Sunday 16 September 2018

Induction Heat Treatment Process


With 6 induction heat treating machines, we soften or harden metal through targeted heating, hardening, tempering, or annealing. We specialise in induction heat treating a range of metal parts, such as drive shafts, bearings, axle shafts, camshafts, and sprockets.

Induction Annealing for Metals

Our induction heat treatment process is best suited for enhancing the ductility of steel, stainless steel, and carbon steel parts without compromising on the dimensional stability of the materials. In addition, our induction heating process is environmentally friendly and offers higher heating intensity compared to conventional metal treatment techniques.

Induction Hardening Capabilities

Factors such as electrical properties of pieces, the coupling efficiency of coils, and the degree of temperature change required are taken into consideration during induction heat treatment. Our Zion Z scan induction heat treated features a 6 position rotary index table and easy-to-maintain hydraulics. The Zion Z scan induction heat treated is capable of heat treating pieces with diameters up to 1 1/4" and lengths up to 20".

Tempering Services

Provide your design specifications for your piece part and allow us to generate a quote.


Sunday 9 September 2018

Air & Fuel Oil Coolers - Turbine Lubrication System Components


Air Oil Coolers

Two basic types of oil coolers in general use are the air-cooled and the fuel-cooled. Air oil coolers are used in the lubricating systems of some turbine engines to reduce the temperature of the oil to a degree suitable for re-circulation through the system. The air-cooled oil cooler is normally installed at the forward end of the engine. It is similar in construction and operation to the air-cooled cooler used on reciprocating engines. An air oil cooler is usually included in a dry-sump oil system. This cooler may be air-cooled or fuel-cooled and many engines use both. Dry- sump lubrication systems require coolers for several reasons. First, air cooling of bearings by using compressor bleed-air is not sufficient to cool the turbine bearing cavities because of the heat present in area of the turbine bearings. Second, the large turbofan engines normally require a greater number of bearings, which means that more heat is transferred to the oil. Consequently, the oil coolers are the only means of dissipating the oil heat.

Fuel Oil Coolers  
         
The fuel-cooled oil cooler acts as a fuel oil heat exchanger in that the fuel cools the hot oil and the oil heats the fuel for combustion. Fuel flowing to the engine must pass through the heat exchanger; however, there is a thermostatic valve that controls the oil flow, and the oil may bypass the cooler if no cooling is needed. The fuel/oil heat exchanger consists of a series of joined tubes with an inlet and outlet port. The oil enters the inlet port, moves around the fuel tubes, and goes out the oil outlet port.




Thursday 30 August 2018

Effect of cryogenic treatment on case-hardening steels


Process alternatives to optimize their final properties

Induction hardening faridabad
In the field of Induction Hardening in Faridabad, it is usually considered that cryogenic temperatures are those below 120 K (-153°C). Consequently, conventional subzero treatments, often referred to as shallow cryogenic treatments and usually performed at temperatures around -80°C, cannot be regarded as real cryogenic processes.

Cryogenic temperatures couldn’t be achieved until the late 19th century and, therefore, the emergence of cryogenic treatments in industry is relatively recent. The development of this technology has been based mainly on empirical results. The basic research of the transformations produced in the materials when exposed to cryogenic temperatures is usually conducted with significant delay with regard to development of practical applications.

In general, cryogenic treatments have been considered as separate operations, added to the conventional heat treatments. This is something that has conditioned the development of knowledge in this field, and also the reliability of the results obtained with these processes. Maybe this happens because, very often, this technology is used in tools and finished components, without paying much attention to the previous operations. This approach doesn’t enable a good control over the process results since these depend on the material history before the cryogenic treatment. And, obviously, the previous heat treatments play a crucial role.

In this regard, the consideration of cryogenic treatments as independent operations is a mistake. The right way to contemplate them is not as a supplementary step, but as an integral part of the overall heat treatment process. Only in this way its full potential will be exploited, selecting the route that is most adequate in each Case Hardening in Faridabad depending on the material considered and the application in which it will be used.
Induction hardening faridabad

We will try to illustrate it with an example. Let’s consider a case hardening steel like 18NiCrMo5, which is commonly used in applications where high yield strength and good wear resistance are required (shafts, gears, cams, etc.). The heat treatment process of this steel starts with a cementation step in order to increase the carbon content in the surface of the component. The subsequent quenching, followed by a tempering cycle at not more than 200°C, provides a very hard surface while the core remains soft and tough.

When considering the cryogenic treatment of a component made of case hardened steel, two basic strategies could arise. One is to apply it to the already heat treated part, that is, after tempering. The other one is to perform the cryogenic process after quenching but before tempering.

Several investigations focused on studying the effects of cryogenic treatments in this steel grade have been carried out in recent years, but the results seem confusing and sometimes even contradictory. Actually, this happens because in most of these studies only one of the two approaches has been considered, not taking into account that the results that are obtained with each of the treatment strategies are significantly different.



Thursday 23 August 2018

Induction Heat Treatment Process


With 6 induction heat treating machines, we soften or harden metal through targeted heating, hardening, tempering, or annealing. We specialize in induction heat treating a range of metal parts, such as drive shafts, bearings, axel shafts, camshafts, and sprockets.

