Abstract: Apparatuses and processes for evaluating degradation and potential failure of components in an industrial heat treatment system include means and steps for establishing process settings for a baseline process cycle, collecting sensor data for at least one non-process control performance parameter during the baseline process cycle to establish a set of benchmark performance data, performing a calibration process cycle using the established process settings and collecting sensor data for the at least one non-process control performance parameter to establish a set of calibration performance data, and comparing the calibration performance data to the benchmark performance data.

Abstract: A method and apparatus for measuring quench characteristics of a fluid. The apparatus includes a probe with an energy input device electrically connected to a display unit to monitor temperature, media flow characteristics and media heat transfer characteristics. The method includes continuously measuring thermal energy transfer in a quenching media by measuring the surrounding fluid's heat transfer relative to input probe energy.

Abstract: A method and apparatus for measuring quench characteristics of a fluid. The apparatus includes a probe with an energy input device electrically connected to a display unit to monitor temperature, media flow characteristics and media heat transfer characteristics. The method includes continuously measuring thermal energy transfer in a quenching media by measuring the surrounding fluid's heat transfer relative to input probe energy.

Abstract: An apparatus (10) for the production of brazed aluminum products on a continuous flow basis includes, in sequence, a flux application zone (12), a tunnel furnace (14), a cooling zone (15,16) and a transportation element (25) for conveying (26) component parts or products though the apparatus, the transportation element including a closed loop conveyor having both conveying (26) and return (27) runs within the tunnel furnace.

Abstract: An apparatus (10) for the production of brazed aluminium products on a continuous flow basis includes, in sequence, a flux application zone (12), a tunnel furnace (14), a cooling zone (15,16) and a transportation element (25) for conveying (26) component parts or products though the apparatus, the transportation element including a closed loop conveyor having both conveying (26) and return (27) runs within the tunnel furnace.

Abstract: According to one embodiment of the invention, a gas generator system includes a combustion chamber having an insulation coupled to an inside surface thereof, a retort having a catalyst therein disposed within the combustion chamber, and an access door coupled to a side of the combustion chamber. The access door allows removal of the retort from the side of the combustion chamber. According to another embodiment of the invention, a gas generator system includes a combustion chamber having an insulation coupled to an inside surface thereof, a retort having a catalyst therein disposed within the combustion chamber, and a recuperator disposed proximate an open bottom of the combustion chamber. The recuperator prevents secondary combustion air from traveling in a direct path into the combustion chamber from outside the open bottom of the combustion chamber and raises the temperature of the secondary combustion air.

Abstract: Disclosed is a part-handling apparatus for a heat-treating furnace system and its use in transferring parts such as bearing races into, through, and out of a quench tank while avoiding any part-to-part contact and thus preventing nicking of parts. The apparatus includes a charge elevator formed of closely-spaced rails divided into lanes and which lowers parts into a quench fluid. A walking beam system for moving parts along the tank has movable rails which mesh with stationary rails and with the rails of the charge and discharge elevators when the elevators are located in their lowermost positions and includes a frame which is movable vertically and longitudinally. A push-off device near the tank discharge end pushes parts from the discharge elevator either directly onto an in-line conveyor of a washer or tempering furnace or onto a rotatable arm which alters the travel path of the parts a selected angle such as 90 degrees before delivering the parts to the conveyor of the washer to temper furnace.

Abstract: An improved gas generator in which the composition of gas generated in a heated reactor is maintained when the flow rate from the reactor is adjusted. To accomplish this, the generator includes two diverting means responsive to the flow rate. The first diverts a portion of the reactant mixture before it enters the reactor, the diverted amount being insufficient to change the composition of the generated gas. The second diverts a portion of the generated gas to a burner for heating the reactor.

Abstract: A continuous carburizing furnace system is disclosed having at least two series-connected rotary furnaces. The rotary carburizing furnace, a rotary equalizing furnace, and a rotary diffusion furnace which may be included between the carburizing and equalizing furnaces, allow trays of parts to be discharged from any position at any time by suitable rotation of their hearths, thus allowing parts with different cycle times to be run simultaneously in each rotary furnace. Each donut-shaped rotary furnace includes one or more captive chain type pusher mechanisms mounted in vertical fashion within a central area or hole, and the rotary carburizing furnace is multi-zoned and includes wall-mounted fans for uniform circumferential control of the gaseous atmosphere within its annular chambers.

Abstract: Disclosed is a method of controlling the atmosphere of a heat-treating furnace whose atmosphere consists essentially of a carrier gas of CO, H.sub.2 and N.sub.2 produced from a mixture of methanol and nitrogen. In accordance with the present invention, the ratio of flow of methanol to flow of nitrogen is varied to maintain the CO content of the furnace atmosphere at a predetermined value. This renders more effective the control by conventional means of the flow of additive gases to maintain the carbon potential of the furnace atmosphere at a predetermined value. The flows of methanol and nitrogen may be controlled based on monitored CO content only, or their control may be interrelated to monitored carbon potential as well.

