Professional Documents
Culture Documents
History 4
METALLURGY 8
Powder Metallurgy 46
HEAT TREATMENT 70
Vacuum Hardening,Tempering 74
Sintering 88
Deep-Rooted Competence
The process and systems know-how available within ALD Vacuum Technologies is based
on developments over the past 85 years successfully brought about by the firms Degussa,
Heraeus and Leybold. During that period, these companies worked together in a number
of ways.
1916 1987
HERAEUS enters the field of vacuum DEGUSSA AG acquires all shares of
metallurgy when it succeeds in melting chromium-nickel Leybold-Heraeus GmbH, which is then
conditions.
1991
1930 Degussa spins off its Durferrit business
including Degussa Industrial Furnaces, while
LEYBOLD starts manufacturing
industrial vacuum equipment. Leybold AG sheds its vacuum metallurgy
1950
DEGUSSA decides to build
vacuum furnaces. 1994
The vacuum metallurgy and vacuum heat
treatment businesses become part of the
1998 2002
On August 3, 1998, Safeguard International Introduction of new heat treatment
Fund, L.P., Wayne, PA, USA acquires all system, type ModulTherm®.
shares of ALD Vacuum Technologies.
2003
1999 Cooperation with AFC Holcroft, Wixom,
ALD Vacuum Technologies enters the Michigan.
Own & Operate Business.
2005
2000 2 nd US Own & Operate factory started
in Port Huron, Michigan.
Decision about Own & Operate in USA.
ALD enters into the vacuum coating
2001
Start up of the Own & Operate Business.
6 Know-How is our Business
ALD Vacuum Technologies supplies ALD is noted for its superb know-how
equipment and systems for thermal and basis, high investments in research and development
thermochemical treatment of metallic and its strategic alliances.
materials in solid and liquid form. The Close collaborations with well-known manufacturers in
company`s competence consists on the operator companies have strengthened its position as a
one hand of its mastery in vacuum process technology supplier of
and on the other hand of its know-how in designing key technologies to major growth markets.
custom-tailored
system solutions for use in this field.
Worldwide Technology
and Market Leader
ALD plants are built for operation around ALD services include professional support
the clock, seven days per week. As and in emergencies as well as preventive
when the need for service arises, a global maintenance for plant equipment and the refurbishment
network is available to send urgently needed of older systems to boost
spare parts or an experienced service plant availability to the highest possible level.
technician. ALD has subsidiaries in 6 Our services at a glance:
countries worldwide and representations
in many others. Our marketing and service ■ Delivery of spare parts and consumables;
network and replacement part stocks at ■ Repair services;
strategic locations enable us to react at short ■ Maintenance and inspection;
notice. Additionally, our headquarters in ■ Equipment refurbishment.
Germany operate a customer support center
with dozens of experts who assist whenever
special know-how is required.
Head Quarters
and joining together new process combinations. to new developments in electronics and offshore and
and ladle metallurgy, melting and remelting, as well cons, partially overlapping each other
as casting and metal-powder technology, have led in their techno-economic potentials. Therefore, the
to high-quality metallurgical products tailored to proper selection of technology is the most demanding
will yield further improvements as dialog with the producer of the materials
purity powder for homogeneous, high- strength parts. production of turbine blades, which reduce fuel consumption by up to 30% and
emissions by 15% and more.
VACUUM INDUCTION
MELTING AND CASTING
Vacuum induction melting (VIM) is one of the Vacuum induction melting makes possible
most commonly used processes in secondary metallurgyeffective degassing of the melt and extra- ordinarily
applied for refining treatment in precise adjustment of alloy
the liquid state and adjustment of chemical composition composition, since the temperature, vacuum,
and temperature. To achieve gas atmosphere, pressure and material
the increasing quality demands on the transport (e.g., through stirring of the bath)
resulting material and at the same time can be adjusted independently of one
■ save raw materials such as alloying another. Besides the exact concentration
elements due to higher yield; and of alloying elements, the content of trace
■ save energy, elements is also important for many alloys. Sampling
Effective such as dephosphorization and desulphurization, are ■ Selection of a more stable refractory
degassing / limited. VIM material for crucible lining;
distillation
metallurgy is primarily aimed at the pressure-dependent ■ Stirring and homogenization by electro-magnetic
reactions, such as stirring or purging gas;
reactions of carbon, oxygen, nitrogen ■ Exact temperature control to minimize
and hydrogen. The removal of harmful crucible reactions with the melt;
volatile trace elements, such as antimony, tellurium, ■ Suitable deslagging and filtering
selenium, and bismuth in vacuum induction furnaces is techniques during the casting process; Application
of considerable ■ of a suitable launder and
practical importance. tundish technique for better oxide
removal.
