Project Overview: End-to-End Heat Treatment Furnace Commissioning

KONFU Enterprise is proud to share a case study detailing our recent successful commissioning of a complete heat treatment furnace for a valued client. This project showcases our comprehensive support, from initial logistics to final operational handover, even amidst the challenges of a global pandemic.

Comprehensive Furnace System Components

The complete heat treatment line was meticulously packed and shipped in four 40-foot containers and one 20-foot container. The system is composed of several critical components designed for a seamless fastener treatment process:

• Endothermic Gas Generator: Provides the controlled atmosphere necessary for high-quality heat treatment.
• Feeding Machine: Automates the loading of fasteners into the production line.
• Front Washing Machine: Pre-cleans parts to remove oils and contaminants before treatment.
• Hardening Furnace: Heats the fasteners to the required austenitizing temperature.
• Oil-Quenching Apparatus: Rapidly cools the parts to achieve the desired hardness.
• Rear Washing Machine: Cleans the parts after quenching.
• Tempering Furnace: Reheats the fasteners to a lower temperature to adjust final hardness and toughness.

Dedicated On-Site Technical Support

At KONFU, our commitment extends beyond machine delivery. We provide robust after-sales technical support. Understanding the urgency, we promptly arranged for our President, James, and our senior technician, Lin, to travel to the client's facility. Despite strict travel and quarantine regulations, our team navigated the complexities to ensure on-site presence for this critical phase. Working collaboratively with the client's technicians, our experts meticulously installed all components in sequence and conducted rigorous testing to confirm normal and efficient operation.

The Fastener Heat Treatment Process Explained

The automated process, facilitated by a mesh belt conveyor, ensures consistent and high-quality results for screws:

1. Initial Washing: Screws are fed into the system and first pass through a hot water wash to remove cutting oils and contaminants, protecting the mesh belt and ensuring a clean surface for treatment. Detergent may be used for exceptionally greasy parts.
2. Hardening (Quenching): The screws are heated to approximately 900°C in the hardening furnace. They are then rapidly cooled by immersion in an oil tank, a process which significantly increases their hardness.
3. Secondary Washing: A second wash is performed to remove quenching oil.
4. Tempering: The final step involves reheating the screws in the tempering furnace to around 550°C. This process reduces brittleness and allows for precise adjustment of the final hardness and mechanical properties to meet specific application requirements.

Successful Inauguration and Partnership

The entire installation and commissioning deployment was completed over approximately two weeks. The project concluded with an inauguration ceremony hosted by the client, celebrating the successful launch of their new production line. The ribbon-cutting by our President James and the client symbolized not just a new start for their operations, but the strengthening of a successful partnership built on trust and technical excellence.

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