1. business and industrial
2. manufacturing

International Magazine for Industrial Furnaces
Heat Treatment & Equipment
03 I 2014
ISSN 1611-616X
Vulkan-Verlag
www.heatprocessing-online.com
nd E-040
Halle 4.1/Sta
E-040
Hall 4.1/Booth
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HybridCarb und EndoSave den Prozessgasverbrauch in signifikante Weise reduzieren.
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in mind. Combustion optimized using the EcoFire system ensures highly efficient energy
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www.ipsen.de
INFORMATION
BASIC DATA
PRODUCT PREVIEW
All about the HK 2014 in
Cologne (Germany)
Details and site plan of the
new venue
The latest product highlights
from the HK-Exhibitors
The best of 10 years
heat processing
Pre-order now!
heat processing –
10 years – anniversary edition
The anniversary issue celebrating ten years of the “heat processing“ technical journal showcases the best articles published during the past decade in this, the international journal for thermoprocess technology. This edition opens with prefaces
from Dr. Timo Würz, of the VDMA (German Engineering Association) and Dr. Hermann
Stumpp. The editorial team has selected two articles from each year of publication.
Burners & Combustion, Induction Technology, Heat Treatment – the range of topics
encompasses the entire thermoprocessing field.
The expert articles track, in a retrospective, the technological and economic developments in the thermo-process industry. Numerous well-known industry figures from
the business, management and academic worlds have also contributed. Technical articles with up-to-date contemporary content and an industry perspective for the future
round off heat processing‘s anniversary issue. The final, essential, feature: the Hot Shots
– selected series of high-impact images focussing on fascinating technological topics.
Vulkan-Verlag GmbH, Friedrich-Ebert-Straße 55, 45127 Essen
HEAT TREATMENT CONGRESS 2014 – SPECIAL
www.vulkan-verlag.de
Edition hp, 1st edition 2014, approx. 180 pages, in full colour,
Brochure, DIN A4
ISBN: 978-3-8027-2975-1
Price: € 40.-Publication: late August 2014
Hot-Hot-Heat
KNOWLEDGE FOR THE
FUTURE
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| 80636 München
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PAHPAE2014
heat processing
3-2014
HEAT TREATMENT CONGRESS 2014 – SPECIAL
GENERAL INFORMATION
Heat Treatment Congress 2014
T
he Heat Treatment Congress’ move to Cologne is in full
swing. Once again, this year’s lineup of high caliber presentations will include several that are guaranteed to be the icing
on the cake. As the plenary speaker visitors will be able to listen
to Prof. Harry Bhadeshia from Cambridge University who will
hold lecture on “Extraordinary bainitic steels”. To report on the
successful evaluation of the pre-competitive collective
research program, the organizers have invited Burkhard
Schmidt, Managing Director of the research division of the
German Federation of Industrial Research Associations (AiF).
Detlef Dauke from the Federal Ministry for Economic Affairs
and Energy will make a short welcoming speech in the name
of the Ministry.
The organizers are especially happy to welcome Dr. Joachim
Wüst, Vice-President and Counsel of the festival committee of
the Cologne Carnival and President of the “Große Kölner” as a
guest speaker. He will introduce participants to the “kölsche”
way of life with the motto: “Hey Kölle do bes e Jeföhl” (Cologne
dialect: Cologne, you are a feeling).
Besides hosting the Heat Treatment Congress 2014, the city
of Cologne has much more to see. The Cologne Cathedral, built
between 1248 and 1880, is always worth a visit and its towers
offer a fantastic view over one of the oldest cities in Germany.
Whether visiting the Romano-Germanic Museum, looking
around the Roman Praetorium or taking a walk past the medieval city gates – Cologne’s 2,000-year history can be felt everywhere. Situated directly on the Rhine and marked by narrow
3-2014
heat processing
gables and high slated roofs, the Old City of Cologne stands out
with its unmistakable, historically appearing character.
Visitors who arrive by car have to note that effective 1 January 2008, Cologne’s downtown area was declared a “low emission zone”. This means that only vehicles with one of the stickers
for Emission Groups 2 to 4 are allowed to enter this area. The
Koelnmesse exhibition centre will remain accessible for all types
of vehicles, even if they do not bear one of the aforementioned
stickers. All of the routes for driving to and from the exhibition
centre can be found at: www.koelnmesse.de
However, only vehicles that bear the pertinent sticker will be
allowed to drive outside of these routes. Trade fair visitors can
apply for a sticker that allows them to drive into the environmental zone at: www.umwelt-plakette.de
Starting now it is possible to register for the congress and the
exhibition via the new HK ticket shop. The ticket shop provides
all visitors with the opportunity to administer their address data
and print or download onto their phones their own personal
admission code for the event. The congress will be simultaneously translated German/English vice versa. In this way the organizer AWT (Association for Heat Treatment and Materials Technology) creates a forum for international knowledge transfer. This
also addresses a significantly increased demand on the part of
foreign visitors.
