The requirements of heat-treatment furnaces are as follows:
■ Uniform heating of the work. This is necessary in order to prevent distortion of the work due to unequal expansion, and also to ensure uniform hardness.
■ Accurate temperature control. The critical nature of heat-treatment temperatures requires the furnace be capable of operating over a wide range of temperatures, but it must be easily adjustable to the required process temperature.
■ Temperature stability. It is essential that the temperature is not only accurately adjustable but once set the furnace must remain at the required temperature. This is achieved by ensuring that the mass of the heated furnace lining (refractory) is very much greater than the mass of the work (charge). It can also be achieved by automatic temperature control, or by both.
■ Atmosphere control. Should the work be heated in the presence of air, the oxygen in the air attacks the surface of the metal to form metal oxides (scale). This not only disfi gures the surface of the metal, it can also change the composition of the metal at its surface. For example, in the case of steels, the oxygen can also combine with the carbon at the surface of the metal. Reducing the carbon content results in the metal surface becoming less hard and/or tough. To provide atmos- phere control, the air in the furnace is replaced with some form of inert gas which will not react with the work-piece material. Alternatively the work may be heat treated by totally immersing it in hot, molten salts.
■ Economical use of fuels. It is essential – if heat-treatment costs are to be kept to a minimum – for the furnaces to be run continuously and economically on a shift work basis since the fuel required to keep fi ring up furnaces from cold is much greater than that required for continuous running. Thus it is more economical for small workshops to contract their heat treatment out to specialist fi rms who have suffi cient volume of work to keep their furnaces in continuous use.
■ Low maintenance costs. Furnaces are lined with a heat-resistant material such as fi rebrick. Since a furnace must be taken out of commission each time this lining is renewed, it should be designed to last as long as possible.
3.17.1 Semi-muffl e furnace
Figure 3.16 shows a semi-muffl e furnace. The fl ame from the burner does not play directly onto the charge, but passes under the hearth to provide ‘ bottom heat ’ . This results in fairly uniform heating. The advantages and limitations of this type of fur- nace are as follows:
Advantages
■ Relatively low initial cost.
■ Simplicity in use and maintenance.
■ Fuel economy.
■ Fairly rapid heating.
■ Heating is fairly uniform.
■ Limited atmosphere control can be achieved by varying the gas-air mixture through a system of dampers. The fl ue outlets are situated just inside the furnace
door so that any atmospheric oxygen that may leak past the door is swept up the fl ue before it can add to the scaling of the work.
■ Reasonable temperature control.
■ Reasonable temperature stability due to the mass of the furnace lining.
Limitations
■ Heating is still relatively uneven compared with more sophisticated furnace types.
■ Atmosphere control is somewhat limited. Although oxidation can be reduced by careful control of the gas-air mixture, some scaling will still take place and there will be still be fl ue gas contamination of the work.
3.17.2 Muffl e furnace (gas heated)
Figure 3.17 shows a full muffl e furnace. You can see from the fi gure that the work is heated in a separate compartment called a muffl e. The work is completely isolated from the heat source (fl ame) and the products of combustion. The advantages and limitations for this type of furnace are as follows:
Advantages
■ Uniform heating.
■ Reasonable temperature control.
■ Good temperature stability due to the mass of refractory material forming the muffl e and the furnace lining compared with the mass of the work.
■ Full atmosphere control is possible. Any sort of atmosphere can be maintained within the muffl e since no combustion air is required in the muffl e chamber.
Limitations
■ Higher initial cost.
■ Maintenance more complex and costly.
Flue gases
Component
Hearth provides
‘bottom heat’
Furnace arch (focuses radiated heat on component.
Also circulates flue gases to promote uniform heating) Firebrick (refractory) lining
Heat source
Figure 3.16 Gas-heated semi-muffl e furnace
■ Greater heat losses and slow initial heating results in lower fuel economy unless the furnace can be operated continuously.
3.17.3 Muffl e furnace (electric resistance)
Figure 3.18 shows a typical electric resistance muffl e furnace. The electric heating elements are similar to those found in domestic electric ovens. They are independ- ent of the atmosphere in which they operate. Therefore they can be placed within the muffl e chamber itself, resulting in a higher operating effi ciency compared with the gas heated muffl e furnace and more than offsets the higher energy cost for Figure 3.18 Electrically-heated muffl e furnace: (a) the electric resistance
furnace; (b) heating element
Controlled atmosphere to prevent oxidation
Component Muffle
chamber
Flue outlet
Heat source
Figure 3.17 Gas-heated muffl e furnace
electricity compared with gas. The advantages and limitations of this type of furnace are as follows:
Advantages
■ Uniform heating of the work.
■ Accurate temperature control.
■ Ease of fi tting automatic control instrumentation.
■ High temperature stability.
■ Full atmosphere control.
■ Comparatively easy maintenance.
Limitations
■ Higher energy source costs.
■ Lower maximum operating temperatures, as above 950°C to 1000°C the life of the resistance elements is low.