Quenching of large dies and molds with a newly developed 15bar SuperTurbo* vacuum furnace Rockford Thomas Wingens, International, Inc. 0 Introduction The main focus of the vacuum heat treatment of die casting molds is to reduce distortions while using the necessary, easily controlled processes. A slight follow-up trimming can achieve a smooth finished surface. Slower gas quenching reduces deformation, but some particularly large molds exhibit grain boundary precipitation, shortening die life.

For die-casting tools, with the application of high-pressure gas quenching with faster quenching rates, the heat treatment quality has been significantly improved in the past decade and the sensitivity to failure has been greatly reduced. The use of faster quench rates increases the amount of deformation and subsequent machining, but the risk of quench cracking is acceptable as a cost of an overall improvement in tool life.

This article will discuss the vacuum heat treatment of very large molds (over 5 metric tons) using the newly developed IPSEN SuperTurbo* vacuum furnace with 15 bar nitrogen gas quenching combined with directional cooling. The result is superior mechanical properties and minimal deformation.

With the application of vacuum heat treatment of molds, the requirement for mold heat treatment in the 1980s and 1990s focused on the deformation control, especially for the large H13 (1, 2343) die blanks, because the reduced deformation saved the use of The cost of subsequent machining. There are fewer and fewer methods for achieving low deformation mainly through the use of very slow gas quenching of less than 30*F (17*C) per minute, which results in the precipitation of grain boundary carbides and the reduction of die life due to reduced impact toughness. It is adopted (, 2).

The North American Die Casting Association (NADCA), together with many major companies in the die-casting industry, issued some documents recommending a minimum surface cooling rate of 50*F (28*C) per minute. By selecting high-quality mold materials and using the best heat treatment basis, the North American auto industry adopts similar heat treatment specifications of DC-9999-1 in 1995 through the GMPT of the automobile company and the AMTDDC2010 in 1999 of Ford. Save hundreds of millions of dollars in costs.

The use of a good thermocouple arrangement and interrupted cooling (isothermal hold) can accurately control the cooling rate and deformation of the draw blank. On large molds, the cooling rate is still below 50*F (28°C) per minute. Due to the large temperature difference between the surface and the core during quenching, large deformations occur and mold cracking may result. It is often necessary to machine the cooling holes into the quenched part, and the use of the material is sometimes insufficient.

2 Qualified 丨 113 Allegiance 1 Vacuum Furnace Technology Advances In the industry's demand for faster but more uniform cooling of large molds, Ipsen International has adopted a 360C heating zone with convection-assisted heating. barTurboTreater*. As the industry's fastest quenching furnace for large molds, Ipsen has performed several tests on the surface of 16' H13 cubes according to General Motors' driveline heat treatment specifications (). Test Tables The mold heat treatment industry in North America prefers a furnace that can rapidly and uniformly quench quenched die blanks weighing 4.5 tons (10,000 pounds). A circular hot zone with convective heating is generally used, and for GMFT 3 test CM drive system H13 takes a cube, isometric wet grip (surface/core) time/field 4 hours, test block, etc. With the application of 12-bar TuibTrater* with convection-aided heating, Ipsen fulfills the requirements of the mold industry for reliable vacuum furnaces that are rapidly and uniformly cooled.

Some of the outstanding features of SuperTurbo(), a large-scale series of large-scale vacuum furnaces with advanced charging technology and advanced charging technology for complex geometries of molds, tools and components, include: 1) Quenching pressures of up to 15 bar; 2) Cooling and isothermal holding in controlled air flow direction; 3) Reliable water-cooled motors starting with low-current power supply (LCP); 4) Convection designed with flapper nozzle (FlapperNozzle*) Auxiliary heating.

For different geometry loads and part sizes, the cooling air flow is programmed (see ), providing good control for higher part hardness and faster quenching with minimum distortion. The high-quench directionality can be controlled by a workpiece thermocouple, and the combination of six cooling fire detection pressures, directional cooling, and an Ipsen water-cooled motor (LPC) with LCP startup significantly improves the quench quality of large parts. LCP startup reduces motor start-up time and cooling time, which greatly reduces the energy cost during the required peak current of the starter motor.

A German heat treatment plant that requires improved energy costs and efficiency in the cycle time and meets the high quality requirements for large molds at competitive prices.

As a result, the manufacturer exceeded the requirements for the metallurgical performance and part deformation of the H13 (1, 2344) mold through the technical conditions of the transmission system of the automobile company, significantly saving the energy cost and improving the quality of the parts, thus being a more efficient heat treatment.

