ALD-Holcroft Vacuum Technologies P roviding Profitability Through Technology

One-piece-flow with multi-zone vacuum heat treatment

World first
Increasing costs and demands on small parts manufacturing require new solutions for more efficient production. The SyncroTherm vacuum heat treating system provides the means to optimize the process chain. The continuous onepiece-flow leads to more effective and ecological production and improved quality.

Efficiency which pays off

ALD-Holcroft leverages more than 40 years of technological experiences in the production of vacuum heat treatment systems. Now, for the first time, heat treatment can be integrated directly into the mechanical production line with the latest development in vacuum heat treatment SyncroTherm.

Vacuum heat treatment

Heat treatment of parts in vacuum prevents damaging oxidation which occurs in a standard protective atmosphere. Case hardening in vacuum is carried out through low pressure carburization using acetylene as a carbon source. The parts are carburized without surface oxidation in a clean, non-polluting process. Subsequent high pressure gas quenching with nitrogen provides dry and clean parts with reduced distortion.

New perspectives
Modern heat treat equipment for low pressure carburizing and high pressure gas quenching are generally installed in the near vicinity of the production site. However, they are not integrated directly into the mechanical production line. ALD-Holcroft, a technology leader in vacuum case hardening, offers a unique system which provides the means to integrate heat treatment directly into the production line. This enables synchronization with the soft machining production operations, leading to entirely new perspectives in automation and manufacturing velocity.

Reproducible one-piece-flow results

Heat treatment integrated in the production line leads to more efficient and more ecological production processes. The duration of the heat treatment can be reduced to the point where the production cycle is maintained without interruptions, generating a continuous one-piece-flow. The workpieces are charged in one layer, on one carrier, instead of in one big conventional multi-layer batch. These so-called 2D-charges produce rapid and very homogeneous heat treatment in all process steps and further guarantee reproducible results.

SyncroTherm

Everything under control: The SyncroTherm Control concept

The One-Piece-Flow Principle
With the one-piece-flow principle, the heat treatment of large batches is converted to treatment of single components. The parts are charged in one layer on one workpiece carrier. The flat-panel heating elements installed in top and bottom of each hot zone radiate the heat directly onto each part, heating these 2D-charges rapidly and homogeneously. Using micro-alloyed steel, parts are processed at high temperatures (above 1000C / 1832F) without undesired grain growth. Further, the single-layer charge provides the possibility to control high pressure gas quenching which is customized for various parts, shapes and dimensions. Technology The SyncroTherm system consists of a pressure-tight chamber in the front which serves primarily as quench chamber as well as loading chamber. The treatment chamber located behind this chamber comprises a cold loading area with a telescoping loader and up to six hot zones which are arranged one upon the other. Each hot zone may hold one workpiece carrier. The treatment chamber always remains under vacuum and is separated from the quench/loading chamber by a pressure-tight door.
Soft machining Heat treatment Hard machining Soft machining Heat treatment Hard machining Soft machining Hard machining Conventional production Heat treatment, central hardening shop

The Process An external handling system places single parts on the workpiece carrier and transports it through the front opening in the quench chamber, which initially serves as a loading chamber. The chamber is evacuated of all unwanted oxygen. The telescoping loader, integrated in the treatment chamber, places the workpiece carrier into a vacant hot zone. In the hot zone, the strong radiant heat rapidly and homogeneously heats the parts to treatment temperature according to the individual recipe, such as carburization, annealing and diffusion. Temperature and process gas supplies are controlled independently

in each hot zone. After carburizing, the telescoping loader returns the workpiece carrier with the processed parts to the quench chamber. The chamber is flooded with quench gas (nitrogen) to a maximum pressure of 6 bar. The high powered gas blower directs the quench gas flow over the parts for rapid and homogeneous quenching. Subsequently, the chamber is vented to atmosphere and the carrier containing the processed parts is transported out of the chamber. The external handling system disassembles the workloads and transports them to the respective stations for further processing.

