Automatic hardening machine 4D QUENCH

Overview
4D QUENCH is a vacuum heat-treatment system for individual quenching of components (gears, shafts, bearing races, rings, sleeves, etc.) made from carburizing or through-hardening steels. The system combines vacuum heating with high-pressure nitrogen quenching to limit oxidation and metallurgical alteration while providing precise distortion control, repeatable results and full part-level traceability. It is suitable for integration into in-line production and automated manufacturing cells.

Features

• Individual part hardening by vacuum heating and high-pressure nitrogen quench
• Integration with CNC cells and in-line production
• Capacity scalable up to ~1,000,000 pieces/year depending on configuration
• Adaptable working zone dimensions
• Customizable system configuration
• Compact footprint with low utility consumption
• 4D quenching using adjustable quench nozzles and rotating table
• High-pressure nitrogen as quench medium (oil- and helium-free)

Advantages

• Control and reduction of quench-induced distortion
• High precision and repeatability of heat-treatment results
• Elimination of intergranular oxidation/attack (IGO/IGA)
• No surface oxidation during heating due to vacuum environment
• Improved surface quality compared with conventional oil quench
• Designed for high-volume and continuous production
• Operational flexibility with on-demand start/stop
• Fully automated process with part-level monitoring and 100% traceability
• Removes need for oil, helium, copper masking or stop-off paints
• Reduces fixtures, material logistics and manual handling
• Eliminates oil vapor, washer chemicals and fire/radiation risks

Parts (typical applications)

• Mechanical transmission components: gears, rings, shafts, sleeves, bearing races

Technologies

• Bright hardening by high-pressure gas quench (4D quench)

Industries

• Automotive
• Transmission
• Bearing manufacturing
• General machinery
• Aerospace

Materials

• Carburizing grades and standard through-hardening steels traditionally quenched in oil
• Higher-alloy and special steels suitable for gas quenching

Technical specifications

• System composed of a vacuum heating chamber and a high-pressure nitrogen quench chamber with part transfer mechanisms
• Vacuum heating protects part surfaces from oxidation and unwanted metallurgical changes
• Proprietary arrangement of cooling nozzles provides uniform cooling from all sides (3D cooling)
• Rotating table adds the fourth dimension to enhance quench uniformity (4D quench)
• Adjustable nozzle pattern to match part size and geometry
• Nitrogen quench delivers cooling comparable to oil with improved uniformity and repeatability
• No need for oil or helium quench media
• Single-piece flow enables integration with CNC and in-line manufacturing
• Eliminates many heat-treatment fixtures and reduces material logistics and cycle time
• Reduces hard machining time and associated costs
• Full automation with part-level monitoring and 100% traceability
• Compact design with low utility consumption and footprint
• Customizable configuration and adaptable working zone
• Configured for high-volume production (up to ~1,000,000 pieces/year depending on setup)