Tag Archives: hardening

Allgemein

Schwartz: Three hardness zones in the same blank

Two new techniques boost heat treatment flexibility in press hardening structural parts made of 22MnB5

Schwartz: Three hardness zones in the same blank

A sheet metal part after heat treatment in the thermal printer

At the Thermprocess trade fair, Schwartz will be premiering two innovations developed in-house for the press hardening of sheet metal: tailored tempering with a „thermal printer“ produces different hardness zones in the part, while a dew point control system for the air atmosphere of roller-hearth furnaces reduces the risk of oxygen-induced embrittlement.

Tailored tempering

The new „thermal printer“ enables the user to create multiple regions of different hardness in the same sheet metal blank. A targeted, localized heat treatment exposes the part to a locally varying time/temperature curve. Thus, in addition to the hard martensitic areas obtained by conventional press hardening, it is possible to produce soft zones with a microstructure comprising ferrite, pearlite and bainite.

By this accurately focused heat treatment, Schwarz achieves a very narrow hardness transition area in the product. The thermal printer can provide a 250 °C temperature differential over a width of only 60 mm. On a tailored tempered blank subjected to a 550 °C holding temperature, hardness measurements in the soft zone revealed a bainitic microstructure having a hardness of 350 HV. The area of transition to the hard zone was only 30 mm wide.

The printer is integrated into a press-hardening line in the furnace-to-press transfer section. In a dual configuration using two printers, cycle times of around 20 seconds can be achieved with this process.

Schwartz uses a mathematical model based on finite-difference modeling to model the temperature pattern across the blank, from which the parameters for temperature distribution in the printer are then derived.

Dew point control

At Thermprocess, Schwartz will also present their three-zone dew point control system for roller-hearth furnaces for the first time. The technology manages the dew point in three separate, individually controlled zones via the supply of very dry air.

This development was driven by the observation that in aluminium-silicon (AlSi) coated parts, cracks due to hydrogen embrittlement may occur in the base material after the press hardening process. Accordingly, even loads below the material’s limit of elasticity may result in its fracture. The phenomenon is likely to be caused by sub-dew point conditions during heat treatment.

With the new dew point control system, the dew point inside the roller hearth furnace can be precisely controlled and brought down to as low as -20 °C. One central element of this system is an automatically self-„tuning“ laser measuring cell developed specifically for this application case. Unlike capacitive systems, it delivers precise results in a few seconds‘ time.

For the measurement the laser light is reflected by a mirror. Since the system evaluates the diffuse reflection, it provides precise measurements even when the mirror is dirty, in contrast to conventional sensors. A window is the only optical component with exposure to the sample chamber. This design makes for a reliable and maintenance-friendly measurement.

Schwartz at Thermprocess 2015 (Düsseldorf, 16 – 20 June):
Hall 09, Stand F42

About Schwartz
Schwartz develops and manufactures high-efficiency heat treatment systems for annealing, hardening, forging, sintering and tempering ferrous and nonferrous metals. In each of these processes, the heat treatment can be carried out under air, protective gas and/or reactive atmospheres.

Especially for the heat treatment of aluminium, Schwartz designs and builds equipment based on high-convection heating, e.g. by the jet heating method.

Over the decades, Schwartz GmbH has come into the spotlight time and again for its innovative systems. One example is the technology of press-hardening sheet metal, which was pioneered by Schwartz along with the associated environmental protection solutions. At one German automotive manufacturer, equipment supplied ex Simmerath saves huge amounts of CO2 each year – the cuts are equivalent to the emissions of a small city with a population of 32,000.

At the Simmerath headquarters site, around 3,000 sq.m. of floorspace are dedicated to the manufacture, assembly and commissioning of heat treatment equipment. There are currently 110 people employed at the Simmerath factory; the company has a total workforce of 150 employees worldwide.

In 2011, the manufacturing subsidiary Schwartz Heat Treatment Systems Asia (Kunshan) Co. Ltd. was founded in Shanghai, PR China. Another subsidiary, Schwartz Inc. of Oswego, Illinois (U.S.A.), has been active since 2012. Now as before, all equipment is fully erected, heated up before shipment, and subjected to pre-commissioning at the production facility (Simmerath and Kunshan).

Firmenkontakt
Schwartz GmbH
Elke Müller
Edisonstraße 5
52152 Simmerath / Germany
+49.2473.9488-0
+49.2473.9488-11
info@schwartz-wba.de
www.schwartz-wba.de

Pressekontakt
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstraße 83
52072 Aachen / Germany
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Allgemein

Infrared emitters and UV lamps speed up production and improve quality

The coating of foils, the printing of labels or the gluing of electronic components are very different and demanding applications. They all require innovative production processes to remain nice to look at, durable and scratch-proof.