Abstract: Disclosed are a method and apparatus for clean, low loss melting of aluminum using heat transfer by convection and radiation in separate stages. Heat input to a melter stage is provided by silicon carbide tubes into which gas-fueled burners fire so that the tubes radiate heat to a molten aluminum bath. Combustion products exiting the silicon carbide tubes pass through recuperators, preheating burner combustion air. The combustion products then are piped to a preheater stage and formed into jets of hot gases. The jets are directed into convective contact with solid aluminum stock as the stock is transported along a conveyor, preheating the stock to a temperature of about 1,000.degree. F. The solid stock then is fed to the charge zone of the melter stage and melted by contact with the molten bath.

Abstract: Heat-treating apparatus which includes an insulated furnace compartment through which stock to be heat-treated is passed. Perforated tubes are arranged in the furnace and they are heated to radiance by burners which also generate products of combustion which are ejected through the perforations at high velocity to impinge upon a surface or surfaces of the stock being heat-treated. The combination of radiation and convection enhanced by the impingement of the jets upon a surface of the stock provides highly efficient primary heat transfer. The burners are designed to insure that rapid combustion takes place at a point removed from the perforations to avoid flame issuing from the perforations. The tubes are sized and spaced to enhance secondary heat transfer from gases in the furnace compartment and from the walls of the compartment to the stock.

Abstract: A high temperature furnace chamber includes a roller hearth for supporting and transporting workpieces to be heated. The rollers are supported at each end by a rotary sleeve having an inner diameter larger than the outer diameter of the rollers. Rotary movement of the sleeves transmits rotational forces to the rollers. Clearance provided between the rollers and the sleeves allows for roller dimensional variation during various furnace operating conditions.

Abstract: A ceramic tube recuperator for recovering energy from hot flue gases, in which a multiplicity of heat exchange elements connected to a cold air inlet manifold and a hot air outlet chamber extend upwardly into a flow passage for hot flue gases. Each heat exchanger comprises an inner open ended tube extending into the cold air inlet manifold, and an outer ceramic tube having a closed upper end and an open lower end communicating with the hot air chamber. An essential feature of the invention is that the lower end of the ceramic tube is sealed solely as a result of resting on an annular seal, so that the ceramic tube may be removed and replaced simply by lifting and lowering through an access opening in the flue passage.

Abstract: A system is described for precise monitoring and control of the carbon content of the atmosphere of a furnace such as a carburizer used in the heat-processing of steel parts. The disclosed apparatus includes a sampling system for withdrawing a gas sample from the atmosphere within a furnace and an analyzer for producing signals indicative of the partial pressures of at least two gaseous components such as carbon dioxide and carbon monoxide. The analyzer preferably utilizes selective absorption of narrow-band infrared radiation signals in determining these signals. A processor combines the signals indicative of partial pressures with parameters obtained from measurements of furnace temperature, and calculates carbon potential of the furnace atmosphere. The processor output is coupled with an atmosphere control which maintains desired levels of carbon potential in the atmosphere of the furnace by, for example, regulating the flow of an enriching gas to the furnace.

Abstract: A method and apparatus are disclosed for heat-treating parts in a furnace system which uses a minimum total amount of energy. The self-contained, continuous heat-treating system includes components such as a carburizer, a tempering furnace, and a part cooler. Energy transfer between these and other components operable at different temperatures and/or energy requirements are used to maximize thermal efficiency of the system.

Abstract: The invention relates to controlled atmosphere heat treating furnaces and particularly to furnaces for bright annealing of copper or its alloys. A new concept is proposed for conserving energy uses by first having a separate atmosphere producing system that fires constantly, independent of the temperature control and secondly having a cooling system that only extracts the excess heat produced by the combustion for atmosphere. In this way the furnace may be maintained at the desired operating temperatures regardless of variation of the work load, yet all of the heat generated by the atmosphere producing device is released within the furnace thereby eliminating unnecessary heat losses.

Abstract: A crucible furnace for high-temperature melting of metals or other materials which includes a capped vessel for serving as a crucible to hold a charge of material to be melted, a solid baffle surrounding and closely spaced from the vessel to form a restricted passageway and a refractory wall surrounding and widely spaced from the baffle to form a combustion chamber. Fuel is supplied at the base of the combustion chamber and mixed with air preheated by a compact internal recuperator operative from exhaust gases exiting the restricted passageway. The fuel is burned in the combustion chamber, heating the baffle which in turn radiates heat to the vessel containing the charge. Several of the elements forming the combustion and heat transfer system also serve as structural elements providing rigid support to internal components when the furnace is upright and when it is tilted to pour off melt.

Abstract: A furnace for receiving continuously advancing stock in linear array is assembled from a number of independent furnace units. In each unit, a furnace chamber surrounds the advancing stock with a radiative wall. Each chamber is fired by gas burners which surround the stock at the chamber exit. The burners include a series of gas jets which feed the fuel, with or without air, radially into the chamber toward the stock and a series of air jets which are paired with the gas jets to feed combustion air axially into the chamber.

Abstract: The invention relates to a recuperator having an improved core within the primary heat transfer surface. This core, by its unique construction, achieves a combination of reradiative and convective heat transfer which outperforms either of these separate modes while maintaining a low pressure loss. The core consists of a series of radial plates between which are a series of triangular baffles arranged at an angle with the horizontal of 45.degree. to 70.degree.. The baffles intercept the flow of flue gas and gently channel the flow of gas into a swirling pattern, thereby enhancing convective heat transfer while maintaining low pressure loss. The staggered triangular baffles also tend to reflect radiation that would otherwise be lost back to the primary heat transfer surface.