HEAT TREATMENT FURNACES

THERMOVISION Pvt. Ltd.

 

HEAT TREATMENT FURNACES 

Bench top Furnace

Electric resistance Furnace bench-style box furnace is ideal for batch heat treating small loads to be used in Universities and research institutes.

The furnace is 10 kW power heats to 1000 deg C with easy-to-replace wire wound heating elements in removable holders. A horizontal swing door seals the 12 in H x 14 in W x 24 in L chamber. A ceramic hearth plate supports the work load and protects the floor brick. The programable digital temperature controller with safety microswitch and on/off main control switch are housed in a side mounted panel, and a rear mounted Type K thermocouple senses chamber heat.

 

Industrial Heat treatment Furnace

For general workshop and auto industry

• Maximum temperature ratings up to 800°C
• Electrically heated
• High pressure air distribution ducts
• Heavy duty exterior plate construction
• Combination ceramic insulation
• Air operated vertical lift door
• Roller or rail hearth
• Hearth rated at 750 kg.
• Main power disconnect switch
• Programmable temperature control
• 380/3/50 power supply
  

ALUMINUM SOLUTION HEAT TREAT FURNACES

 

 

(Imported Unit refurbished)

The purpose of solution heat treatment is to evenly dissolve the alloys contained in the aluminum and then rapidly quench it to retain the grain structure. The aluminum alloy is heated and held at a temperature sufficiently high for a definitive amount of time to achieve a nearly homogenous solid solution where all constituents have dissolved. After rapid cooling, the material is in an unstable state. Our company has designed standard aluminum heat treat ovens and custom furnaces to accommodate quench delays as quick as 3 to 5 seconds. Common uses included the solution heat treatment of aluminum extrusions, sheet metal, and castings. Our goal is to provide an accurate reliable aging solution-treatment process while providing repeatable results and efficiency of material handling and workflow. Our aluminum heat treat ovens and processing equipment include drop bottom furnaces, horizontal quench furnaces, quench tanks, air quenches, and aluminum age ovens.

Drop Bottom Quenching Furnaces

 

A Vertical or Drop-bottom aluminum heat treat furnace is used to solution heat treat aluminum alloys larger components or many components in the basket. The furnaces are typically used when very fast water quench times are required. The furnaces are designed to meet all requirements of Aerospace Material Specifications. The quenching solutions can include water, water-air MIST, glycol, oil, oil-air MIST or air. Because of the height of these systems, they are typically installed in a pit. The quench tank and load/unload station is typically mounted on a moveable cart underneath the furnace.

The furnace heating capacity must be in enough to heat the aluminum parts to the desired temperature. Temperature uniformity in the heating chamber is very important. For the purpose the quenching furnace utilizes a high-capacity recirculation blower to deliver heated air with a combination airflow arrangement. This type of uniform airflow ensures even heat distribution throughout the work chamber and excellent temperature uniformity.

The furnace utilizes an electrically operated lifting/lowering mechanism that moves the component basket in and out of the furnace chamber from the bottom of trhe furnace and provides a quench time as low as five (5)  to eight (8) seconds, which combined with the load capacity of up to 1,000 Kg. or more makes it the ideal choice for an aluminum solution treatment system.

Furnace is equipped with a bottom door sliding sideways in two parts for opening the chamber for loading and unloading process.  When closed, the door is tightly clamped against the bottom frame of the furnace to prevent cold air leakage which can disrupt the temperature uniformity of the load and increase operating expenses.

The door consists of a tightly compressed ceramic fiber seal that is self-adjusting and will maintain a superior seal that will last years before replacement is required. For opening and closing of the door a robust mechanical / pneumatic system makes it fast and reliable. Opening width is maintained using a precision control system and indication on the control panel.

As the heated components in the furnace are ready to quench, the bottom door is opened sideways to lower the structure of  basket /fixture containing Aluminum parts comes out from the furnace is at once dropped in the quenching tank for the purpose.

