1.1.  summary

Product model: GC-RZK-1000E

The vacuum ingot furnace system requires the use of vacuum magnetic levitation melting method, which is a comprehensive gold treatment technology that uses High-frequency or medium frequency alternating magnetic fields to form electromagnetic forces that counteract gravity during metal melting, causing the molten material to suspend and detach from the collapsed inner wall. It is mainly used for melting high melting point and volatile alloys.

The melting furnace should include a high vacuum chamber vacuum system, a composite pressure measuring device, a melting system, a water cooling system, an exhaust system, an electronic control system, and a test bench, etc. It should be able to operate in a vacuum state and achieve online continuous temperature and pressure measurement functions. The equipment requires a reasonable internal design of the furnace body and strictly prohibits the occurrence of vacuum discharge.

A vacuum furnace is an internally heated cold wall vacuum heating equipment with high thermal efficiency and good furnace temperature uniformity. It can also quickly heat and cool the processed workpieces, effectively shortening the workpiece heat treatment cycle and improving production efficiency.

The vacuum furnace adopts advanced automation and intelligent equipment in China to achieve automatic programming and process random changes, ensuring automatic heating and quenching under vacuum conditions. Especially in the combination of energy-saving in furnaces, quenching speed, workpiece deformation and other advantages, especially in the design of air ducts and heat exchangers, the equipment has higher cost-effectiveness

Provide different types and levels of configurations for users to choose from based on their different needs.

1.2 Application

The vacuum ingot furnace system is applied in fields such as aerospace/aviation, weapons, automotive, electronics, and mechanical industry.

The vacuum ingot furnace system is a single chamber horizontal vacuum heat treatment equipment with a 6 bar air cooling function, suitable for quenching materials such as high-speed steel and high alloy steel molds, annealing of soft magnetic materials and titanium alloys, and various vacuum heat treatment processes such as vacuum brazing.

Equipment configuration

The high vacuum chamber is composed of two main parts: the furnace body and the furnace cover.

1. The furnace body is made of 304 stainless steel or materials with equivalent or better performance, and is connected by arc welding or equivalent or better connection methods. The surface is polished to ensure that the outer surface temperature of the furnace shell does not exceed 60 ℃ during operation

2. The furnace cover is equipped with a locking device, and there is an observation window on the furnace cover that can observe the melting situation inside the furnace. The observation window has a filter function to protect the eyes;

3. The furnace body is equipped with vacuum extraction interface, power inlet and water inlet interface, protective atmosphere filling interface, exhaust port with one-way valve, etc;

4. Cold state ultimate vacuum ≤ 5.0x10-2Pa, the system starts pumping from the atmosphere and can reach 5 * 10-1Pa in 60 minutes, with a pressure rise rate not exceeding 1Pa/h

5. Overall leakage rate ≤ 2.0x10-9Pa.m3/s;

6. The maximum operating pressure is ≥ 0.3 MPa (absolute pressure).

Vacuum system

Used for obtaining ultra-high purity in the system, it can improve the vacuum degree and the purity of gas pipelines to enhance the purity of melted alloys

The vacuum system consists of a molecular pump, an oil-free dry pump, a high vacuum valve pipeline, joints, and a control unit;

1. Under cold and no-load conditions, the system starts to extract air from the atmosphere and can reach 2Pa in 30 minutes and 5.0X10-1Pa in 60 minutes;

2. A high vacuum valve and a high vacuum chamber are installed between the vacuum system and the high vacuum chamber

Leakage rate ≤ 5.0x10-11Pa.m3/s, Pressure range: 0-0.5MPa (absolute pressure):

3. The vacuum system operates in an automatic sequence to provide safety interlock functionality.

Composite pressure testing device

Direct vacuum meter and secondary instrument are used for measuring and displaying the vacuum degree of the system

The main function of the composite pressure measuring device is to measure the pressure value inside the vacuum chamber, consisting of a vacuum gauge and a digital pressure sensor.

1. Using a composite pressure device to measure vacuum degree and system pressure, the measurement range should include

1.0x10-3Pa to 3.0x105Pa;

2. Measurement range of direct air meter: 1.0x10-3Pa to 1.0x102Pa;, Accuracy: ± 15%% FS:

3. Measurement range of digital pressure sensor: 1.0x10-1Pa~3.0x105Pa, degree: ± 0.5% FS;

4. Working temperature: 0-50 ℃:

5. The pressure and vacuum values can be displayed in real-time.

Melting system

Used to achieve heating and melting

1. The refining system consists of a heating electric furnace, a tank yard, and an infrared temperature measurement device

2. Refining temperature: ≥ 2300℃

3. Heating method for refining, induction heating, heating power can be manually adjusted

4. Water cooled crucible made of copper.

Water cooling system

Used for thermal insulation and cooling of the furnace body during the smelting process, as well as thermal insulation and cooling of the water-cooled storage yard

1. Centralized water supply, with each joint designed to be water tight and vacuum tight,

2. The water-cooled integrated pipeline mainly consists of valves, pipelines, pressure gauges, thermometers and other related devices, with functions such as water temperature over temperature, water cut-off alarm, and automatic cutting off of heating power supply.

3. Equipped with circulating water cooling function;

4. The refrigeration function is provided by the refrigeration machine.

Exhaust system

Used to blow the vacuum chamber to exhaust the melting process, ensuring stable pressure inside the vacuum chamber

The air supply and exhaust system mainly consists of an air supply device, a flow control device, and an exhaust device. It can achieve continuous and stable flow of atmospheric gas in the chamber during the melting process, and maintain a pressure change range of ≤ 0.05MPa in the vacuum chamber.

1. Gas supply device: blow emotional gas into the melt in the vacuum chamber at a maximum gas supply flow rate of ≥ 1L/s; Maximum blowing pressure method 0.3MPao

2. Flow control device: controls the air supply flow rate;

3. Exhaust device: When the pressure inside the vacuum chamber exceeds the specified value, it automatically exhausts to the outside, so that the maximum pressure inside the vacuum chamber does not exceed 0.3MPa. The exhaust device is equipped with a one-way valve to prevent air from flowing back into the vacuum chamber at any time.

Electric control system

Control the working status of the induction furnace

1. Flat IGBT or similar high-frequency or intermediate frequency induction power supply

2. The electronic control system is designed with a main control power supply to provide power for mechanical pumps, molecular pump composite pressure measurement devices, melting systems, infrared temperature measurement devices, and water cooling systems. It is also designed with water and power outage protection functions

3. The switches and display instruments involved in the electronic control system are all integrated on a single control panel, including: main control power switch, vacuum system pump start and stop buttons, vacuum degree display instrument, heating system power adjustment knob, current, voltage, power display instrument, melting temperature, yard cooling water temperature display instrument, valve switch knob, etc,

4. Can achieve control over heating power;

5. Provide electrical, self-control, and instrument connection materials required for the DCSPLC process system

6. According to the process requirements, it is possible to trigger alarms for phenomena such as overheating and overpressure. (For more information, please call our company)