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New bottom-loading vacuum furnaces for the aerospace industry Introduction to C.Moller, Ipsos International Ltd. Vertical vacuum furnaces can be used for different workpiece configurations and are particularly suitable for parts with a circular cross-section and can be stacked. Parts, such as those commonly used in the aerospace industry (jet engines or turbine components), some of which require the use of brackets before heat treatment, and these brackets may be relatively heavy to handle. Keep the part's geometry. In many cases, the bracket is even heavier than the part itself. Therefore, greater loading capacity is required in a vertical vacuum furnace.
Many different heat treatment processes can be performed in a vertical vacuum furnace. Including: brazing, annealing, solution treatment, aging treatment, hardening and stress relief. These different heat treatment processes require different temperature ranges, vacuum ranges, cooling capabilities, and better temperature uniformity. There are different functional options in the design and manufacture of this vacuum furnace, which makes it possible to produce vacuum furnaces that can be adapted to different industries, including different parts of the aerospace industry and the requirements of different treatment processes.
We assembled a team of sales and designers from Ipsen Germany and the United States and proposed the task of designing a new vertical vacuum furnace with the necessary functions to meet all industrial applications. This new type of vacuum furnace combines the best ideas of the different designs and sales staff of Ipsen, and it can be said that this vacuum furnace is a product of global cooperation. As a result of this project, the design of this vacuum furnace has been standardized. This type of vacuum furnace can be produced in any Ipson plant with the same quality and performance, and wherever the vacuum furnace is purchased. Production and installation, the end user can get the same benefits. Therefore, in the new GlobalV and VR vacuum furnaces, the GlobalV name has a built-in gas cooling system installed above the furnace, while the GlobalVR name has an external gas cooling system installed on the ground (see) .
1Features and Benefits Design features are designed to provide the end user with easy maintenance, higher reliability, and improved furnace performance through the best practices of the Ipson design and sales staff. Other features include a smaller footprint and a more aesthetic appearance. The new features and advantages are as follows: The vertical vacuum furnace of the GWwlV6060S vertical vacuum furnace has a small footprint of approximately 18%. Convection-assisted heating (optional) This feature reduces the heating time of the workpiece. The degree of reduction in heating time will be determined by the workpiece geometry and process parameters. In general, 30% of the process time can be saved in high temperature processing, and 50% of the process time can be saved in low temperature processing. Convection-assisted heating generally uses 2 bar pressure to optimize the process time, and it only works in furnaces that use graphite hot zones.
The hot zone has no moving parts. All heating and cooling functions are realized without moving any part of the hot zone. In this new design, there is no cover, no cooling airflow diverting device, no mechanical device to cool the nozzle. The advantage of this design is that it can improve reliability and reduce maintenance requirements.
Water-cooled cooling motor. The use of a water-cooled cooling motor protects the bearing and lubrication from the harmful effects of heat generated in the furnace during heating and cooling cycles. In addition, because water cooling can provide better heat dissipation, the motor can increase power to 250% of normal power in a short time. This allows the workpiece to cool quickly at high temperatures.
Bottom cooling gas jet. Cooling nozzles are also installed at the bottom of the hot zone. Cooling spray is also arranged around the cylindrical hot zone. This is a typical example of a workpiece mounted using a jig. All the cooling gas flows out at the top of the hot zone. This design also uses the hot air floating property to help the gas flow cycle.
Ground height feature panel. The functional system used. Including water, pneumatics, gas backflushing systems, pressure switches and main electrical terminals are all mounted on a panel and placed on the ground for the purpose of easy inspection and adjustment. End users will no longer need to climb up the ladder to adjust the systems on these stoves.
Simplified lifting system. The lifting mechanism of the bottom tray of the furnace has been simplified to reduce the number of parts while using a self-lubricating sliding guide. Maintenance needs have been minimized. In addition, since the lifting mechanism will not need to be removed before the furnace is shipped, the final installation of the equipment is also simplified.
