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4D High Pressure Gas Quenching - A Leap in Performance vs. Press Quenching

机译：4D高压气体淬火 - 性能的跃入与压榨淬火

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Thermal processing and quenching of steels for hardening is a well-established practice performed by various techniques over the centuries. A common thread has been the unpredictable nature of the size change during the quenching process, which is known as dimensional change or distortion. Material distortion is the undesired trade-off between the development of proper mechanical property and the necessity of rapidly quenching the material from elevated temperatures into a quenching media (i.e. brine, water, polymer, oil, gas, molten salt, etc.). Due to this compromise, users have been attempting to reduce part distortion because once a component is hardened, it becomes very difficult and costly to remove excess material or form the part back into its original shape. When one looks at the bearing and gearing industries, materials typically are hardened via austenitizing and quenching. Not only do these components require high hardness and wear/corrosion resistance, they also require high dimensional precision to tight tolerances as well as repeatability of results. One of the most common way to reduce material distortion when quenching is a method by which a heated component is placed in a special fixture and a steady force is applied to the component, which allow the part to resist material deformation when the quenching media is applied. This method of quenching is known as "press quenching" and requires specialized equipment, manual or robotic handling, custom die sets and high maintenance as well as being operator dependent to achieve consistent results. It is well known that machining after heat treatment is one of the most costly and difficult tasks to complete in the entire manufacturing life cycle. This is why an extreme amount of engineering is devoted to the prevention of distortion of a component to ease the post heat treatment machining operations. With the ever prevailing desire to lower the cost of raw materials and still maintain proper mechanical performance, extreme amounts of pressure are applied to the heat treatment process to bring up the quality level of the low cost steel. When using these low quality steels, they are prone to high levels of distortion during the quenching process, such that they distort more than the allowable amount and either become too challenging to hard machine or are not able to be used all together. ～4% of the price for a hardened component is attributed to the removal of post heat treatment material to so that it meets the finished size requirements. When users can control distortion, they lower the overall cost of the component. This paper will introduce the latest achievements in the advancement of distortion control by way of 4D High Pressure Gas Quenching (HPGQ) versus press quenching. Both processes quench a single part at a time but the 4D HPGQ process does not subject a part to any clamping forces or issues associated with liquid quenching inconsistencies. The 4D HPGQ process results in every single part being heated and quenched identically the same at surprisingly low gas pressures thus producing extremely accurate dimensional variation with highly repeatable results. 4D HPGQ systems are easily integrated into current manufacturing environments and the process is a revolutionary advance in quenching technology, which has been shown to reduce or even eliminate the need for expensive & difficult post hardening manufacturing processes.
机译：用于硬化钢的热处理和淬火是由几个世纪以来各种技术进行的良好的实践。淬火过程中的尺寸变化的常量性质是不可预测的，这被称为尺寸变化或失真。材料变形是适当的机械性能的发展与快速淬火材料从升高的温度释放到淬火介质（即盐水，水，聚合物，油，气体，熔盐等）之间的不希望的折衷。由于这种折衷，用户已经尝试减少部分失真，因为一旦部件硬化，就会变得非常困难并且昂贵，以将多余的材料形成或者将部分形成回到其原始形状。当一个看轴承和齿轮行业时，材料通常通过奥氏体化和淬火硬化。这些部件不仅需要高硬度和耐磨性/耐腐蚀性，它们还需要高尺寸的尺寸精度，以​​密切公差以及结果的可重复性。减少材料变形的最常见方法之一是一种方法，通过将加热部件放置在特殊夹具中，并且施加稳定力施加到部件上，这允许该部件在施加淬火介质时抵抗材料变形。这种淬火方法称为“压制淬火”，需要专门的设备，手动或机器人处理，定制模具套和高维护以及操作者取决于实现一致的结果。众所周知，热处理后的加工是在整个制造生命周期中完成最昂贵和最困难的任务之一。这就是为什么致力于预防部件的失真来缓解后热处理加工操作的原因。随着较普遍的愿望降低原材料成本并仍然保持适当的机械性能，极大的压力适用于热处理过程，以提高低成本钢的质量水平。当使用这些低质量钢时，它们在淬火过程中容易出现高水平的变形，使得它们比允许量更扭曲，并且对硬机变得过于挑战，或者无法一起使用。 〜4％的硬化部件的价格归因于去除后热处理材料，使其符合成品尺寸要求。当用户可以控制失真时，它们会降低组件的总成本。本文将在通过4D高压气体淬火（HPGQ）与压紧淬火的方式介绍变形控制进步的最新成果。这两个过程一次猝灭单个部分，但是4D HPGQ过程不会将部分与液体猝灭不一致相关的任何夹紧力或问题。 4D HPGQ工艺导致每个单个部分被加热并淬火相同，在令人惊讶的低气压下相同，因此产生极其精确的尺寸变化，具有高度可重复的结果。 4D HPGQ系统很容易集成到当前的制造环境中，该过程是淬火技术的革命性进步，已被证明可以减少甚至消除对昂贵和困难的硬化制造过程的需求。

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