The Ipsen patent was the first of its kind in the industry before the emergence of a circular hot zone with multidirectional cooling. Using a convection-assisted heating combination with an Ipsen baffle nozzle () saves 33% cycle time while maintaining precise control even for some of the most demanding applications. Baffle nozzles are a major achievement in convection heating technology. As the injection nozzle of the cooling gas, the flap valve nozzle is simple and reliable (8). It does not require a complicated connection or transmission mechanism. This is designed to reduce the heat loss from the high temperature zone while improving the temperature uniformity during heating. It has been demonstrated that convective heating significantly reduces the cycle time, especially for large cross-sectional or dense loads. These superior technologies also reduce energy consumption, reduce maintenance troubles and costs, and save time and money.

Directional cooling and isothermal holding; 2 LCP-activated water-cooled motor; 3 Hot zone made of molded graphite element and graphite felt (Calfoam*); 4 Convection-assisted heating combined with baffle nozzle (FlapperNozzle 1M) design; 5 up to 15bai High-pressure gas foreign; 6 computer interface equipment.

3 Heat treatment of large molds The heat treatment of very large molds poses great difficulties for heat treatment workers. When fast cooling is used to maintain the high hardness level of the mold, the cooling rate is limited by the thermal conductivity of the thick material. This leads to a significant temperature difference between the surface and the heart during quenching, which can lead to large deformations or even the risk of cracking. It has been shown that the combination of several smaller molds distracts those problems caused by water cooling during operation, and that the destruction tests on some mechanized equipment show a reduced tendency to damage in the case of a combined mold. Examples of handling large and heavy-duty tools and dies with the new SuperTurbo* are shown with 0~13. *9 Rapid and uniform heating and cooling of 34.3 tons (9330 pounds). Upsetting and Underforging of 27丨4 Materials The molds in the following examples are confidential and cannot be shown. It is one of the 10 sets of aluminum die-casting molds used in the newly developed car wash. Its size is 65X61X18 (660mmX * The heat treatment cycle for the treatment of the mold is shown in 4. The mold is heated gradually with convection heating to 1*C evenly), then heated with a flat graphite rod heating element to the gas and converted by thermocouple The cooling distribution on the workpiece is uniformly cooled by the controlled airflow pattern. The 750*F (400*C) interrupted cooling enters the isothermal hold phase, allowing a large amount of heat from the heart to pass to the cooler surface for equalization to avoid mold deformation or even cracking.

4 Results Diameter (20 mm) test bars were machined from the ingate of 5.7 metric tons of H11 die blanks. Tensile strength, impact value and microstructure were evaluated on the processed samples. The collected data shows very good results in hardness and microstructure (5, 16). The impact value of 220~280J measured at the surface and the core far exceeds the expected 80~150J. The additional 0.2"(5mm) material allowance is more than enough.

The treatment was carried out in the summer of 2003. Good results were obtained during the subsequent use of the mold (Table 1). Table 1 Results after the mold treatment Surface Core Microstructure: very thin and fine. Particle Size: Tensile Strength/N.mm Yield Strength/N.mm Elongation/% Neck/% Impact Strength/J ​​5 Conclusions and Future Prospects For more than a decade, mold life has increased with the use of high pressure gas quenching (pressure is often Faster quenching speeds above 10 bar).

In the automotive industry, which has parts weighing over 3 tons, the use of very large die-casting tools has become a major measure for manufacturing cars of good quality and light weight at low cost.

With the application of high-quality hot work tool steel combined with the use of the latest vacuum furnace technology, the tool life has been significantly improved, and the deformation has been further reduced. Now very large molds can do this.

(Translation by Yuan Xiaoyue, Jiangxi Academy of Sciences).

Shanghai Fati Industry & Trade Co., Ltd. 0 Shanghai Fati Industry & Trade Co., Ltd. is a professional company providing heat treatment technology services and consulting. The company has extensive cooperation with well-known manufacturers of heat treatment equipment and process materials at home and abroad to provide professional heat treatment technology services for heat treatment plants and internal heat treatment plants and workshops. The main business includes: Ang this technology teaches this 嫂 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 用 嫂 多 多 多 多 多 多 多 多 多 多 《 《 《 《 《 《 《 《 《 《硪 防 防 防 防 涂料 各 防 防 防 防 防 防 备件 防 备件 备件 备件 备件 备件 备件 备件 备件 要 要 要 要 要 要 要 要 要 要 要 要 要 要 要 要 要 要Welcome new and old customers come to negotiate business with us.

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