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Integrated Salt Bath Heat Treatment System for Large Steel Samples

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Integrated Salt Bath Heat Treatment System for Large Steel Samples

Integrated Salt Bath Heat Treatment System for Large Steel Samples

Client Objective

A leading materials engineering client required a comprehensive and automated heat treatment system tailored to process large steel components under precise thermal conditions. The system needed to include salt bath capability alongside muffle furnaces and a robust handling mechanism for controlled metallurgical transformations, with strict control over uniformity, surface quality, and hardness profiles. 

Our Solution: A First-of-its-Kind Pressure Cycling System 

Ants Innovations delivered a fully integrated customized heat treatment setup combining a front-loading muffle furnace, top-loading muffle furnace, a 150-liter salt bath furnace, and a semi-automatic lifting and handling system, all unified under a centralized digital control panel. This modular yet synchronized arrangement allows for seamless transition of heavy components between different thermal environments. 

System Architecture & Features

Top-Loading Muffle Furnace

  • Heating Zone: 400 × 300 × 450 mm 
  • Max Temp: 1100°C (continuous operation for 12 hours) 
  • Construction: Ceramic pin supports on all sides and base; Super Kanthal heating elements 
  • Controls: PID with thyristor regulation; K-type thermocouples 
  • Safety: Emergency stop, over-temperature protection, hinged insulated lid 
  • External Body Temp: ≤ 50°C for operator safety 

Salt Bath Furnace

  • Capacity: ~150 liters | 550 × 450 × 750 mm (internal chamber) 
  • Max Temp: 600°C 
  • Medium: Molten salt for uniform thermal transfer 
  • Lining: Replaceable SS310 stainless steel for corrosion and high-temperature resistance 
  • Mobility: Mounted on caster wheels with locking for repositioning 
  • Monitoring: Integrated thermocouple and PID-based temperature controller 

Lifting Mechanism

  • Drive: Bidirectional stepper-gear motor 
  • Transfer Time: <10 seconds between furnaces 
  • Capacity: 20 kg samples 
  • Safety: Motorized clamps, monorail trolley with electric hoist and chain pulley block for secure handling 

Front-Loading Muffle Furnace

  • Heating Zone: 200 × 200 × 300 mm 
  • Max Temp: 1100°C (continuous operation up to 48 hours) 
  • Features: Dual thermocouples, Super Kanthal heaters, inert gas inlet/outlet support

Centralized Control Panel

  • Interface: HMI + PID controller 
  • Functions: Programmable heat treatment cycles, emergency tripping, real-time data logging and monitoring 

Standout Engineering Highlights

  • Uniformity & Thermal Precision: 
    Immersing samples in the salt bath minimizes thermal gradients, ensuring uniform heating—critical for metallurgical consistency. 
  • Replaceable Furnace Lining: 
    SS310 interior can be replaced for longevity and minimal downtime in corrosive environments. 
  • Mobility & Modularity: 
    Caster wheels and modular construction allow relocation, maintenance, and system scalability. 
  • User Safety: 
    Integrated emergency shutoffs, thermocouple monitoring, and over-temperature protection ensure secure operation at all stages. 

Metallurgical Processing

Precise tempering, annealing, and hardening of steel with consistent surface hardness and microstructure control.

Surface Engineering

Salt bath nitriding and carburizing of shafts, tools, and fasteners for enhanced wear resistance.

Tool & Die Manufacturing

Heat-treated dies and molds exhibit dimensional stability and reduced fatigue over repeated use.

R&D and Academia

A highly controlled setup for testing new heat treatment techniques and alloy behaviors.

Metallurgical Processing

Precise tempering, annealing, and hardening of steel with consistent surface hardness and microstructure control.

Surface Engineering

Salt bath nitriding and carburizing of shafts, tools, and fasteners for enhanced wear resistance.

Tool & Die Manufacturing

Heat-treated dies and molds exhibit dimensional stability and reduced fatigue over repeated use.

R&D and Academia

A highly controlled setup for testing new heat treatment techniques and alloy behaviors.

Outcome

This integrated salt bath heat treatment system provided our client with seamless, precise, and repeatable control over the thermal processing of large steel samples. It has since become an integral part of their workflow in both production and material evaluation, significantly enhancing treatment accuracy and safety. 

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