A Guide to Selecting Heat Treating Equipment
Do you always feel confident when selecting heat treating equipment? ¿Se siente siempre seguro cuando selecciona equipos de tratamiento térmico?
There are many factors involved when making a purchase. Often, key considerations may be missed. Read this guide on how to select and buy new equipment by Carlos Carrasco, founder of Carrasco Hornos Industriales.
This original content article was originally published in Heat Treat Today’s November 2021 Vacuum Furnace print edition in English and Spanish.
Founder
Carrasco Hornos Industriales
Why Is This Guide Helpful?
There are many reasons to select industrial furnaces carefully. One is the cost of the furnace. Another is realizing heat treating will affect the product and the bottom line. There is more specialized engineering in heat treating equipment than is apparent from the outside.
The purpose of this guide is to help engineers make the best equipment selection. The decision will affect not only the project, its budget, and results, but will also reflect the buyer’s knowledge. After the heat treating equipment is selected, the realization may occur that perhaps insufficient thought was given to potential maintenance problems or the work required to keep it in top working condition.
The following steps, gathered from more than 50 years of experience in the fields of manufacturing, sales, and maintenance, will be a useful guide to selecting heat treating equipment that will please both management and operators.
Step One: Quote Request
When requesting a quote, management knows the exact requirements the heat treated products must have. A reliable supplier should be able to understand all requirements for a quote. Requests must be clear, concise, and contain at least the following information:
- Heat treating processes that will be carried out on the equipment
- Shape, general dimensions, and weights of the product(s) to be heat treated
- Production volumes per hour, day, or month
- Number of hours available for heat treating
- Part material
- Fuel type, or if the heating will be done with electricity
- Voltage available in the plant
- Space available for installation of equipment
- Special considerations for handling loading and unloading
Furnace manufacturers need the above information to begin to create a series of options for the equipment that will be most suitable for the required processes. For example, hourly production defines: the dimensions of the space to heat the load, the type of furnace (continuous or batch), the amount of heat to be released in the furnace, the loading and unloading method, and the devices for accommodating or transporting the load such as trays, baskets, or conveyor belts. All these considerations influence both the initial cost and the operating cost, because in the end, the cost of the proposed equipment and its functionality are directly related to the specifications of the request for a quote.
It is difficult to attempt to use one furnace for all heat treating processes or to attempt to take into account future production needs that may not be necessary. It is impractical to carry out several processes that require different temperatures or have different production volumes. Trying to do so leads to oversized and over-budget equipment.
Step Two: Supplier Selection
Quote requests should only be submitted to manufacturers with the technical capacity and experience to prepare an offer that satisfies the request. Always use references from previous installations with similar quote requirements.
Considering the potential for financial gain, the cost of heat treating equipment can be appealing. The design and construction of heat treating equipment involves a considerable amount of engineering resulting from expensive investments in research and development. This research and development is influenced by user feedback detailing equipment failure. This feedback creates opportunities for manufacturers to fix equipment issues. Without the added benefit of other heat treater’s feedback, equipment failure is more likely. Finding a manufacturer with experience is crucial.
Only suppliers with experience and solid technical capacity will be able to guarantee results from the start. The goal is to receive equipment that requires no corrections after the first load leaves the furnace and to not have to rework the design.
Step Three: Study and Evaluation of Offers
A failed project is too much to risk, and so the responsible supplier will invest time and money in the study and preparation of the offer.
Every responsible supplier has been disappointed by an offer read backwards — when the potential customer reads the price first. Is the overriding need to stay within a certain budget or for heat treating equipment that is capable of processing parts to meet specifications? A careful reading of the offer may justify the cost of the furnace in relation to production needs. If there is a confusing section of the offer, it is important to clarify with the supplier. Investment in production equipment is very important, but it is even more important that the investment be profitable.