Starting now you can find the final program of events for the
2014 Heat Treatment Congress and all information on the exhibition on the individual HK website: www.hk-awt.de
39
BASIC DATA
HEAT TREATMENT CONGRESS 2014 – SPECIAL
Heat Treatment Congress 2014
Basic Data
Location
Koelmesse
Messeplatz 1
50679 Köln, Germany
Entrance West
Opening hours
Wednesday, 22 October 2014, 9.00 - 18.00 h
Thursday, 23 October 2014, 9.00 - 18.00 h
Friday, 24 October 2014, 9.00 - 14.00 h
Organiser
Arbeitsgemeinschaft Wärmebehandlung und Werkstofftechnik e.V. (AWT)
Paul-Feller-Straße 1
28199 Bremen, Germany
Tel.: +49 (0) 421 / 5229339
Fax: +49 (0) 421 / 5229041
E-Mail: [email protected]
Internet: www.awt-online.org
Entdecken Sie die Koelnmesse
Discover the Koelnmesse
A5
7
Zo
o
Fees
Complete program: 690 €
Speakers and university employees:
385 €
1-day-ticket:460 €
2-day-ticket:575 €
Transferrable ticket for exhibitors:
320 €
Practitioner’s seminar (only in German language)
- One seminar:
150 €
- Both seminars:
290 €
All prices incl. 7 % VAT.
brü
ck
e
all
se
es
M
ee
Eingang Nord
Entrance North
Congress-Centrum Nord
Congress Centre North
rd
No
Rheinpark
we
g
Boul
evar
d
CC Nord
ee W
est
sc
i
älz
Pf
seall
sse
Me
raße
lee S
üd
Barmer Straße
Autobahnkreuz Köln-Ost
A3 Frankfurt/Oberhausen
A4 Olpe
-
Eingang Ost
Entrance East
Congress-Centrum Ost
Congress Centre East
Deu
Eingang Süd
Entrance South
r St
seal
ime
Mes
e
eis
Kr
3, 4
CC Ost
Hauptbahnhof
Central Station
rR
he
l
Eingang West
Entrance West
ing
tz-M
ülhe
Theater am
Tanzbrunnen
Staatenhaus
am Rheinpark
Mes
Rheinterrassen
Messehochhaus
A3 /A4
Aue
n
Tanzbrunnen
Messeplatz
City
Bahnhof Köln Messe / Deutz – Sonderhalte ICE- und IC-Züge
Train Station Köln Messe/ Deutz – Special stops rapid trains
Hohenzollernbrücke
LANXESS arena
1, 9
40
aße
raße
Opladener Straße
3, 4
Dom Cathedral
City
heat processing
A4, Aachen
3-2014
HEAT TREATMENT CONGRESS 2014 – SPECIAL
Focus on Innovation.
HeatTreatmentCongress Cologne / AICHELIN Group booth E-060.
www.aichelin.com
3-2014
heat processing
41
HEAT TREATMENT CONGRESS 2014 – SPECIAL
PROGRAM
Heat Treatment
Congress 2014
Program
Wednesday, 22 October 2014
PRACTITIONERS’ SEMINAR (only in German language)
9:00 - 10:30 h
Nitrieren im Gas und im Plasma – Bauteilbezogene
Verfahrensauswahl unter wirtschaftlichen Gesichtspunkten
Marco Jost
10:30 - 10:45 h
Coffee break
10:45 - 12:15 h
Wärmebehandlung – Fehler, Schäden und Ursachen
Peter Sommer
or
9:00 - 10:30 h
Wärmebehandlung – Fehler, Schäden und Ursachen
Peter Sommer
13:50 - 14:30 h
Plenary lecture
Hey Kölle, do bes e Jeföhl
Joachim Wüst
INTEGRATION OF HEAT TREATMENT INTO
THE ­PRODUCTION
Chairmen: Michael Lohrmann, Berthold Scholtes
14:30 - 15:05 h
Survey lecture
Integration of heat treatment into the production line
Wilfried Goy
15:05 - 15:30 h
Integration of heat treatment into mechanical large
scale production – based on the example of modern
gear production
Karl Ritter
15:30 - 15:55 h
Direct integration of plasma nitriding into manufacturing
Uwe Huchel
15:55 - 16:15 h
Coffee break
LEIGHTWEIGHT
Chairmen: Dieter Liedtke, Marco Jost
16:15 - 16:40 h
Lightweight forging initiative
Hans-Willi Raedt
THERMOCHEMICAL PROCESSES
Chairmen: Dieter Liedtke, Marco Jost
10:30 - 10:45 h
Coffee break
10:45 - 12:15 h
Nitrieren im Gas und im Plasma – Bauteilbezogene
Verfahrensauswahl unter wirtschaftlichen Gesichtspunkten
Marco Jost
42 16:40 - 17:05 h
Recent development on the microstructure and the
mechanical properties of carbonitrided parts, part 1:
Heat treatment and microstructure
Matthias Steinbacher
13:30 - 13:40 h
Opening
Michael Lohrmann
17:05 - 17:30 h
Recent development on the microstructure and the
mechanical properties of carbonitrided parts, part 2:
Load capacity of spur wheels
Simone Lombardo
13:40 - 13:50 h
Welcome speech of the city of Cologne
18:00 h
General meeting of AWT members
heat processing
3-2014
Thursday, 23 October 2014
THERMOCHEMICAL PROCESSES
Chairmen: Michael Jung, Hans Werner Zoch
9:00 - 9:25 h
Research on low pressure carbonitriding with amines
David Koch
9:25 - 9:50 h
Ammonia based closed loop control for defined
plasma nitriding and nitrocarburizing – first results
Sebastian Bischoff
9:50 - 10:15 h
Coffee break
10:15 - 10:30 h
Welcoming speech from the Federal Ministry for
Economic Affairs and Energy
Detlef Dauke
10:30 - 10:50 h
Plenary lecture
Perfect link between science and industry – Results
from the accompanying evaluation of the pre-competitive collective research program
Burkhard Schmidt
HEAT TREATMENT CONGRESS 2014 – SPECIAL
PROGRAM
13:55 - 14:20 h
Simulation of heat treatment processes also for “nonsimulation experts”
Stefan Braun
14:20 - 14:45 h
From current to structure: FE-simulation of induction
hardening of a calendar roll
Jörg Neumeyer
14:45 - 15:10 h
New applications of numerical simulation in induction
surface hardening processes
Dirk Schlesselmann
15:10 - 15:30 h
Coffee break
15:30 - 15:55 h
Adaptive finite element simulation for multifrequency induction hardening in 3D
Thomas Petzold
15:55 - 16:20 h
Numerical optimization of the carburizing process
for function-related construction details of steel
components
Andreas Diemar
HIGH ENERGY HEAT TREATMENT
Chairmen: Rainer Braun, Olaf Irretier
10:50 - 11:00 h
Granting of the Paul-Riebensahm-Award 2013 to
Martin Beck
11:00 - 12:00 h
Plenary lecture
Extraordinary bainitic steels
Harry Bhadeshia
12:00 - 13:20 h
Lunch hour
SIMULATION OF HEAT TREATMENT PROCESSES
Chairmen: Jörg Kleff, Klaus Löser
13:20 - 13:55 h
Survey lecture
Simulation of case hardening processes – state of
the art
Matthias Steinbacher
3-2014
heat processing
16:20 - 16:55 h
Survey lecture
High-energy heat treatment – What energy beams
can achieve in the field of surface treatment today?
