Mobile Quench

Mobile QuenchCold Chamber, 20 Bar

Mobile Quench

Mobile Quench

Mobile Quench

Treatment Module Transfer Module Quenching Chamber

Vacuum system

Convection Fan

Heater

Charge Table

Furnace door, insulated & vacuum tight

Transport Fork

Energysupply

Pressure tight Door Heat Exchanger

Movement

Docking

Workload Transport Scheme

Mobile Quench Module

Mobile Quench

ModulTherm

Mobile Quench

25% larger volume capacity.

External radial fans for homogeneous and uniform gas speed distribution over the load.

ModulTherm – CharacteristicsMoving Quench Module

Precise reproducibility via accurate control of cooling gas flow

Proven power chain

Quench Sequence Video

Power Chain

Mobile Quench

Cold Chamber Advantage

Multi Chamber Furnace(Cold Chamber)

Backfill time to final pressure >> 10 sec

Backfill time to final pressure << 10 sec

Gas flowsthrough the charge and inpartaround the charge

Hot walland hot graphite elements

Gas must flow throughthe charge

Cold Wall

Single Chamber Furnace(Hot Chamber)

Mobile Quench

Top / Down Gas Flow

Reversing Gas Flow Increased Quenching Uniformity

Modular Design Flexible and Expandable

Compact Chamber Design Short Gas Recycling Cycles

Mobile Quench

Reversing Gas Flow Increased Quenching Uniformity

Modular Design Flexible and Expandable

Compact Chamber Design Short Gas Recycling Cycles

Bottom / Up Gas Flow

Mobile Quench

Fan Style Advantage

• Use of 2 radial fans• homogeneous gas inlet flow above the

load by using a guide system in the gas duct

• 100% load density• no wake behind the hub• no swirling of the gas flow

• high gas flow uniformity ⇒ homogeneous hardness distribution ⇒ lower distortion

• 2 axial fans• In homogeneous gas inlet flow above the load

• wake behind the hub:

• shortfall of hardness at parts positioned in the wake

• possible spreading of hardness• 100% load density not achievable (loading map)

Wärme-tauscher

Wärme-tauscher

Wake behind the hub

Radial Fans Axial Fans

Mobile Quench

Cooling curves in the tooth root of Truck- Gear Wheels (GW)

0

100

200

300

400

500

600

700

800

900

-50 0 50 100 150 200 250

Time /sec.

Tem

p. /

°C

GW bottom, no rev.

GW, top, no rev.

gas-temp. bottom, no rev.

GW bottom, with rev.

GW, top, with rev.

gas-temp. bottom, with rev.

Reverse Gas Flow Quenching

Quench behavior in the tooth root of heavy truck gears

Mobile Quench

300

320

340

360

380

400

420

440

460

No reversing With reversing

Co

re h

ard

nes

s at

Mid

-to

oth

/ H

V30

Bottom minBottom averageBottom maxTop min Top averageTop max

Gas flow Gas flow

300

310

320

330

340

350

360

370

380

390

400

No reversing With reversing

Co

re h

ard

nes

s at

To

oth

ro

ot

/ HV

30

Bottom min

Bottom average

Bottom max

Top min

Top average

Top max

Gas flow Gas flow

300

310

320

330

340

350

360

370

380

390

400

No reversing With reversing

Co

re h

ard

nes

s at

Bu

lk /

HV

30

Bottom minBottom averageBottom maxTop min Top averageTop max

Gas flow Gas flow

BulkBulkTooth Tooth rootroot

Mid-Mid-toothtooth

Reverse Gas Flow

Core hardness with and without reversing the gas flow

Modified SAE 5120

Mobile Quench

- Material - Chem. Composition - Delivery Condition

- Part Geometry - Dimension, Form - Manufacturing

- Load Weight

- Gas paths - Gas Fan(s)

- Heat Exchanger(s)

