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Hubei CAILONEN Intelligent Technology Co., Ltd

Hubei Cailonen Intelligent Technology Co., LTD. (formerly Wuhan Electric furnaceFactory) is the designated professional, design and research of the Ministry of Machinery Industry Development, production and sales of industrial electric furnaces large-scale state-owned restructuring enterprises Industry, is the China Heat Treatment Association, Hubei Casting Association, WuHan forging industry association governing unit. Since the restructuring of the company, it has rapidly grown into a Chinese high-end heat treatment manufacturing enterprise with strong research and development strength, complete design software, advanced processing technology and complete production equipment, with an annual output of 500 sets of large-scale standard heat treatment equipment and 30 sets of non-standard production lines. Many years of experience in the industry, in cooperation with a number of well-known universities in China, the existing professional team R & D is committed to providing customers with professional solutions. The main products are: Intelligent tempering production line, new energy lithium battery anode material granulation pre-carbonization production line, new energy vehicle lightweight thermoforming production line, new energy ling production line, all-fiber electric heating trolley furnace, all-fiber gas heat treatment (forging) trolley furnace, large variable capacity trolley furnace, protective atmosphere box tempering production line, hanging cylinder liner tempering production line, microcomputer controlled carburizing/nitriding furnace Vacuum furnace, well furnace, mesh furnace, roller sintering furnace, aluminum alloy quenching (solution, aging) furnace, all hydrogen hood bright annealing furnace, ADI salt isothermal quenching production line, rotary kiln baking furnace, medium frequency furnace, high frequency furnace, induction melting furnace, induction hardening production line, and other standard and non-standard heat treatment equipment. According to the requirements of users, we can provide a full set of technology and services such as product heat treatment process plan formulation, heat treatment workshop design, heat treatment equipment selection and design and manufacturing, installation and commissioning, production operation, after-sales maintenance, etc., to ensure the safety and reliability of customers before and after using products. Products involved in aerospace, shipbuilding, iron and steel, metallurgy, chemical industry, ceramics, automobile, casting, forging, sanitary ware, mining....... And other fields. Solutions can be developed according to different application scenarios and requirements.

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Sealed Box-Type Multipurpose Furnace 2025-09-01 Sealed Box-Type Multipurpose Furnace A sealed box-type multipurpose furnace is a versatile heat treatment equipment, widely used in the heat treatment processing of metal materials. The following is a detailed introduction to it: Equipment Composition A sealed box-type multipurpose furnace production line usually consists of a heating furnace, a cleaning machine, a tempering furnace, a material conveying cart, a material warehouse, a lifting platform, and a control system. Different numbers of unit equipment can be selected according to the requirements of different products and output to form a multi-functional flexible production line. Heating Methods The main heating methods include electric heating (hot air circulation), gas heating, graphite heating, etc. Temperature Range The temperature inside the furnace is generally 800-1000℃, and the temperature in the quenching tank is 150-600℃. Structural Features Furnace Chamber Design: The furnace chamber is built with a circular furnace chamber or high-quality imported anti-carburizing bricks, and an all-fiber structure can also be selected. It has good furnace temperature uniformity and excellent atmosphere fluidity. Heating Elements: The radiant tubes adopt low-voltage power supply, which features good safety, long service life, and easy replacement. Cooling System: It is equipped with a large-capacity oil tank, a specially designed diversion system, and a variable-frequency speed-regulating stirring device. The oil temperature can be automatically controlled. Additionally, cooling methods such as water cooling, protective gas cooling, and salt bath isothermal cooling can be selected. Sealing and Atmosphere Control: It adopts a high-efficiency sealing structure, such as a cylinder-pressed sealing door, to prevent atmosphere leakage. The high-precision atmosphere control system can accurately establish the carbon potential inside the furnace. The available atmosphere types include methanol + enriching gas, methanol + N₂ + enriching gas, or Rx atmosphere + enriching gas, etc. Control System: It is controlled by a programmable logic controller (PLC), featuring simple operation, convenient maintenance, and high automation. It is equipped with a high-precision temperature controller, a thyristor power regulator, etc., with a temperature control accuracy of ±1℃. It also has a complete fault self-diagnosis and safety interlock control system. Main Functions It can be used for various heat treatment processes such as carburizing, carbonitriding, hardening, surface hardening, quenching, normalizing, annealing, and bright processing. Application Fields It is widely used in industries and sectors such as electric power, coal, papermaking, petrochemicals, cement, agriculture and animal husbandry, medical research, and teaching. Especially in the fields of machinery manufacturing and auto parts processing, it is widely applied for heat treatment of various types of complex parts.

