make room for this new technology, the company is continuing construction of its 15,000 square foot addition.
Amidst the context of the coronavirus (COVID-19), Solar views this period as an opportunity to set new paths of transformation and growth for the company, and thus came to decision to continue their planned expansion. “We have had to think on our feet," said Bob Hill, President of SAWPA, "find innovative solutions and pivot quickly, to change protocols to protect our employees and to safeguard our business."
SAWPA builds new Vacuum Furnance for VOQ line at their expanding site. (Photo source: SAWPA)
Patrick McKenna, President and CEO (source: Ipsen USA)
Ipsen USA, Cherry Valley, Illinois, announced yesterday, July 29th, that it has been appointed as the Vacuum Technology Excellence Center for the global Ipsen organization. Ipsen USA, located west of Chicago near Rockford, Illinois, was one of the two Technology Excellence Centers announced yesterday. The other, Ipsen in Kleeve, Germany, will serve as the Atmosphere Technology Excellence Center.
According to the statement issued by Patrick McKenna, CEO of Ipsen USA, the focus on one field of technology (i.e. vacuum technologies), will enable faster-paced innovation and a sharper focus on equipment performance and quality. McKenna further noted that the global restructuring came after months of market analysis to understand the needs of the company’s customers. The resulting drivers for the organization’s global changes were a) increased customer demand for technical services, b) identical metallurgical outcomes worldwide, and c) solutions for processing newly developed materials. The establishment of these Technology Excellence Centers will allow the global organization to properly address market needs for current and future customers, as well as allow for faster response times supported by new advanced service products in all regions of the globe currently serviced by the company.
As a result of this change, new furnace equipment will be manufactured at fewer locations around the world, focusing instead on specialization. The US location will exclusively build all types of vacuum furnaces, while the Germany location will build the atmosphere batch and continuous systems. Additionally, Ipsen India will continue to build atmosphere furnaces for the India and Southeast Asia markets. The China and Japan locations will no longer manufacture new furnaces, but will continue to focus their energy on customer service and the sale of new equipment from the Excellence Centers.
The customer relationship with the company will remain unchanged as customer support will continue at all global locations. Sales, service, and support teams remain local in each region to guarantee speed of response. All plants remain open in all regions as the aftermarket support of customers is more than half of Ipsen’s annual business. Activities such as upgrades, local inventory of parts and service will continue to be fully supported on a local basis.
This consolidation of equipment manufacturing sites together with the uncertainty of the global pandemic does result in a reduction of staff, which is a regrettable but necessary outcome.
For more information, please contact Patrick McKenna, President & CEO Ipsen USA at Patrick.McKenna@IpsenUSA.com or +1 815-332-2591.
A global automotive supplier has placed an order for an electrically heated continuous belt brazing furnace to be installed in Mexico in the 4th quarter of 2020.
Abbott Furnace Company will design and manufacture the industrial furnace for brazing of fuel delivery components and their Mexico location will install and provide after sale support of the four (4) zone line that is rated for 2,150° F and includes a 24” wide belt and silicon carbide domed muffle.
An international aerospace manufacturer orders two furnaces for its factories in the USA and Singapore. While both are single-chamber vacuum furnaces, they will serve different functions. One will be used for the heat treatment of exotic electrical steels, and the second will be used for annealing parts produced by 3D printing technology.
The furnace purchased for the heat treatment of exotic electrical steels has diffusion vacuum levels and a horizontal chamber. The chamber has the workload size of 24” x 24” x 36” and a 1300 lb. hearth capacity. Additionally, each furnace has a single-chamber, high pressure gas quench heat treat system adaptable to a wide variety of thermal processing applications including annealing, brazing, hardening, LPC and LPN, normalizing, solution heat treating, sintering and tempering.
Two SECO?WARWICK Vector Furnaces (photo source: SECO/WARWICK)
Each of the furnaces were bought from SECO/WARWICK Vector furnaces lines. This is the manufacturer's first purchase for a US installation from this supplier. The Vector furnaces lines are used in multiple applications within the aerospace sector, including heat treating turbine blades and landing gear, as well as in the aerospace aftermarket to maintain fleets of aircraft.
Maciej Korecki, Vice President of Vacuum Business Segment, SECO/WARWICK (photo source: SECO/WARWICK.com)
“SECO/WARWICK Group," commented Maciej Korecki, Vice President of Vacuum Business Segment at SECO/WARWICK, "has delivered hundreds of Vector heat treat systems worldwide, many of which are in steady use supporting the aircraft industry. We offer Vector with either a horizontal or vertical chamber depending on part configuration and the process needs of the customer, and we support each customer all over the world with a dedicated team of aftermarket professionals to keep them running at peak efficiency.”
Vector 3D builds upon the single-chamber vacuum furnace technology to combine the advantages of gas quenching capabilities with the growing requirements of the additive manufacturing market. The result allows customers to perform processes such as sintering, debinding, stress-relieving, aging or solution heat treatment, which are essential for the metal 3D printing sector. It has numerous applications in such industries as aerospace, automotive, medical and energy.
Solar Atmospheres of Western PA is currently installing a new rapid quenching vacuum furnace that will ultimately eliminate the need for costly helium while increasing production throughput. In helium's place, the new furnace will use nitrogen only in the hardening process.
Solar Manufacturing Rapid Quench Furnace for Solar Atmospheres of Western PA (photo source: Solar Atmospheres)
The new 48” x 48” x 96” deep 10 bar vacuum furnace is produced by Solar Manufacturing. The important difference in this furnace from its older model is the cooling design, which is equipped with a 600 HP blower designed motor. This will allow the new furnace to outperform its older model by processing larger and heavier workloads with the use of nitrogen only.
Bob Hill, President, Solar Atmospheres of Western PA
“The difference in operating costs is a no brainer,” states president of Solar Atmospheres, Bob Hill. “To marginally harden one 2000-pound high-speed tool steel roll die in our older 2 bar vacuum furnace, the use of light helium gas was a necessity. The prohibitive cost of a two atmosphere helium backfill was $1,065. Our new furnace will enable us to fully harden three 2000-pound roll dies at once using the more cost-effective process gas of nitrogen. In contrast the cost of a 10 atmosphere backfill of nitrogen will be only $89.” Hill predicts that with these increased efficiencies and savings, his normal ROI on a new piece of equipment will be significantly advanced.
Once operational, Hill will author a technical paper with the actual cooling data derived from these similarly sized vacuum furnaces.
A family-run, commercial heat treating plant in Rzeszów, Poland, Kuczma Hardening Plant, will expand its heat treating capabilities with a new single-chamber vacuum furnace. A particular addition to this furnace is the directional cooling, which will allow the plant to perform quenching from both the sides and the top and bottom in order to precisely adjust the gas cooling system to the batch configuration.
The Vector® vacuum furnace from SECO/WARWICK is equipped with 1.5 bar gas quenching pressure. It will increase the capacity of the Kuczma Hardening Plant and will enable the plant to process parts with dimensions up to 600x600x900 mm. This furnace model specializes in heat treating many types of materials and metal alloys; additionally, its functionality includes gas hardening and tempering, annealing, brazing and degassing.
"Kuczma Hardening Plant," said Jerzy Kuczma, Kuczma Hardening Plant owner, "specializes mostly in vacuum quenching in gas, oil and gas nitriding of injection mould components and dies... On one hand, the SECO/WARWICK furnace will enable us to process larger components and increase our output for smaller ones on the other it will enable directional cooling sideways or top/bottom."
The hardening plant also performs carburizing, quenching, and tempering under protective endothermic atmosphere as well as clean stress relieving under nitrogen atmosphere.