Rolf Zenker
16:55 - 17:20 h
A new combined surface treatment technology for
tribological-loaded Al alloys
Erik Zaulig
17:20 - 17:45 h
Electron-beam cladding of wear-resistant coatings on
corrosion-resistant steels
Anne Jung
18:00 h
Reception – Bestowal of the
Karl-Wilhelm-Burgdorf-Award
43
HEAT TREATMENT CONGRESS 2014 – SPECIAL
PROGRAM
Friday, 24 October 2014
MANUFACTURING AND RESIDUAL STRESSES
Chairmen: Brigitte Haase, Peter Krug
9:00 - 9:35 h
Survey lecture
Manufacturing and residual stresses
Volker Schulze
9:35 - 10:00 h
Mechanical surface treatment by micro peening
Regina Weingärtner
10:00 - 10:25 h
Residual-stress fields as a consequence of turning
operations of differently heat treated shafts made of
steel SAE 6150
Wolfgang Zinn
10:25 - 10:50 h
Shell hardening by high speed quenching
Friedhelm Frerichs
10:50 - 11:15 h
Internal intensive quenching
Jürgen Hofmeister
QUALITY CONTROL
Chairmen: Winfried Gräfen, Hansjürg Stiele
12:00 - 12:25 h
Report from the AWT expert-committee 20 “Sensors
in heat treatment”: Test bench for qualifying oxygen
probes – first results
Heinrich Klümper-Westkamp
12:25 - 12:50 h
Heat treatment and nondestructive testing: finding
surface cracks using laser-thermography
Matthias Ziegler
LEGISLATION
12:50 - 13:15 h
Brussels: News for our industry
Franz Beneke
13:15 h
Publication of Paul-Riebensahm-Laureate 2014
Peter Krug
13:20 h
Summary
Michael Lohrmann
13:30 h
End of the event
11:15 - 11:35 h
Coffee break
11:35 - 12:00 h
Simulation of the time-dependent evolution of the
hardness and residual stresses in inductive heat
treatment procedures
Frank Schweizer
Visit us at the HK 2014
22 - 24 October 2014
Koelnmesse, Cologne
Germany
Vulkan-Verlag
Hall 4.1 / Booth G 018
44 heat processing
3-2014
HEAT TREATMENT CONGRESS 2014 – SPECIAL
PRODUCT PREVIEW
Boost
productivity.
Cut costs.
Modernizations for quality and reliability
Excellent engineering services stand out from the crowd …
especially when it comes to intelligent revamps. It’s about
nothing less than upgrading existing plants to meet future
market demands – one of today’s central challenges.
That’s where our whole wealth of experience comes in.
After all, our job is to help you increase your productivity
while improving quality. Equally significant here is smart
planning, for instance taking advantage of scheduled maintenance stoppages and minimizing production losses.
Your bottom line: You save time and money.
Countless completed projects prove our quality and
reliability as a global specialist in metallurgical plant and
rolling mill technology.
SMS SIEMAG AG
Eduard-Schloemann-Strasse 4
40237 Düsseldorf, Germany
3-2014 heat processing
Phone: +49 211 881-0
Fax:
+49 211 881-4902
E-mail: [email protected]
Internet: www.sms-siemag.com
45
HEAT TREATMENT CONGRESS 2014 – SPECIAL
PRODUCT PREVIEW
Hardening centre for crankshafts
E
fficient 4-cylinder engines form the basis for the passenger car drive concepts of the future. This calls for innovative approaches to the hardening process which can be ideally implemented with Alfing’s BAZ KW600 hardening centre.
The hardening centre is a new addition to the existing product range and was developed specially for 4-cylinder
crankshafts. It is designed on the principle of machining centres and is suitable for crankshafts of up to 600 mm in length.
Emphasis was also placed on good energy efficiency, a high
throughput, low operating costs and ease of operation. The
pin bearings are hardened in module 1 and the main bear­
ings in module 2 of the two-module system. An optional
extension can also be integrated for the hardening of flanges,
journals and gear wheels. The full encapsulation of the working areas permits complete extraction of quenching fumes.