 

 

Furnace Specifications

Solution Treatment Furnace

Type of Furnace                            Electric heating

Furnace power                              150 KW

Working Temperature                   700 °C  ± 5°C 

Furnace Inner size                        1500x1500x1500 mm

(Heating Chamber)                        Diameter 1500mm x Ht. 2000mm

Furnace door                                 Door opening 1500x1500 mm ( Diameter 1500mm)

Outer Size of furnace body            2500x2200x3000 mm

Load capacity                                750-1000 kg

 

 

Quenching systems       

Bulk water with temperature control

A large SS tank filled with controlled specifications water for Bulk Quenching.  The temperature of water for quenching in all the systems will be of desired specifications for a particular process. It is ranging from 5°C  to 25°C and in addition other controls like;

-        Temperature control

-        Flow rate control

-        Sufficient volume available

MIST of water-air spray with temperature control

In addition to bulk water column quenching system it may contains MIST quenching system using air-water mixture and water jet stream quenching jets system.

The temperature of water for quenching in all the available systems will be of desired specifications for a particular process. It is ranging from 5°C  to 25°C. 

To maintain the distortion in the thin Aluminum parts after quenching in solution treatment the water air MIST is very useful process. Pressurized Mist is impinged upon the surface of thin parts with desired quenching temperature gives excellent quenching results in the part.

To control the impingement pressure the MIST production system contains following:

-        Temperature control

-        Pressure control

-        Flow rate control

-        Impinging distance control

-        Sufficient volume available

 

 

 

 

 

ALUMINUM AGING OVEN

Aluminum aging ovens are used to manufacture durable, heavy-duty components for long-term use. The aluminum aging process is a time and temperature-dependent change in the properties of certain alloys and increases the hardness of the alloy. Heat-treatment speeds up the process to achieve the desired end-use properties (referred to as artificial aging). Except for strain aging and age softening, it is the result of precipitation from a solid solution of one or more compounds. For each alloy susceptible to aging, there is a unique range of time-temperature combinations to which it will respond.

After solution treatment and quenching, hardening is achieved either at room temperature (natural aging) or with a precipitation heat treatment (artificial aging). In some alloys, sufficient precipitation occurs in a few days at room temperature to yield stable products with properties that are adequate for many applications. These alloys sometimes are precipitation heat treated to provide increased strength and hardness in wrought or cast products. Other alloys with slow precipitation reactions at room temperature are always precipitation heat treated before being used.

Precipitation heat treatments generally are low-temperature, long-term processes. Temperatures range from 115 to 190 °C times vary from 5 to 48 h. Choice of time-temperature cycles for precipitation heat treatment should receive careful consideration. Larger particles of precipitate result from longer times and higher temperatures; however, the larger particles must, of necessity, be fewer in number with greater distances between them. The objective is to select the cycle that produces optimum precipitate size and distribution pattern.

 

Age Hardening furnace Specifications

 

Type of Furnace                            Electric heating

Furnace power                              80 KW

Working temperature                     300 °C  ± 5°C 

Furnace Inner size                        1500x1500x1500 mm

(Heating Chamber)                        Diameter 1500mm x Ht. 2000mm

Furnace door                                 Door opening 1500x1500 mm ( Diameter 1500mm)

Outer Size of furnace body            2000x2000x2500 mm

Load capacity                                500 kg

Baking and Heat treatment Furnace

Baking of moulds in the foundry requires the temperatures from 200°C to 420 °C. Oven baking strengthens the mold and hardens the cavity surface. A baked mold provides better dimensional control in the cast product, compared to green molding. Applications are generally limited to medium and large castings in low to medium production rates. The Baking and heat treatment furnace will be much useful for other metallurgical processes in the work place.

 

The furnace heating capacity must be in enough to heat the metal or ceramic parts to the desired temperature. Temperature uniformity in the heating chamber is very important.