The heat treating equipment must satisfy a production need and certain metallographic specifications. Consequently, the dimensions of the space where the parts will be placed may be the main factor in the design of the furnace. This is because metals are only capable of heating up to a certain temperature at a rate that is determined by the heating method, geometry, and load arrangement. Only experienced vendors can make the correct calculations to meet the production needs of the project. Be sure to understand the calculations that lead to the sizing of the proposed system.
How are the parts supported and/or transported within the furnace? This is a point of great importance for the initial cost of these components and for the costs of future maintenance. Keep in mind that any mechanism that works at high temperatures will always be problematic for maintenance and replacement. Cast link belts, for example, have a higher initial cost, but they withstand heavy loads longer than metal mesh belts. However, there is a notable difference in the cost of components made of chromium-nickel alloy and those of carbon steel. Since chromium-nickel materials are able to withstand higher temperatures, their use is recommended and almost essential.
Furnaces tend to deteriorate rapidly where the heat is being lost. Make sure the door design is the best possible to avoid heat loss. Be sure that all doors included in the design are necessary. Doing so will save maintenance costs.
When it comes to quenching, oil or water circulation systems are extremely important, as is tank capacity. Otherwise, the quenching medium may overheat, causing unsatisfactory results.
In an oven intended for low temperature operations 356°F–1,112°F (180°C–600°C), for example tempering processes, it is necessary to have a fan to recirculate the hot air from the furnace. The uniformity of the temperature in the parts and the speed at which they heat up depends on the speed of recirculation, the weight of the air, and the design of the furnace, which must force the passage of air optimally through the load with the use of deflectors, screens, or distribution plenums. In high temperature furnaces, 1,292°F–2,192°F (700°C–1200°C), the heat transfer depends on the radiation toward the load and its exposed surface, so a recirculation fan is not necessary. Heat treatment is a critical process and temperature pyrometers must have the necessary precision.
List any doubts about the offer and ask the supplier to clarify at length in writing. The answers will make it easier to do a second analysis of the offer and compare it with other offers. In addition, the written clarifications will be a record for review by other collaborators on the project. Ask for feedback and observations on the proposals to get a second opinion.
Ask suppliers to provide a list of similar installations. Industry colleagues are generally unbiased in their comments about their experience with a particular supplier.
Finally, make a comparison chart in the most objective way possible. Keep in mind the fact that offers often do not include some subjective issues that may be important for a final selection. For example, some vendors are likely to have greater knowledge and experience in certain processes, simply because they have invested time and money to fi nd the best solutions to the process and those experiences could be beneficial.
Step Four: The Price
Understanding the scope of the received proposals that meet production and quality requirements is not all that goes into selecting heat treating equipment. After all this, there are still significant differences between various suppliers. Price is one of these differences. At this stage, the industrial furnace manufacturer will need to justify costs. It will be easy to tell if the manufacturer is thinking of the buyer as a future satisfied customer, or only of the economic benefits the sale will bring.
Conclusion
There are innumerable cases in which the equipment was poorly selected: “The substation and/or the cooling tower did not have the capacity;” or “The equipment is not what we expected;” or “They never told us that the furnace needed gas in those capabilities.” These are just a few of the possible comments everyone has heard.
Selecting heat treating equipment should be done slowly, analyzing all the options, weighing the differences between providers, and seeking clarification. Ask the supplier for multiple equipment options like requesting spare parts for the first year of operation.
Ultimately, time will tell if the furnace selected was the right choice. These recommendations provide a guide to making that decision. We sincerely hope that these recommendations will guide you in the selection of industrial furnaces for heat treating.
About the Author:
In addition to being the founder of Carrasco Hornos Industriales — furnace experts, consultants, and independent sales representatives for various furnace companies and spare parts — Carlos Carrasco is the founder and former president of ASM International, Mexico Chapter with more than 50 years of experience in the heat treat industry.
For more information:
Contact Carlos at contacto@carrasco.com.mx or at www.furnacexpert.com
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