VIM Chamber Furnaces Product Line ALD offers a complete product line
of VIM furnaces with charge
The product line is based on the weights varying from 1 kg up to
chambertype VIM (Vacuum Induction 30 tons for the making of:
Melting) or on the compact VIM-VIDP ■ Semi-finished products, such as:
furnace design. Depending on production - Wires, strips, rods
and economical requirements, the VIM - Ingots and electrodes
furnace technology can be expanded by - Targets
different implements. These are: - Structural parts
VIM-VMC
The VIM-VMC-furnace is a two- chamber
VIM
Typical charge weights: 0.5-15 metric tons single- chamber
VIM-HMC
Typical charge wheights: 0.5 to 20 tons; two-chamber
of superalloys.
1 Melting/Cast Chamber
2 Charging Chamber
3 Control Room
1
VID/VIDIST/VIDP 19
■ Optimum control of the furnace by its compact design with a small melt
chambers
The vacuum chamber size is reduced to
a minimum - the result is lower pressure,
Fast furnace change
■ <1hour with hot crucible shorter pumping time or smaller pump
■ Separate crucible break out and for crucible exchange, high flexibility in
relining stations
■ Vacuum drying of crucible available
Easy to maintain
■ Power cables and hydraulic lines are
outside the melting chamber - leaks do
not affect the vacuum
■ Simplified maintenance of the vacuum
pumps with effective filter system
■ Smaller vacuum pumping system
■ Tried and tested components
■ Preventive fault diagnostic
■ No large vacuum chamber to clean
■ High-quality superalloys or
special steels;
■ Critical copper alloys and
oxygen-free copper. VIDP production unit at ThyssenKrupp VDM
3
5
7
2 4
6
ELECTROSLAG
REMELTING (ESR)
Electroslag Remelting (ESR) ESR 23
ESR has been known since the 1930s, as the preferred production method for
but it took approx. 30 years before it high-performance superalloys that are used
became an acknowledged process for today in industries such as aerospace and
mass production of high-quality ingots. nuclear engineering as well as for heavy
The ESR technology is of interest not only forgings. Ingots are obtained with purity
for the production of smaller weight ingots levels that were unheard of some years
of tool steels and superalloys, but also of ago. Other branches of engineering are
heavy forging ingots up to raw ingot following the examples of the "high-tech"
weights of 165 tons. pacesetters and insist on new, high purity
levels that can be obtained from ESR with
Process Technology and Process the latest, most sophisticated equipment.
Characteristics
Metallurgy of the Electroslag Slags for ESR are usually based on calcium
Remelting Process
fluoride (CaF 2), lime (CaO) and alumina
(Al 2O 3). Magnesia (MgO), titania (TiO 2)
Due to the superheated slag that is and silica (SiO 2) may also be added,
continuously in touch with the electrode depending on the alloy to be remelted.
tip, a liquid film of metal forms at the To perform its intended functions, the slag
electrode tip. As the developing droplets must have some well-defined properties,
pass through the slag, the metal is cleaned such as:
of non-metallic impurities which are removed ■ Its melting point must be lower than
by chemical reaction with the slag or by that of the metal to be remelted;
physical flotation to the top of the molten ■ It must be electrically efficient;
pool. The remaining inclusions in ESR are ■ Its composition should be selected to
very small in size and evenly distributed in ensure the desired chemical reactions;
the remelted ingot. ■ It must have suitable viscosity at
remelting temperature.
Shielding of the melt space with protective At the end of the 1960s, the concept of
atmosphere has been the latest trend in using ESR plants to manufacture large
recent years. Remelting under increased forging ingots gained acceptance.
pressure to increase the nitrogen content in Increasing demand for larger electrical
the ingot is another variation of ESR. ESR
power generating units required forging
furnaces can be designed for remelting of
ingots weighing 100 tons or more for manufacturing
round, square and rectangular (slab) ingots.
of generator and turbine
shafts. ALD's largest ESR furnace,
Finally, computer controlled process
commissioned in the early 1970s, allows
automation has been developed to
to manufacture ingots of 2,300 mm
perform similarly to ALD's automatic melt
control system (AMC) described under VAR. 165 ton ESR furnace
Important to mention here is that ALD's
electrode immersion depth control into the
slag is based on slag resistance or slag
resistance swing. Using the resistance
parameter automatically decouples the
immersion depth and remelting rate control
loops which are otherwise cross-influencing
each other.