The furnace utilizes an electrically operated lifting/lowering mechanism that moves the Job / component basket in and out of the furnace chamber from the bottom of the furnace and provides a process time as low as five (10)  to eight (20) seconds, which combined with the load capacity of up to 1,000 Kg. or more makes it the ideal choice for the process requirement.

Furnace is equipped with a bottom door for opening the chamber for loading and unloading process along with the load.  When closed, the door is tightly clamped against the bottom frame of the furnace to prevent cold air leakage which can disrupt the temperature uniformity of the load and increase operating expenses.

The door consists of a tightly compressed ceramic fiber seal that is self-adjusting and will maintain a superior seal that will last years before replacement is required. For opening and closing of the door a robust mechanical / pneumatic system makes it fast and reliable. Opening width is maintained using a precision control system and indication on the control panel.

Industrial heat treating furnaces

The heat treatment process involves intentionally changing a material’s physical, and sometimes mechanical, properties through the application of heat. Heat treatment furnaces are made in a variety of shapes, sizes and provisions to match the specific application. Heat treatment applications include annealing, curing, tempering and quenching.

A.   High temperature furnaces for laboratory

Ideal for a variety of applications – from university labs and research labs – to production applications, high temperature Laboratory furnaces combine excellent temperature control with reliable temperature uniformity. Our furnaces include Temperature programming for a number of segments and automatic shutdown feature if the furnace exceeds maximum temperatures, so safety will never be an issue. 

       

Our heating furnaces and drying ovens for laboratory are designed to deliver exceptional performance, precise temperature control, and uniform heating, ensuring accurate and reliable results. With user-friendly operation, durability, and advanced safety features, our Lab Ovens and bench top furnaces are the perfect choice for scientific research, industrial processes, and quality control procedures.

STANDARD FEATURES

• 1000°C maximum operating temperature
• 5 to 10 litre chamber volumes
• Ambient to 1000°C in as little as 20 minutes
• Rapid thermal response from free radiating coiled wire elements
• Low thermal mass insulation for high energy efficiency
• Soft closing, vertical lift door keeps heated surface away from the user
• Digital temperature controllers with single ramp to set-point & process timer
• Soft closing door keeps heated surface away from the user

 

 

B.  Pit Furnace

Pit furnaces are preferable when work pieces are very long and need to hang vertically to minimize distortion during heating, or for very large loads which are best handled with an overhead crane. For atmosphere processes a pit furnace configuration provides a positive seal that is critical to the success of the process.

Our pit furnaces are designed be versatile workhorses: they handle both large workpieces and small parts loaded in baskets. We provide designs for atmosphere and direct fired applications. We have manufactured various sizes of pit furnaces for different industries. Our standard pit furnaces can hold up to 3000 Kg., range from 24 in. to 70 in. in diameter and are between 36 in. and 144 in. deep. We have built engineered-to-order designs with heavier loadings and larger dimensions such as soaking pits for reheating aluminum and steel billets.

We have a well-known reputation for providing solutions that are rugged and built to last using mostly indigenization. Our furnaces have proven to be extremely reliable due to our robust design practices. A big part of that is how we design our casings with heavy plate that is supported large sectioned structural shapes. Steel plate lids assist in saving energy and provides access to lid mounted components. Furnace casings are welded gas tight or are properly gasketed to prevent atmosphere contamination and excess heat loss. We understand how casings grow and shrink during the furnace cycles and engineers the right thermal expansion joints into our designs.

Pit Type Electrical Resistance Furnace

Specifications:

Power 65KW

Rated temperature 1000C +- 10C

Chamber Size, Dia 650xH1800mm

Power Voltage 380/3/50

 

 

 

 

Refurbishment of PIT Furnaces HMC

This furnace is for heat treating of the job after forging. This Furnace Can also be used for Tempering  and quenching operation. This furnace have following specifications.

