ZLQ-ZQ Single Chamber Vacuum Aluminum Brazing Furnace
INTRODUCTION
It is mainly used for vacuum carrier gas brazing of intercoolers, oil coolers, radiators, air conditioning evaporators, condensers,radar grid antennas, waveguides and various plate warp or segment heat exchangers of automotive environmental protection products.
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) |
| ZLQ-300ZQ |
2400x800x800 |
1000 |
±3 |
0.3 |
800 |
300 |
4x10-1 |
| ZLQ-350ZQ |
2400x1000x1000 |
1200 |
±3 |
0.3 |
800 |
350 |
4x10-1 |
| ZLQ-450ZQ |
2500x1200x1200 |
1500 |
±3 |
0.3 |
800 |
2000 |
4x10-1 |
PRODUCT FEATURES:
ZLQ-zQ series vacuum gas-carrier heating aluminum brazing furnace is mainly used in the vacuum gas-carrying blazing furnaces of engineering machinery heat exchanger,hydraulic pump station heat exchanger, automotive heat exchanger and other plate-fin heat exchangers.
1.The low vacuum constant pressure inert gas protects and replaces the high vacuum aluminum brazing, which has shortened the vacuum time and raised the parts heating rate.
2.Outer circulating cooling fan has improved the cooling rate and shortened the discharging time.
3.The analog plate automatic control or the IPC automatic control are optional.
4.The working cycle is approximately 3.5 hours (high vacuum brazing 6-8 hours)
5.The power consumption of the single furnace is about 450 degrees (high vacuum aluminum brazing 800-1200ºC
),energy consumption uses the real-time monitoring.
PROCESS INTRODUCTION:
1.Open the furnace to let the workpieces in and close the door.
2.Open the bypass valve,start vacuum
3.When the furnace vacuum degree is s670pa, start the roots pump.
4.When the vacuum degree in the furnace reaches ≤3Pa, start heating, after heating to the furnace temperature > 360 °C, close the vacuum valve of the main pump, turn off the roots pump and mechanical pump, open the bypass pump-open the bypass valve and slow charging valve, the system automatically fillsand evacuates, keeps the pressure in the furnace within a certain range, and carries out inert gas replacement.
5.During the heating, the furnace body is always kept in a certain pressure range for cyclic replacement, and the filling rhythm is adjusted by the furnace pressure control system and the micro-charging system, and the program is completed automatically.
6.Heating,heat preservation and brazing end power off to stop heating.
7.When the furnace and furnace temperature are cooled off to about 58o degrees, shut off the bypass valve, shut off the micro-charging valve, open the inflation valve to inflate to 0.6 bar and start the air-cooled motor cooling, wait for the furnace temperature to drop to about 450 degrees, turm off the air-cooled motor.
8.Open the bleed valve to balance the pressure outside the furnace in the furnace, prepare for the furnace, wait until the furnace pressureis restored to the atmospheric pressure, then close the furnace bleeder valve (automatical delay control). Open the door in place,remove the workpieces, and close the furnace in place.
9.The whole process control is completed by fully automatic control
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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