2 vacuum furnace pump system performance 35-inch diffusion pump and the new Stokes 1839 pump set (see), which includes a 412J mechanical pump pumping speed of 510 cubic meters per hour, and a new type of Roots pump with a sealed motor . Its rotational speed is 3 600 rpm, and the maximum shaft speed is 4400 m3 per hour. The Roots pump uses a variable-frequency motor, which means that it can be started at atmospheric pressure. The variable speed controller controls the motor current and gradually adds the motor speed as the air pressure in the furnace decreases. GV6060 pumping curve, such as. Note that this furnace has a volume of nearly 19 m3 and a vacuum of 104 mbar only takes 10 minutes. 3 Heating performance of the furnace 6060 has undergone many heating tests, including convection and radiation heating, temperature uniformity, and heat loss. The hot zone uses a full graphite design, where the graphite insulation layer has a thickness of 50. The heating element, furnace and cooling nozzle are also made of graphite.
The design of the cooling nozzle has been patented with a flap that can be flipped to prevent cold air from entering the hot zone during convection heating. An arc-shaped graphite heating element was used in the cylindrical section of the hot zone to provide additional charging space. This curved shape of the graphite heating element reduces the number of connectors by 50% compared to the original polygonal heating element.
60x60 cooling gas sneeze 3.1 Convection and radiation heating Four stainless steel cylinders with a wall thickness of 12mm mounted on a stainless steel support were used for this test (see). The total weight is approximately 1200 kg. Thermocouples are mounted in small metal blocks welded to different parts of the cylinder surface, including the top, middle, and bottom. 4 thermocouples are mounted on the top, 4 on the bottom and 1 in the middle. See also. The workpiece was heated to 650 rpm using convection and radiant heating at 22C/min and then heated from 650C to 1100*C using radiant heating at a rate of 22 *C/min. Results can be seen in and .
The sum is the result of a 1 1200 charge heating test for convection and radiant heating. The graph shows that using convection heating to 650*C is faster and more uniform than using radiant heating. In the process of using radiant heating to 650C, the maximum deviation displayed by the thermocouple is 400C; in the process of using convection heating to 650C, the maximum temperature difference displayed by the thermocouple is only 2(1)C radiation to 650C for 100 minutes, while the convection heating is only 60 minutes ( Save time by 40%). The total time for heating to 1100C using convection plus radiation is also relatively short. It takes 150 minutes for pure radiation to be heated to 1100C and only 110 minutes for heating using convection and radiation (27% saving time). 3.2 The temperature uniformity test includes both ends of the hot zone. The heating elements and the three annular belts on the cylinder are arranged in the upper, middle, and lower positions, respectively. Please see. A test fixture with 9 K-type thermocouples was used in the temperature uniformity test. Four thermocouples were placed on top, four on the bottom and one in the middle. See the bracket.
Three temperature tests were performed using radiant heating. Two temperature points were tested using 538C, 816C, and 1093C using convection heating. Uniformity of 538C and 816C convection heating temperatures were tested with the cooling nozzle closed and kept open. Check the role of the cover. In the entire temperature uniformity test, the five heating segments were adjusted only at 538C to achieve the best uniformity, and the same adjustment was used in other temperature tests.
The heating section that needs to be adjusted at 538C only depends on whether radiant heating or convection heating is used. The results of the heating temperature uniformity test are shown in the results of the radiative heating uniformity test. The figure shows that the temperature uniformity of the radiant heating at 538C and 816C is very good. The thermocouple temperature difference at 1093C is better (4C) but all readings are below the set point. The result of the 545678IQ thermocouple numbered radiant heating homogeneity test results for the further improvement of the temperature uniformity recommendation is to use an independently controlled heating zone in the furnace. This will allow each heating section to be independently adjusted at each temperature set point. The uniformity test of opening and closing of the nozzle cover shows that the temperature uniformity is not ideal when there is no cover plate blocking effect. The temperature difference rises approximately twice as the cover is opened. This test proves the advantages of this patented nozzle (see 3. 3 Heat Loss Test Results during the heat preservation phase of the heating temperature uniformity test, and at the same time the steady power consumption is measured to obtain loss through the heat insulation layer and loss into the furnace shell water jacket. The total amount of heat was tested for heat loss under both radiant heating and convection heating conditions, and heat loss testing was performed both on opening and closing of the cooling nozzle cover under radiant heating and convection heating. It is the overheating of the thermocouple socket in the furnace, which leads to the error of the millivolt value at high temperature.The socket thermal protection cover must be used.
