Vacuum Carburizing Furnace with Automatic Control and Simulate System

Vacuum Carburizing with Acetylene Furnace

The AvaC vacuum carburizing process is a technology exclusive to Ipsen that uses acetylene to virtually eliminate the soot and tar formation problem known to occur from propane, while greatly increasing carburizing power even for blind or through holes.

One of the most important advantages of the AvaC process is high carbon availability, ensuring extremely homogenous carburizing even for complex geometries and very high load densities. The AvaC process involves alternate injection of acetylene (boost) and a neutral gas, such as nitrogen, for diffusion. During boost injection, acetylene will only dissociate in contact with all-metal surfaces allowing for uniform carburizing.

The most remarkable benefit to AvaC can be found when the different hydrocarbon gases for low-pressure carburizing are evaluated for their penetration power into small-diameter, long, blind holes. Vacuum carburizing with acetylene results in a complete carburizing effect along the whole length of the bore because acetylene has a totally different carburizing capability than that of propane or ethylene.

Benefits of the AvaC process:

• Continuous high-throughput capability
• Guaranteed process repeatability
• Optimum acetylene gas deployment
• Open, maintenance-friendly modular system
• Increased carbon transfer
• Reduced process time
• Improved microstructure, increased stress resistance, and superior surface quality of parts
• Economical extendibility for capacity increase
• Various quenching capability with helium, nitrogen, mixed gases, or oil

Advantages over atmosphere furnaces:

• Better work environment with cold-wall design, which provides lower shell temperature
• No costly exhaust hoods or stacks required
• Faster start-ups and shutdowns
• No endothermic gas generators required
• Gas quench furnaces require less floor space and no post-washing to remove quench oils
• No pits or special foundation requirements needed

APPLICATIONS
Single chamber horizontal low pressure Carburizing gas quenching furnace (air cooling by vertical gas flow type) has many functions like carburizing, gas quenching and pressure air-cooling. Is mainly used for quenching, annealing,tempering of the die steel, the stainless steel, the high-speed steel, the higent processes like one-time high-carburizing, pulse carburizing and so on.
 

Characteristics

1. High intelligent and efficient. It is equipped special developed vacuum low-pressure carburizing simulation software.
2. High cooling rate. the cooling rate is increased by 80% by using high efficiency square heat exchanger.
3. Good cooling uniformity. Uniform cooling by convection from double-fans.
4. Good temperature uniformity. heating elements are evenly arranged 360 degrees around the heating chamber.
5.No carbon black pollution. The heating chamber adopts the external insulation structure to prevent the pollution of the carbon black in carburizing process.
6. Long service life , Using the carbon felt as the heat-insulation layer of the heating chamber.
7. Good carburized layer thickness uniformity, Carburizing gas nozzles are evenly arranged around the heating chamber, and the thickness of carburized layer is uniform.
8. Less deformation of the Carburizing workpiece , higher production efficiency and energy cost is saved more than 40%.
9. Smart and easy for process programming, stable and reliable mechanical action , automatically, semi-automatically or manually alarming and displaying the faults.
10. Frequency conversion control gas quenching fan, optional convection air heating, optional 9 points temperature survey, several grades and isothermal quenching.
11. With whole AI control system and an extra manual operating system.
 

Standard model specification and parameters
 

Customized optional ranges
 

1. Energy saving: By using our self-owned registered patented technology of energy saving, our furnaces saves 20%-40% energy than other brands in heating. Reduces muh cost.
2. High Intelligent Control system:All our furnaces are equiped with our high intelligent control system, it can realize one button operation by the recorded data and record the processs in Computer.
3. Advanced Voltage control technology, lower current in same power to avoid the melting of cables, and raise safety level.

Graphite Hot Zones
Graphite hot zones are long-lasting and can deliver excellent ROI. They are robust, economical to repair and incorporate hearth designs with high creep strength.

All-Metal Molybdenum Hot Zones
If your process is susceptible to graphite contamination, a molybdenum hot zone can meet your needs. Our moly hot zone elements feature a "double-U" profile which makes them easy to install and replace.

Custom Constructions
We offer custom hot zone construction such as graphite insulation with moly heating elements, for applications with unique requirements.
 

1. Most important: Human. Human is the most important point in every work. We have complete training courses for every new worker, and we have rating system to rate every worker to a level (junior, middle, high), different level workers are apponted to different jobs with different salary. In this rating system, it's not only the skills, but also rate in responsibility and error rate, executive power etc. By this way, workers in our factory are willing to do the best in his work.And strictly follows the quality management rules.
2. Best materials and components: We only purchase the best materials on market, we know that saves 1 dollar in material would cost 1000 dollars in final. The key parts like electric components and pumps are all brand products like Siemens, Omron,Eurotherm, Schneider etc. For the other parts made in China, we choose the best factory in industry and signed product quality guranntee contract with them,to ensure every component every parts we use in the furnace is the best quality products.
3. Strict Quality management: We have 8 quality check points in the processes of furnace producing, Examination in each check point is carried by 2 workers and 1 factory manager is responsible for it. In these check points, materials and components, and every aspects of the furnace are double checked to ensure its quality. At last, before the furnace leaves factory, it should be final checked with heat treatment experiments.