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© 2019 IpsenThis document contains proprietary information of
Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Low Pressure Carburizing and
Corresponding Furnace SolutionsMatthias Rink
Head of Process Technology
Ipsen International GmbH, Kleve
Värmebehandlingskonferensen, 9 – 10 oktober 2019
på Louis De Geer Konferens i Norrköping
© 2019 IpsenThis document contains proprietary information of
Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Industrial Load with 900 Nozzles
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Industrial load with 10200 “Nozzle bodies”
Detail view
Total view
© 2019 IpsenThis document contains proprietary information of
Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Hardness Profiles of three nozzle
bodies from layer 1, 6 and 12
400
450
500
550
600
650
700
750
800
0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40
Abstand von der Oberfläche [mm]
Härt
e [
HV
1]
Härteverläufe von drei Düsenkörpern
T = 930 °C
t = 70 min
20 bar N2
Distance from surface in mm
Hard
ne
ss
in H
V1
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Time
Temperature T
Pressure p T
p
CCarbid
CSurf.
CLim.CCore
CD1 CD2 CD3 CD4
1
1+2
1+2+3
1+2+3+4
Carbon Profile Development
10 - 1000 Pa
2. D
iffu
sio
n
4. D
iffu
sio
n
3. C
arb
urizin
g
1. C
arb
urizin
g
850 - 1100 °C
AvaC® Process Procedure
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
0
1
2
3
4
5
6
40 50 60 70 80 90 100
pre
ssu
re [
mb
ar
]
duration [ min ]
carburize 1 carburize 2diffuse 1 diffuse 2
Cycle with pulsed pressure
6
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
0,2
0,3
0,4
0,5
0 20 40 60 80 100
depth in the blind hole [ mm ]
case d
ep
th [
mm
]
C2H2
t = 86 min
T = 900 °C
16MnCr5
p = const.
p = pulsed
Case depths with constant and pulsed pressure
7
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Monolayer Carbon
Carbon Transfer with Acetylene
© IWT Bremen
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Sensors
9
Standard Sensors/Controlled Process Parameters:• Furnace
Temperature
• Furnace Pressure
• C2H2-Flow
• Boost-/Diffusion Times
Additional Monitoring Sensors:• H2-Sensor
• O2-Sensor
Controlling Sensors (research procects, not in use)• C2H2-flow,
boost duration (under development)
• Carbon Transfer (available since years, not reliable)
© 2019 IpsenThis document contains proprietary information of
Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Carburizing in Hydrocarbons
Advantages
No internal oxidation
Complex geometries
Higher carbon transfer
Faster carburizing
Shorter cycle duration
Large CHD
Higher temperatures
Very small CHD
Lower gas consumption
Lower consumption expenses
No thermal radiation, no flames
Environmental friendly
No conditioning of the furnace
Disadvantages
Formation of soot and tar
Too high carbon content in edges
and tips
Effusion of Mn, Cr, Si
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
High Temperature Carburizing
Material: 14NiCrMo13-4
CHD = 2,0 – 2,3 mm
Carburizing Temp.: 1050 °C
Cycle Time: 10,5 h
© 2019 IpsenThis document contains proprietary information of
Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Example: Mining Shafts
Specification:
Material: 25NiCrMo12-5
Surface hardness: > 60 HRC
CHD 600: 0.9 - 1.2 mm external
> 0.30 mm internal
Core hardness: 400-500 HV30
Results:
Surface hardness: 62-64 HRC
CHD 600: 0.90-0.94 mmexternal
0.77 mm internal
Core hardness: 460 HV30
T= 950 °Ct= 185 min
p= 1,5 bar N2
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© 2019 IpsenThis document contains proprietary information of
Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
REQUIREMENTS:
Hardness under the surface: >697 HV1 (60HRC) at 0.3 mm
depth
Core hardness: 402-471 HV30 (41-47 HRC)
CHD 650HV1: 0.8-1.2 mm
SAMPLE PARTS SPECIFICATION
Name: Bearing, outer ring
Material: M50NIL
Dimension: Øo= 66.5 mm
Øi= 46.7 mm
l=66.5 mm
Weight of part: 0.95 kg
Example: AvaC of aerospace bearings
HEAT TREATMENT
LPC (AvaC) temperature: 910 °C
LPC time: 20 h
Annealing: 580 °C, 2 h
Hardening temperature: 1080 °C
Sub-zero treatment:
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Wind Power
Material: 18CrNiMo7-6
Weight: 128 kgMaterial: 18CrNiMo7-6
Weight: 60 kg
© 2019 IpsenThis document contains proprietary information of
Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Hardness Profile after Case Hardening
Härteverlauf
0
100
200
300
400
500
600
700
800
0,0 0,5 1,0 1,5 2,0 2,5 3,0
Tiefe in mm
Härt
e in H
V1
Grund
Flanke
Distance from surface in mm
Hard
ne
ss in
HV
1
Root
Flange
Furnace: T²T (AvaC), 12bar, N2)
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Vacu-Prof 4 - Modul, AvaC®-Simulation
© 2019 IpsenThis document contains proprietary information of
Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Furnaces for Low
Pressure Carburizing
Turbo²Treater, etc.
