Around 40% of the energy used in industry in Germany is consumed in heat treatment. In times of climate change as well as constantly rising energy costs, energy efficiency is therefore one of the most important issues.
The following savings potentials enable cost-optimized production:
The zones to be heated can be precisely determined.
Due to very high energy densities in the workpiece, short heating times can be realized.
Precise regulation of the heating temperature is possible.
The start of the process has a short lead time.
We will be happy to advise you on the disposal of your waste. Please note the following information in particular. The operator must ensure responsible disposal and recycling of the waste. When disposing of waste, it must be separated by type.
The relevant regulations on hazardous waste disposal apply to the disposal of cleaning agents, lubricants, coolants, electrical components, cables, etc., as well as mechanical components.
Oil and oily waste, as well as lubricating greases, represent a high hazard potential for the environment. For this reason, disposal is carried out by specialized companies.
Dismantling of the system must be carried out by trained specialist personnel in view of any mechanical or electrical hazards.
Especially during installation, repair and maintenance work, substances hazardous to water, such as lubricating greases and oils, quenching agents and liquids containing solvents, must not contaminate the soil or enter the sewage system. These substances must be stored, transported, collected and disposed of in suitable containers.
When removed from the hardening plant, the workpiece is wetted with quenching medium due to the quenching process. Depressions or holes on the workpiece may be filled with quenchant. This causes quenchant to be discharged from the machine. Measures to reduce the discharge of quenchant must be specifically discussed between the customer and EMA Indutec.
EMA Indutec will be pleased to advise you in the use of the required process chemicals.
We recommend using a specialist company to treat the necessary cooling water if no in-house specialists are available.
Failure to comply with the cooling water specification (see link) can result in shortest possible rust-through times, hose destruction and massive cooling capacity-reducing deposits, which can lead to considerable malfunctions and operational downtimes.
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The active ingredients of a quenching solution (polymer quenching medium) become reversibly insoluble at high temperatures and precipitate from the solution on the hot steel surface during the cooling process. This means that the polymer quenchants cause a "plastic film" to form on the red-hot component surface when the components are run in. This slows down the heat transfer. The risk of warpage and cracking is reduced. Depending on the concentration, an insulating film of varying thickness is formed and the cooling intensity can thus be controlled within wide limits.
The process of film formation is reversible, i.e. if the parts cool down to the temperatures of the liquid again, the film dissolves completely and the hardened workpieces fall with a clean surface. The "drag-out" or discharge and thus the consumption remains low.
The concentration of the solution should be checked once a day. In addition to the daily concentration check, it is advisable to check and maintain the solution according to a specified test schedule. If necessary, additives should be added with regard to foam formation, fungal and bacterial attack and corrosion protection.
Concentration control can be done simply by measuring the refractive index with a hand refractometer or similar device and comparing it with the product-specific concentration table.
The optical density can be noticeably altered by introduced foreign substances, so that it is advisable to carry out an additional check at longer intervals by checking the viscosity. In this case, only the effective concentrate fractions are recorded. The viscosity is determined, for example, with an Ubbelohde capillary (supplier: Schott & Gen., Mainz). Various laboratories carry out control tests free of charge, which experience has shown are not possible in many hardening companies due to the lack of suitable laboratory facilities. The microbial control of the solutions can be carried out in a simple way, e.g. with the dip-slides SABOCLED available from Petrofer-Chemie.
At EMA Indutec, we successfully use the following lubricating grease in our machines and systems: Lagerstar Zen-Vog from Emka Schmiertechnik GmbH in 74626 Bretzfeld-Schwabbach. We would be pleased to inform you about the properties and use of this product.
Protective gases protect the metal surface from undesirable changes or specifically influence the surface properties. It should be noted that even small amounts of residual oxygen or oxygen compounds such as water or carbon dioxide can still have a negative qualitative effect at higher temperatures. For this reason, only gases that are very inert, participate in only a few chemical reactions and are economical or inexpensive can be considered for this purpose.
Inert gases do not or hardly form chemical compounds. These include nitrogen and, at low temperatures, carbon dioxide, as well as all noble gases (argon, helium, neon, krypton, xenon and the radioactive radon).
Experience indicates that nitrogen is usually the most suitable protective gas. Nitrogen is a colorless, tasteless, odorless, and nonflammable gas. It is lighter than air and considerably less expensive than argon or helium, for example, and does not undergo any chemical reactions with most metal surfaces up to approx. 1,000 °C. EMA Indutec has developed a variety of solutions for hardening processes under inert gas and thus has many years of experience in inert gas hardening.
The equipment we supply is free of substances covered by the REACH regulation.
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