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Productivity, quality & efficiency & efficiency increase in high temperature processes Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt J. Demmel, 7th Nov. 2011

Contents 1. Introduction: Singularities of High Temperature Processes 2. New Materials innovate HT-Processes 3. Applications of new CFRC-racks in HT-Processes 4. Automation of Handling in HT-Processes 5. Integration of HT-processes in the Production chain 6. References and Contact 6. References and Contact J. Demmel, 7th Nov. 2011 Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt

1. Singularities and Importance of High Temperature Processes High Temperature => hardening, brazing, sintering, CVD Processes => permanent temperature > 500°C (932°F) Quality Cos ts HEAT TREATMENT HARD MACHINING SOFT MACHINING PROCES S Delivery reliability Production requirements J. Demmel, 7th Nov. 2011 Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt

1. Singularities and Importance of High Temperature Processes HEAT OTHER TREATMENT MANUFACTUR PROCESS E PROCESSES in a range of hours or in a range of hours or in a range of in a range of Execution time Execution time days s econds or minutes s low because of the long Degree of reaction rapid, short term s et up and proces s time through medium high inves tment for new Productivity increase investment significative equipment, however through inves tment performance increas es s mall lead time reduction can be achieved duration of days or weeks Maintenance Maintenance the machines the machines can be can be because of the furnace because of the furnace and repair repaired in a short time cool off and heat up time most of the costs are almost all costs are fix Cost s tructure variable costs costs (3-4 working shifts) (1-3 working s hifts ) J. Demmel, 7th Nov. 2011 Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt

2. New Materials innovate HT-Processes The Nailable Ceramic CFRC: Carbon Fibre Reinforced Carbon Reinforced Carbon Stress-Strain Curves (Source: Petzow, G., 1988 ) J. Demmel, 7th Nov. 2011 Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt

2. New Materials innovate HT-Processes Specific Strength Density strength / density [N m / g] strength / density [N m / g] 250 10 200 8 density [g/cm³] density [g/cm³] 150 20°C 6 20°C 1000°C 1000°C 100 1000°C 4 50 2 0 0 2D-CFC heat Inconel 600 ODS- 2D-CFC heat resistant Inconel 600 ODS- resistant Superalloy steel Superalloy steel Strength Coefficient of Thermal Expansion yield strength R p0,2 [N/mm²] 600 20 500 15 400 20°C K -1 ] yield strength R 300 C.T.E. [10 -6 K 1000°C 1000°C 10 10 20°C 200 1000°C 5 100 0 0 2D-CFC heat resistant Inconel 600 ODS- 2D-CFC heat resistant Inconel 600 ODS- steel Superalloy steel Superalloy -5 J. Demmel, 7th Nov. 2011 Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt

3. Applications of new CFRC-racks in HT-Processes Vacuum brazing racks  Results for our customer: Comp. Modine, • Increase in loading capacity of 50 % 2 plants in Germany 2 plants in Germany • Improvement of handling • Improvement of handling Situation before • Enhanced product quality • Profitability (amortization ~1 year) J. Demmel, 7th Nov. 2011 Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt

3. Applications of new CFRC-racks in HT-Processes New CVD-rack Comp. TTC, Barcelona, Spain Barcelona, Spain  Results for our customer: • Less distortion of the parts • Less energy consumption • High Profitability • High Profitability Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt J. Demmel, 7th Nov. 2011

3. Applications of new CFRC-racks in HT-Processes  Results for our customer: Annealing Racks (with oil • Increase in loading capacity of approx. 70 % quenching) quenching) • Improvement of handling • Improvement of handling Comp. Wiha, Germany • Enhanced product quality (less distortion) • Profitability (amortization ~1,2 years) Situation before Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt J. Demmel, 7th Nov. 2011

4. A utomation of Handling Automatic Furnace Feeding Furnace Feeding Comp. Lemken, Germany Results for our customer: Situation before • Ergonomic working conditions instead of heat and manual handling of work-pieces weighing up to 20 kg up to 20 kg • Flexibility (> 50 products) and profitability J. Demmel, 7th Nov. 2011 Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt

