High Temperature Components

Refractory Metals in Furnace Construction and Engineering

Global Leader in High Temperature Furnace Products

PLANSEE is the leading manufacturer of powder-metallurgically processed refractory and special metals.
Based on our core competences in the areas of high performance materials, emerging applications and technologies, we have been manufacturing products and components made from molybdenum, tungsten, tantalum, niobium, chromium and their alloys for more than 85 years. Refractory metals have various beneficial properties for use in high-temperature processing equipment: high melting point and correspondingly low vapour pressure, low thermal expansion and heat capacity as well as excellent high temperature strength and creep resistance. Through the development of special high performance alloys based on Mo and W (such as TZM, MLR, WVM, etc.) PLANSEE has succeeded in significantly improving the microstructural stability and creep strength in comparison to the pure metals. PLANSEE together with its affiliates PLANSEE USA and JAPAN VACS METAL is the worlds largest producer of vacuum furnace hot zones and engineered components and offers the most extensive range of high temperature products.

CONTENTS
Furnace Construction and Engineering Page
2 4 5 7 8 9 10 12 13 14 15 16 18 19 Global Leader in High Temperature Furnace Products Application Fields of PLANSEE Materials Broad Product Range Customized Solutions for Individual Demands Advantages of PLANSEE Materials Product Portfolio for High Temperature Furnaces Hot Zones for High Temperature Furnaces Charge Carriers, Trays and Boats Components for Special Equipment Standard Components and Mill Products Availability of Standard Mill Products PLANSEE Materials for Furnace Construction The Worldwide PLANSEE Network Further Application Fields of PLANSEE Materials

Details about quality and recommendations about the use of materials and products are for descriptive purposes. They are based on the results of our research and development work and on practical experience. Statements about certain properties are made to the best of our knowledge but are offered without guarantee. Statements on these matters shall always require specic agreement in writing. All rights reserved, especially those relating to translation into foreign languages. This brochure, or parts thereof, may not be duplicated without the express approval of PLANSEE.

Application Fields of PLANSEE Materials

Refractory metal components are used in a wide range of industries and applications for high-temperature furnaces and thermalprocessing plants. Some important fields of thermal application for refractory metal products are: - Sintering of metals and ceramics - Powder processing (calcining, reduction, agglomeration) - Brazing, high-temperature annealing and heat treatment - Metal injection moulding (MIM) - Annealing of stainless and electrical steel in N2/H2 atmospheres - Aerospace including maintenance, repair and overhaul (MRO) - Medical technology - Electronics and semiconductor industries - Lighting industry - Production of nuclear fuel - Thermal waste treatment - Research and development
Sintered MIM parts
Photo: Parmaco Metal Injection Molding AG

Turbine blades after repair treatment

At the component design stage solutions are tailored to the application, taking into account important process parameters such as temperature, size, atmosphere, environment, temperature uniformity and load. PLANSEE works in close partnership with both OEMs and end users for all requirements of new equipment and replacement parts.

Standard mill products

Furnace components and spare parts

Complex engineered components

Broad Product Range

PLANSEE offers the widest range of refractory metal mill products and finished parts for thermal processing equipment available anywhere in the world. Semi-finished products in standard dimensions can be supplied in a matter of days from worldwide distribution centres. Finished parts ranging from simple parts cut from sheet to complex furnace hot zones are manufactured at sites in Europe, Asia and America following uniformly strict quality guidelines. PLANSEE supplies: - Standard mill products (plates, sheets, ribbons, rods, wires) and simple cut pieces according to customers needs, despatched from central store - Laser- or water jet-cut pieces with user-defined profile according to customer drawing (EDI possible) from our cutting center - Processed and assembled components such as boats, charge carriers, thermocouple protection tubes and other furnace components according to customer drawings - Complex components (hot zones, radiation shields, charge carriers, HIP parts, tubes for rotary furnaces and other engineered parts) are designed and manufactured by PLANSEE together with the customer Our innovative and experienced employees are ready to meet every challenge. Together with the customer they find the right product design using the best choice of materials for individual applications.
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Customized Solutions for Individual Demands

PLANSEE offers much more than the on-time delivery of high-quality mill products and finished components for industrial plants and furnaces. The customer can call on PLANSEEs entire service package as a world market-leader. Especially important is the expertise of our engineering in materials, products and applications. - Innovative materials and design concepts - Individual product solutions - Customer support at the design concept stage - Realisation of turn-key solutions - Engineering at the highest level - Use of modern design tools including CAD, finite element analysis or 3-D modelling - On-site repair work and fitting of replacement parts - Consultation partner throughout the entire project In many cases selecting the most suitable material and design to fit the requirements leads to a noticeable improvement of the entire plant. We also ensure future competitive advantages for our customers through continuous improvements in our materials, products and capabilities.

