Vacuum Metallurgy - ALD Vacuum Technologies

Vacuum Systems and Technologies for
Metallurgy
Heat Treatment

SOLUTIONS ARE OUR BUSINESS
ALD Vacuum Technologies AG supplies systems
and processes for thermal and thermochemical
treatment of metallic materials in solid and liquid
form. The company`s competence consists on the
one hand of its mastery in vacuum process technology
and on the other hand of its know-how in
engineering custom-tailored system solutions.
WORLDWIDE TECHNOLOGY
AND MARKET LEADER IN:
Vacuum Metallurgy:
Engineering and supply of systems and processes for treating
metallic materials in liquid form – particularly vacuum systems for
the melting, casting and remelting of metals and alloys, as well as
special coating equipment for turbine blades.
Vacuum Heat Treatment and Sintering:
Processes and systems for heat treating metallic materials, brazing
and sintering.
ALD is noted for its superb know-how basis,
leadership in research and development and its
strategic alliances. Close collaborations with
“blue chip customers” have strengthened its
position as a supplier of key technologies to
major growth markets.

Vacuum Metallurgy
Vacuum metallurgy is presently entering a new phase wherein it is reevaluating the experience gained from
continuously developing established processes and joining together new process combinations. Advanced
vacuum processes such as, steel degassing and ladle metallurgy, melting and remelting, as well as precision
casting and metal-powder technology, have led to high-quality metallurgical products.
The use of these special metal-making processes in
modern, efficiently functioning production systems
greatly reduces costs. The recycling of revert from
the processing of costly materials contributes to the
economy´s cost-effectiveness. Examples of the products
that have been derived from these technologies include
highly alloyed special steels and superalloys, refractory
and reactive metals with ultrahigh purity and a fine
grain structure, precision castings with directional and
single-crystal structures, forgings in near net shape,
and high-purity powder for homogeneous, highstrength
parts.
16 ton VIDP
melting chamber in pouring position
The resulting materials of high strength and reliability
contribute to demanding applications in the aircraft
industries and power generation, while the high-purity
products contribute to new developments in electronics.
The proper selection of technology is the most
demanding task the plant builder has to solve in close
dialogue with the producer of the materials and the
consumer. This particular challenge is the keystone of
the business philosophy of ALD Vacuum
Technologies AG, Hanau/Germany.
EB/PVD coater for mass production
20 ton ESR furnace capable of melting
under protective atmosphere

Vacuum Heat Treatment and Sintering
Heat treatment is a sequence of heat
treatment steps in which a workpiece is
exposed completely to time-temperature
sequences in order to change its internal
structure so as to achieve the required
features.
Overpressure vacuum sintering furnace type
VKPgr 50/50/170, 1,600 °C, 60 bar, maximum
gross charge weight up to 1,700 kg.
Hardening and Tempering
The hardening process is a type of heat treatment
comprising austenitizing and quenching of the part.
The necessary requirements are selected in which
the austenitic structure is changed into martensitic
structure. The part undergoes tempering treatment
after hardening in order to obtain high ductility and
toughness.
Brazing
Brazing is a process for combining similar metals,
whereby a liquid phase is created between them by
melting additional material/brazing alloy. Hereby,
the solidus temperature of the base metal is not
reached. The lower pressure reduces the oxides on the
surface of the workpiece and thus creates the requirements
for wetting by the liquid alloy.
Case Hardening
Vacuum carburizing processes with or without
plasma are used in the gear industry as well as for
producing fuel/ diesel injection systems to withstand
highest mechanical stresses and to lower manufacturing
cost.
Multi-chamber vacuum furnace with 8 treatment
modules for carburizing automotive gear parts
After the highly efficient vacuum carburizing
step the parts are quenched with inert gases under
higher pressures. This dry quenching method saves
subsequent cleaning steps and reduces distortion
of the quenched parts which saves or reduces cost
intensive hard machining. Beside these advantages
this newly developed and already introduced technology
enables new manufacturing strategies and
is environmentally friendly.
Sintering
The sintering process takes place in vacuum or
under protective gas at the appropriate temperature
for the material. A defined, reproducible sintering
atmosphere without atmospheric oxygen is important.
At certain pressures and temperatures the process
gas feed during sintering with argon, N 2 , H 2 , CH 4 ,
CO 2 and others influences the structure and chemical
composition of the workpiece.
ModulTherm
Highest flexibility of process and
production volume are a result of the modular design
Following the vacuum sintering process, 6 to 10 MPa
argon gas may be introduced into the furnace at
sintering temperature to further reduce porosity and
to ensure the material quality of high-performance
hard metal tools and other sintered parts.