165 ton ESR ingot, 2,300 mm diameter x 5,000 mm long essential that a sufficiently high amount of
nitrogen above the solubility limit under
normal pressure is introduced into the molten
steel and that nitrogen loss is prevented
during solidification. As the solubility of
nitrogen is proportional to the square root
remelting, the nitrogen pick-up via the gas Due to the absence of oxygen in the furnace Schematic of IESR
furnace
phase is insufficient. The nitrogen must, atmosphere, desulfurization via the gas 1 Electrode feed drive system
therefore, be supplied continuously during phase is no longer optimal. However, sulfur 2 Ball screw
3 Pivotable furnace support
remelting in the form of solid nitrogen- is today taken care of by ladle metallurgy
gantry
bearing additives. The high pressure in in the making of steel electrodes. 4 Load cell system
the system serves exclusively to retain 5 Electrode ram
6 Electrode stub
the nitrogen introduced into the molten Two furnace concepts are available, one
7 Protective gas chamber
steel. The pressure level depends on the with a protective hood system of relative 8 Slag pool
composition of the alloy and on the desired tightness, the other with a fully vacuum- 9 Ingot
10 Mold assembly
nitrogen content of the remelted ingot. tight protective hood system that allows
11 High current contact
the complete exchange of air against an assembly
Remelting under Inert Gas inert gas atmosphere prior to starting the 12 Power cables
13 Ram guiding system
Atmosphere (IESR) remelting process.
14 Maintenance platforms
1
As a consequence of ALD's development
work in PESR processing, ALD nowadays recommends
gas. 4
The following results have been obtained:
■ Oxidation of electrode and slag is
completely avoided;
7
5 3
■ Oxidizing loss of elements such as Ti,
Zr, Al, Si, etc. is almost completely
6
avoided. This is especially important
when remelting high Al and Ti-contai-
ning alloys, like superalloys with very 8
Electroslag Remelting under Thus, the advantages of both ESR and VAR
Vacuum (VAC-ESR) are combined in one process. That is of
interest for superalloys or titanium remelting.
Pressurized/Vacuum Systems
Completely sealed systems for ESR
operations under vacuum, inert gas, or
increased pressure. These systems are Schematic of PESR
furnace with stationary
particularly suited for producing ESR mold
ESR Applications:
■ Tool steels for milling cutters,
7
mining, etc.;
6
■ Die steels for the glass, plastics and
automotive industries;
■ Ball-bearing steels; 8
■ Steels for turbine and generator shafts;
■ Superalloys for aerospace and power
turbines; 9
■ Nickel-base alloys for the chemical
industry;
■ Cold rolls.
VACUUM
ARC REMELTING (VAR)
Vacuum Arc Remelting (VAR) VAR 31
titanium scrap.
EB Features
■ Electron Beam Guns
■ ALD offers electron beam guns of 60,
a series of EB guns with 60, 300 and
300 and 600 kW power with highly
600-kW beam power at 25-45 kV.
advanced beam deflection controls;
■ System designs are implemented with
■ EB Drip-Melt Production Furnaces
melting powers of up to 3,600 kW;
for production of refractory metal ingots up
■ Ceramic-free melting process for
to 400 mm in diameter and 3,000 mm
circular, square and rectangular ingot
length, beam powers up to 2 MW with 2,
shapes.
3 or 4 guns.
EB Applications
■ EB Cold Hearth Production
■ Remelting of high-purity refractory
Furnaces
materials such as Nb and Ta;
for production of reactive metal ingots and
■ Titanium production for the chemical
slabs, including material recycling. Ingot
and aerospace industries;
weights up to 15 tons, total beam power
■ Zirconium production for the chemical
above 3 MW with up to 6 guns.
industry;
Vacuum precision casting furnace with central water-cooled Liquid Metal Cooling for
heat sink and central baffle (patented)
DS/SC Solidification
1Mold moving device
23-zone resistance mold heater
3Mold heater lifting and lowering device
4Temperature measuring device For the production of large directionally
5Ingot charger
6150 -1,000 lbs furnaces solidified (DS) and single crystal (SC)
7Central heat sink and baffle
8Lifting and lowering device components high thermal gradients are
for central heat sink
4
9 Vacuum pump set 3 required. In order to provide the highest temperature
5
gradient and a flat solidification
front, ALD's patented "central baffle with
heat sink" may be applied. The "central
baffle with heat sink" provides an improved
thermal environment during solidification
2
of particularly large DS/SC components.