Mo, TZM, ML, WRe, MoRe, SIBOR, W, WL, W VM, T a, Nb

PLANSEE Materials for High Performance

The materials used in high-temperature furnaces and engineered components are regularly subjected to extreme thermal and mechanical loading as well as harsh chemical environments. PLANSEE High Performance Materials based on refractory metals exhibit many advantageous properties to withstand these demanding conditions. Advantages of PLANSEE materials: - High melting point permits operation up to 2800 C / 5072 F - Excellent high temperature strength - Suitable for use in protective atmospheres (e.g. Ar, He, N2, H2) - Very low heat capacity reduces energy consumption - Minimum distortion during rapid temperature changes - Resistance to aggressive chemical environments - Dense metallic surface avoids the absorption of gas and moisture - Complex shaping by metal-forming and machining processes - No contamination of equipment or product (carbon- and binder-free materials) In addition to pure refractory metals, PLANSEE offers advanced high-performance alloys such as ML, TZM or WVM. The addition of dopant elements in combination with special thermo-mechanical processing routes significantly improves the material properties and therefore the performance of the finished products. For the first time the use of molybdenum in oxygen-containing and oxidising atmospheres up to 1700 C / 3092 F has become reality by means of the new SIBOR coating.
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High temperature vacuum batch furnace

High temperature continuous furnace

Hot isostatic press (HIP)

Product Portfolio for High Temperature Furnaces

PLANSEE supplies materials and components for various high-temperature furnaces. The two most important types are batch and continuous furnaces operated under vacuum or protective atmosphere. Batch furnaces allow very flexible operation, in which furnace parameters such as temperature, heating and cooling rate, cycling time, furnace atmosphere and batch size can be changed from one cycle to the next. PLANSEE supplies important furnace components which can stand up to these changing conditions: - Complete hot zones - Radiation shields - Heating elements and connectors - Furnace fixtures, racks, grids, sheets, boats, etc. - Hearth components such as rails, posts and caps - Sintering boxes and retorts - Gas feeding and quenching systems - Thermocouple protection tubes - Replacement parts - Small parts (screws, bolts, nuts, pins, wires, etc.) Continuous furnaces allow very efficient, frequently automated operation with a high throughput of similar parts. For troublefree operation high reliability is demanded from furnace components, where dimensional and form stability as well as life time are critical. PLANSEE components for continuous furnaces are ideally suited to meeting these demands. - Pusher plates - Boats, frames and trays - Heating elements - Element connectors - Fixing hooks and clamps - Thermocouple protection tubes - Small and spare parts
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Photo: Powdermetal/ABB

Photo: Schmetz GmbH

Photo: ELINO

Hot Zones for High Temperature Furnaces

PLANSEE is the world's leading manufacturer of metallic high-temperature hot zones. Through continuous development in materials and design PLANSEE is able not only to offer various standard and specialised hot zones, but sets the trend in technical progress, for example in the form of low-energy hot zones (ENERZONE). Hot zones are both designed together with the furnace OEM for new installations and offered to end users as exchange units for existing furnaces. In the latter case the performance and durability of the hot zone can almost always be improved in comparison to the original. The service package for replacements includes the complete dismantling of the old and installation of the new hot zone. PLANSEE supplies the whole spectrum regarding: - Materials: Mo, W, Ta, Nb and their alloys - Shielding/insulation: hybrid hot zones with graphite or ceramic fibre insulation - Dimensions: hot zones ranging from very small to extremely large - Temperature: from 1000C / 1832F to 2800C / 5072F - Design: round, rectangular, vertical, horizontal or special types - Replacement of graphite with metallic hot zones (usually without needing to change the transformers)
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Examples of high-temperature hot zones engineered and built by PLANSEE

