ZY(Q)2-ST Vacuum Carburizing Furnace
INTRODUCTION
It is mainly used for oil quenching, bright quenching of tool steel, mold steel, bearing steel, spring steel, stainless steel, etc.
ZY(Q)2-ST double chamber vacuum carburizing furnace is a double chamber oil quenching (gas quenching) vacuum furnace with the low pressure carburizing function, which is mainly used for vacuum hardening of tool stee, die steel, bearing steel, spring steel and other materials, for vacuum carburizing and hardening treatment of 20CrMnTi,20# steel and other low-carbon alloy steel parts.
Control method: IPC system, the hardening and carburizing process is completed automatically.(manually)
Process medium: Carburizing usses acetylene, proliferation uses high-purity nitrogen.
Selectively: can select dual-chamber gas quenching, double chamber oil quenching or three chamber oil gas quenching and other three quenching methods.
TECHNICAL SPECIFICATION
| Model |
Effective Working
Dimensions(mm) |
Load Capacity(kg) |
Temperature Uniformity(ºC) |
Pressure
Rising Rate
(Pa/h) |
Maximum
Temperature
(ºC) |
Heating
Power
(kW) |
Ultimate
Vacuum
(Pa) |
Gas Cooling Pressure(bar) |
| ZYQ2-40ST |
450x300x300 |
80 |
±5 |
0.5 |
1320 |
40 |
4x10-1 |
2 |
| ZYQ2-65ST |
600x400x400 |
150 |
±5 |
0.5 |
1320 |
80 |
4x10-1 |
2 |
| ZYQ2-80ST |
700x500x500 |
250 |
±5 |
0.5 |
1320 |
120 |
4x10-1 |
2 |
| ZYQ2-150ST |
900x700x600 |
500 |
±5 |
0.5 |
1320 |
150 |
4x10-1 |
2 |
| ZQ2-150ST |
900x700x600 |
500 |
±5 |
0.5 |
1320 |
240 |
4x10-1 |
6,10,12 |
| ZQ2-220ST |
1500x800x800 |
800 |
±5 |
0.5 |
1320 |
300 |
4x10-1 |
6,10,12 |
PRODUCT FEATURES:
Advantages of the vacuum low pressure vacuum carburizing
*carbon transfer rate is high
*short processing cycle
*does not produce carbon black and tar
*achieve uniform and high qualified carburizing;large furnace loading capacity,high production efficiency
*the drawbacks of internal oxidation are overcame; High brightness after oil quenching, gas quenching
*The use of electro-copper plating,nickel plating and other special coatings, which can achieve selective carburizing
*No thermal radiation, no flame, no exhausted gas
Typical cases about acetylene vacuum carburizing
1.Acetylene vacuum carburizing gas quenching process of diesel engine fuel injectors:
The material of the fuel injectors is low-alloy chromium-nickel steel, requiring for uniform carburizing.The carburization equipment is double chamber vacuum gas quenching carburizing furnace.The carburizing temperature is 910ºC,after the carburization 6-1o bar pressure nitrogen proceeds fast quenching under 860ºC temperature in the quenching chamber, tempering under 170ºC.
The processing results: falt surface hardnessis HV1760, the core hardness is HV1450,the layer hardness distributes smoothly; the depth of carburized layer is 0.6mm, the depth difference of the inner and outer deep layers on the nozzle cross section is 0.1mm.After gas quenching workpieces are clean,white and light,and do not need to been cleaned again. The same time,this kind of treatment has overcome the common internal oxidation disadvantages of the gas carburization.
2.Acetylene vacuum carburizing oil quenching treatment of power metallurgy gears
The gear material composition is GrMo steel of 0.35%C, 0.5%Mn.
Technical requirements: surface hardness >HV1700.Gear rim carboncontent is1.0%hardening layer depth is 0.35mm.
Processing parameters: carburizing temperature is 900ºC,carburizing time=70min, oilquenching,160ºC tempering.
Processing results: surface hardness is HV1780, hardening depth is 0.4mm, core hardness is HV1300.
ADVANTAGES AND FUNCTIONS OF VACUUM HEAT TREATMENT
Heat treatment is an important basic process to improve the performance, reliability and service life of mechanical parts.
Heat treatment can maximize the excavation and play the potential of metal materials, so that mechanical parts can fully meet the performance requirements and service life under various service conditions.The advantages of vacuum heat treatment are no oxidation, no decarbonization, no pollution; clean surface,small distortion; excellent comprehensive mechanical properties;wide application; high automation; high production effciency, stable product quality and energy saving.Vacuumheat treatment can be widely used in annealing, annealing, oil(gas) quenching,high pressure (high flow rate) gas quenching, vacuum carburiza-tion, vacuum sintering, vacuum brazing and other fields.
The process characteristics of vacuum heat treatment are vacuum degassing, vacuum degreasing effect, vacuum purifica-tion effect and vacuum protection effect.
Degassing of vacuum: stel parts in the vacuum heating process reduce the furnace pressure, that is, increase the vacuum degree, the residual gas (H, N, CO, etc.)in the steel will escape (degassing), thereby improving the mechanical properties of steel parts, mold parts after vacuum quenching, plasticity,impact toughness will be improved, thereby prolonging the service life.
Vacuum degreasing effect: vacuum degreasing furnace has been widely used in metal foil, wire drawing and precision degreasing treatment of metal partswith small hole mesh. Because the grease attached to these objects belongs to theordinary aliphatic group, which isa compound of carbon, hydrogen and oxygen, its vapor presure is high, and when heated in a vacuum,it willquickly decompose into gases such as water vapor,hydrogen and carbon dioxide, and they are easily evaporated and pumped out by the vacuum pump. However, before vacuum heat treatment, the workpiece should stillbe cleaned and loaded into the furnace.Avoida large amount of grease to contaminate the furnace and contaminate the vacuum pump to avoid damaging the performance of the vacuum pump.
