Fixtures

Vacuum Carburizing Symposium 2014
Modern LPC Fixtures a complete review
Welcome to ALD Vacuum Technologies GmbH

Dedicated People for Demanding Jobs

Modern LPC-Fixtures a complete review
Gerhard Welzig, ALD Vacuum Technologies GmbH
LPC Fixture Materials:

- Cast Alloy Fixtures
- Carbon/Carbon Composite
Fixtures
- Ceramic Composite Fixtures

Cast Alloy Fixtures

Cast Alloys for LPC Fixtures

Code
Typical Analysis
Fe
Ni
Cr
Si
Nb
Mn
Al
X 40 Ni Cr Si Nb 38 18
(HR 32)
42
0,4
38
18
1,5
yes
Ni Cr 28 W
(HR 23)
22
0,4
48
28
1,5
Special LPC-Alloy
(Mancellium)
0,1
75
16
0,4
0,5
yes
Source: Cronite Klefisch GmbH



Advantages of special LPC Alloys:

-
Low carbon pick-up

Less sticking of parts to fixture
Lower permanent growth
Less embrittlement
Better Resistance to thermal cycling
Longer lifetime

Cast Alloys for LPC Fixtures

Code
Price Relation
Typical Lifetime
Cost per Cycle
X 40 Ni Cr Si Nb 38 18
(HR 32)
100%
400 cycles
100%
Ni Cr 28 W
(HR 23)
125%
700 cycles
72%
Special LPC-Alloy
(Mancellium)
145%
1000 cycles
58%

Alloy Fixture Design
Standard fixture with

heavy load
Long distance between

supports

Conventional Fixture
for Shafts
Custom made grids with
optimum partition
Massive intermediate
grid

supports
10

for Shafts
Custom made grids with

optimum partition
Standard posts and

spacers
Standard base grid
11

for Gears (hanging)
Standard design allows

mixed loads

supports
12

for Gears (hanging)
Variable horizontal and

vertical distance
Standard base grid
13

Modern Fixtures for

Shafts
Additional central
support
Easy positioning of parts

on center pins
14

Flexible Fixture for

Shafts
Variable horizontal and

vertical distance
Standard posts and

spacers
Standard base grid
15

Flexible Fixture for

Shafts
Same parts usable for

different kinds of shafts
16

Modern Fixture for

Sliding Shaft (DCT)
Additional supports
Integral posts and

spacers
Minimized wall thickness
17

Modern Fixture for

Gears (11 layers)
Multiple additional
supports
Integral posts and

spacers
Minimized wall thickness
18

Modern Fixture for

Final Drive Gears
Open structure allows

automated loading
19

Minimum Distances in
densly packed LPC
Loads
Minimum horizontal
distance: 7mm (all
tolerances used)
Minimum vertical
distance: 40mm
including grid of 1215mm
Rounded and rough
surface prevents
masking effects
20

Alloy Fixture Problems

Carbon and Carbide
deposits on surface
Distortion
Cracks due to
embrittlement
21
Source: Graphite Materials GmbH

Carbon/Carbon
Composite Fixtures
22

Carbon/Carbon Structure
Woven Graphite Fibers
Multiple
Soaking
and
1000C
+
final
2000C
Heat
Treatment
Resins
Source: Schunk Group
23

Carbon/Carbon Main Material

Parameters
Low Density
High mechanical Strength

No Creeping
24
Low Thermal expansion
Typically 80% lower fixture weight

Slim design allows more Layers
Dimensional stability over complete lifetime
Energy savings


Parameters
Alloy fixture
dimensions: 26 x 21
gross weight: 66 lbs
distortion after 9 month in service
Carbon/Carbon fixture
dimensions: 26 x 21
gross weight: 4.4 lbs
In service since 10 years without distortion
In some applications Carbon/Carbon fixtures have proven

very long lifetimes
25


Parameters
26
Oxidation at temperatures above 350C (660F) in air

Eutectic contact reaction with steel at temperatures above
1050C (1920F)
Risk of breaking in rough handling
Porosity

Carbon/Carbon: Newer Material

Developments
Unidirectional Carbon/Carbon
Composites
(SGL Performance)
- Higher stiffness
- Lower porosity
- Larger plate dimensions available
27
Aircraft and Automotive Applications

might Drive future Materials
Development and Production Costs
Schunk UniGrid
- Fibers directly layed in grid shape
- Fibers are not cut
- 100% material usage