RVHT-QGP 20 bar, etc
Single Chamber,
Two Chamber Chamber (Oil or Gas)
Multi Chamber Furnaces, and
Automatic Furnaces Lines
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Ipsen Turbo2Treater®
19
Size M Installation at Customer
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Ipsen Turbo2Treater®
20
• Graphite insulation
• Graphite load hearth
• Graphite heating elements
• Heating Power:
“S-size”: 75 kW/ 84 kVA
“M-size”: 150 kW/ 166 kVA
“XL-size”: 270 kW/ 297 kVA
• Special gas distribution
system
• Heating chamber door
closing system (3 closing
positions with 1 turn
• Load thermocouple feed
through connections
Graphite
Heating Chamber
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
21
Single chamber vacuum furnace line
Atlas Copco; Sweden
Fully automatic vacuum furnace line
Loader 1.500 kg, rotating to both sides
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
22
Fully automatic vacuum furnace line
Loader 1.500 kg, rotating to both sides
Atlas Copco; Sweden
Single chamber vacuum furnace line
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Ipsen RVHT-524 - 20bar
23
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Oil quench vacuum hardening furnace
24
Maintenance door
for easy and safe
access
RVFOQ-524
Furnace back side
with heating
chamber
Vacuum pump
system
Vacuum tight
inner door
Available standard sizes: S, M, XL
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Single and two chamber vacuum furnace line
25
Israel
© 2019 IpsenThis document contains proprietary information of
Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
ARGOS Multi Chamber System
26
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Example: Automotive shaft
Part: Shafts
Material (approx.):20MnCr5
Dimensions: l= 250 mm
Ø= 30 – 70 mm
SH: 58-62 HRC
CH: > 340 HV
CHD: 0.5 + 0.4 mm
Carb.-temp. 950 °C
Quenching: 20 bar, N2
27
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Charge (similar dimensions)
28
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Automotive Results
29
Surface hardness: 61-62
CHD: 0.58 – 0.83 mm
Core hardness: 345-380 HV10
100
200
300
400
500
600
700
800
0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00 1,10 1,20
1,30 1,40 1,50
Hä
rte
/Ha
rdn
ess [H
V1
]
Abstand zur Oberfläche/Distance to surface [mm]
Härteverlauf/Hardness shape
Flanke
Fuß
CHD550 = 0,84 mmCHD550 = 0,84 mmCHD550 = 0,83 mm
CHD550 = 0,58 mm
Quenching: 20 bar, N2
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Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
PressureTemperature
Vacuum
Nitro
gen
Vacuum
Vacuum
or
Nitro
genAcety
lene
Acety
lene
Am
monia
Nitro
gen
time
Low Pressure Carbonitriding Cycle AvaC®-N
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reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Summary
AvaC®(-N) Process Description
Boost / Diffuse process
Pulsed Pressure Process
Acetylene pressure < 10 mbar (Ammonia pressure < 40
mbar)
Process Advantages High carbon transfer rate
Optimum case uniformity
Part-to-part, load-to-load repeatability
Absence of internal oxidation and accurate case uniformity lead
to enhanced component
quality
High furnace availability/reliability due to minimization of
soot or tar formation
No post cleaning process (with high pressure gas quenching)
Furnaces for AvaC
Depending on part size and throughput, Ipsen can provide
the right furnace solution for low pressure carburizing
© 2019 IpsenThis document contains proprietary information of
Ipsen. It is submitted in confidence, and may not be
reproduced or used for any other purpose or disclosed to others
without written authorization from Ipsen.
Contact:
[email protected]