Efficient drive systems and assemblies as well as optimized
inductors guarantee low energy consumption, good process
reliability and maximum availability. Minimum space requirement, full accessibility on one level and a standard height of
only 2.3 m are all revolutionary features of this type of hardening machine. Preceding and subsequent processes can
easily be integrated. Connection to portal systems can be
performed in the same way as for existing technologies for
machining centres.
Maschinenfabrik Alfing Kessler GmbH
www.alfing.de
Hall 4.1 / Booth B-021
ATEX Certificate for steel degassing vacuum systems
D
egassing, especially those with oxygen insufflation, as in
VOD and RH-OB methods, produce potentially explosive
gases. Vacuum components and equipment with ATEX
approval enable safe and cost-efficient solutions for mechanical vacuum solutions. Today, the standard mechanical
vacuum pumps already fulfil high requirement for safety.
Nevertheless, in case there are uncertainties regarding the
flammability of gas mixtures which need to be handled by
the pump sets, the user will have to conduct a risk analysis of
the various plant parts to define the relevant explosion protection zones. The result will most probably be the definition
of an explosion Zone 1 for the inner part of the vacuum system. For this assessment, components with an ATEX-certificate Category 2 (inside) for gases can be the easy solution.
Thus way the user can reach the highest safety standard for
his employees with relatively low investment expenditure.
ATEX vacuum solutions from Oerlikon Leybold Vacuum
consist of pumps and components that meet the specification
of ATEX Cat 2 (i) G IIC T2. This equipment can be combined into
ATEX certified vacuum systems. To meet the requirements, an
additional gas cooling and temperature control between the
pumps is provided to prevent gas temperatures from exceed­
46 ing the defined limits. Furthermore, all pumps are controlled
and monitored by a specially programmed frequency con­
verter. Regarding the vacuum pump set, potential ignition
sources such as overheating or electrostatic charging must be
considered, which will be achieved with the usual attention
during design and manufacturing of ATEX-certified pumps. In
particular, the pumps must be protected efficiently against
overload by too high pressure differences in order to avoid
excessive temperatures. This is valid for all possible operating
point starting with high suction pressures, passing to medium
operating pressures, that are to be hold over a longer time as
for example during delayed pump down in the VD-process or
during the oxygen blow phase in the VOD-process, down to
lowest end pressures with its high compression ratios. The
vacuum solutions of Oerlikon Leybold Vacuum consist of two
different standard pump models only, combined into threestage vacuum systems. Such three-stage designs allow highest
suction speed combined with lowest power consumption.
Oerlikon Leybold Vacuum GmbH
www.oerlikon.de
Hall 4.1 / Booth F-058 - G-059
heat processing
3-2014
PRODUCT PREVIEW
Digital pyrometry reinvented
S
ensortherm introduces another Metis sensor to its Metis
series product line. Known as the Metis M3, it has an
advanced design, customization, and adaptability. The sensor
has the ability to be used in ambient temperatures up to
80 °C, with fibre optic versions on the optical head rated up to
250 °C. The integrated keypad and 10-digit display enable all
settings to be easily manipulated by the user for a variety of
applications.
The device offers manually adjustable focus optics, fixed
focus optics, or remote motorized focus options. The precise
alignment of the target is accomplished by laser, through lens
sighting, or real-time colour video. It is available in either single wavelength or two colour pyrometer versions. Superior to
analogue technology and based on the latest electronic and
digital signal processing, the M3 provides convenient universal configuring. Equipped with many new features, such as
digital inputs and outputs as well as an increased accuracy of
0.25 %, it meets the highest industry demands. The sensor’s
built-in video chip offers the ability to view in real time a
colour composite video that can be displayed on a video
monitor or PC using a standard off-the-shelf video to USB
frame grabber.
The high-speed serial digital interface and two high-resolution 16-bit analogue current outputs are adjustable and
configurable for a precise output of temperature measured
values. Optionally, a PID controller can be integrated or the
pyrometer can be equipped with Profinet, Profibus or Ethernet to couple to a master controller.
Sensortherm GmbH
www.sensortherm.de
Hall 4.1 / Booth A-002
AFC-Holcroft:
Strength and Innovation since 1916.
Powerful Solutions for the Future.
As a privately owned company with thousands of installations worldwide,
AFC-Holcroft is a worldwide leader in the heat treat equipment industry.
One of the most diverse product lines in the heat treat equipment
industry: Pusher Furnaces, Continuous Belt Furnaces,
Rotary Hearth Furnaces, Universal Batch Quench (UBQ)
Furnaces and Endothermic Generators.
Robust construction and long service life,
designed for ease of maintenance.
ogne
HK 2014 Col
4, 2014
October 22–2
d E-038
an
Hall 4.1, St
UBQ: Universal Batch Quench Furnace.
Ultimate in flexibility and versatility.
Modularly constructed universal batch system
with state-of-the-art technology.
Delivers consistently high quality with predicable
and repeatable results.
Various global facilities in North America, Europe
and Asia for fastest local delivery, service and support.
Get in touch with us today to learn more about how
we can improve your production processes and
how we can give you the edge over the competition.
