Tag Archives: tempering


Tenova LOI Thermprocess: new hardening machines for flexible adaptation

Quenching and tempering of wheels for high-speed trains – Hardening in combination with mathematical model enhances process security

Tenova LOI Thermprocess: new hardening machines for flexible adaptation

Wheels at the exit of a hardening furnace before they are transferred to the new hardening tables

The newly developed wheel rim hardening machines from Tenova LOI Thermprocess adapt flexibly to rolling stock wheels of different shapes and sizes, allowing operation without interruptions to production even if wheel sizes are frequently changed. In combination with a mathematical quenching model, the new machines significantly reduce the time required for tests and also ensure higher process security.

With the individually controlled nozzles, the wheel rim hardening machines are so flexible that they can be used for treating wheels of almost any dimensions. The new control system allows the cooling table program and the adjustment of the nozzles to be changed from batch to batch. This means that batch changes can be completed automatically without any interruption to production. Nevertheless, precise repeatability of the quenching and tempering processes is ensured for each specific batch.

The designers of the hardening tables were faced with the task of developing an extremely robust system without using any sensitive mechanisms. As a result, the new tables have significantly fewer parts than those previously used. The tables consist mainly of standard components available from stock, meaning that spare parts can be delivered quickly.

Especially for plants in countries with high ambient temperatures, it is important to note that the new tables use water temperature ranging from 30 to 35°C. It is no longer necessary to cool the water to 20°C.

Mathematical model saves time and enhances process security

The new hardening tables immediately proved themselves in practice on a recently installed fully-automated quenching and tempering line for railway rolling stock wheel rims. LOI used a mathematical model developed especially for hardening as well as a quenching program computer. Using this computer, quenching parameters are calculated to ensure that the wheels reach the specified values, even after product changes.

Using this model, LOI has reduced commissioning times from up to one year to a few weeks. The customer saves material and laboratory time and can also start production earlier.


The furnace technology used in heat treatment plants has already reached a very high standard. In contrast, on many manual or semi-automatic treatment lines, the quality of quenching still depends on the qualification and experience of a few employees. The hardness required is normally reached but the microstructure does not always meet the requirements set out in standards. Especially for high-speed train wheels, it is crucially important for process parameters to be reproducible within very tight limits.

To date, the development of programs for new products and the running-in phase following product changes have been extremely time-consuming and have resulted in considerable material losses. Until wheels meet the required specifications, they must be destructively tested so that metallurgical parameters can be inspected over the cross-section of the wheel.

The model developed by LOI receives the specified properties of the finished wheel as inputs and calculates quenching parameters from the geometry of the wheel and the material composition. This procedure is independent of the various national standards which need to be applied.

About LOI

LOI Thermprocess is a company of the Tenova Group focusing on the heat treatment of steels and aluminium. More than 4,000 industrial furnaces bear the LOI name, making LOI a brand that stands for quality, economics and continuity.

The treatment of metals calls for a profound knowledge of metallurgy, physical and chemical processes and a number of engineering disciplines. Many years of practical experience are equally important. The unique background of the LOI team has laid the foundations for the company’s strong position on the international market.

LOI has developed mathematical models for the highest possible quality levels in production on the basis of precise knowledge of the physical relationships involved. LOI sees itself as a technological partner to the customer and its plant designs are closely linked to the requirements faced by customers’ products.

We not only have the know-how to build economical, reliable industrial furnaces. We also have in-depth knowledge in the following areas:
– Quenching processes using liquid and gaseous media
– Coating and thermochemical surface treatment processes
– Thermal surface cleaning in reactive atmospheres
– Automation and throughput optimization
– Burner technology

LOI Thermprocess GmbH
Andrea Kehry
Am Lichtbogen 29
45141 Essen

Regina Reinhardt
Süsterfeldstraße 83
52072 Aachen


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.

Schwartz GmbH
Alexander Wilden
Edisonstraße 5
52152 Simmerath

Regina Reinhardt
Süsterfeldstraße 83
52072 Aachen


Experience the soldering process live at Rehm Thermal Systems

A new Technology Center offers a wide range of possibilities

Experience the soldering process live at Rehm Thermal Systems

Endoscopic examinations of BGAs

Which procedure for soldering, tempering or coating is best suited for which application? How can a specific temperature profile be created? And what technology can be used to reduce voids in the soldered joint? Whether it is competent advice, process demonstration or technical training – as leading manufacturer of thermal system solutions for the electronics and photovoltaics industry, Rehm (http://www.rehm-group.com/) offers a wide range of possibilities in its Technology Center. Last year, a high-tech application and demo center was created at the head office in Blaubeuren, Germany, on a total of 460 m2, where customers can test the systems, get to know the technology behind them and perform comprehensive soldering attempts. Furthermore, the specialists at Rehm discuss innovative solutions for new applications and methods together with the customers in order to optimise production processes in the long term.