 

Temperature                       = 1000ºC

Temperature Uniform         = ± 5ºC

 Heating Zones                   = 10

Power                                 = 700 KW

Working Zone Dia.              = Ø 1300  Working Zone  Ht.               =10000 mm

Inner Diameter                    = 1600 mm

Furnace height                   = 11000 mm

 

Furnace Description:

 

           The Furnace is for heating of job Ø300- Ø1000 x H 9000 mm. Furnace body consists of already made by the customer using thick steel shells. These shells are flanged at the both ends with M.S. plate of appropriate thickness.

           The furnace shells are lined with High Alumina refractory bricks, blocks for heater face, refractory insulation bricks and ceramic material for back insulation. The existing configuration is much suitable for converting into electric resistance furnace. Only the openings already used for gas blowers or other purposes were blocked and finished using fire cement and fire bricks.

           Heating Zones sized 1000 mm high and there are ten heating zones vertically for equalizing the temperature through the hot zone. The Upper space of 1000 mm is specific for job handling devices. Each heating zone comprise of 3 heating elements connected in STAR configuration.

Heating elements are configured in ROB (Rod Over Bend). This configuration is the best suited technique for such large furnaces. The elements are made using suitable materials and the wire diameter or the strip size is carefully chosen for fulfill the power requirement and the size of the heating zone.

 

 

For heating elements KANTHAL A1 and its equivalent FeCrAl strip has been selected with a size of 15x2.0 mm, which will provide sufficient advantage for the surface loading of this heavy gauge. Three heaters are connected using Star configuration in one heating zone. The power of each zone is 78KVA. Heaters hanged on the furnace wall using SS304 wire 6mm diameter according to the hanging scheme. Heaters were welded with SS rods diameter 16mm and 1200 mm length to connect the power cables outside the furnace body.

Furnace power is 780 KW and  its power is controlled using PID programmable controllers and digital power thyristors.

K type thermocouples with SS sheathing was used to monitor the temperature in each heating Zone. Standard sheath material 304 SS and Sheath diameter 10 mm  and thermocouple Length 1200 mm. Thermocouple signals transmitted  up to the programmable temperature controller in the control panel using compensation wires Type  K  a pair of stranded wires ; 0.2 mm². This pair twisted together then screened with Mylar Aluminum tape in contact throughout by a bare tinned copper drain wire, HR PVC sheathed and class 1.

Power cables 70mm² single core was used to provide the power to the heating elements. These cables were put in ducts using the facility walls and special hangers. The power cable connectors on the furnace side was tightened to the element terminals and the control panel side with the terminal block arrangements.

Control Panel and Power Thyristor panel is designed to minimize the power losses and to ease the operator. This panel is located near the transformer room for this purpose. This panel is made using good manufacturing practices. The Size of the panel is  14ft. (L) x 6.5 ft. (Ht)  x 3 ft. (D) . it was made using BWS ; 14 gauge steel sheets, polyester powder coated in white colour.The Control panel is housed in the dust proof room glass lined and temperature controlled atmosphere.  

The subjective furnace project is situated in the Hydraulic Press shape of HMC, Taxila. The complete project comprised of re furbishment of Two identical furnaces. It was the refurbishment of already existing gas fired Pit furnaces to convert it to Electric Resistance Furnaces for heat treatment of steel jobs. Previously the facility was run for heat treatment of long shafts using natural gas burners. For the development of new products the technological requirements existed for the refurbishment of the furnace and converting to the electrical resistance heating system.

The furnace walls were refurbished using refractory materials in the form of blocks and fire bricks. A fire brick or a block of refractory ceramic material used has been designed mainly to withstand high heat, but should also usually have a low thermal conductivity to save energy. Usually dense bricks are used in applications with extreme mechanical, chemical, or thermal stresses, such as the inside of a furnace, which is subject to abrasion from high temperatures.

Refractory bricks have been used for this furnace

Alumina > 55% and Fe₂O₃ < 1.0%      density = 1.6 g/ cm³

Refractory Bricks dimensions; 230*100*75 mm

High Alumina Fire Bricks: 230*100*75*60 mm

Fire clay, Fire cement, Mortar, Sodium silicate, Alumina powder

Alumina fiber Insulation Blanket

The furnace lids were only refurbished using the existing set of seals only adding a few more items for mechanical fitting on the furnace top.