For further information please visit
www.afc-holcroft.com
AFC-Holcroft USA · Wixom, Michigan
AFC-Holcroft Europe · Boncourt, Switzerland
AFC-Holcroft Asia · Shanghai, China
Phone: +1-248-624-8191
Phone: +41 32 475 56 16
Phone: +86-21-58999100
3-2014
heat processing
47
HEAT TREATMENT CONGRESS 2014 – SPECIAL
PRODUCT PREVIEW
Hybrid charging stick for thermal treatments
T
he GTD Graphit Technologie GmbH offers patent-registered hybrid-systems for thermal treatments. The latest
product development is the GTD hybrid charging stick for all
charges, that are hardened in a hanging or upright way. The
stick has an inlay made of C/C (Carbon-fibre-reinforced Carbon) which is surrounded by steel. C/C as a high-strength
composite material consisting of carbon-fibre provides a
heat-resistance of the charging stick in inert gas or vacuum
furnaces at temperatures up to more than 1,200 °C. In that
way it prevents any deformations of the stick long-term. The
steel cover saves the inlay from abrasion of sharp-edged
components and covers the charge against carbon contamination. Individual braces prevent equable charging of the
components, for example rings.
The new hybrid charging stick is part of the patent-regis­
tered GTD hybrid system, which also includes a hybrid grid
that employs a combination of C/C and ceramic parts. Decisive arguments for the use of carbon materials are the high
load capacity combined with tensile and flectional resistance
especially when used in automated processes. The low density and the light weight of C/C makes handling much easier
and also ensures an excellent energy balance
GTD Graphit Technologie GmbH
www.gtd-graphit.de
Hall 4.1. / Booth D-079
Boron-free and copper-free stop-off paints
A
new labelling requirement for stop-off paints will take
effect on 15 June 2015. Stop-off paints will then be subject to the GHS, the Globally Harmonised System of Classification and Labelling of Chemicals. Stop-off paints containing
boron can easily be removed by washing and are made of the
raw materials boron trioxide, borax and boric acid. Copperbased stop-off paints can mostly be removed by sandblasting and contain copper, copper(I) oxide or copper(II) oxide.
While the first version will, in future, be labelled as toxic for
reproduction within this classification, the version containing
copper will be classified as environmentally dangerous. That
means that the new labelling will clarify one thing: All stop-off
pastes currently used in the industry or in the market pose a
risk not only to the environment in general but also to the
individual person.
For more than 20 years, DAM Härtetechnik GmbH has
been a worldwide active and leading company which special­
ises in the development and manufacturing of stop-off paints
for the heat treatment of steel.
The company reacted to the new GHS regulation with
new developments. These products are used like traditional
stop-off paints for gas carburising and vacuum carburising,
nitriding and nitrocarburising, for plasmanitriding, annealing
and oxidation, for induction hardening and brazing. The
48 name of these new stop-off products is Luiso®. What is new is
the fact that these products are both boron-free and copperfree and ensure optimal protection properties. They have, in
addition, a neutral odour and do not contain any solvents.
Any residues remaining after the heat treatment can be
removed easily by washing with water. Even their viscosity
and flow can be controlled by water. The objective behind
the development of these new stop-off pastes was to
­strongly improve their environmental performance.
Three additional products (Luiso W30, W34 und W36) are
offered for gas carburising for case depths of up to 6 mm. And
the new product line also includes two products for nitriding
and nitrocarburising: Luiso W21 which is ceramic-based and
the Luiso W25 paste which can be used both for nitriding and
nitrocarburising. The product portfolio contains, in addition,
two hardness protection paints each for vacuum carburising
(W44 and W45) and annealing (W61) as well as two pastes
which cover the field of plasmanitriding (W51 and W53). The
product offer is rounded off by a kneadable protection mass
(W63) to seal off hardening boxes, small or large holes.
DAM Härtetechnik GmbH
www.dam-gmbh.de
Hall 4.1 / Booth A-071
heat processing
3-2014
PRODUCT PREVIEW
A modular approach to production
A
global rise in component production has increased demand
for heat treatment systems capable of meeting production
needs today, yet scalable for future production. AFC-Holcroft
offers many thermal processing solutions, and highlights one of
the most flexible heat treating furnace designs available – the
UBQ (Universal Batch Quench) system. The UBQ is capable of
running a variety of metallurgical processes, and can be delivered as a single unit or as a complete, fully automated cell integrated with companion equipment such as tempering furnaces,
pre-heat furnaces, spray-dunk washers, forced air cool stations
and more. With its modular design, additional cells can be
added for maximum productivity with consistent, repeatable
metallurgical results.
Another modular, flexible product featured is AFC-Holcroft’s EZ-Series endothermic gas generator, offering a maintenance- and operator-friendly design. A 5:1 turn down ratio
provides substantial savings in operating costs vs. nitrogen
methanol; often with return on investment less than one year.
Units can be provided individually, or up to three units
grouped into an array; each unit having standalone plug-andplay type control.
When consistent high volume production is needed, the
company offers its classic pusher-style furnace for continuous
throughput under protective gas atmosphere. The pusher-style
furnace design allows the furnace chambers to be combined
into one, or separated into multiple chambers for independent
control over temperature and atmosphere.
AFC-Holcroft
www.afc-holcroft.com
Hall 4.1 / Booth E-038
Innovative Heat Treatment Systems
2014:
Visit us at HK
E 078
d
an
Hall 4.1, St
For hot-form hardening,
hardening, annealing,
sintering and brazing etc.
Also under protective and
reactive atmospheres
schwartz GmbH
Edisonstrasse 5
D-52152 Simmerath
Germany
schwartz Heat Treatment Systems
Asia (Kunshan) Co. Ltd.
