 |
The IntensiQuench(SM) Process
for Heat Treating of Steel Parts |
| About
35 years ago, Dr. Nikolai Kobasko of the Ukraine discovered
the "intensive quenching" phenomenon for heat
treatment of steel parts. Intensive quenching is defined
as very rapid cooling, usually with pure water quenchant,
at a rate several times higher than the rate of "normal" or
conventional quenching, continuing through the martensite
phase. In contrast to common quenching practices, Dr.
Kobasko’s research shows that very fast and very uniform
cooling actually reduces the probability of part cracking and
distortion, while improving the surface hardness and durability
of steel parts. |
| Since
his discovery, Dr. Kobasko and his colleagues conducted
hundreds of laboratory and field validation experiments.
They developed computer models for intensive quenching
technology and applied the technology to many production
heat-treating plants in countries of the former Soviet
Union as well as China and Bulgaria. Dr. Kobasko and his
colleagues chronicle the proven benefits of intensive quenching
in over 150 technical papers. Since 1998, Akron Steel Treating
Company of Akron, OH, USA has conducted hundreds of experiments
with a variety of steel parts proving the effectiveness
of the intensive quenching technique, known as IntensiQuench(SM) process.
A detailed description of the IntensiQuench(SM) technology
is presented in technical papers. |
| With
IntensiQuench(SM) processes,
heat-treating will never be the same. |
| This
technology offers a proven design tool for implementing
the technology for a wide variety of steel and with varied
part geometry. Examples from technical papers are summarized
here: |
| Steel
part |
Type
of Steel |
Lifecycle
Improvement |
| Truck
half-axles |
4340
(oil quench); AISI 1045 (intensive quench) |
760% |
| Shaft |
81B40
(oil quench); AISI 1045 (intensive quench) |
800% |
| Concrete
Breaker Point |
4340
(oil quench); AISI 1078 (intensive quench)
|
From
1 hour (in oil) to no failure |
| Punches |
High
Speed Steel |
50-100% |
| Dies |
AISI
52100 |
50-100% |
| Intensive
quenching provides significant part lifecycle improvement
due to improved mechanical properties and the presence
of beneficial compressive stresses on the surface of the
parts. The lifetime of the intensively quenched parts
made of plain carbon steel proved to be 50% - 800% longer
than parts made of alloy steel and quenched in oil. |
| Proven Advantages of
Intensive Quenching include: |
| Commercial
heat treaters will benefit from the following IntensiQuench(SM)
process benefits: |
- Minimizes
part cracking and scrap
- Minimizes
part distortion (less grinding and post-machining operations-saving
thousands of manufacturing dollars)
- Uses
less costly, environmentally friendly quenchant (usually
plain water) instead of hazardous oil, resulting in
the significant reduction of the heat treatment costs
and related pollution
- Additional
cost savings from less environmental waste, waste steam
management, cleaner plant, cleaner parts, lower insurance,
better work environment, etc.
- Achieves
the greater productivity of the quenching equipment
since IntensiQuench(SM) processes
provide much faster cooling rate
- The pollution
free quench facilitates the integration of heat treating
into manufacturing cells
|
| In
addition to the benefits to commercial heat treaters, part
designers and captive heat treaters will benefit from the
following: |
- Increases
the depth of hardness
- Achieves
the same or better metallurgical properties while using
lower alloy steel resulting in significant cost savings
in material.
- Smaller,
lighter IntensiQuench(SM) parts
can do the work of heavier sectioned oil-quenched parts.
- Provides
an optimum combination of high compressive stress on
the surface and a high-strength, wear-resistant, fully
quenched layer of optimum depth, or a relatively soft,
but properly strengthened core-all resulting in
longer part life at a lower cost.
|
| Heat
treating equipment manufacturers will benefit by expanding
their business to manufacturing pollution free quenching
equipment for their customers and incorporating IntensiQuench(SM) computer
modeling into their designs. |
For more information
about Intensive Quenching, visit www.intensivequench.com
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