The furnace facilitate the project for heat treating variety of new jobs and already in progress jobs using this modern technical facility.

The project was started in Feb. 2022 and its finalized in July, 2022. 

 

 

 

C.  SEALED QUENCH FURNACE

Seal Quench Furnaces are widely utilized in various industries, including automotive, aerospace, tooling, and general manufacturing, where heat treatment of metal components is necessary to achieve specific material properties and performance characteristics. Sealed Quench Furnaces has revolutionized the heat treatment industry in the last few decades thanks to its versatility, easy integration in automatic treatment lines, providing flexibility of metallurgical processes, product mix and layout, with maximum quality heat treatment in terms of reliability, predictability and repetitiveness. These plants are normally coupled with companion equipment like Preheating and Tempering Furnaces, Washing Machines, Stationary Table, Scissor Lifts and fully automated one or more Charge Transfer Cars- all designed for maximum reliability.

The use of a sealed chamber in Seal Quench Furnaces allows for controlled quenching and minimizes the risk of distortion or cracking in the heat-treated parts. The quenching medium can be selected based on the desired properties and the specific requirements of the components being processed.

 

The sealed quench is a batch furnace in which the heating and quenching chambers are combined in a single unit. The two chambers are separated by a refractory lined door which can be opened to allow the hot charge to be transferred from the heating chamber to the cooling chamber. The furnace is loaded at the front door and unloaded at the rear door.

Some of the available options also include:

·        Heating System can be electrically heated through radiant tube heaters type E or Gas Fired through high efficiency recuperative burner system type G.

·        Gas used for heating and process can be LPG/Propane/Natural Gas supplied.

·        Available in the versions of Straight Through or TWO DOOR (TYPE CBUT) furnaces with one or more chambers, and In-Out or SINGLE DOOR (TYPE CBUR) furnaces with frontal loading/unloading.

·        Furnace atmosphere possible:

·        With Endo-gas and LPG/Propane/Natural gas

·        With Methanol and LPG/Propane/Natural gas

·        With Methanol + Nitrogen and LPG/Propane/Natural gas

·        With Direct Gassing Process by LPG/Propane/Natural gas and Air

·        Gas Carburizing possible:

·        With direct quenching

·        With intermediate cooling

·        With charge cooling under protective gas

·        Oil Cooling possible by Air or Water.

·        SCADA (Supervisory control and data acquisition system) to provide operational control, standard recipes and recipe management

·        Fully Automatic and Man less installation operated from the control room

 

In this design, the quench rack has two sets of rollers, one above the other so that the furnace can still be loaded whilst the load just treated is still in the quenching oil on the lower set of rollers. In a similar way, the furnace can still be loaded whilst the load just treated is being atmosphere cooled on the upper rollers.

 

 

D.Powder/coating paint curing ovens

Size  6 ft( wide)  7ft. (ht) 12ft. (L)

Required Temperature       200C

Av. Daily running ime 8-10 Hrs. 

Electric Heating Box  = 35 KW

 

 

 

 

 

 

 

 

 

 

 

  

E. CVI Furnace 2

 

Furnace Type                     Vacuum Electric Furnace

Power                                 150 KVA

Process                               CVD  or  CVI

The Furnace is used for CVI process. The process of Chemical Vapor Infiltration is using a unique technology for the production of Carbon - Carbon Composite. Carbon preform  which is made by carbon filaments and fibers is filled with pyrolitical Carbon in the porosity of the preform. This poly carbon is then carbonized and ultimately graphitized at higher temperatures.

Carbon perform is heated in the vacuum tight heating chamber and methane gas is introduced which is pyrolyzed , forming pyrocarbon only in the pointed deposition zone. A thermal gradient is established with in perform so to favour the rate of deposition in the radial direction. For this purpose Graphite heater is positioned in the center of the heating chamber, carbon perform around it is heated by joule heat to a high temperature of 900°C.Carbon perform with low thermal conductivity and rapid flow of methane gas flow cooled the exterior surfaces of the perform help in producing this temperature gradient.