In addition, the new Technology Center has state-of-the-art equipment of a complete SMT production line – from paste printers and placement machines to reflow soldering systems. Rehm Thermal Systems offers all thermal processes for heat transfer as the only manufacturer. The customer can choose between systems with convection, condensation, infrared and contact heat. Soldering processes and procedures for coating (assembly protection) as well as respective drying, transport and handling systems are demonstrated live for different applications on site. „We can run pilot batches under real conditions, to precisely define optimum parameters for the assembly of the customers. But at the same time there is enough room to develop new ideas together“, says Chief Executive Officer Johannes Rehm.

The application specialists of Rehm take an advisory capacity, provide support when selecting a suitable system or create individual process parameters. „Each product has different criteria during production. During direct application of vacuum, condensation and convection soldering methods, we can accurately determine the advantages and disadvantages for the product to be produced and find the optimum process. In a second step it is then possible to further refine additional parameters like pre-heating time, temperature regulation and cooling off time. With the options in our demo center we respond flexibly to the desires of our customers“, says Helmut Öttl, Head of the Application and Project Management division.

Even the production of prototypes or mini series can be realised in the Technology Center near Rehm. „We can also create the right profiles for innovative assemblies, which have special features with regard to mass, shape or material“, says Öttl.

Furthermore, a complete coating line for selective Conformal Coating with optional vacuum module is available for underfill processes, to optimise protection for assemblies against environmental impacts.

But the Technology Center (http://www.rehm-group.com/index.php?module=Pagesetter&func=viewpub&tid=2&pid=40&bch=el&newlang=eng) also provides extensive equipment for the documentation or analysis of test results. The heat distribution on the electronic assembly for example displays a modern thermal imaging camera. Process-related temperature differences become visible based on the thermal images. This enables creation of the best possible reflow soldering profiles to minimise these temperature differences. In an X-ray system with digital imaging system the soldering results can be examined for pores (voids) or other features. A fly inspector, equipped with LED or UV light and zoom function enables accurate, visual control of the assemblies. Furthermore, different microscopic examinations as well as endoscopic examinations of BGAs can be performed with a micro inspector. „Our aim is to improve assembly production of the customers not only with regard to quality, but also sustainability“, says Helmut Öttl.

For special applications and solutions for the professional repair of assemblies, selective soldering equipment is available. Furthermore, a cleaning bath, temperature cabinet (-70 °C to 180 °C) and a shear test device up to 50 N are available for further applications.

What“s more, the Technology Center also provides optimum conditions for training and events. „Ideally we can combine soldering (http://www.rehm-group.com/index.php?module=Pagesetter&func=viewpub&tid=9&pid=2&bch=el&newlang=eng) theory and practice here. Imparted knowledge, which can be practically implemented in our workshops immediately, remains fresh in the memory. At the beginning of April we received great feedback for the fully booked seminar series on the optimum reflow profile and void-free soldering“, says Dr. Hans Bell, Head of the Research and development division at Rehm.

In order to be able to present the complete product with regard to soldering to the customer in this context, Rehm is supported by well-known companies in the industry, which provide respective systems. „We thank our partners for this“, says Johannes Rehm. „We can now combine everything under one roof – advice and customer care, technical know-how, the illustrative demonstration of complete production lines and the exchange of knowledge and experience in the seminars. These options are very popular with our customers“. Rehm takes this opportunity to continue to offer more events in the next few months, where the Technology Center is a central setting.

Do you need support for a specific application or would you like to experience the topic of soldering live in our demo center? Please make an appointment on info@rehm-group.com. Information on current events and seminar series can be found on our Internet page on www.rehm-group.com in the media area.

Rehm Thermal Systems was founded in 1990 by Johannes Rehm and is a provider of reflow soldering systems and drying systems for the electronics industry as well as a manufacturer of fast firing systems and solar dryers for the metallization of solar cells. With „Simply. More. Ideas.“ our goal is to become technological leaders in all areas of production and offer our customers sustainable, future-oriented products.

Rehm Thermal Systems GmbH
Frau Department Marketing
Leinenstrasse 7
89143 Blaubeuren-Seissen
+49 7344 9606-0

APROS Int. Consulting & Services
Frau Volker Feyerabend
Rennengaessle 9
72800 Eningen


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.

Wire Koerner GmbH
Peter Kordt
Profilstraße 9
58093 Hagen/Germany

Regina Reinhardt
Süsterfeldstraße 83
52072 Aachen/Germany