Vacuum purifcation:the metal surface has oxide film, slight rust,nitrides,hydride,etc,whenheated invacum,these compounds are reduced,decomposed or volatilized and disappear, so that the workpiece obtains a smooth surface.
Vacuum protection: when almost all metals are heated in an oxidizing atmosphere, the metal surface willoxidize and lose the luster of the metal, and vacuum heating canmake the metal material maintain the original surface brightness.
PRODUCT SELECTION
The selection of the vacuum furnace mainly involves the structure of the furnace, the size of the effective heating area, the pumping speed of the vacuum pump and the selection of the material of the heating room.
Through the vacuum range of the product, the temperature treatment of the material and other factors, so as to choose the most appropriate product equipment
Selection of effective heating zone
Vacuum furnace furnace size can be according to the heat treatment single product size, shape and a furnace capacity. Vacuum furnace is divided into horizontal (single chamber, double chamber, multiple chamber structure) and vertical vacuum furnace (slender parts suspension or plate parts heat treatment), limited by the structure and cost of horizontal single chamber structureis Ithe most commonly used vacuum heat treatment furnace, vertical vacuum furnace due to the layout has lifting transmission system, procurement cost slightly higher, our commonly used horizontal vacuum furnace effective area size is as follows:
| Furnace size |
Recommended effective working area mm |
| Experimental type, smal vacuum furmace |
300x200x200 450x300x300 |
| Medium vacuum fumace |
600x400x400 700x500x500 900x600x600 1200x600x600 |
| Large vacuum furmace |
1200x800x800 1500x800x800 2100x800x800 4000x1200x1200 |
| Giant vacuum furmace |
6000x1300x1300 9000x1550x1830 |
Vacuum selection
The working vacuum should be selected according to the material and heating temperature. First, the working vacuum required for no oxidation heating should be met, and then the surface brightness, degassing and evaporation of alloy elements should be comprehensively considered. The working vacuum of commonly used materials is recommended as follows:
| Vacuum heat treatment |
Recommended working
vacuum |
Vacuum brazing |
Recommended working vacuum |
| Steel (alloy tool steel, structural steel,bearing steel) |
1-10-1Pa |
Aluminum products |
10-3Pa |
| Alloy steel containing Cr, Ni, Si, etc |
10Pa |
Copper base products |
10-1-10-2Pa |
Stainlesssteel,high-temperature alloy,iron,nicke,
oobaltbase |
10-2-10-3Pa |
Nickel-based products |
10-2-10-3Pa |
| Titanium alloy |
10-3Pa |
Multicomponent alloy product |
10-1-10-3Pa |
| Copper alloy |
133-13.3Pa |
High speed steel Tempering |
1.3-10-2 |
High speed steel Tempering
Vacuum furnace shell is the working space from the sealed container, is also the basis of the furnace parts installation, furnace shell for double wall water cooling compression container, should have enough mechanical strength and stability, prevent force and heat after deformation and damage. According to the shell material is divided into all carbon steel material, and inner wall stainless steel material but other for carbon steel material
Selection of heating and thermal insulation material
The equipment can choose dfferent heating elements and heat insulation layers according to different operating temperatures.
The commonly used heating element materials are heat-resistant stel(CrzoNi8o), high-purity graphite, molybdenum and alloys,etc.The temperature range is as follows. In addition to the selection of the above materials, it is necessary to comprehensively consider the energy consumption and stability under long-term use.
| Operation Temperature |
Heating Element Selection |
Insulation Layer Selection |
| 800ºC and below |
High temperature nickel-chromium aloy |
Stainless steel |
| 800ºC-950ºC |
(Cr20Ni80)High temperature nickelchromium aloy |
Heat resistant steel + stainless steel |
| Heat resistant steel +graphite felt |
| 950ºC-1100ºC |
Molybdenum metal+stainless steel |
Molybdenum metal or heat resistant steel |
| Molybdenum metal + graphite felt |
| 1100ºC-1300ºC |
Molybdenum-lanthanum alloy |
Molybdenum-lanthanum alloy+ stainless steel |
| High purity graphite |
Graphite soft felt +Graphite hard felt |
| 1300ºC-1600ºC |
Molybdenum-lanthanum alloy |
Molybdenum-lanthanum aloy + stainless steel |
| Isostatic pressed graphite |
Graphite soft felt + Graphite hard felt |
| Tungsten alloy+Molybdenum |
Tungsten alloy+Molybdenum-lanthanum alloy +stainless steel |
| 1600ºC-2100ºC |
Isostatic pressed graphite |
Graphite soft felt + Graphite hard felt |
| Tantalum |
Tantalum+Molybdenum-lanthanum alloy+Stainless steel |
Selection of control system
Standard type: Temperature programmable and automatic action control with imported temperature control instrument and programmable controllras thecore, equipped withanalog board.The configuration is reasonable andeconomical.
Touch screen control system: Temperature programmable and automatic action control with imported temperature control instrument and programmable controller as the core, equipped with touch screen, touch scren to realize equipment operation interface,processediting,faut diagnosis
Computer group control system:One ormore vacuum furnaces andotherheating furnaces centralized control systemwith imported temperature control instruments, industrial computers and genuine confguration software as the core data acquisition, process programming, process storage, report management, etc.
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