Convective heating uniformity test results such as 1, 2 convection heating uniformity test results show that at two temperatures (538 * C and 8J6 * C), the temperature uniformity is very good (6 * C and 8 * C), In addition, the heat loss test for convection heating shows that the 3=, and Zhao Yan also sees muscle gazing, the heat loss is 60%~85% more than when the heat loss is close. For radiant heating, the cover is opened or closed. The effect on heat loss is negligible.
4 Furnace Cooling Performance The cooling system used in the cooling test was the same as the one used in the heating test. The design of the cooling system was such that the hot air passing through the workpiece first passed through the vane and then forced into the heat exchanger. This arrangement ensures that all the air flow through the blades flows through the heat exchanger. It also ensures that the workpiece in the furnace can be cooled to the same temperature as the cooling water inlet as much as possible, since the air stream will not be compressed after it flows through the heat exchanger. The standard water-cooled motor has a power of 160 kW. The cooling test is carried out under 2 bar nitrogen.
The results of the cooling test are as follows: 4. Time/min. Compared to other 2 bar nitrogen quench furnaces, the cooling rate of the test piece seems to be good. When cooling with 2 bar, the current of the water-cooled motor never needs to exceed its normal current, so the advantages of the water-cooled motor cannot be demonstrated in this test. Later, we suggested adding the cooling fan size to take full advantage of the additional capacity of the water-cooled motor. The cooling rate achieved in this test also demonstrates that the cover plate in this particular nozzle can normally open during cooling to allow the cooling airflow to enter the heating chamber.
The GV 60602 bar test results shown in this report reflect only one function of this new type of vertical vacuum furnace. There are several optional features in this new design to make this type of furnace particularly suitable for special requirements, workpiece requirements and process requirements. All options are as follows: Convection heating. Convection heating is not standard. The use of convection heating is entirely determined by the workpiece and the process. Although it is applicable to most users, it makes sense to use this as an option. Convection heating is limited to furnaces that use graphite hot zones. Convection heating can be used in furnaces with cooling pressures above 2 bar, but the convection heating pressure is still limited to 2 bar. Full metal hot zone. In some processes, particularly in the aerospace industry, the presence of graphite is not allowed on certain workpieces. Some titanium alloy parts are contaminated with graphite. Some brazing processes cannot be performed in a graphite-containing environment. For these situations, the all-metal hot zone will be an option. The hot metal zone can provide a completely clean environment in some special applications. The hot metal zone allows the furnace to reach a higher vacuum in a shorter period of time and maintains a high degree of vacuum during processing. The hot metal zone is more expensive to purchase and maintain than the graphite hot zone, and its service life is only half that of the graphite hot zone.
At the same time, the heat loss rate of the metal hot zone is twice as high as that of the graphite hot zone, so more energy is needed to perform the same processing cycle.
Different pump systems. The GV product line can use different vacuum pump systems. The required diffusion pumps, mechanical pumps, Roots pump specifications and manufacturers can be changed according to the requirements of end users and the needs of the process. Using multiple diffusion pumps and mechanical pumps in one furnace is also an option.
Two bottom loading trays. In some applications, it is necessary to use a second bottom loading tray that can be moved to the side of the furnace. If the time for loading and unloading is the same as the length of a treatment cycle, or if multiple different charges are required during the day, it is worth considering using two bottom loading trays to add the number of fillings per day. We will provide a quick connection and disconnection method with the furnace.
Built-in or external gas cooling system. The Global product line will offer built-in and external gas cooling systems as options. The built-in cooling system provides the most compact design possible and a small footprint. At the same time it also has the advantage of less backwash gas per cycle and shorter evacuation time. The external cooling system can be used when the height of the workshop or the height of the vehicle is limited. In both scenarios, water-cooled motors will be used.
Cooling pressure options. Commonly used quenching pressures are available in 2, 6, 10, and 15 bar. A variety of backflush gases are available as options. Controlled cooling through mechanical regulating valves can also be achieved in the design of the furnace. As an option to control cooling, inexpensive mechanical control valves can be used instead of expensive variable frequency control systems.
(Nanchang Iron and Steel Works Co., Ltd. Lai Yong Lai translation) a/ stupid
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