9
A further improvement of the solidification conditions for
6
large DS/SC components is
1
7 provided by the liquid metal cooling (LMC)
process. In the LMC process, the mold is immersed for
solidification of the components
8 into a liquid cooling bath, either consisting
CASTING 43
method is the solution to overcome major limitations of LEICOMELT® furnaces are basically induction melting
the induction melting method furnaces, they can be charged with
■ The copper crucible avoids any One of the salient features is the combination
contamination of the charge material; of the alloying itself and subsequent pouring
■ Electromagnetic stirring of the melt in one temperature.
provides excellent thermal and
chemical homogenization of the melt. ALD is marketing LEICOMELT® furnaces with
melt volumes within the range of some cubic
The cold wall induction crucible is made of centimeters up to 30 liters. Tilt pour and bottom-pouring
a plurality of water-cooled copper segments systems are applied. Static
that allows the induction field to couple and and centrifugal investment molds or
heat the charge material. The induction field permanent molds made of special alloys
creates a vigorously stirred melt throughout complete the range of casting techniques.
LEICOMELT® - Three-
Chamber Version, remote
controlled
8 Crucible carriage
9 Control desk
3
10 Centrifugal drive system
11 Mold arrangement
12 Lock valve
13 Skull crucible
14 Consumable electrode 15
15 Electrode feeder ram
4 5
14
6
8 13
12 9
11
10
POWDER METALLURGY
and Inert Gas Atomization the coarse and the fine powder fractions
are separated from the atomization gas.
The metal powder is collected in sealed containers
The standard design of a vacuum inert
which are located directly
gas atomization (VIGA) system comprises
below the cyclones.
a Vacuum Induction Melting (VIM) furnace
where the alloys are melted, refined and degassed. The
ALD has developed atomization systems
refined melt is poured
where a variety of melting processes can
through a preheated tundish system into
be combined with inert gas atomization.
a gas nozzle where the melt stream is disintegrated by
The atomization systems built by ALD have
the kinetic energy of a
a modular design and are applicable from laboratory
high pressure inert gas stream. The metal
scale (1- 8 l crucible volume),
powder produced solidifies in flight in
through pilot production (10 - 50 l crucible
the atomization tower located directly
volume) up to large-scale atomization systems
underneath the atomization nozzle. The
(with 300 l crucible volume).
powder gas mixture is transported via
temperature measuring devices and Each vacuum induction furnace has a rated batch capacity of 2,000 kg.
A gas recycling system recovers the inert gas for reuse.
a redundant tundish system.
Ceramic-Free Metal
Powder Production
the melt and the ceramic lining and nozzle material, nozzle system and is atomized with inert
ceramic inclusions in the melt gas. The EIGA process was originally developed for
can occur, which influence the material reactive alloys such as
properties of high-strength PM-components titanium or high-melting alloys. It can also
in a negative manner. Reactive metal be applied to many other materials.
powders, such as titanium based alloys,
cannot be produced with this method
at all, due to the reactions between the
reactive melt and the ceramic lining. In
order to overcome the "ceramic problem"
it is necessary to use melting techniques
where the melt is not in contact with
ceramic lining material. Additionally,
Schematic view of Schematic view of the
a refining of the melt during the melting the EIGA system PIGA system
melted and atomized without any melting an inductively heated discharge nozzle,
crucible at all. The melting of the electrode also made of a copper base material.
is accomplished by lowering the slowly This ceramic-free discharge nozzle system
rotating metal electrode into an annular guides the liquid metal stream into the gas atomization
induction coil. The melt stream from the nozzle, where it is disintegrated
The produced semi-finished products are Behind the cyclone and the filter system,
subjected to secondary processing steps, the "dust-free" gas is repressurized using a
such as heat treatment, rolling, forging, extrusion or 2-stage compressor unit. The compressors
HIP. The process is used extensively to manufacture have to be gastight to prevent contamination
billets for a of the recirculated inert gas. After each compressor, a
wide range of appications in aluminium gas buffer tank is used to
alloys, copper alloys, special steels and minimize pressure fluctuations during the atomization
superalloys. process. This results in stable atomizing process
conditions with respect
to atomization pressure and gas-flow rate.
