Three large bearing sets being removed from Metlab180" diameter by 156" high carburizing furnace from the hardening temperature (1550°F) for subsequent quenching into agitated, hot oil. Parts were carburized to a case depth in excess of 0.200" ECD. Fixture and component weight is about 40,000 pounds.
1.) Load of torsion bars, manufactured from 4340 steel, normalized in the vertical position to maintain straightness. Parts measure approximately 3" in diameter by 6' long.
2.) 26,000 pounds of low carbon steel flat wire being prepared for spheroidize annealing. Spheroidize annealing is an intermediate processing step to allow the wire to be further rolled to a smaller gage without cracking.
1.) 19,000 Pound double helical pinion shaft carburized to an effective case depth of 0.250" being quenched into 20,000 gallons of agitated, warm oil. Pinion was heat treated vertically one of two Metlab 54" diameter by 180" deep pit furnaces. It was control heated to 1750°F, held at temperature for almost 200 hours, then slow cooled, reheated to the hardening temperature, quenched, tempered, deep frozen and retempered.
2.) Large steel mill gear, carburized to 0.250" ECD, being moved into the quench tank. Gear measures approximately 10' in diameter by 3' tall, and weighs 30,000 pounds.
Large gear for an industrial applicationnitrided to a 0.040" case depth. Gear measures 12' in diameter by 12' tall and weighs approximately 24,000 pounds. Gear hub, bore and web faces have been masked to prevent nitriding to allow for post heat treatment machining.
Compounds of the element boron will vaporize and react with steel and other alloys to convert a diffused layer at the surface of parts to an extremely hard compound, which has superior wear resistance. Parts are borided by heating them in a furnace in an atmosphere containing these boron compounds. The parts, heated to temperatures in the 1800°F range for several hours, can be used directly after the boriding treatment in applications requiring extreme wear resistance. Examples would include spray nozzles, rock drilling tools and cement processing equipment. The thickness of boride layer obtained is determined by the temperature, and time at temperature, as well as material composition. Generally low to medium carbon and stainless ...
When tools and other heat treated metals are cooled to very cold temperatures, -120°F or below, unstable phases are transformed, making the part very stable at normal use temperatures. This treatment is performed by slowly cooling the parts in a controlled bath of liquid nitrogen or other refrigerant, and held until the temperature of the part has reached the target temperature, then returning the part to room temperature. The resulting part will have low distortion tendency, and often is significantly stronger and tougher.
Special vessel fabricated from Monel, a high nickel-copper alloy selected for its corrosion, stress relieved by Metlab. Stress relieving was done under a hydrogen-nitrogen atmosphere.
Oxides, paint or other solid contaminants can be removed by impinging all or selected areas of a part with an abrasive material. The abrasive, which is a powder of aluminum oxide, steel shot, glass beads or other sand-like material, is sprayed at the part using pressurized air through a directed spray nozzle. This process is used to prepare parts for further machining, coating or painting, and is also used as a final step in the manufacturing process to improve the surface appearance of the parts. The surface texture varies from a matte gray to shiny, determined by the type of abrasive used and the spray conditions.
Metlab has a staff of degreed metallurgists, with a total of more than 50 years experience in material selection, heat treating, and property determination of ferrous and non ferrous materials. This experience is applied to helping customers with proper material and heat treat selection, to optimize the design/property relationships for a wide variety of customer products, as well as process and plant rationalization. Metlab also offers failure analysis.
Black Oxide processing provides an extremely cost effective form of protection and adds to the components resistance to corrosion. The process adds no dimension change to the component dimensions and improves the visual quality while offering lubricity. In addition, thin parts can withstand bending stretching and handling. Black oxide coats all surfaces of a component.
Typical applications are fasteners, machined components, stamped components, gun and ammunition, tools and dies, power tool components, automotive parts, exercise equipment (weights), electronic hardware and also architectural finishing.
Metlab | 1000 E. Mermaid Lane | Wyndmoor, PA 19039 | 800-319-7359 | 215-233-2600 | Fax:215-233-5653