5. Integration of HT-processes in the Production chain INTEGRATION LEVELS OF HIGH TEMPERATURE PROCESSES IN THE PRODUCTION CHAIN material flow Heat treatment & and process Hard machining maching integration Soft machining Heat treatment Hard machining Heat treatment material flow integration Buffer but no process Soft machining Hard machining integration Heat treatment Soft machining Hard machining Workshop B Heat treatment no integration Soft machining Hard machining Workshop A Workshop A Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt J. Demmel, 7th Nov. 2011

5. Integration of HT-processes in the Production chain S oft machining Heat treatment Hard machinig P R ODUC TION real C APACITY capacity maximum capacity S oft machining Heat treatment Hard machinig A-Teile A A PR ODUC TION C C APAC APAC ITY ITY A maximum B B capacity real C C capacity B P R ODUC TION S EQUENC E OUTS OR C ING C S oft machining Heat treatment Hard machinig maximum P R ODUC TION capacity C APACITY real capacity PR ODUC TION S S EQUE EQUE NCE NCE P R ODUC TION Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt J. Demmel, 7th Nov. 2011 S EQUE NC E

6. References and Contact References CFRC racks Herzog, Germany Realisation of CFC-carriers for the carburisation (oil) of drive elements Hilti, FL & USA CFC-rack for the vacuum hardening of drills MAN, Germany MAN, Germany Planning of optimised charge carriers for gearwheels and pinions Planning of optimised charge carriers for gearwheels and pinions Modine Europe Realisation of CFC-carriers for vacuum brazing of heat exchangers Philips, Netherlands CFC-rack for the vacuum annealing of tools NN 1 , Great-Britain Realisation of CFC-carriers for vacuum process for aviation engines TTC, Spain CFC-carrier for CVD-coating Wiha, Germany Realisation of CFC-carriers for the Annealing (oil) of allen keys NN 1 , Germany CFC-racks for case hardening (oil) of stabilizers for cars CFC-racks for case hardening (oil) of stabilizers for cars Pratt & Whitney, Canada Realisation of CFC-rack for the vacuum process (with partner) 1 Projects and/ or names of our customers can not be quoted because of a non-disclosure agreement. J. Demmel, 7th Nov. 2011 Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt

6. References and Contact References Heat Treatment & Production Braun (Gillette), Germany Automatic loading of continuous furnaces with parts Durotec Planning of an automatic loading device for heat treatment fixtures for driving shafts for driving shafts Huawei, China Development of a handbook for production development according to DFA and DFM regulations Lemken, Germany Automation of handling of plough components in heat treatment installations MAN, Germany Implementation of improved production processes between soft treating and hard treating NN 1 Automatic feeding & handling of parts for continuous furnaces Wiha, Germany Wiha, Germany Automatic feeding and handling of hexagonal allen keys by means Automatic feeding and handling of hexagonal allen keys by means of a SCARA robot 1 Projects and/ or names of our customers can not be quoted because of a non-disclosure agreement. J. Demmel, 7th Nov. 2011 Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt

6. References and Contact - Development Fraunhofer Technology Development Group Nobelstraße 12, D-70569 Stuttgart Dipl.-Ing. Jörg Demmel Telephone: Telephone: +49 (0) 711/970-3621 +49 (0) 711/970-3621 Facsimile: +49 (0) 711/970-3998 Email: joerg.demmel@teg.fraunhofer.de Internet: http://www.teg.fraunhofer.de Department: Production Processes Group: Group: Production Engineering, Application of New Materials J. Demmel, 7th Nov. 2011 Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt

6. References and Contact - Sales with our Co-operation Toyo Tanso USA: Sales Area‘s & Sales Person‘s Northwest TOM STORMS East Coast JACK VITALE Phone : (503) 661-7700 Fax: (503) 669-9107 email : tstorms@ttu.com Phone : (508) 528-4969 Fax: (508) 541-7437 email : jvitale@ttu.com Mid-Atlantic DOUG GARDA Southwest LOWELL JOHNSON Phone : (412) 921-1407 Fax: (412) 921-4030 email : dgarda@ttu.com Phone : (972) 434-8117 Fax: (972) 353-4322 email : ljohnson@ttu.com Archivierungsangaben: K:\3pp\0PP\OE\Marketing\Akquifolien\Praesentation-englisch.ppt J. Demmel, 7th Nov. 2011