Inert Gas Recycling
In case the permissible impurity levels in
the atomization gas are set very low, the
At a certain batch size of the atomization
oxygen, hydrogen and nitrogen contents
system, recycling of the inert gas is recommended, to
can be monitored at several locations in
reduce the total inert
the gas circulation loop.
gas consumption and thus achieve a
more economical production process.
For large-scale atomizing systems this type
ALD offers two different process
of gas recycling is economically operated
technologies to recycle the inert gas.
in a pressure range up to 50 bar.
If a higher gas supply pressure is required, supply pressure of approx. 100-200 bar can be
the recycling concept described above achieved.
has to be changed to the principle of
reliquefying the argon by using evaporating Operational experience with large scale
liquid nitrogen as the refrigerant. In this atomization systems equipped with the
situation, the 2-stage compressors with recycling systems described above, shows
the pulsation buffer are replaced by a that the yield of the recycled gas for both Argon recycling system
based on liquefaction
concurrent flow argon liquifier and a set recycling systems is in the range of 90-95 %.
of high-pressure liquid argon pumps.
Schematic layout
of the argon re- liquefying
system
with high-pressure
liquid argon pumps
and high pressure
gas receivers
VACUUM TURBINE
BLADE COATING (EB/PVD)
electron beam, which melts from corrosion caused by hot air and to compensate the
and evaporates metals as well as ceramics. different thermal expansions between the superalloy
are used in the field of optical coatings bond coating absorbs mechanical stresses
for lenses and filters, in the area of semiconductor between the component and the protective
manufacture, for the coating ceramic coating. Bond coatings are applied
of packaging web and many other high- in separate manufacturing steps. MCrAlY
volume applications. A system for coatings bond coatings were originally developed
of turbine components was first introduced with EB/PVD methods. Today low pressure
Parts from metals and alloys, such as titanium only small stresses occur in the workpiece
and various superalloys, that are hard to and the grain size remains nearly
shape and are used in jet-engine parts unchanged. Another advantage of this deformation
subjected to high stresses, as well as metals method is the "near net
such as molybdenum which retain high shape" potential and the related savings
strength at high temperatures are usually in materials plus a greatly reduced need
finished by hot isothermal forging (HIF). for subsequent machining. HIF systems
Hot isothermal forging (HIF) has developed from ALD feature:
in recent years into an important - and for ■ The multizone billet heating furnace;
many applications indispensable - process ■ The multizone die-heating system;
for producing high-quality parts in "near ■ The microprocessor-controlled system
net shape". for temperature control.
IWQ furnaces are suited for many common ■ Vessel material is resistant to
heat-treatment, melting and distillation aggressive gases such as Cl, F and HF
processes in which reactivity or the special properties of at T 600°C;
the material, metal-based alloy ■ Standard quartz tubes with length
or mixture require a complete or partial of 2,000 mm and diameters up
treatment under vacuum or protective gas. to 1,000 mm;
applications in industry and research pumps. ALD also has industrial experience
with extraordinary requirements in high-temperature with and provides safe solutions for high-
processes, such as: temperature hydrogen furnaces.
■ Vacuum annealing, degassing and
refining
For ultrahigh-vacuum applications, a special
■ Sintering of metals and ceramics Liquid- ALD double-chamber concept has been
■ phase sintering and metal proven to permit an ultimate vacuum in the
impregnation heat treatment chamber of <10-8 mbar at
■ Vacuum brazing and active-metal 1850 °C.
brazing
■ Vacuum material testing All furnaces are equipped with state-of-the-
art PLC process control and visualization.
Each WI furnace is sized and configured WI 800/1100 High Vacuum resistance furnace -
for a specific process and application with buttom loading system
Heat Treatment is the process in which All of these processes need a temperature
metallic/steel parts are exposed completely up to 1.000 °C and higher as well as
or partially to time-temperature sequences especially developed furnaces to achieve
in order to change the mechanical and/or corrosion such ranges. From the past there are well-known
properties. There are numerous application areas, e.g.: technologies for the above processes, e.g.:
■ Tempering atmospheres
■ Aging
■ Case hardening
■ Nitriding
Brazing
Brazing is a process for joining components, whereby a
filler melts under temperature
and joins the components together after solidification. In
this process, the solidus temperature of the parts to be
joined is
not reached. In high temperature brazing
(above 900 °C) which ideally happens
in vacuum, the atmosphere (vacuum)
takes on the duties of the fluxing agent.