Typical quality attributes of PLANSEE hot zones are: - TIG welded stainless steel structure for support frame and plenum - ML for components subjected to extreme thermal and mechanical load, such as heating elements, element supports, hot face and gas nozzles - Optimum choice of the type of heating element for the given application (ribbon, sheet, wire, rod, stranded wire, mesh) - Double V-groove design and free flowing support for wide ribbon heating elements - Radiation shielding design guarantees low energy consumption over long-term operation - U-rails (ML or TZM) replacing standard rails in hearth design for minimum material usage and easy sliding of the workpiece during thermal expansion In recent years annealing boxes and retorts have been introduced in advanced furnace design of hot zones, which can ensure better temperature uniformity and controlled gas flow. Here PLANSEE offers well-engineered and long-lasting solutions, which have been proven excellent performance.
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Photo: ALD

Charge Carriers, Trays, Plates, and Boats

The special quality of PLANSEE charge carrying fixtures (racks, grids, baskets, base plates, boats, trays) is based on the outstanding properties of PLANSEE High Performance Materials. The choice of material has a significant effect on the functionality and reliability of the entire plant. Therefore PLANSEE prefers to use ML and TZM in furnace furniture, which exhibit up to 10 times the creep strength of and have better ductility than pure molybdenum. The advantages of PLANSEE High Performance Materials are exploited with the help of modern design tools to achieve high strength, form stability, and easy handling for smooth operation together with minimum material usage: - Rails, posts, caps and grids - Furnace racks, inserted, screwed or riveted - Stackable charge carriers with fixed or variable spacing - Base plates, boats and frames for pusher furnaces As an option trays, plates and boats can be supplied with ceramic coatings to prevent them from reacting with or sticking to the products being processed. - Riveted boats for walking-beam furnaces - Intermediate trays and frames - Special requirements according to customer demand

Various types of furnace fixtures

Various types of furnace fixtures

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Tube for rotary furnace (ML)

Components for Special Equipment

In metallic HIP (Hot Isostatic Press) plants sintering, joining and densification processes are carried out at temperatures up to around 1450C / 2642F and gas pressures up to 200 MPa. This emerging technology faces continuously increasing demands with respect to large dimensions, high temperatures and rapid temperature changes. This is also an area where PLANSEE supplies key components of high quality with long service life. - Metallic components in PLANSEE High Temperature Materials such as TZM and ML - Mantles and support baskets with integrated heating systems - Charge support plates and furnace hearth with bottom heating - Gas circulation devices - Fixings and spare parts

Rotary furnaces
Rotary furnaces offer an efficient method for homogenous treatments of bulk material, powder and waste. PLANSEE supplies the tubes for such furnaces, specially adapted to the application. - Almost unlimited dimensions through multi-part design - Increased gas tightness through multi-layer construction and coating - SIBOR coating for use in oxidising atmospheres or highly corrosive media

Special Parts and Engineered Components

PLANSEE works in partnership with its customers. The effect: Many developments in the steel industry, waste incineration and plant construction have been implemented successfully in recent years.

Hot zone with annealing muffle

HIP mantle (TZM)

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Standard Components and Mill Products

PLANSEE always has a comprehensive range of standard components and mill products in stock, deliveries can be made in a few days. Various material grades based on Mo, W and Ta are available. - Sheets, plates and foils - Rods with random or cut length - Small parts such as screws, bolts, nuts, rivets and washers - Rails and posts for load support - Threaded rods - Support studs, bolts and pins - Wires and bundled wires for heating elements - Tubes and thermocouple sheaths - Ceramic isolators Mill products are offered in standard dimensions, aimed specifically at furnace applications, particularly for heating elements and radiation shields. The table on page 15 provides an overview of the main standard components and typical mill product dimensions. Additional stock sizes are available via PLANSEE Express, and non-standard sizes are offered on request.

PLANSEE Express
Mill products in standard sizes are offered online via PLANSEE Express, with the following advantages: - Easy, rapid order processing - Guaranteed availability - Shortest possible delivery times - High delivery reliability An overview of all the products available from PLANSEE Express together with information on the ordering procedure can be found at www.plansee.com.

