Innovative equipment to convection cool powder metallurgy parts in a controlled, recirculated atmosphere

Posted by Tom McDevitt on Mar 23, 2016 8:00:00 AM

After many months of planning and production in the shop, Rose Corporation recently shipped a convecool that is a specialty of our industrial furnace division.

The Rose Corporation’s industrial furnace engineers worked with the customer to understand the performance criteria for the new ConvecoolTM , and working with Rose’s project management team developed a design and manufacturing plan to deliver the high quality solution this customer expects from our Drever Convecool.

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According to Project Manager, Bob Skorupsky, “It was a challenging piece of equipment to fabricate because it was an odd & complicated design to layout and build, especially the internal air duct zones.”  The piece was primed and finished with Flame Control Coatings Temperkote 600 degree paint.  

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Bob was happy to report that we beat our estimated hours and our skilled work force did a fine quality job all throughout production.  This is great for our customer and for our company so thank you to all involved in the project!

This new Drever Convecool was very similar to our customer’s three existing Convecools; however the design included customer preferences for items such as a specific brand variable frequency drive, control panels and operator pedestal layouts, and other changes designed to standardize the newest Convecool with the existing design of the customer’s other Drever Convecools.  The only notable difference is the elimination of Drever’s old, water-cooled fan using instead our new nitrogen purge fan; therefore eliminating the costly Syntron sealing method associated with the water-cooled fans.

According to Tom McDevitt, GM of the industrial furnace division, this piece of equipment was designed for our customer is used to cool powder metallurgy (P/M) parts in a controlled, recirculated atmosphere.   The parts are conveyed through the equipment in carriers.  The carriers are moved through the equipment using an indexed, pusher system.

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The parts are rapidly cooled in the unit by impinging them with recirculated, cooled atmosphere.  The atmosphere is directed onto the parts by high-velocity nozzles.  The atmosphere, heated by the parts, is re-cooled using a water-to-gas heat exchanger.  Using manually-adjustable dampers, the unit is divided into two zones of control, so that the cooling profile may be adjusted.

This Convecool was manufactured to Drever’s gas-tight weld specifications as the Convecool is designed to operate with a furnace atmosphere of 97% nitrogen and 3% hydrogen.  Our customer is not planning to use the atmosphere capabilities of the Convecool; however wanted to have the capacity should production demands make it necessary at some future date.  Over the approximate 26’ feet effective cooling length of this Convecool, powdered metals parts will cool from 1700 degrees F to 110 degrees F, and at an extremely controlled rate of temperature reduction as the parts move through the Convecool. 

The Convecool has a maximum 1500 lb/hr part loading capacity, but will typically run at an hourly part loading rate of 1050 lb/hr.  The maximum cooling rate capacity of this new Convecool is 270 degrees F/min, with a minimum cooling rate of 60 degrees F/min.  Such versatility in cooling rates and capacity is what makes our Drever Convecools so desirable.

Just as we supported this customer with a custom designed application for their convection cooling needs, The Rose Corporation provides the same, customized engineered support for all types of industrial furnace needs including Bright Annealing, Powdered Reduction, Sintering, Strand Annealing, Atmosphere Generation, and more.  And we design and manufacturer all types and configurations of industrial furnaces such as Box, Tip-Up, Roller Hearth, Car-Bottom, Vacuum Furnaces, Electric Arc Furnaces, etc.

The Rose Corporation’s Industrial Furnace division manufactures for customers world-wide all types and configurations of industrial furnaces such as batch type reheat and forging, tip-up, roller hearth, bell, car-bottom, vacuum, electric arc, and many more for both atmosphere and non-atmosphere, batch and continuous applications.  The Rose Corporation has manufactured industrial furnaces under both our RoseTM  and DreverTM  furnace brands, as well as manufacturing customized furnaces to our customer-supplied design.  We also manufacture dissociative, atmosphere generating equipment. 

In additional to the manufacture of new furnace equipment, The Rose Corporation reconditions and modernizes customer’s existing equipment to maximize production capacity and reduce operating costs.  We offer a full line of furnace spare parts such as rolls, bearings, hi-temperature gaskets, mop curtains, glo-plugs, control systems, muffles, retorts, hearth tiles, refractory, electrode holder assemblies and sub-parts, water-cooled electric cables, roof cooling cables, alloy belts, burner radiation tubes, and much, much more.

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