HEAT TREATMENT 73
The process of heat treatment has been an inert gas, usually nitrogen up to 2 bar,
used for centuries in order to specifically is filled into the furnace after evacuation.
change the properties of components. In By circulating the gas during heating,
the course of development, the processes excellent temperature uniformity is reached,
have fundamentally changed. Up to the which has a positive effect on reducing
early 20th century the processes were conducted in a distortion. Convective heating up to 900 °C
normal atmospheric environment. The use of also shortens the cycle time. Subsequently,
protective gases the load is heated in vacuum to the required
has further improved the quality of the austenitizing temperature. After an adequate soaking
components. time at austenitizing temperature
the parts are cooled using gas quenching.
Heat treatment development experienced
a significant boost with the introduction of The type of gas used and the necessary
vacuum technology. At first, this technology pressure depends on the part (material, geometry) as
was only used for special materials in well as on the required
aviation technology but soon widely spread treatment results. Most parts of cold and
to harden high alloyed tool steels. hot work tool steels as well as high-speed
steels can be hardened with nitrogen at
The following reasons are essential for the a quenching pressure up to 10 bar.
change to vacuum technology:
■ Reduced distortion
■ Clean and dry parts, no oxidation Simple
■ and reproducible treatment
of parts
■ Fully automated processes
■ Hardening and tempering in one
Vacuum chamber furnace
system
Mid and some low alloyed tool steels, Double-Chamber Vacuum Furnace,
such as ball bearing steel 100 Cr 6, require quenching Type DualTherm®
gases with better thermal proper- The double-chamber vacuum furnace,
ties such as helium, or higher quenching type DualTherm® ideally combine heating
pressures up to 20 bar. Most of the low and quenching processes. This furnace
alloyed steels like case hardening steels has been especially developed for case hardening in
are requiring increased quenching speeds vacuum.
which may not be achievable in single-
Gear shafts treated in chamber vacuum heat treatment furnaces. This two-chamber system operates according
DualTherm® furnace
These parts have to be quenched in a to the in/out principle and its design
"cold quenching chamber". ALD has is similar to conventional sealed quench
developed such furnace types: furnaces. At the beginning of the process,
the fore chamber of the furnace serves
■ Double-chamber vacuum furnace, as the loading chamber and after heat
Type DualTherm® treatment as the gas quenching and
■ Linked multi-chamber furnace, unloading chamber. After placing the
Type ModulTherm® charge into the fore chamber, it is
■ Special furnaces transported to the treatment chamber
DualTherm® furnace
via an internal transport system.
The basic version consists of a rail-mounted ■ treatment chambers at the same time Convective
shuttle system, comprising the transfer heating
module and the quenching chamber. ■ Short and identical transfer times
This shuttle moves between two or more stationary ■ between treatment and quenching
treatment chambers where the chamber
number of chambers can be adjusted to Quenching with reversed gas flow
capacity needs. Easy access to all ■ The transport system is not exposed to
components is guaranteed by the modular ■ heat or thermo-chemical reactions
design. This innovative furnace concept Easy access to all system components
combines modular components and system availability ■ Maintenance during production
with flexibility and maximum reproducibility of the heat ■
treatment process.
Special gears
78
ModulTherm® Components
Module Purpose
Quenching chamber High-pressure gas quenching
Transfer module Load transport between treatment/quenching chamber and
loading/unloading of the treatment chambers
Treatment chamber Heat treatment processes
Transfer module
Special Furnaces
In addition to the furnaces for hardening, tempering,
case hardening, annealing,
sintering and brazing processes, ALD is particularly
experienced in the production
of special systems. These special
applications accrue from various industrial
sectors and include annealing treatments
for special alloys in the aviation industry as
well as furnaces for the treatment of special
materials.
■ Vacuum Carburizing
Vacuum-Based
Carburizing Processes
Methane CH 4
75 % <3%
Propane C 3H8 82 % ~ 25 % ~
Acetylene C 2H 92 % 60 %
2
* in weight-%
** % of carbon transferred from gas into load
Temperature (°C)
940
850
20
Pressure (bar)
Quenching
20
Convective
Heating
1
10-1 Carburizing Diffusion Time
10-3
10-5
84
Air 1 bar
N 2 6-10 bar
(hot chamber)
He 20 bar
(hot chamber)
He 20 bar
(cold chamber)
N 2/He 1 -
(10) / 20 bar
Salt quench
(550 °C)
Fluidised bed
Circulated oil
(20-80 °C)
phases which occur during quenching in quenching. Heat transfer all over the
liquid media: film boiling, bubble boiling part is more homogeneous and the risk
as well as the convection phase. The of distortion is reduced. Excellent process
individual phases are characterized by control for the entire quenching process is guaranteed
very different heat transfer coefficients, by the control of gas pressure
which lead to big temperature gradients and gas velocity. With these parameters,
in the part, causing distortion of the part. the quenching speed can be adjusted to
Gases don't show phase changes during the parts requirements.
