Induction Hardening / Heat Treat & Quench

Contaminants are generated in the induction heating and quench cooling operations. These contaminants must be removed from the process consistent operations. Read how ZGF Maggie and Tornado technologies are the best choice!

Heat treatment has been defined as the controlled heating and cooling of a metal for the purpose of obtaining very specific metallurgical properties to meet the work requirements of a part, component, tube, etc. Many components are heat treated to meet customer requirements for specific metallurgical properties. By design, the quench fluid should only impact the cooling aspect of the heat treat operation. However, the cleanliness of quench fluid impacts both the heating and the cooling aspects of the operation.

Fluid Cleanliness is Critical

Fluid cleanliness is critical in these operations; but is often overlooked leading to a variety issues and challenges. Scale formed during the process that remains in the quench solution or re-deposits on the coil or on the part can cause several problems if not removed, including:

  • inconsistent surface hardness → off specification parts and higher scrap rates
  • hot spots on coil / arcing → reduced coil life and inconsistent metallurgical properties
  • plugged quench ring nozzles → low flow results in insufficient cooling and poor metallurgical properties and part distortion
  • inaccurate measurement of quench fluid concentration / improper cooling rate → poor metallurgical properties and part distortion
  • reduced machine and machine component life → higher maintenance and total operating costs
  • reduced quench fluid life → increased quench expenditures, disposal costs, and labor
  • reduced machine up time → loss of productivity and higher total operating costs

Poor, ineffective filtration:

  • increases operating costs,
  • negatively impacts quality, and
  • reduces productivity and profitability.

ZGF technology removes contaminants effectively and efficiently

Historically, the industry has relied on bag filtration and/or centrifugal separators. Bag filtration is inconsistent, and easily and often circumvented at the operator level. Centrifugal separators are not effective at removing particles smaller than 50 - 75 microns but can be part of an overall solution. The primary issue in induction operations of ferrous components is not the induction equipment or the quench fluid; it is the inability to remove scale from the process. ZGF Maggie technology effectively and efficiently captures and removes the ferrous contaminants from the process.

For high flows and heavy loading applications, centrifugal separators can be part of an overall solution. Centrifugal separators are effective at removing the medium to large sized particles (50 - 75 microns, and larger). The ZGF Tornado separator is the future of centrifugal separation technology. The innovative separator utilizes an internal blade design. The blades create a unique and beneficial flow path through the separator that increases the “G – Force”, resulting in more effective and efficient particle removal.

The Tornado is a simple but extremely innovative device. The Tornado has no moving parts and no media. Tornado effectively removes particles without any regular maintenance.

If you want to learn more about ZGF Tornado technology, then download the Tornado Product Data Sheet  or click on the Tornado animation link. The animation shows how the patented blade design results in increased particle velocity and higher applied “G-forces”.  As the fluid spins through the length of the separator, the particles are forced to the outer wall to the low velocity solids collection zone at the bottom of the separator.  The clean fluid is directed back up and into “clean zone slots” and out the top of the separator.

Maggie technology is an ideal solution for maintaining the cleanliness of quench/cooling fluids in ferrous metal induction operations. ZGF Maggie technology effectively and efficiently captures and removes the ferrous contaminants from the process. ZGF technology is the best available technology for filtering quench fluids in induction heat treat operations.

To learn more on where ZGF Maggie technology can provide value in your quench operations, click to download Process Diagram, Induction Hardening / Heat Treat (Quench).

ZGF Maggie technology can provide significant value in induction operations. Maggie is:

  • fully automatic
  • consistent & reliable
  • non-disposable
  • energy efficient - utilizing a minimal amount of electricity and air during purge
  • able to remove ferrous particles down to 1 micron
  • able to effectively and efficiently remove scale from quench fluids which:
    • extends induction coil and quench fluid life,
    • minimizes maintenance and labor,
    • reduces machine component wear,
    • minimizes the environmental footprint of the process
    • maintains a consistent and reliable process resulting in improved quality, higher productivity and lower total operating costs

ZGF technology can be installed in-line or as a side-stream filter

ZGF Maggie technology can be installed in-line or as a side-stream filter. To learn more about ZGF Maggie technology, download the Maggie Product Data Sheet or view the Maggie in action by watching the Maggie video.

To learn more on where ZGF Maggie technology can provide value in your quench operations, click to download Process Diagram, Induction Hardening / Heat Treat (Quench)

ZGF technology provides value

ZGF technology can provide significant value in your induction hardening / quench operations. Click on Success Stories to jump to the Success Stories / Case Studies page to learn how ZGF technology provides value. 

Click on the link below to learn how implementation of ZGF technology was able to reduce operating costs, improve process reliability and quality, and reduce the environmental footprint of a heat treat / quench operation.

Simplicity, consistency, reliability and the lowest cost of ownership make ZGF technology the best solution and value for removing scale and fines from quench fluid!

ZGF is your preferred partner.

 Filtration should not be a burden.

 Filtration should be a tool that improves quality and reduces cost.

Let us help you meet your objectives and make your job easier!

 

 Please contact us today for a free consultation or request a quote.

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