- Loading

- Process flow

- Kind of Flow

- Gas (N2, He, H2)

- Gas pressure

- Gas velocity

HPGQ ParametersMaterials

Mobile Quench

Nitrogen Helium

Gas

Qu

ench

ing

Pre

ssu

re

10 b

ar20

bar

- Hot-/Cold working Steels X155CrMo12 1(D2) X38CrMoV5 1(H13)- High Speed Steels (1.3343)- Ni-Alloyed Case Hardening Steels (18CrNi8, 17CrNiMo6)

- Ball Bearing Steels (Small Sizes) 100Cr6 (SAE 52100) 100CrMn6- Heat Treatable Steels 42CrMo4 HH (4140 HH)

- Low Alloyed Case Hardening Steels (16MnCr5, 20MoCr4, SAE 8620)- Ball Bearing Steels (Medium Sizes) 100 Cr6 (SAE 52100) - Al-, Ti-Alloys

ALD-Patented

Material, Part Dimension and Hardness Specif.determine Quenching Process Parameters

HPGQ Process Matrix

Mobile Quench

20

25

30

35

40

45

50

0 5 10 15 20 25 30 35 40 45

Hardness (HRC)

Jominy Distance (mm)

20NiCrMo2 (SAE 8620)

20MoCr4 (SAE 4118)

16MnCr5 (SAE 5115)

20MnCr5 (SAE 5120)

20NiCrMoS6-4

18CrNiMo7-6

20

bar

He

20

bar

N2

Jominy Curves of steel grades with

high hardenability acc. to EN 10084

Core Hardness InfluencesCase Hardened Steel

Mobile Quench

∆ Ovality of Outer Diameter (mm)

Oil A : Houghton Quench A

Oil B : Bellini FN

10 bar He

20 bar HeCold Chamber

0

0.01

0.02

0.03

0.04

0.05

0.06

10 barHe

20 barHe

Oil A Oil B

Average andStandard Deviation

n=12

7

12

6

Material: SAE 52100 (D=70 mm, H=15 mm, S=5 mm)

Dimensional ChangesBearing Rings

Mobile Quench

Process ComparisonDrive Shafts

Shaft Length up to 750 mm (29.5 inches)

Material 17CrNiMo6 (similar SAE 9310)

Past H. T. Process

Gas Carburizing

Quench in Salt Bath

Distortion over Length of Shaft Average 3 mm (0.12 inches)

Straightening Scrap 20 %

New H. T. Process

Vacuum Carburizing with

High Pressure Gas Quench with 8 bar Helium

No Washing – Clean and Dry Parts

Distortion over Length of Shaft Average 1.0 mm (0.039 inches)

Less Straightening Work

No Scrap

Significant CharacteristicsProduct Quality

Mobile Quench

500 kg gross Load of Pinions, 20 bar Helium, SAE 8620

High Pressure Gas QuenchingProduct Quality

Mobile Quench

02468

101214161820

1 2 3 4 5 6Roundness (1/1000 inch)

Nu

mb

er o

f P

art

s

Gas Carburizing

with Oil Quench

Vacuum Carburizing with

High Pressure Gas Quench Material: SAE 8620 Part Weight: 1.5 kg (3.3 lbs)

Drive Shafts

Significant CharacteristicsDistortion Comparison

Mobile Quench

0

10

20

30

40

50

60

µm

left flank

right flank

ÖlabschreckungGasabschreckung dyna-misch (20 sec.- Ventila-torstopp)

Gasabschreckungohne Dynamik

spread of helix slope deviation after heat

treatment

f Hβ ,max - f Hβ ,min

0

100

200

300

400

500

600

700

800

900

30 60 90 120 150Zeit / s

Tem

p. /

°C

dynamisch

konventionell

Ventilatorstopp Wiederstarten des Ventilators

Material: SAE 5115

(16MnCr5)

Quality Control – Gas QuenchingDynamic Quenching