Process Advantages
The main advantages of high pressure gas
quenching are reduced distortion which
20 bar
ALD-Patented
- Ball Bearing Steels (Small Sizes) - Low Alloyed Case Hardening Steels
(16MnCr5, 20MoCr4, SAE 8620)
100Cr6 (SAE 52100) 100CrMn6
Heat Treatable Steeks
- Ball Bearing Steels (Medium Sizes)
42 CrMo4 HH (4140 HH) - 100 Cr6 (SAE 52100)
Al-, Ti-Alloys
-
10 bar
Material, Part Dimension and Hardness Specification determine Quenching Process Parameters
CASE 87
HARDENING
Number of Parts
20
18
16
14
12
10
0
25 50 75 100 125 150
Runout (∝ m)
Vacuum Carburizing & Gas quench Gas Carburizing & Oil quench
SINTERING
■ of Magnets
For more than 50 years, ALD and it's predecessors The sintering process happens in vacuum
have manufactured sintering or under protective gas at the appropriate temperature
furnaces for hard metals, cermets, magnets, for the material. A defined, reproducible sintering
MIM products and special oxide ceramics. atmosphere without atmospheric oxygen is important.
At
The sintering process consolidates particles certain pressures and temperatures the
in a coherent, pre-determined solid structure. process gas feed during sintering with
Mass transport in the atomic range happens argon, N 2, H 2, CH 4, CO 2 and others
during this process. Single-phase powders may influence the structure and chemical
are sintered at 2/3 to 4/5 of their melting temperature, composition of the workpieces.
multi-phase powders (mixtures)
are sintered near the solidus of the lowest
melting phase.
Following the vacuum sintering process, for hard metal materials and powder metallurgical
hard metal tools and other sintered parts. ■ Sintering of hard metal tools and
micro drills
■ Sintering of MIM parts (metal injection
moulded)
Vacuum furnace for dewaxing and vacuum sintering, 4 different dewaxing processes
type VKPgr 50/50/170 with integrated rapid cooling system
■ High temperature uniformity
■ Special graphite felt insulation with
long service life
■ Graphite heating with integrated,
closed graphite muffle
■ Two integrated and one external rapid cooling
systems to reduce cycle time Metallurgical
■ treatment of workpieces
using process gases
■ Operating pressure 6 MPa or 10 MPa
Coated, cemented carbide drills
SINTERING 91
The features of this furnace line are: Pusher furnace for sintering of MOX pellets type GWSmo
■ One single furnace performs up
to 4 different dewaxing processes
■ High temperature uniformity
■ Graphite insulation
■ Graphite heating
■ Integrated, controllable rapid cooling
system
■ Metallurgical treatment of workpieces
using process gases
Engineering
Know-how
Operating System Provider Engineering Plants
Company (OEM, TIER1) & Processes Vacuum Process
Technology
ALD Service Centers Customer ALD Vacuum Technologies
Optimized Plants
Furnace Manufacturing and Service On the other hand, the prompt feed-back
- a good match? of operating knowledge and experiences
is invaluable to our technical departments
The economic efficiency of the 'New for further development of our furnace
Technology' (vacuum case hardening and technology.
high pressure gas quenching) became
apparent in heat treatment in the 2nd half ALD as commercial Heat Treater?
of the 1990's and a growing number of
projects demanded vacuum or plasma car- burizing with It is not our intention to enter the market
high pressure gas quenching. Following 6 years of as a commercial heat treater. On behalf
continuous success of one customer at a time we are acting to
we finally decided to develop our Own achieve a solution to a problem which is
& Operate strategy and since then have not yet economically solved in the market.
taken over the heat treatment for our The market development of 'commercial
customers in selected projects. heat treatment' is part of the strategy of
our customers, however, we do not consider
Thus, two objectives are pursued: on this business area a core competence.
one hand, the customer benefits from The strategy rather caters to products with customer
our process know-how while immediate specific growth potential, since
investments for new technological the 'New Technology' is entailing a high
equipment are not required. added value of the parts to be produced.