Carbon/Carbon Fixture Costs
Direct Cost Comparison is difficult and has to be checked

for each application
Experience from some projects show 2.5 3 times higher
prices compared to alloy.
Alloy prices change with Nickel world market price.
Nickel price variation of

last 5 years:
15,000 30,000 $/t
Source: finanzen.net
28

Carbon/Carbon Fixture Design
Water Jet Cutting

- For light and medium weights
- Flexible design
- High waste of material
Interlocking Design (Fingerjoint)

- For high loads
- Tight tolerances for press fits needed
- Optimum material usage
29

10 Layer Load of
Syncro Rings
C/C spacers,
Si hardened
C/C Plates, water jet cut
C/C Centering pins
C/C Base Frame
Fixture Design from

1998. Same Fixtures
still in use 2014.
Automated loading of
parts.
30

C/C Plates, water jet

cut, in Combination
with Alloy Base Grid
Alloy spacers
C/C Plates, water jet cut
Alloy Base Grid
31

C/C interlocking Grids
32

Grid for shafts

Different parts on standard grid
33


One-Piece-Flow Applications in Heat Treatment will Require automated Loading
and Unloading of Fixtures and Fixture Transport.
C/C will be increasingly used because of dimensional stability over complete
lifetime.
2 layer OPF load for

automated parts handling
34

Carbon/Carbon Fixture Problems
Masking: Smooth
surface hinders
transport of Acetylene
to part surface
Countermeasure:
elevated position of part
by pins or profiling of C/C
surface
Broken edges by
rough handling
Countermeasure:
no transport by pushers,
use telescope systems
or chain conveyors
35

Ceramic Composite
Fixtures
36

Ceramic Composite Main Material

Parameters
WHIPOX :
Wound
Highly
Porous
Oxide Composite
37
New Material from Aerospace Application

Pure Oxide Ceramic, resistant to Corrosion and
Oxidation
Mechanical Parameters similar to Carbon/Carbon
Resistant to thermal Shoc
No Contact Reaction with Steel

Drying and
Sintering
Ceramic Composite Manufacturing
Winding on Core
Drying and
Sintering
Wound Product
Taking from Core

38
Forming
Formed Product

Ceramic Composite Fixture Design
Example of Fixture
Design Elements
Bars
Wire Mesh
Posts
39

First Vacuum
Carburizing
Application for Ring
Gears
Part Carrier from Tube
Grid from Bars
40

First Vacuum
Carburizing
Application for Ring
Gears
Ceramic Composite
Fixture after 20
Carburizing Cycles
41

Thank you
Credits:
42

Fixtures

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Fixtures

Caricato da

Copyright:

Formati disponibili

Vacuum Carburizing Symposium 2014

Modern LPC Fixtures a complete review

Welcome to ALD Vacuum Technologies GmbH

Vacuum Carburizing Symposium 2014

LPC Fixture Materials:

Vacuum Carburizing Symposium 2014

Cast Alloy Fixtures

Vacuum Carburizing Symposium 2014

Cast Alloys for LPC Fixtures

Source: Cronite Klefisch GmbH

Vacuum Carburizing Symposium 2014

Source: Cronite Klefisch GmbH

Vacuum Carburizing Symposium 2014

Source: Cronite Klefisch GmbH

Vacuum Carburizing Symposium 2014

Advantages of special LPC Alloys:

Low carbon pick-up

Vacuum Carburizing Symposium 2014

Cast Alloys for LPC Fixtures

Cost per Cycle

Vacuum Carburizing Symposium 2014

Alloy Fixture Design

Standard fixture with

Long distance between

Vacuum Carburizing Symposium 2014

Alloy Fixture Design

Long distance between

Vacuum Carburizing Symposium 2014

Alloy Fixture Design

Custom made grids with

Standard posts and

Vacuum Carburizing Symposium 2014

Alloy Fixture Design

Standard design allows

Long distance between

Vacuum Carburizing Symposium 2014

Alloy Fixture Design

Variable horizontal and

Standard base grid

Vacuum Carburizing Symposium 2014

Alloy Fixture Design

Modern Fixtures for

Source: Cronite Klefisch GmbH

Easy positioning of parts

Source: Cronite Klefisch GmbH

Vacuum Carburizing Symposium 2014

Alloy Fixture Design

Flexible Fixture for

Variable horizontal and

Standard posts and

Standard base grid

Vacuum Carburizing Symposium 2014

Alloy Fixture Design

Flexible Fixture for

Same parts usable for

Vacuum Carburizing Symposium 2014

Alloy Fixture Design

Modern Fixture for

Integral posts and

Minimized wall thickness

Vacuum Carburizing Symposium 2014

Alloy Fixture Design

Modern Fixture for

Integral posts and