The SyncroTherm vacuum heat treating system is equipped with an easy-to-operate system to control, monitor and document all processes.

SyncroTherm Control
This data base hosted by a PC system supports the following functions: system control operating modes recipe creation and management data back-up load record generation alarm management touch-PC-solutions, integrated in switch cabinet optional: redundant PC solutions connection to several recipe clients

Plant control
A Siemens PLC manages all activities within the SyncroTherm system including temperature, pressure and gas flow. The system is operated via touch panel which communicates with a host computer, installed in the switch cabinet. The host computer manages all documentation and secures the traceability of individual processes.

Operation
The SyncroTherm control concept is designed for high operating safety standards and ease of operation. The recipe client provides convenient recipe creation and batch management. Process-relevant data can be accessed and edited at all times. This saves time, prevents extra costs and contributes to quality management.

One-Piece-Flow production: Total automation

Multi-zone processing: Semi-automated

SyncroTherm

Advantages at a glance
The SyncroTherm opens up entirely new opportunities for more effective and economical production of high-quality parts. This new and unique technology improves productivity and treatment quality in addition to providing high environmental compatibility.

Technology at a glance
The SyncroTherm can be precisely customized to production requirements. The most important technical data is listed as follows:

Environment
environmentally-friendly process and system technology dry quenching without the disposal of waste washing water no thermal exposure to the surrounding area of the plant low energy and process gas consumption high energy efficiency due to low thermal loss on-demand plant operation low noise emission (< 75 dB) no CO2 emission clean working environment without oils, vapors and flames

Quality
individual processes, customized for various parts reduction of heat treat distortion complete quality documentation for each load high reproducibility with easy process control optimal part surfaces high temperature uniformity high carburization uniformity on the part and in the charge

Operating efficiency
more effective and efficient production rapid hardening in the sequence of soft and hard machining reduced cycle times simplified logistics maximum availability reduced hard machining due to minimal part distortion easy maintenance within shortest time possible 24/7 operation low consumption costs due to high energy efficiency and small gas quantities compact, space saving heat treatment module

Charge dimensions Charge weight Maximum temperature Number of hot zones Maximum quench pressure Space requirement Cycle time / workpiece carrier

Length 600 mm (24) Width 500 mm (20)

Height 150 mm (6) [including workpiece carrier]

Maximum 50 kg [including workpiece carrier] (110 .lbs) Neutral hardening 1250C (2280F) 3-6 6 (10) bar Length 6 m (20) 7.5 minutes Width 4 m (13) Height 3.8 m (126) Low pressure carburization 1100C (2012F)

Integration of the SyncroTherm vacuum heat treatment module in the FELSOMAT FlexLine production line.

SyncroTherm

Advantages at a glance
The high production and process flexibility are creating new ways to individually adapt production to the respective demands. The results are reduced production costs, improved efficiency, increased productivity and environmental compatibility.

Your reliable partner

The SyncroTherm heat treatment system is designed for a 24/7 operation. In order to guarantee smooth continuous operation, ALD-Holcroft is part of a worldwide network of experienced specialists who offer universal service for the entire process chain. Repairs, installations, preventive maintenance and remote services are always performed in a highly professional manner. We have established warehouses at strategically favorable locations, which store original spare parts to reach each ALD-Holcroft SyncroTherm heat treatment module fast and reliably.

Our service overview

supply of spare parts and consumables repair service service and inspection modern factory installations operator training preventive maintenance professional support in emergencies

ALD-Holcroft Vacuum Technologies Co., Inc.

SyncroTherm is a registered trademark of ALD Vacuum Technologies GmbH. Specifications subject to change without notice. 2012 All rights reserved. ALD-Holcroft Vacuum Technologies Co., Inc. WG-3297 04/12 3M

49630 Pontiac Trail Wixom, MI 48393-2009 USA Ph: 248.668.4130 Fx: 248.624.3710 E-mail: sales@ald-holcroft.com

www.ALD-Holcroft.com