94
In co-operation with 'Heat Gruppe' the first and was even conducive for the furnace
project was realised in 1999 in Limbach- Oberfrohna, business. As a result, customers like DANA, Visteon
close to Dresden, Germany. VACUHEAT took over the and Stackpole could be added to
heat treatment our customers reference list.
of fuel injection components, like injection
nozzles. The Piezo technology for nozzle
injection systems promises a high growth
rate while demands on precision and
cleanness are accomplished by the 'New Technology'
only.
ALD has been chosen by GM Powertrain treatment of additional 1,500 gears per
for the heat treatment of all 23 parts of day. This time the production site is Mexico
the latest six gears automatic front drive. where the start of production is planned
This is one of the biggest orders ever for March 2008 with 3 ModulTherm® lines.
placed for heat treatment in the US.
Contract negotiations with a well-known
In June 2006, the new operating site supplier in China's automotive market
in Port Huron, MI, started its production. are almost concluded. Start of production
Three lines of ALD's type ModulTherm® is scheduled for the near future.
with 6 treatment chambers each were
installed for GMPT's first phase, heat ALD Service - Expertise in New
treating 1,500 gears per day. Technology
■ 10 DualTherm®-furnaces
■ 8 ModulTherm®-furnaces
■ 2 Continuous Plants with Plasma
Carburising
USA Germany
Metallurgy: ALD Own & Operate GmbH
ALD Vacuum Technologies, Inc. Wilhelm-Rohn-Str. 35
18, Thompson Road 63450 Hanau, Germany
East Windsor, CT 06088, USA Phone +49 (6181) 307 3123
Phone +1 (860) 386 72 - 27 e-mail: klaus-juergen.heimbach@ald-vt.de
e-mail: info@ald-usa.com
VACUHEAT GmbH
Heat Treatment: Hohensteiner Str. 11-13
ALD - Holcroft Vacuum Technologies Co. 09212 Limbach - Oberfrohna, Germany
49630 Pontiac Trial Phone +49 (3722) 4022 13
Wixom, MI 48393, USA e-mail: vacuheat@vacuheat.net ALD Vacuum Technologies GmbH
Phone +1 (248 ) 668 4016
e-mail: karl-heinz.grosse@ald-vt.de Wilhelm-Rohn-Strasse 35
USA
ALD Thermal Treatment, Inc.
63450 Hanau, Germany
1101 Carolina Pines Drive
Great Britain Blythewood, SC 29016, USA Phone +49 (6181) 307- 0
ALD Vacuum Technologies Ltd. Phone +1 (803) 2330660
First Floor
276 High Street
e-mail: sborchardt@aldtt.net Fax +49 (6181) 307- 3290
Guildford, Surrey GU 1 3JL, UK
Phone +44 (1483) 45 44 34 e-mail: info@ald-vt.de
e-mail: info@aldvactech.co.uk
ALD Thermal Treatment, Inc.
2656 24th Street
Internet:www.ald-vt.de
Port Huron, MI 48060, USA
Phone +1 (810) 966 5021
Far East e-mail: rpeters@aldtt.net
ALD Thermo Technologies Far East Co., Ltd.
10F. Shinjuku Nomura Bldg.
1-26-2 Nishi-Shinjuku, Shinjuku-Ku
Tokyo 163-0558, Japan Mexico
Phone +81 (3) 33 40 37 26 ALD Tratamientos Termicos
e-mail: Peter.Lang@ald-vt.de Santa Maria Industrial Park
Saltillo, Coahuilla, Mexico
Phone +49 (6181) 307 3107
e-mail: barbara.ahrens@ald-vt.de
Poland
ALD VT Polska Sp. z. o. o.
Holenderska 6,
05-152 Czosnow, Poland
Phone +48 (22) 78 51 082
e-mail: a.karwice@ald-vt-polska.pl
China
ALD Liaison Office
c/o C&K Development Co., Ltd.
Rm. 1102, South Office Tower
Hong Kong Plaza
283 Huai Hai Zhong Rd.
Shanghai, 200021, China
Phone +86 (21) 63 85 - 55 00
e-mail: ald@ald-vt.cn
Russia
ALD Vacuumyje Technologii OOO
ul. Bolschaja 40, str. 2
109017 Moskau, Russia
Phone +7 (495) 787 6733
e-mail: ald@metallurg.com.ru