Furnace Construction

The furnace  typically consists of the Basic Furnace Chamber Assembly, the Evacuation System, the Process Gas System, the Power Supply, the Temperature Control Instrumentation, and the Furnace Mounting System.  The vacuum furnace vessel is manufactured with stainless steel, including the chamber, water jacket, and all flanges. Process gas and vacuum pump manifolds are also made with stainless steel, as well as any additional piping which may come in contact with the process gases. Rubber gaskets are used as vacuum seals on small diameter piping where practical, and Viton O-rings on larger diameter flanges such as the upper & lower lids and vacuum pumping system ports.

The furnace chamber is made of stainless steel-304. It is a double wall water cold and flanged. The flanges are also water cold. Feed through for electrical current and thermal couple are located from the side of the cylindrical vessel. The viewing and vacuum port is on the top and gas inlet from bottom of furnace.

The whole furnace power system is interlocked by a gas pressure interlock and a water flow interlock that shuts down the power of hot zone if cooling water flow is reduced or closed off /or/ if gas pressure drops below the set point.

 

 

Specifications

                      Temperature                                         =   1500°C

                      Graphite Heating Element        O.D.   = 268 mm

                                                                  I.D.     = 260 mm

                                                                  Height = 600 mm

 

                      SS Furnace chamber         ID      = 800 mm

                                                                  O.D.  = 865 mm

                      Furnace chamber              HT     =1000 mm

                     

 

 

 

 

 

 

 

F. CONTRL PANEL FOR FURNACES

 

 

 

 

 

 

 

Light gray shell

Black shell

 

 

 

Light gray shell

Black shell

 

 

 

 

DKEASY-3PH-4MA20-200A-3S-F-S-380-50-220-P-10-UN

 

 

 

 

 

 

 

 

 

Data Logger

Features

·        Input channels are isolated for all inputs except RTD

·        Communication (RS 485/RS232) with software up to 4 Alarms, 3 Inputs, I/O.

·        Common/ Independent Low & High Alarm relays for each channel.

·        24VDC Power supply for 2 wire transmitters – on 3 channels.

·        High accuracy (14 bit resolution), μP based.

·        Self Diagnosis function: Input fail safe operation.

·        Extended alarm function.

·        Advanced parameter protection function can be set to avoid any illegal operation.

·        Flow integration with temp & Pressure compensation for steam & supersaturated steam.

·        EMI /ESD protection; CE approved

·        Data logging software

 

 

TECHNICAL SPECIFICATION:

No. of Channels	4, 8, 12, 16
Sensor Input	Thermocouple, Pt-100, (4-20)mA, (0-1)V etc... (each channel can be of different input type)
Range	Subject to specified input
Accuracy	Better than +/- 0.1% of the range
Alarms	Common or individual high and low with relay and driver outputs
Data Logging	Real Time with programmable log time and storage time
Interface	Parallel for Printer and Serial (RS232/RS485) for PC with window based software (Modbus ASCII Protocol)
Data Storage	2K to 128K memory bank
Supply Voltage	110/230VAC, 50/60 Hz, 24VDC
Operating / Storage Temperature	0-500C Max. / 0-700C Max. @ 10-85% Rh (Non-Condensing)
Size	192x96 mm.

Paperless Recorder

MULTI COLOR TOUCH SCREEN PROCESS PAPERLESS RECORDER with pen drive& RS232 communication and memory Twenty Thousand Per channel

• Make: IFC Model No: TPLR -120-8U
• Size: 96x96mm, Display Size;8 Inch Multi Color
• Input: Universal, Range: As Per Output
• No of channel :8 Channel
• Operating Voltage:230VAC/50Hz
• Windows based software package suitable for Paperless Recorder.