278 JuJin Road
Zhangpu Town Kunshan City
Jiangsu Province
215321, P.R. China
For more information visit: www.schwartz-wba.com
3-2014
heat processing
schwartz, Inc.
2015 J. Route 34
Oswego IL 60543
USA
49
HEAT TREATMENT CONGRESS 2014 – SPECIAL
PRODUCT PREVIEW
Industrial furnaces made in Germany
N
olzen Industrieofenbau produces in the fourth generation “made in Germany” – since 1919 – industrial furnaces and heat treatment plants for annealing and hardening of
metals. With own casing and insulating construction, retorts
manufacturing as well as switchgear production, the company located in Wuppertal offers competence in consultation, construction and manufacturing solutions for economically and individually designed heat treatment processes.
Nolzen delivers energy-efficient standard furnaces and
customised solutions in electric- and gas-heated version for
temperatures up to 1,300 °C. Pit type furnaces, boogie hearth
and chamber furnaces belong to the core business for largevolume components and heavy load weights. Pit type
furnaces for nitriding, case hardening and annealing have
already been realised up to a diameter of 4,500 mm or a
depth of 11,000 mm. Boogie hearth and chamber furnaces
are designed in all dimensions, up to 50 m3 volumes and load
weights of more than 100 t.
The company offers “everything out of one hand”. Beside
the development of new furnace design its special main focus is
on engaged after sales service which encloses the servicing and
maintenance as well as modernisation and the process optimisation of furnaces. On account of the nearly 100-year-old experience in industrial furnace design, the high manufacturing depth
in production as well as the robust construction method of the
furnaces Nolzen stands for efficiency of specially developed
and produced furnaces. Today the company grants a guarantee
from up to 5 years on industrial furnaces to its customers.
Artur Nolzen Industrieofenbau GmbH + Co. KG
www.nolzen.de
Hall 10 / Booth A-005
Precision temperature control to increase efficiency
and profitability
I
nvensys Eurotherm, a global supplier of measurement and
instrumentation for process and machine control applications, has launched a family of new precision PLC products
aimed at significantly increasing the profitability and efficiency of heat treatment and thermal processing. The new
E+PLC series combines precision measurement and control,
secure data recording, and a variety of visualisation solutions.
Previously to obtain optimum performance and meet
accurate pyrometry specifications (e.g. AMS2750E), companies needed to separate products for temperature control,
data recording and visualisation. This was costly and inefficient. Combining all these products into one easy to use, flexible and highly functioning precision PLC platform simplifies
commissioning and reduces engineering time. The E+PLC
also targets operational efficiency and makes regulatory compliance much easier.
The high precision temperature control ensures the correct
temperature is obtained quicker and stays at the optimum
level required without deviation, ensuring high quality results
first time without wasting time waiting for operating temperature to be reached. This increases throughput of a furnace or
thermal treating machine in comparison with traditional PLC
based control. Fast acting PID with overshoot inhibition can
enable an extra furnace batch cycle to be completed within
any 24 hour period. By eliminating damping of PID sets and
relying on Eurotherm’s overshoot inhibition customers can
50 heat aggressively up to temperature with the confidence of
keeping within the required set point temperature tolerances.
The E+PLC range also includes secure data logging designed
to meet the requirements of thermal treatment standards such
as CQI-9 and AMS2750E. The precision measurement circuitry
also assures compliance with accuracy specifications, aids conformance to System Accuracy Tests (SAT) and improves the output from Temperature Uniformity Surveys (TUS).
Key features and benefits of E+PLC include:
■■ Easy to commission precision PID control blocks with
auto tuning.
■■ Set point programmer.
■■ Precision measurement of process variables to give accurate, repeatable results which translates to minimum
energy usage.
■■ Total data integrity and secure recording, keeping valuable process records safe by using highly robust file storage strategies to protect against power and network failures.
■■ An open Codesys platform, a de facto industry standard.
■■ Integrated HMI software platform with a variety of visualisation options.
Invensys Systems GmbH Eurotherm
www.eurotherm.de
Hall 4.1 / Booth E-091
heat processing
3-2014
PRODUCT PREVIEW
Elektrowärme; Heat processing 2014
Tube
furnaces
Induction hardening systems
182 x 31 1/8 4c
HEAT TREATMENT CONGRESS 2014 – SPECIAL
c\aaa\anzeigen\vulkan\EW HP 13.qxd
Protective gas furnaces
www.linn.de
Induction heating
Heat processing 3 /14
Universal-InduktionsHärteanlage.
Team solutions from a single source
Rohröfen
Induktions-Härteanlagen
T
he KompetenzTeam, a materials engineering division of
MWS Dr. Schreiner VDI at Munich, is preoccupied with the
formation of working groups for project implementation,
accumulate knowledge, researches, developing and organ­
izes symposia, seminars and workshops. An annual symposium in Munich, for over 30 years, provides professionals a
Elektrowärme 3 /14
platform for exchange among colleagues, access to expertise
and specific information from the work areas. The next meet­
ing of “Härterei 2015” takes place between 19 and 20 March
2015 in Munich instead.
In addition to the focus on the German speaking countries
(D, A, CH), the team of experts, in materials technology, also
maintains contacts throughout Europe and demonstrated
experience in China and overseas. Together with partners
they offer analysis, systems engineering and heat treatment
Schutzgasöfen
as a service, which expands on the workpiece- and partsclean- www.linn.de
ing. The Central Association of Surface Technology (ZVO) and
the Association of Industrial Parts Cleaning e.V. (FIT) will host
together with the KompetenzTeam, Induktionsthe 24th Fachtagung
erwärmung
Industrielle Teilereinigung on 12 and 13 March 2015 in Munich.
