1 Overview
Heat treatment is one of the most important basic processes in a wide range of applications in any area of ​​the national economy that involves mechanical manufacturing. It is a metal material that is processed under carefully controlled heating and cooling conditions to achieve the desired performance or service life by changing the microstructure inside the material. The specific requirements are often in the following aspects: (1) softening the material, improving the forming performance, improving the machining efficiency and production efficiency; (2) improving the strength and toughness of the material, increasing the life of the component; (3) improving the workpiece while ensuring the core performance of the material. Surface strength, hardness, wear resistance, fatigue and corrosion resistance; (4) development of new materials and special physical materials for the existing special materials to obtain special physical and chemical properties to meet medical, aerospace, biological, optical, electronic (5) Improve the production and processing of traditional materials, refine the structure of materials, greatly improve the strength and toughness, and fully utilize the potential of materials to meet the ever-increasing industrial needs; (6) Applied physical and chemical deposition methods Make a qualitative leap in the performance of the surface of the material, meet the needs of high-speed and high-precision processing and the requirements of high wear resistance and corrosion resistance; (7) Apply nanotechnology and composite technology to produce materials with special properties.
Metal products and workpieces are heat treated to achieve the required structure, performance and service life, and should be completed according to precise production methods, even in the precise and reliable operation of the cleaning equipment, according to scientific and advanced technology, strict management The entire process is completed and a high level of dispersion with zero dispersion is obtained. Strict management includes process execution management, equipment management, quality management, energy management, environmental management and human resource management. These management projects are clearly defined in the certification of quality assurance systems and environmental protection systems. For an investment company, it should attach great importance to the certification of ISO9000, QS9000 and ISO14000. To achieve these certifications, we can find and identify fixed customers in the fields of enterprises and automobiles, aerospace, machinery, chemicals, metallurgy, textiles, tools and molds, and strive to maintain long-term cooperative relations.
Entering the 21st century, human beings are increasingly demanding environmental protection. China has taken environmental protection as a basic national policy and has begun to promote cleaner production, requiring green heat treatment to produce clean products. The implementation of green heat treatment is fundamentally for the sustainable development of mankind. The World Commission on Environment and Development stated in the report “Our Common Future†that “sustainable development†is “the development that meets the needs of the present without compromising the ability of future generations to meet their needsâ€. It is easy to understand that we must do the rational development and utilization of natural resources, and at the same time do the protection of natural resources and the protection of the environment. For a company, we must handle the relationship between development and efficiency, development and innovation, and also deal with the relationship between development and resources, development and the environment. Good entrepreneurs must handle these relationships well and be good at handling them. In the process of seeking survival, seeking benefits, and seeking development.
2. Advanced technology and equipment for heat treatment at home and abroad
2.1. Level of advanced technology and equipment for heat treatment abroad
As one of the most important basic process technologies in the mechanical manufacturing industry, heat treatment technology is widely used in the entire industrial field. In the full play of material potential, energy conservation, clean production and sustainable development of human society, the expansion of heat treatment technology must not be ignored. The industrialized countries in the world have invested a lot of money to develop this technology. Since 1996, many developed countries in the United States and Japan have formulated development plans and targets for heat treatment technology in the 21st century. The 2020 vision of the US heat treatment industry sets out the goals and main signs of current and future foreign heat treatment advanced technology and equipment levels.
2.1.1 Development strategy of advanced heat treatment technology abroad: The strategic goal of foreign heat treatment technology development is sustainable development, product quality improvement, energy conservation, precise production, and improved production efficiency. Domestic development must be taken as the focus. These five aspects are actually interrelated and constrained.
The first thing involved in sustainable development is the environment, and heat treatment is inseparable from the environment and energy. Many of the production materials and residual materials used in the heat treatment process may be sources of pollution. Heat treatment workers should rationally choose technologies to avoid the formation of harmful residual materials, and apply advanced and harmless treatment methods to the harmful substances that must be produced to meet the national or international safety emission standards, and research and development regeneration and duplication. usage instructions. There are many studies abroad, and of course the investment is quite large.
The energy consumption of heat treatment accounts for about 20-30% of the machinery manufacturing enterprises. In the mid-1990s, China's annual energy consumption for heat treatment was about 8.6 billion kWh (about 1% of total power generation), and the national heat treatment turnover was about 5 billion yuan. In 1996, the total amount of heat treatment power in the United States was 5.1 billion degrees, 40.7% lower than that of China, while the national heat treatment turnover was 15 billion US dollars. The total exchange rate at that time was 124.5 billion yuan, 24.9 times that of China. It can be seen that the energy consumption of heat treatment in China lags far behind that of developed countries. Therefore, the improvement, improvement and development of heat treatment equipment and current heat treatment processes in China are necessary, and the prospect of energy conservation is great. In addition, the cost of heat treatment for machinery factories in China accounts for about 40% of the production cost of the products, which of course seriously affects the reduction of product costs. Note that electricity is secondary energy, power generation efficiency is generally 30 to 40%, and heat treatment production efficiency is as high as 80%, then the comprehensive thermal efficiency of electricity consumption is only 24% to 32%. For heat treatment furnaces that use primary energy natural gas, plus the use of flue heat energy, the overall thermal efficiency can reach 60% to 65%. For this reason, under the premise of solving the technology of controlling the furnace temperature, it is very advantageous to apply natural gas to reduce energy consumption, reduce costs and improve production efficiency. Japan has applied well in this regard.
The improvement of the quality of the heat-treated products and the precise production process involve the improvement of the quality, reliability and control technology of the heat treatment equipment, as well as the quality reproducibility of the heat-treated products and the improvement of the product performance. The realization of the high index requirement of the heat treatment equipment is an important prerequisite for the quality dispersion of the heat treatment product to be zero. Foreign heat treatment equipment comprehensively controls the process parameters of the whole process of heat treatment, and is developing towards automation, integration, flexibility and intelligence. In our country, the controlled atmosphere heat treatment applied in the 1960s is only used in some large enterprises and a few professional factories. Nationally, the controllable atmosphere furnace and vacuum furnace are less than 5% of heat treatment equipment, and some equipments with high labor intensity, serious pollution and high energy consumption still account for a large number. Many heat treatment companies still rely mainly on manual operation, and have not yet controlled the carbon potential or just the initial control. The quenching medium is only water and oil (mainly mechanical oil). Under these conditions, improving product quality and producing accurate products is only empty talk, which requires the full consideration of the corporate leadership.
The realization and guarantee of the above projects will naturally achieve a reduction in production costs and an increase in labor productivity.
It is precisely this way that foreign industrialized countries have planned and worked hard, and China should also strive for these goals. The vision of the US heat treatment industry in 2020 can be summarized as follows: using the latest CAD (computer-aided design) program and heat treatment database, computer simulation simulation technology and precise control technology to achieve a comprehensive control and system for highly flexible and intelligent heat treatment management. The goal of the heat treatment industry is: first-class heat treatment quality, zero mass dispersion rate; process cycle shortened by 50%; heat treatment workpiece distortion to zero; heat treatment energy utilization rate increased to 80%; heat treatment environmental impact reduced to zero; heat treatment cost reduced 75%; achieve high productivity and profitability; work environment is clean, comfortable and safe. Others involve: heat treatment workers are well trained to master advanced technology and operational skills. The government further reduces the burden for enterprises, stimulates the development of heat treatment enterprises and technological progress, and encourages investment and bank loans. Production, official, academic, research and association (association, association) cooperation to accelerate the advancement of advanced heat treatment technology.
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