Induction Annealing for Metals
Our induction heat treatment process is best suited for enhancing the ductility of steel, stainless steel, and carbon steel parts without compromising on the dimensional stability of the materials. In addition, our induction heating process is environmentally friendly and offers higher heating intensity compared to conventional metal treatment techniques.

Induction Hardening Capabilities
Factors such as electrical properties of pieces, the coupling efficiency of coils, and the degree of temperature change required are taken into consideration during induction heat treatment. Our Zion Z scan induction heat treater features a 6 position rotary index table and easy-to-maintain hydraulics. The Zion Z scan induction heat treater is capable of heat treating pieces with diameters up to 1 1/4" and lengths up to 20".

Tempering Services
Provide your design specifications for your piece part and allow us to generate a quote. Start this induction heat treating process by selecting the "Request information" button.




Thursday 16 August 2018

Metal Case Hardening


Induction hardening faridabad
Zion is a leading provider of Induction Hardening heating services, including induction hardening, with plants in Michigan, North Carolina and Ohio. Induction hardening is a metal heat treatment process that offers a controllable and localized method of heat without contact to the metal parts or components being heated. The heat is generated by inducing an electric current to flow into a specific area of a part. This provides an economical, targeted and rapid heat treating of conductive materials.

Why use induction hardening?

Induction hardening is favored for parts that are subject to heavy loading. Typical applications include axles, saw blades, shafts, stampings, spindles, gears and most symmetrical parts. Induction hardening is widely used for surface hardening steel, but can be used with other materials as well.

             Carbon steels
             Alloy steels
             Stainless steels
             Powder metal
             Cast iron
             Copper
             Aluminum

Why choose Zion Industries for induction hardening?

We specialize in induction heat treating for unique part configurations. We can accommodate extreme part diameters and lengths for rolls/shafts and gears. Our power supplies range in size from 5 kW to 300 kW and in frequency from 1 kHz to 450 kHz. Zion has developed an excellent reputation as a commercial heat treating company, producing high quality, on-time work at very competitive pricing.
Although we specialize in high volume production runs, we also have the capabilities to develop prototypes and complete process development work for parts. Zion Industries strictly adheres to ISO/TS16949:2009 standards. We pride ourselves in being one of the largest, most innovative, privately-owned induction heat treating companies in Ohio, Michigan, and North Carolina. For more than four decades, we continue to build an unparalleled reputation for providing innovative process solutions and utilizing state-of-the-art technology and equipment.



Monday 30 July 2018

Tempering



Tempering is a low temperature (below A1) heat treatment process normally performed after neutral hardening, double hardening, atmospheric carburizing, carbonitriding or induction hardening in order to reach a desired hardness/toughness ratio.

Benefits

The maximum hardness of a steel grade, which is obtained by Induction Hardening in Faridabad , gives the material a low toughness. Tempering reduces the hardness in the material and increases the toughness. Through tempering you can adapt materials properties (hardness/toughness ratio) to a specified application.

Application & materials

Tempering can be divided into three main groups:

  • Low temperature (160-300°C): used for case hardening components and cold working tool steels. Typically, hardness requirement is around 60 HRC.
  • Tempering of spring steels (300-500°C): used for spring steels or similar applications. Typically, hardness requirement is around 45 HRC.
  • High temperature (500°C or higher): used for quenched and tempered steels, hot working tool steels and high speed steel. The hardness will vary from 300HB to 65HRC dependent on the material.

Process details

The tempering temperature may vary, depending on the requirements and the steel grade, from 160°C to 500°C or higher. Tempering is normally performed in furnaces which can be equipped with a protective gas option. Protective gas will prevent the surface from oxidation during the process and is mainly used for higher temperatures. For some types of steels the holding time at the tempering temperature is of great importance; an extended holding time will correspond to a higher temperature. Depending on the steel grade a phenomenon known as temper brittleness can occur in certain temperature intervals. Tempering inside this temperature interval should normally be avoided. These areas are shown in the steel suppliers steel catalogues, as well as the most suitable temperature depending on hardness requirements.




Sunday 22 July 2018

What's the difference between single shot hardening and traverse hardening?


Induction hardening faridabad

There are two methods of heating when using induction: eddy current heating and hysteretic heating. When it comes to hardening, however, the two main types are known as single shot hardening and traverse Induction Hardening in Faridabad. Single shot hardening systems employ the use of rotated components in the induction coil, and the entire area is heated at the same time for a pre-determined amount of time using either a drop quench system or a flood quench system. Single shot hardening is typically used in applications in which no other method will reach the intended result, for example, hardening the flat face of hammers and producing small gears.

Traverse hardening, on the other hand, uses an induction coil for the workpiece to pass through progressively. A following quench spray or ring is used, This process is often used in the manufacturing of shaft type components, including axle shafts, steering components, drive shafts, excavator bucket pins, and power tool shafts. The workpiece is passed through a ring type inductor, which usually features a single turn.

Traverse hardening applications are also used in the manufacturing of certain edge components, including paper knives, lawnmower bottom blades, hacksaw blades, and leather knives.
Ultimately, understanding the processes and details of various induction hardening methods is the key to determining which heat treatment type is best suited for your application needs. For more information about induction heating accessories and other induction equipment for sale, contact Inductwell pvt Ltd