Infrared emitters and UV lamps speed up production and improve quality

Heraeus Noblelight develops special drying and curing solutions tailored to the production process.

The coating of foils, the printing of labels or the gluing of electronic components are very different and demanding applications. They all require innovative production processes to remain nice to look at, durable and scratch-proof. Heraeus Noblelight infrared and UV systems increase production speed and improve the quality of the drying process.

Easy retrofitting at a paper coating line
By simply retrofitting a Heraeus Noblelight infrared system, Smith & Mclaurin in Great Britain were able to speed up and improve their production of labels.

Smith & Mclaurin Ltd is a leading manufacturer and global supplier of self-adhesive labels, tags and tickets. Based at Johnstone, Renfrewshire, the company is selling reels of materials to printing houses and processors that manufacture finished labels and tags for a wide range of end users such as supermarkets, pharmacies, logistics companies and food-processing companies.
An important part of the production process is the application of silicone materials to the label strips. Provided with an adhesive, the silicone is attached to the rear of the label strips and then dried and cured. Previously, this was done using a 20 years-old combined system of infrared and hot-air oven. However, increased demand required a higher speed of the production line and the existing infrared oven was unable to manage this.
Smith & Mclaurin had already successfully been operating a carbon infrared system (CIR) at another line and so the engineers contacted Heraeus and retrofitted a 192 kW CIR oven directly downstream of the existing hot-air oven. The CIR system comprises two modules with 96 kW each, which were installed above the line, each module being equipped with 15 medium-wave carbon emitters arranged in 10 individually controllable zones. This allows the output to be increased from 0 kW to 192 kW in ten equal steps to meet the specific requirements of the production process.
„The success of this second infrared installation further increases our confidence in the technology,“ comments Iain McCourty, Engineering manager at the Renfrewshire site. „The ability of the Carbon medium wave system to provide heat instantaneously and uniformly through the applied coatings has ensured that we can now increase line speed. At the same time, the controllability of the system means that we are obtaining a much more reliable, and hence better quality, adhesive cure.“

Efficiently cross-linked with optimal use of energy
In order that coatings, paints or inks remain nice to look at, durable and scratch-proof, they need to be dried and cured sufficiently and optimally. This requires that wavelengths as well as UV light intensity and dose be adjusted to the photoinitiators of the varnish formulation or the coating.
Heraeus Noblelight offers different UV solutions for the pretreatment or curing of paints, inks and coatings. The range includes innovative LED technology, special surface lamps (UVC Cure) or conventional UV medium-pressure lamp systems as well as microwave-powered UV lamp systems. Based on curing process, material, coating and ink or lacquer formulation, the UV solutions are tailored to the individual process requirements.
The different UV systems emit intensive UV light in the wavelength range of 200 to 400 nanometres. The wavelengths of the lamps are optimised for the photoinitiators of the lacquer system or coating to achieve efficient and sufficient cross-linking. This enables higher production speeds and improved process reliability. The processing of the surface can continue without much delay or the surface is scratch-resistant or durable at the end of a curing process.

From start to finish: Heraeus UV light sources accompany the entire production process.
Prior to application of the coating or printing, the surface tension can be reduced and the surface energy increased by means of VUV radiation (vacuum UV). Due to the resulting changed wetting properties, materials can be processed further better and faster. After that, the UV coating or printing is cured. Intensive microwave-powered UV medium-pressure systems with appropriate doping or UV LED systems are used for this. Selection of a suitable UV solution also allows intermediate curing steps. Finally, the surface can be further improved by means of a special UVC cure system. Similar to UV LEDs, the system emits monochromatic UV radiation in the UVC range. This makes surfaces significantly more scratch-resistant.

Heraeus UV solutions can be used depending on which process step is to be optimised. The use of advanced UV LED technology is a promising option to lower the energy consumption and heat generation. UV LEDs are ozone-free and long-lasting. This makes maintenance easy and saves money. The current developments of UV LED coatings and lacquers enable curing with UV LEDs despite the monochromatic spectrum. Conventional UV technologies such as UV medium-pressure lamp systems dry and cure paints across a wide, polychromatic spectrum with a very high intensity. This allows high speeds and reliable curing processes. The cured paints or inks give the surfaces a brilliant appearance.

All UV and IR systems can be used separately or in combination to tailor the drying and curing solution to your requirements. Application experts give advice as to how drying and curing processes can be optimised and energy can be saved by the purposeful use of UV and IR radiation – for premium, scratch-resistant and durable surfaces.