On the HeatTreatment Congress 2014 in Cologne provides
the KomptetenzTeam the companies Ahotec eK, Graphite
Materials GmbH, Spectro Analytical Instruments GmbH, TAZ
GmbH and Uttis srl. Here, interested visitors can meet the
booth makers of these companies and get information about
news, facts and scope.
MWS Dr. Schreiner VDI
www.kompetenzteam.com
Hall 4.1 / Booth A-021
New controller generation
B
ased on the successful carbon, nitriding, dew point
and temperature controllers Mesa Electronic GmbH is
introducing a new family of MCon controllers to the market. The new generation of controllers provides controllers
for any application. MCon type Carbo is the new C-level
controller with a total of three different control loops enabling the customer to regulate the C-level, furnace temperature and oil bath temperature. MCon type Nitro regulates
the nitriding factor Kn and furnace temperature. MCon
type TP is used for dew point control of an endogas generator, MCon type Uni is a universal controller used to control up to three different process factors. All controllers are
equipped with the latest technologies such as touchscreen colour display, multiple analogue inputs and outputs as well as a wide variety of communication protocols.
3-2014
heat processing
Complex processes can be carried out with the program
controller option. By means of control tracks all MCon controllers can control the process without SPS and thus
reduce costs. MCon controllers provide the ability to communicate with different automation systems via communication protocols such as Modbus RTU, TCP, Ethernet and
Profibus. An integrated data logger allows the recording of
process data during the entire process. To be flexible, the
customer can order and configure each controller with a
desired number of analogue or digital inputs and outputs.
Mesa Electronic GmbH
www.mesa-international.de
Hall 4.1 / Booth D-029
51
HEAT TREATMENT CONGRESS 2014 – SPECIAL
PRODUCT PREVIEW
Chamber furnace heat treatment plant for big size rings
R
ecently a customer in Mexico expanded his production
facility with the IOB chamber heat treatment furnace
plant system consisting out of four chamber furnaces, one
charging machine and two quenching baths. In this furnace
plant system it is possible to heat treat rings up to a diameter
of 4,300 mm. Following processes can be executed: hardening, tempering and normalizing. For the quenching baths the
choice is between water or polymer quenching.
The properties after heat treatment to be achieved are:
homogeneous hardness at 90° of 300-330 HBN, distortion
(oval) less than 6 mm, charpy impact above 30-35 lbft at ¼"
thickness and Ferrite at the core < 5 %. To guarantee the temperature uniformity and operating the furnace plant economically the furnaces were equipped with natural gas operated high velocity recuperator burners. The uniformity inside
the furnaces: 530-950 °C = ± 5 °C; 450-529 °C = ± 7.5 °C.
The quenching baths are equipped with rotating, lifting
and lowering lifting tables. In addition to the installed agitation and cooling pumps IOB also installed stationary inside
the bath and on to the movable lifting table so-called liquid
jet mixing nozzles for intense agitation. The loading/unloading of the furnaces, baths and deposit tables is done using
the charging machine. In automatic mode the plant here
achieves transit times of approx. 25-30 s between furnace and
bath. A modern measuring and control system with material
tracing and connection to further processing line equipment
will complete the furnace plant system.
IOB Industrie-Ofen-Bau GmbH
www.industrial-furnaces.com
Hall 4.1 / Booth F-091
Heat treatment specialist invests in state-of-the-art
plant technology
F
or the last 78 years, the Hauck Group has been active as a
powerful system supplier to customers throughout
Europe in key sectors such as the automobile industry,
mechanical engineering, electrical engineering, medical
technology, jointing and fastening technology and many
others. At seven locations in Germany, a wide variety of components are processed with almost all the heat treatment
processes in common use (thermal and thermo-chemical),
different surface treatments and galvanic processes. All company locations combine experience and precise production
processes with consistent quality management, quality assurance through in-house inspection procedures, state-of-theart plant technology with backup options, certification in
accordance with all relevant international quality, environment and energy standards and a close relationship with our
customers in the regions.
This year, Hauck has further extended its service and has
invested even more than usual in new plant technology. The
highlight is the new semi-automatic charging system at the
Remscheid site, which is unique in its construction and
design. Significant investments have also been made in the
expansion of nitriding facilities. Fifteen large furnaces are currently in operation, functionally treating more than 40 t of
products per day.
Härterei Hauck GmbH
www.haerterei-hauck.de
Hall 4.1 / Booth E-030
52 heat processing
3-2014
PRODUCT PREVIEW
Simultaneous crack and structure testing
with eddy current
S
ince its founding in the year 1977, Rohmann GmbH has
specialised in non-destructive testing by means of eddy
current. The comprehensive product range extends from
sensors to coils, rotors and universal hand-held devices, to
tailor-made testing systems. Customers from the most varied
branches such as aviation, automotive industry, rail transport
and the steel industry value the work of this family-managed
company.
