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CONTROL & MEASUREMENT


Flexible Smart Mode Pyrometer for Improved Control in


Metal Hardening Processes Substantial product enhancements of Impac IGAR 6 by Advanced Energy provide expanded value for industrial hardening applications


The efficient control of all thermal processes provided by accurate temperature monitoring systems can increase the product quality and durability of finished products significantly. In addition, streamlined and controlled heat treatment processes contribute to both energy and cost savings.


The heating process and energy requirements can be optimized through the use of non-contact temperature measurement and suitable process controllers. Pyrometers assure accurate and precise temperature measurements at a single fixed point and provide the repeatability that is critical in hardening processes. In addition,


pyrometers are capable of the very fast measurement speeds required for the rapid thermal changes of the induction process.


TEMPERING and HARDENING Processes Challenges In order to reach optimal material stability and quality, metal work pieces undergo important thermal processes called tempering and hardening. During these processes, metals are heated for a defined time period, in which they follow a multi-step temperature profile. The quality and durability of the finished parts are significantly influenced by the temperature accuracy, stability and exact timing before the part is quenched.


In the first process stage called tempering, the metal is slowly heated up to a temperature range of 200 °C - 450 °C, depending on the desired properties. This is the stage of the process where the most precise temperature measurement is required, as only a few degrees of deviation can result in undesirable material properties.The challenge for infrared pyrometers in this process is that the metal surfaces tarnish and discolor when heated.


Usually 2-channel pyrometers act very sensitively to this “play of colors” during heating, which can result in measurement errors caused by the change in emissivity of the material surface, which influences both individual channels, and does not occur evenly. As a solution, a permanent correction of the different emissivity changes in both channels would need to be implemented here, but this is technically impossible. Alternatively, in this case measuring with a single-channel pyrometer (e.g. with Indium-Gallium Arsenide detector), which is normally less sensitive to surface discoloration, would help to ascertain stable measurement values.


In the next following process, the metal is now heated up to 850 °C - 950 °C for hardening.


BACKGROUND FACTS:


The emissivity of metals may change over time due to wear, oxidation and dirt. For example, the metal surface will change when it is heated, causing the formation of so-called tarnishing colors, and later rust or scale. All these factors have a vital influence on the emissivity and may cause substantial measuring errors which result in process issues and quality failure.


MARCH/APRIL 2021


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