Heraeus, the technology group headquartered in Hanau, Germany, is a leading international family-owned company formed in 1851. We create high-value solutions for our customers, strengthening their competitiveness for the long term. Our activities focus on a number of markets: chemical and metals, energy and the environment, communications and electronics, health, mobility, and industrial applications. In fiscal year 2013, Heraeus achieved product revenue of €3.6 billion and precious metals trading revenue of €13.5 billion. With some 12,500 employees in over 110 subsidiaries worldwide, Heraeus holds a leading position in its global markets.
Heraeus Noblelight GmbH with its headquarters in Hanau and with subsidiaries in the USA, Great Britain, France, China and Australia, is one of the technology- and market-leaders in the production of specialist light sources and systems. In 2013, Heraeus Noblelight had an annual turnover of 138 Million € and employed 875 people worldwide. The organization develops, manufactures and markets infrared and ultraviolet emitters, systems and solutions for applications in industrial manufacture, environmental protection, medicine and cosmetics, research, development and analytical measurement techniques..

Kontakt
Heraeus Noblelight GmbH
Marie-Luise Bopp
Reinhard-Heraeus-Ring 7
63801 Kleinostheim
+49 6181/35-8547
+49 6181/35-16 8547
marie-luise.bopp@heraeus.com
http://www.heraeus-noblelight.com

Allgemein

30 Years of Schwartz Heat Treatment Systems

Sales have tripled in the past three years

30 Years of Schwartz Heat Treatment Systems

Roller hearth furnace system for the heat treatment of steel blanks prior to hot forming.

Simmerath, Germany, 21 October 2014 – Schwartz Wärmebehandungsanlagen GmbH is celebrating its 30th business anniversary this October. Based on the production of chamber, pit, box-type and shaker hearth furnaces, the company has evolved into a globally leading manufacturer of heat treatment equipment. More than 800 installed systems prove their merits in day-to-day use in the automotive and its supplier industries as well as in steel, aluminium and nonferrous metals processing.

Established in 1984 at Gevelsberg/Germany by Dipl.-Ing. Rolf Schwartz, the company relocated to Simmerath in 1998, setting up a plant on the Rollesbroich Industrial Estate. Today, the Simmerath headquarters site comprises around 3,000 sq.m. of floorspace for the manufacture, assembly and commissioning of heat treatment systems. For the planned addition of a further 1,000 sq.m. of indoor manufacturing space the contracts have already been awarded. There are currently 110 people employed at the Simmerath factory; the company has a total workforce of 150 employees worldwide.

In 2011, the manufacturing subsidiary Schwartz Heat Treatment Systems Asia (Kunshan) Co. Ltd. was founded in Shanghai, PR China. Another subsidiary, Schwartz Inc. of Oswego, Illinois (U.S.A.), has been active since 2012. Now as before, all equipment is designed, produced and commissioned at the Simmerath headquarters plant.

Schwartz develops and manufactures high-efficiency heat treatment systems. The range comprises, e.g.,
-roller-hearth heat treatment equipment for annealing, hardening, forging, sintering and tempering metals;
-continuous-type heat treatment equipment for hardening, forging and sintering strip under a protective gas atmosphere;
-jet-heating systems for forging and pressing blanks.

Over the years, Schwartz has come into the spotlight time and again for its innovative systems. One example is the technology of hot-forming sheet metal, which was pioneered by Schwartz, along with the associated environmental protection solutions. At one German automotive manufacturer, equipment supplied ex Simmerath saves huge amounts of CO2 each year – the cuts are equivalent to the emissions of a small city with a population of around 32,000.

Especially in the past five years, Schwartz has been expanding strongly. Alexander Wilden, the Managing Director, sees his strategy confirmed. „Our customers are evidently satisfied with our work. This is clearly reflected in the figures – in the last three years we have nearly tripled our sales. Certainly, one key aspect of our new system development is the intense cooperation with the two Aachen universities as well as with renowned industrial partners.“

The company places particular emphasis on energy efficiency. Due to their excellent design and the consistent use and recirculation of process heat, Schwartz systems are particularly low on energy consumption while providing high availability rates at the same time.

In late October, the company’s business anniversary will be celebrated at the Simmerath plant with customers from Germany and abroad, together with Schwartz employees. Among the guests will be Thomas Rachel (MP), Parliamentary Undersecretary in the German Federal Ministry of Education and Research.

The program will be rounded out by tours of the company that will include viewings of heat treatment systems under construction as well as of ongoing development projects.