Delivery Programm
VACUUM METALLURGY
PRODUCTION SYSTEMS FOR
■ VACUUM INDUCTION MELTING AND CASTING (VIM/VIDP)
Vacuum Induction Melting Furnaces for Charge Weights from 1 kg up to 30 tons
■ ELECTROSLAG REMELTING (ESR)
■ VACUUM ARC REMELTING (VAR)
■ ELECTRON BEAM MELTING (EB)
■ VACUUM PRECISION CASTING
Vacuum Induction Melting and Casting with Ceramic Crucibles
Liquid Metal Cooling for DS/SX Solidification
Cold Crucible Induction Melting and Casting
Vacuum Arc Melting and Casting
■ VACUUM INERT GAS METAL POWDER TECHNOLOGY
Vacuum Induction Melting and Inert Gas Atomization
Ceramic-Free Metal Powder Production
Inert Gas Recycling
■ VACUUM ISOTHERMAL FORGING
Hot Isothermal Forging for “Near Net Shape” Technologies
■ INDUCTION HEATED QUARTZ TUBE FURNACES (IWQ)
For special applications
■ VACUUM TURBINE BLADE COATING
Electron Beam/Physical Vapor Deposition (EB/PVD) of Protective (MCrAlY) and
Thermal Barrier Coatings (TBC)
VACUUM HEAT TREATMENT
AND SINTERING
■ VACUUM HARDENING, TEMPERING
AND BRAZING
Vacuum Heat Treatment of Cold and Hot
Work Steels as well as High Speed Steels,
Single-Chamber Vacuum Heat Treatment
Systems in Horizontal and Vertical Design
for different load sizes and charge weights
from some kgs up to several tons, but also
multi chamber systems for treating low
alloyed materials.
■ VACUUM CASE HARDENING
Vacuum carburizing with or without
plasma and subsequent high pressure gas
quenching in batch and multi chamber
systems for production volumes of some
kgs per hour up to mass production. Full
product range from single chamber, double
chamber, inline multi to linked chamber
systems are available.
■ VACUUM SINTERING
Vacuum sintering systems for cemented
carbides and rare earth magnets, overpressure
sintering furnaces for sintering cemented
carbides at pressures up to 100 bar, all
in different sizes for loads up to more than
2 tons.

Customer Support by ALD – Worldwide
Engineering Facilities & Operator Companies
Sales Offices
Territories Covered by Representatives
ALD systems are built for operation around the
clock, seven days per week. As and when the need
for service arises, a global network is available to
send urgently needed spare parts or experienced
service technicians. ALD has daughter companies
in 6 countries worldwide and representations in
many others. Our marketing and service network
and spare part stocks at strategic locations enable
us to react at short notice. Additionally, our headquarters
in Germany operate a customer support
center with experts who assist whenever special
know-how is required.
ALD services include professional support in emergencies
as well as preventive maintenance for plant
equipment and the refurbishment of older systems to
boost plant availability to the highest possible level.
Our services at a glance:
■ Delivery of spare parts and consumables
■ Repair service
■ Maintenance and inspection
■ Equipment refurbishment
ALD Vacuum Technologies AG
Wilhelm-Rohn-Strasse 35
D-63450 Hanau
Phone +49 (0) 6181- 307-0
Fax +49 (0) 6181- 307-3290
e-mail: info@ald-vt.de
Internet: www.ald-vt.de
China
ALD China Liaison Office
C&K Development Co., Ltd.
Unit C, 17/F., Seabright Plaza,
9-23 Shell St., HK North Point
Phone +85 (21) 257 - 84888
Fax +85 (21) 257 - 87118
e-mail: cnkchina@online.sh.cn
Far East
ALD Thermo Technologies
Far East Co., Ltd.
Shinjuku Nomura Building, 6 F.
1-26-2 Nishi-Shinjuku, Shinjuku-Ku
Tokyo 163-0558 Japan
Phone +81 (3) 33 40 37 26
Fax +81 (3) 33 40 37 27
e-mail: ald-fe@cello.ocn.ne.jp
Great Britain
ALD Vacuum Technologies Ltd.
The Frensham Suite
13-21 High Street
Guildford, Surrey GU1 3DG
Phone +44 (1483) 45 44 34
Fax +44 (1483) 30 66 41
e-mail: ald.vactech@btclick.com
USA / Canada
ALD Vacuum Technologies, Inc.
18, Thompson Road
East Windsor CT 06088
Phone +1 (860) 386-72 27
Fax +1 (860) 386-72 20
e-mail: rschumann@ald-usa.com