Heat Treatment After Plastic Deformation
Drop-Bottom Solution Heat Treatment Furnaces
For the solution heat treatment of aluminum alloys, drop-bottom heat treatment furnaces are used. Drop-bottom furnaces can be built in a variety of sizes to meet customer requirements. Because solution heat treatment and quenching are combined into a single controllable operation, these furnaces are typically used when very short water quenching times are required.
A drop-bottom furnace sits on a platform, with the quenching tank beneath it. For the quenching process, the furnace platform moves horizontally. The loaded basket is guided into the quenching tank by wire cables. The lifting system can be operated fully or semi-automatically. Recuperative burners or hairpin resistors provide heating.
The average solution period varies depending on the material cross-section:
Heating time: 1.5 hours from 20°C to 540°C
7 seconds of quenching (as the doors start to open)
Maintaining a temperature of 540 °C for 4-5 hours (the maximum furnace temperature is 650 °C).
Sistem Teknik manufactures Class 1 furnaces in accordance with the AMS 2750E process specifications.
Ageing Ovens
Sistem Teknik designs and manufactures aging ovens for aluminum extrusion profiles. We have double-length (16 m) aging ovens with up to 24 baskets and single-length (8 m) aging ovens with 12 baskets. We ensure that production processes after extrusion are completely automated by integrating smart loading cars into the system.
Aging ovens are heated up to 185 °C in less than an hour using electricity or natural gas (indirectly), and the entire heat treatment process takes 6 hours, allowing the application to take place four times per day.
The use of the reversible end flow system (changeable airflow direction) maximizes temperature homogeneity inside the ovens, ensuring excellent hardness along the entire length of the profiles. The system’s recirculation fan moves horizontally through the reversible end flow system, directing hot air generated in the thermo-blocks into the oven. Aging ovens can achieve desired material temperature homogeneity within ±3 °C tolerance based on the particular time intervals during heating.
While two transfer cars at the entrance and exit zones handle the loading and unloading, chain or roller conveyor systems can also be used.
Coil/Foil Annealing Furnaces
Sistem Teknik develops and manufactures furnaces for the homogenization, intermediate, and final annealing of aluminium coils as well as the final annealing and oil removal of aluminium foils. These furnaces are typically designed for the N2 atmosphere, with O2 levels reduced to as low as 0.1 percent.
Our coil annealing furnaces have the desired temperature uniformity within ±4 °C tolerance. Less energy is consumed during the soaking period thanks to the implementation of the fan drive control. The economizer allows for fresh air suction as well as the supply of protective N2 gas, which is heated by the furnace exhaust. This circular system significantly increases energy savings. Depending on the needs of the customer, indirect gas heating (with self-recuperator burners and radiant tubes) or electric heating can be used.
For foil annealing furnaces, Sistem Teknik uses a negative atmosphere system in these furnaces to maximize oil removal. With the use of automated multi-directional smart charging cars and user-friendly PLC and SCADA interfaces, our annealing systems implement industry 4.0 solutions.
Coil Transfer Cars
Sistem Teknik develops multi-directional charging cars for coil/foil annealing facilities. The car, according to the application, can be outfitted with a single or multiple shuttle system to charge furnaces across each other to save space.
Semi-automatic or fully automatic charging cars have loading capacities ranging from 10 to 120 tons and a very sturdy steel construction. For operational safety, the speed of the car and shuttle is controlled by a frequency controller.
Transfer cars are divided into two parts: the transfer car and the shuttle car.
The shuttle car is made of steel profiles for structural rigidity and has a hydraulic system for vertical motion. An encoder and limit switches control the shuttle car’s position.
According to the requirements, the transfer car operates in manual, semi-automatic, or automatic mode by program receipts. The transfer car’s horizontal motion is enabled by the electrical motor drive system, while side positioning is controlled by a laser encoder and limit switches.
Wireless technology allows the car to communicate with the furnaces. Wireless power transfer can also be used to charge the car.
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