Manufacturer Expands Aluminum Heat Treat Capabilities
A provider in the power solutions industry has enhanced its operations with a heat treat drop-bottom furnace for the solution heat treatment of aluminum castings. This installation will increase the company’s production capabilities, with the furnace having a load setting of 48 in (123 cm) wide x 36 in (91 cm) high x 141 in (358 cm) long.
The furnace, the fifth designed and manufactured by NUTEC Bickley, has a single temperature control zone, typically operating at 1000°F (573°C), with a maximum of 1075°F (580°C). The load setting will accommodate up to three baskets, equivalent to around 3600 lb (1635 kg) of aluminum parts per cycle. The furnace has been customized to be indirect gas-fired using radiant tube burners. Additionally, the project incorporates a motorized quench tank, rails, movement system, and load/unload platform with elevator device.
Vice President, Metal Furnaces
NUTEC Bickley
“Efficient and effective solution heat treatment is a vital part of the aluminum casting process,” said Arturo Arechavaleta, vice-president of Metal Furnaces at NUTEC Bickley. “Without the sort of advanced system that we have custom-designed, volume production of high-quality aluminum parts is not feasible. We’re proud to have played an important role in this technology partnership.”
The indirect gas firing is via single centrifugal recirculation that produces a vertical flow pattern. Heating is achieved with four radiant tube burners that have individual flame safety devices. The burner system incorporates a motorized control butterfly valve, and the gas flow is controlled by proportional ratio regulators. This design, with its baffle arrangement, delivers an even flow pattern, providing excellent temperature distribution and control in the furnace’s load chamber and high-efficiency heat recirculation (convection) horizontally across the aluminum castings. Excellent temperature uniformity was always considered an important parameter, and this has been shown to be ±5.4°F (±3°C) under full test in the provider’s manufacturing facility.
In order to maintain excellent thermal efficiency in operation, the furnace walls are fully lined using ultra large proprietary ceramic fiber modules. Their configuration and fixing provide for excellent insulation and long life coupled with low maintenance. The insulation layer is 6 in (150 mm) thick and has a density of 12 lb/ft3 (192 kg/m3).
The installation will see the drop-bottom furnace itself stationary — in a fixed elevated position — with the quench tank and loading car moving to accommodate baskets at the selected position. The furnace has a single, pneumatically operated horizontal slide door. For these particular aluminum castings, the company will employ a motorized water quench system provided by NUTEC Bickley, as well as its rails included leveling and installation. The tank has been designed to accept a full load of pieces within the work basket when the furnace is positioned vertically above it.
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