The basis for successful eddy current testing lies in the
interaction between highly sensitive sensors and the latest
equipment technology. Here, and in addition to a wide range
of standard sensors, Rohmann GmbH offers a wide range of
customized sensors for the most varied testing tasks, supported by a flexibly configurable, fully digital equipment
platform. One component of this equipment platform is the
Elotest IS500 family. It is available as a 19” module or as a separate box-variant for integration into the production line. The
series has a wide range of configuration possibilities up to a
maximum of two test channels. This enables combined crack
testing, with simultaneous structure and material identification testing. In the case of structure testing, the user can
choose between simple 1-frequency sorting, fast sorting at
several hundred parts per second, or multi-frequency testing
as a solution for complex sorting tasks. The product series can
optionally also be equipped with a multiplex option for the
connection of up to eight sensors per test channel, and can
therefore cover a broad range of testing applications in the
course of the production process. If the Elotest IS500 family is
not enough, a universal multi-channel equipment family is
available as an alternative in the form of the Elotest PL500 line.
Rohmann GmbH
www.rohmann.de
Hall 4.1 / Booth E-070
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SyncroTherm®
Efficient and ecological heat treatment
ALD Vacuum Technologies latest development SyncroTherm® offers the highest flexibility for heat
treatment. Hardening and casehardening of small batches is possible in stand-alone units and in
one-piece-flow production with full integration into the manufacturing line. Charging in single
layers leads to short process times and minimum distortion.
heat processing
For 3-2014
more information
please contact us!
ALD Vacuum Technologies GmbH
Wilhelm-Rohn-Strasse 35
63450 Hanau, GERMANY
Phone +49 (0) 6181 307-0
Email [email protected]
Internet www.ald-vt.com
HEAT TREATMENT CONGRESS 2014 – SPECIAL
Protective system control with bus communication
W
ith the protective system control FCU 500, Elster Kromschröder is offering a comprehensive all-round
package for the implementation of current safety standards.
The unit performs the essential functions of a central protective system pursuant to EN 746-2:2010 in multiple burner
applications.
The protective system control monitors various safety
conditions (such as minimum and maximum gas pressure
and air pressure) and carries out a standard-compliant prepurge. The main valves undergo an extended tightness test
in parallel to purge. This tightness test function checks the
system for leaks during system start. A special algorithm saves
time in the case of large test volumes. As an option and in
conjunction with Kromschröder burner control units, an internal safety temperature limiter (STL) or a safety temperature
monitor (STM) for monitoring the maximum furnace/flue gas
temperature or for high temperature monitoring guarantee
increased operational safety.
The functions combined in the FCU 500 can be precisely
adapted to the requirements of the respective heating equipment using parameters. For this, the FCU features an optical
interface via which the parameters can be adjusted using the
PC software BCSoft and data for diagnosis can be read.
The system has been developed for installation in control
cabinets. It features tried-and-tested operating controls on
the front of the unit or can be controlled directly from the
control cabinet door using the external operator-control unit
OCU. Thanks to the Profinet bus module BCM 500, the
FCU 500 can be easily integrated in the process automation
system. This opens up a wide range of options as regards
process control and visualization. The automation system
(controller) and the connected units of the FCU 500 series
(device) communicate via the bus module BCM 500 on two
levels.
The acyclic communication allows information on the
parameters and statistics of the FCU 500 as controlled by the
program to be read. The device master data required for system engineering of the bus module BCM 500 can be read
from the GSD file of the FCU 500. The Internet-based knowledge platform KST (Kromschröder System Technology) is
available as planning support for the protective system as
well as for the design of the entire heating equipment. KST
offers many tools for the effective and safe project planning
of heating equipment.
Elster GmbH
www.kromschroeder.com
Hall 4.1 / Booth C-089
Hardware and software solution for more efficiency
T
he Ipsen EcoFire system burns natural gas
and protective gas for highly efficient
energy usage – with almost no loss. The system
is an intelligent solution, which allows the gas
fired heating system already installed in your furnace to burn
protective gas. It increases
the efficiency of industrial furnace systems
through
intelligent
hardware and software,
saving money and protecting the environment sustainably.
Normally, the protective gas used in a
54 furnace must be burnt off safely. But with the EcoFire system
the protective gas needed in atmospheric heat treatment
furnaces is used for the gas fired heating system. In this way,
the energy content of the protective gas is available for the
heating system. In addition, it’s used to heat the halls in winter
– this saves money and protects the environment at the same
time!
With EcoFire, one not only can use the energy content of
the otherwise useless burnt protective gas, increasing plant
efficiency, but also lower the cost of the natural gas consumption and lower the CO2 emissions.
Ipsen International GmbH
www.ipsen.de
Hall 4.1 / Booth E-040
heat processing
3-2014
Heat treatment using ceramic matrix composites
T
he WPX Faserkeramik GmbH develops and manufactures
heat treatment components made of innovative Whipox®
oxide ceramic matrix composite (OCMC). Whipox® OCMC
consists of pure aluminium oxide fibre ceramic Nextel®
embedded in a pure aluminium oxide matrix. Due to its excellent properties like extreme stability against thermal and
mechanical shocks, thermal insulation, low thermal load,
minimal warping, and good tensile and bending strength, the
material is well suited for charge carriers and furnace lining for
heat treatment processes in the temperature range from 7501,300 °C (1,380-2,370 °F). As it is oxidation- and corrosionresistant, it can be used in atmospheric processes.
3-2014
heat processing
In particular, its open grid structures can be used as systems, components and parts for fast temperature change and
homogeneous temperature distribution. Whipox® allows
improved energy efficiency by significant reduction of carrier
weight, improved product properties by precise temperature
control, increased furnace equipment uptime through noncatastrophic failure, and less rejects due to Carbon contamination. USPs are documented through industrial applications.
WPX Faserkeramik GmbH
www.whipox.com
Hall 4.1 / Booth C-101
55