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E h
Enhancing
i Th
The
Quenchant Performance
By
P.K.Deval
Hardcastle Petrofer Pvt. Ltd
Contents
¾ About
Hardcastle Petrofer
¾ Quenchant Performance - Criteria
¾ Restoration/Repair
of Degraded Quenchant
¾ Up
U gradation
d ti off Quenchant
Q
h t Performance
P f
¾ Methodology
¾ Case Studies
ABOUT
HARDCASTLE PETROFER
¾ Joint
Venture with Petrofer, Germany
¾ Manufacturing
M
f t i Facilities
F iliti att Gujarat
G j t
and J & K
¾ ISO 9001 and ISO 14001 certified
company
¾ Wide Product Range
Product Range
g
Fire Resistant
Hydraulic
Fluids
Heat Treatment
Products
Cutting
Coolants
Drawing
Compounds
Cleaners
Rolling
Oils
Rust
Preventives
Hot
Forging
Die-Casting
Products
Our Focus…
…..…To provide
Quality Solutions to the
Customers through our
P d t and
Products
dS
Services
i
Our Services…
Services
¾
¾
¾
¾
¾
¾
¾
¾
Selection of the Right Product
Development
p
of customized p
products
In--situ modification of quenchants
In
Technical support on system related aspects
Application support
Condition monitoring of our products
Design
g support
pp for q
quench systems
y
Filtration of used oil
Types Of Quenchants
¾ Water
¾ Water
Quenching Additives
¾ Quenching
Q
hi Oil
¾ Polymer Quenchants
¾ Molten Salt Baths
¾ Molten Metal Baths
¾ Gases
Quenchant Performance
¾ Criteria
z
z
z
z
z
z
z
z
Achievement of desired properties
Metallurgical and Dimensional
Achievement of desired finish
Longer service life
Less dragdrag-out or consumption costs
Consistency of quenched results
Absence of quench cracks
Reduced rework or rejection
j
costs
Optimum cycle time
Performance Enhancement
¾ Restoration
/ Repair of
Degraded Quenchant
¾ Up
gradation Of
Quenchant Performance
Quenching Oil Degradation
Indicators
¾ Sludge
Formation
¾ Contamination by scales, water, soot
¾ Increase in acid value / saponification
value
¾ Depletion of additives
¾ Increase/ decrease in viscosity / Flash
Point
Quenching Oil Degradation
¾ Effects
z
z
z
z
z
z
Poor Finish
Loss of Quench Severity
Inconsistent Results
Distortion and Cracking
g
Poor Cleanability
High Drag Out
Quenching Oil Degradation
¾ Remedies
z
z
z
z
Settling
Filtration / Centrifuging
Oil Refining
Addition of additives
Quenching Oil Degradation
¾ Corrective
z
z
z
z
/ Preventive Actions
On--line filtration / centrifuging
On
Periodic cleaning of heat exchanger
Periodic cleaning of tanks
Control of Oil Temperature
Polymer Quenchant
Degradation
Indicators
¾ Foul
Smell
¾ Reduced pH
¾ Change of colour
¾ Increase in Solution Hardness
¾ Increase in electrical conductivity
¾ Change in refractometer factor
¾ Increased tramp oil content
Polymer Quenchant
Degradation
¾ Effects
z
z
z
z
z
Increased Quench Severity
Inconsistent Results
Corrosion of tank / quenched parts
Stickiness
Distortion and cracking
Polymer Quenchant
Degradation
¾ Remedies
z
z
z
z
z
Tank Cleaning / Sanitisation
Addition of additives
Correction factor for refractometer
Maintain higher
g
concentration
Change the bath
Polymer Quenchant
Degradation
¾ Corrective
z
z
z
z
z
z
/ Preventive Actions
On--line filtration
On
Installation of oil skimmer
Periodic cleaning of tanks
Control of water quality
Agitation
g
when not in use
Regular monitoring of bath
Upgradation of Performance
¾ To
9
9
9
9
Improve
Improve….
Quench Severity
Surface Appearance
Distortion Control
Metallurgical Properties
Methodology
Lab Analysis of Tank Sample
z Review & Analysis of Data
z Development Work
z Production Trials
z Formulation For TopTop-ups
z Control & Monitoring
z
Case Studies
I -situ
InIn
it U
Upgradation
d ti
Of Quenchant
Background
Customer :
Manufacturer & 100% Exporter of Gears
for Trucks and Tractors.
Process :
C b i i
Carburising
iin
Sealed Quench Furnace
Quenchant :
Medium speed Quench Oil HQ M
Problems Faced
¾ Low
Core Hardness
& Surface Bainite
In case of some
Heavy Sectioned Gears
Root Cause Analysis
z
Data Collected From
Production Log Books
Inspection Reports
Microstructure Study
Cooling
g Curve Analysis
y
of Q
Quenching
g Oil
Development Work
¾ Additive
Package
Designed
¾ Cooling Curve
Analysis
• Before & After
Results
¾ Additive
Package Added InIn-situ
¾ Additive Addition Under Supervision
¾ Quench
Q
h Results
R
lt S
Satisfactory
ti f t
¾ Special Product developed for
Top-ups
Top¾ Satisfied
S ti fi d Customer
C t
Case Study I
Bright Quenching Of
Marquenched
q
Parts
Case Study
Background
Customer
Reputed Automobile Manufacturer using
HIQUENCH MT 650 satisfactorily since ’94.
Process
•
•
•
Carburised in SQF and CGC Furnaces
Q
Quenching
hi iin HIQUENCH MT 650
Oil Temp. 120 ℃ in CGC, 120 - 140 ℃ in SQF
Problem Faced
¾ Dark
appearance
pp
of q
quenched components
p
¾ High
dirt count of the components
¾ Manual
¾ The
cleaning / buffing required
problem was more severe in
CGC furnace.
Analysis – Process Approach
z
Study of the process
z
Study of system parameters
z
Discussions with
customer
Factors Identified
¾
System Related
¾
Quenchant Related
System Improvements
9 On
On--line
20 Micron filter installed
9 Pre
Pre--cleaning
9 Post
started with our HICLEAN L2
Quench Cleaner changed to HICLEAN L2
9 Furnace
soot blowing frequency and procedure
improved
9 Furnace
9
Controls improved
Shifted to better quality LPG
Product Upgradation
¾
Additive package
d i
designed
d
¾
S
Simulated
lab trials taken
¾
Additive added in quench tank
Result
9Significant
improvement in the
surface appearance achieved
9
Millipore value improved from
8-10 mg to 4
4--6 mg
9Satisfied
9New
Customer
product developed
– HIQUENCH MT 640 BQ
Conclusion
It is possible to
Enhance
Quenchant Performance
With Systematic
y
Approach
pp
&
User – Supplier Collaboration
QUERIES ARE WELCOME
Thank
You !