Mo and ML coils

Spare parts for standard hot zones

Multistranded wire (ML)

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Delivery Program for Standard Semi-Finished Products

Availability Mo
Length x width mm (inch) thickness / mm (inch) 0.127 (0.005) 0.254 (0.010) 0.381 (0.015) 0.508 (0.020) 0.635 (0.025) 0.762 (0.030) 1.0 (0.039) 1.5 (0.059) 2.0 (0.079) 2.5 (0.098) 3.0 (0.118) 4.0 (0.157) 5.0 (0.197) 6.35 (0.250) 7.94 (0.313) 9.52 (0.375) 0.127 (0.005) 0.254 (0.010) 0.381 (0.015) width: 76.2 (3.0) 101.6 (4.0) 127 (5.0)

TZM
Length x width mm (inch) thickness / mm (inch)

ML
Length x width mm (inch) thickness / mm (inch)

W (WVM)
Length x width mm (inch) thickness / mm (inch)

Sheets < 1.0mm (0.039)

609.6 x 1981.2 (24 x 78)

609.6 x 1981.2 (24 x 78)

0.254 (0.010) 0.381 (0.015) 0.508 (0.020) 0.762 (0.030)

508x838.2 (20x33)

0.127 (0.050) 0.254 (0.010) 0.508 (0.020)

Sheets >= 1.0mm (0.039) Cut to requirements

1 - 3 mm: 600 x 2000 (23.6 x 78.7) 4 - 5 mm: 500 x 1000 (19.7 x 39.4)

max size: 600x2000 (23.6x78.7)

1.0 (0.039) 1.5 (0.059) 2.0 (0.079) 3.0 (0.118)

max size: 600x2000 (23.6x78.7)

1.0 (0.039) 1.5 (0.059) 2.54 (0.10) 3.17 (0.125) 5.0 (0.197)

1 - 2 mm: 500 x 1000 (19.7 x 39.4)) 3 - 5 mm: 200 x 600 (7.9 x 23.6)

1.0 (0.039) 1.5 (0.059) 2.0 (0.079) 3.0 (0.118) 4.0 (0.157) 5.0 (0.197)

Plates >=6.35mm (0.25) Hearth rails cut to requirements

max length: 2000 (78.7)

max length: 1828.8 (72)

6.35 (0.250) 7.94 (0.313) 9.52 (0.375)

Coiled sheet Coiled ribbon (Heating elements) Cutting, rolling and grooves applied to requirements

609.6x>7600 (24x>299)

0.635 (0.025) 0.762 (0.030)

Wire Pins cut to length

acc. PLANSEE Express

0.5 - 3.0 (0.020 - 0.118) 3.17 (0.125) 6.0 (0.236) 6.35 (0.25) 8.0 (0.315) 9.52 (0.375) 10.0 (0.394) 19.05 (0.75) 25.4 (1.0)

0.5 (0.020) 0.8 (0.031) 1.0 (0.039) 1.524 (0.060) 2.286 (0.090)

WVM

0.635 (0.025) 0.8 (0.031) 0.9 (0.035) 1.0 (0.039)

Rod Posts cut to length; Heating elements bended to requirements Multistranded wire (Binding wire, Heating elements)

19.05 (0.75) 25.4 (1.0)

6.35 (0.25) 9.52 (0.375) 19.05 (0.75) 25.4 (1.0)

acc. PLANSEE Express

0.35 (0.014) x 3 0.8 (0.0315) x 3 x 7 0.8 (0.0315) x 7 x 7 1.0 (0.039) x 7 x 7 M6 M10 "- 20" UNC "- 20" UNC M6 " UNC M10 "- 20" UNC M6 3.175 x 0.381 (0.125 x 0.015) 6.35 x 0.508 (0.25 x 0.02) 10 x 1 (0.39 x 0.039) 12.7 x 1 (0.50 x 0.039) 16 x 1 (0.63 x 0.039) 19.05 x 1.524 (0.75 x 0.060) 25 x 1.5 (0.98 x 0.059) M6 - 20" UNC

All threads

1000 (39.4)

Hex Nuts Threaded pins with 1 hole (rolled thread)

M6 - 20" UNC M10

Tubes (Thermocouples)

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PLANSEE High Performance Materials for Furnace Construction

Mo
Pure molybdenum finds many applications in high-temperature furnace building because of its high availability, good workability and favourable high-temperature properties (low vapour pressure, high melting point).

TZM (molybdenum doped with titanium and zirconium)

TZM contains small additions of finely dispersed particles (consisting of Ti, Zr and C), which inhibit grain growth at high temperatures. This significantly increases ductility and creep strength. TZM has a higher recrystallisation temperature than pure Mo. It is best suited to components subjected to both high thermal and mechanical loading such as hearth assemblies, racks and fixtures.