About Schwartz

Schwartz develops and manufactures high-efficiency heat treatment systems. The range comprises, e.g.,
– roller-hearth heat treatment equipment for annealing, hardening, forging, sintering and tempering metals;
– continuous-type heat treatment equipment for hardening, forging and sintering strip under a protective gas atmosphere;
– jet-heating systems for forging and pressing blanks.

Firmenkontakt
Schwartz GmbH
Alexander Wilden
Edisonstraße 5
52152 Simmerath
+49.2473.9488-0
+49.2473.9488-11
info@schwartz-wba.de
www.schwartz-wba.de

Pressekontakt
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstraße 83
52072 Aachen
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Allgemein

New patenting furnace saves ten percent on energy

Resource-saving wire production: New measuring technique enables control of furnace atmosphere.

New patenting furnace saves ten percent on energy

Patenting furnace – side view

At Wire 2014, Wire Körner will exhibit the new series of directly heated patenting furnaces fitted with automatic furnace atmosphere control and burner with heat recuperation. With these new energy-saving furnaces, Wire Körner further expands its range of efficient and eco-friendly heat treatment plants for wire. Based on his good experience with the furnace, a German customer has already ordered an extension to the existing unit.

The first unit of this new furnace generation has been in operation for two years. Designed for a throughput of 2,000 t per hour, it processes wire in diameters from 1.5 to 5.5 mm. The plant expansion is expected to be commissioned in April 2014.

By implementing a wide array of innovative features, Wire Körner has increased the efficiency of patenting furnaces for wire and achieved savings on energy consumption of some eight to ten percent compared to conventional furnaces. The very first furnace of this new generation has already been in production for more than two years.

With an innovative sensor, Wire Körner has for the first time realized a system for controlling the furnace atmosphere. Via the furnace control system the air/combustion gas ratio is exactly set within a specified range. The high control precision and stability of the gas/air ratio makes the new furnaces superior to Pre Mix systems. In addition to the savings on energy, controlling the air/gas ratio keeps NOx emissions low and prevents decarburization of the wire. The furnace temperature is adjusted with a precision of +/- 2 °C.

A central recuperator installed in the waste gas duct preheats the combustion air for the high-speed burners to 200 – 250 °C, while reducing the waste gas temperature at the stack from 600 °C to 400 – 500 °C. Already in the preheating zone Wire Körner exploits the thermal energy of the waste gas to heat up the wire entering the furnace. This reduces the energy demand for preheating.

In contrast to previously used burners, the high-speed burners employed by Wire Körner can be adjusted in several steps. This ensures that the burners consume exactly the amount of energy they need, not more.
Wire Körner has brought down heat losses via the furnace wall by optimizing the layout of the wall, among others by means of insulating ceramic fibers. An additional coating ensures a long service life of the furnace wall even under conditions of high CO contents and high flow velocities. An additional, 2.5-cm-thick Microtherm® insulating layer behind the refractory brick lining brings down heat losses even further.

The furnace is directly heated. The heat is transferred into the wire by convection, at flow velocities of up to 120 m/s. This provides much better energy efficiency than heating by radiation.

Wire Körner at Wire 2014 in Düsseldorf, April 7 to 10, 2014:
Hall 9, booth F 51
Bildquelle:kein externes Copyright

About Wire Körner

Wire Körner GmbH designs and manufactures plant and equipment for the complete process chain of wire and narrow strip heat treatment, from the drawn wire through to the finished end product. The range of heat treatment plants comprises bell-type, chamber and channel furnaces for patenting, annealing, galvanizing, hardening, tempering and chemical treatments. The company provides design, engineering, manufacture, erection, commissioning and after sales service. Wire Körner maintains a worldwide network of branches and licensees.

Wire Körner’s numerous quality and efficiency-enhancing innovations regularly attract the industry“s attention. For example, the recently developed wire patenting furnace with an innovative atmosphere control system achieves substantial energy savings, or the recuperative immersion burner for ceramic galvanizing furnaces has been designed for very long service lives, just to mention a few examples.

Wire Körner is a company of the Körner Group, which was established in 1928. Thus the company builds on more than 80 years of experience in industrial furnace technology and auxiliary equipment. Within the group, Zink Körner GmbH specializes in plants for piece galvanizing. TVT Kordt GmbH develops plants for thermal process technology, with a focus on industrial furnaces for the heat treatment of steels, special steels and non-ferrous metals.

Kontakt
Wire Koerner GmbH
Peter Kordt
Profilstraße 9
58093 Hagen/Germany
+49.2331.800680
info@wirekoerner.com
http://www.wirekoerner.com

Pressekontakt:
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstraße 83
52072 Aachen/Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de