ML/MLR/MLS (molybdenum doped with lanthanum oxide)

ML is used whenever embrittlement after recrystallisation must be avoided and when dimensional and shape-stability must be ensured at high temperatures. Heating elements, thermal-radiation shields and sintering boats are good examples. Doping of Mo with small quantities of La2O3 increases the recrystallisation temperature to 1400C / 2552F. After recrystallisation the resultant elongated grain structure with jagged grain boundaries (in contrast to the coarse-grained structure of recrystallised pure Mo) allows a considerable increase in ductility. Furthermore the creep resistance strength of ML is significantly higher than that of the pure metal.
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SIBOR coated Mo
Molybdenum starts to react with oxygen at approximately 400C / 752F and forms a yellow, sublimating oxide at higher temperatures. This reaction excludes the use of unprotected Molybdenum at high temperatures in oxygen containing atmospheres. SIBOR is the first successful coating system to be developed, which reliably inhibits oxidation at temperatures up to 1700 C / 3092F for long periods. Molybdenum-SIBOR also offers considerable protection against corrosive atmospheres and inhibits carburising and nitriding reactions. SIBOR generates a dense, stable coating with a sealing surface layer of SiO2 above layers of molybdenum silicide. Protection against oxidising and corrosive media can be maintained for up to several thousand hours of high-temperature operation.

W
Tungsten has the highest melting point of all refractory metals and possesses excellent resistance to hot gas corrosion. It is brittle at room temperature and must be handled and worked with great care.

WL (tungsten doped with lanthanum oxide)

This material can be worked more easily and has a higher creep strength than pure W.

WVM
WVM is doped with calcium aluminium silicate, which gives it higher form stability at high temperatures than pure tungsten. WVM is used for heating elements for very high furnace temperatures up to 2800C / 5072F in the form of single or stranded wires and mesh heaters.

Ta
Tantalum is easy to work and can be used in cold forming. It is readily weldable and retains its ductility after being subjected to high temperature. However the high material price usually restricts its use to special applications, mainly in corrosive atmospheres.

Nb
Like tantalum, niobium is used in corrosive environments because of its outstanding passivating properties. Niobium is equally suited to welding, but has a lower mechanical strength than tantalum.

1652
Stress for 1% creep in 1000h R p1.0/1000 [MPa]

2012

2372

2732

3092

3452 25
Ductility after 100h exposure at temperature (Impact bending test, relative values, Mo=1)

2012

2642

3272
Temperature [F]

1000

Temperature [F]

100

20 15 10 5 0
Exposure temperature [C]

10

0.1
Temperature [C]

900

1100

1300

1500

1700

1900

1100

1450

1800

Creep resistance (sheet material)

Ductility after high temperature exposure

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PLANSEE Global Network

PLANSEE is the world's largest manufacturer of metallic hot zones and components for furnace construction. Together with its affiliates PLANSEE USA and JAPAN VACS METAL, PLANSEE offers a comprehensive technology package and provides solutions wherever they are needed. Fully owned production facilities in the most important markets and a worldwide service network consisting of sales companies and exclusive agents ensure short delivery times, a high service level and uniform quality standards.

Worldwide Production Network

The worldwide PLANSEE production network is tailored to the current and future needs of our customers. Each development and production centre in the PLANSEE group offers a service support package throughout the region.

Worldwide Sales Network

A worldwide sales network supports the regional production facilities and provides a rapid on the spot response to customer enquiries.

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Further Application Fields of PLANSEE Materials

Based on many years of experience in the field of powder metallurgy, we supply a wide range of products made from refractory metals including molybdenum, tungsten, tantalum and chromium as well as their alloys and composite materials. The unique properties of PLANSEE materials make them indispensable to many industries such as: - Lighting Industry - Electronics - Coating Technology - Medical Technology - Power Technology - Material and Processing Technology

Selection of PLANSEE Products made of High Performance Materials:

Targets for hard coatings

TIG Electrodes

Parts for ion implantation

WCu plasma spray nozzles and electrodes

DENSIMET boring bars used for machining

Insert for Al die casting

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Close to the customer - our global network

PLANSEE manufactures and markets its products worldwide. Production sites in Europe, USA and Japan and a global network of sales subsidiaries and sales partners, enable outstanding customer service and product quality delivered by local teams. Stronger than any alliance and more diversified than single producers, PLANSEE is the most reliable source for high performance components made of refractory metals.

For more information and local contacts please visit our website:

www.plansee.com

We reserve the right to make technical changes for improvement of the product.

7000953 - 699 E 09.11 (2500) RWF