Analysis Approach for Failed Metal Parts 2025-08-29 Analysis Approach for Failed Metal Parts The analysis of failed metal parts must follow the logic of "macroscopic first, then microscopic; phenomenon first, then essence; qualitative first, then quantitative". Its core lies in identifying the failure mode (e.g., fracture, corrosion, wear, deformation) through multi-dimensional testing, then tracing the root cause of failure (design, material, process, service environment, etc.), and finally providing a basis for improvement solutions. Below is a systematic analysis framework covering 6 core steps: I. Preliminary Information Collection: Clarify the Failure Background (Avoid Blind Analysis) The prerequisite for failure analysis is to grasp the "full-life-cycle information" of the part; otherwise, it is easy to deviate from the correct direction. Key information to collect includes: Basic Part Information Part name, application (e.g., shaft, gear, pressure vessel), structural design drawing (focus on stress concentration areas such as fillets and holes); Material grade (e.g., 45 steel, 304 stainless steel, TC4 titanium alloy) and original performance parameters (hardness, tensile strength, corrosion resistance, etc.). Manufacturing and Processing Processes Forming processes (casting, forging, welding, 3D printing), heat treatment processes (quenching and tempering, solution aging), surface treatment (chrome plating, carburizing); Whether there were defects during processing (e.g., welding pores, forging cracks, heat treatment deformation). Service and Operating Conditions Working load (static/dynamic/impact load, load magnitude and direction); Environmental parameters (temperature: room/high/low temperature; medium: air, water, oil, acid-base solution, dust; presence of vibration or fatigue cycles); Operating status before failure (e.g., whether abnormal noise, leakage, or precision degradation occurred; whether failure was sudden or gradual). Historical Maintenance Records Whether the part has undergone repair or replacement; whether similar failures occurred before; whether there was improper operation during maintenance (e.g., overload use, insufficient lubrication). II. Macroscopic Analysis: Initially Determine the Failure Mode (Narrow the Scope Quickly) Macroscopic analysis involves observing the appearance, fracture, and deformation characteristics of the failed part with the naked eye or a low-magnification magnifier (≤100x) to initially identify the failure type and key areas. It serves as the "navigation" for subsequent microscopic analysis. Focus on the following dimensions: Localization of the Failure Site Whether the failure occurred in a "stress-sensitive area" (e.g., shaft shoulder, keyway, thread root), "process weak area" (e.g., weld joint, casting riser), or "material defect area" (e.g., inclusions, porosity); Example: If a shaft fractures at the shaft shoulder fillet, it is likely related to stress concentration; if a pipeline leaks at the weld, welding quality should be prioritized for inspection. Observation of Appearance Characteristics Fracture Failure: Observe the fracture color (presence of oxide color to determine if fracture occurred at high temperature), flatness (flat = brittle fracture, rough = ductile fracture), and presence of radial lines (a typical feature of fatigue fracture, with the starting point of radial lines being the crack source); Corrosion Failure: Identify the corrosion type (pitting: local small holes; uniform corrosion: overall thinning; intergranular corrosion: cracking along grain boundaries; stress corrosion: accompanied by cracks and corrosion traces); Wear Failure: Observe whether the worn surface has abrasive scratches (abrasive wear), adhesion marks (adhesive wear, e.g., "seizure" of metal surfaces), or fatigue spalling (contact fatigue, e.g., spalling of gear tooth surfaces); Deformation Failure: Measure key dimensions of the part (e.g., shaft diameter, plate flatness) to determine if they exceed tolerances (e.g., "thermal deformation" at high temperatures, "plastic deformation" under overload). Verification of Macroscopic Mechanical Properties Sample the "non-failed area" of the failed part to test hardness, tensile strength, yield strength, etc., and compare with design requirements to determine if failure was caused by substandard material properties (e.g., insufficient hardness after heat treatment). III. Microscopic Analysis: Deeply Locate the Essence of Failure (Core Link) After narrowing the scope through macroscopic analysis, microscopic testing methods are used to observe the material’s microstructure, fracture details, and element distribution, revealing the "microscopic mechanism" of failure (e.g., brittle fracture due to coarse grains, cracking due to intergranular corrosion). Common methods and application scenarios are as follows: Testing Method Core Function Applicable Failure Types Optical Microscopy (OM) Observe microstructure (grain size, phase composition, defect distribution) Improper heat treatment, intergranular corrosion, casting defects Scanning Electron Microscopy (SEM) Observe fracture morphology (nanoscale details) and surface morphology Fracture (determine brittleness/ductility/fatigue), wear, corrosion Energy Dispersive Spectroscopy (EDS) Analyze micro-area element composition (qualitative + semi-quantitative) Corrosion (detect corrosion product composition), wear (detect abrasive particle composition), material inclusions X-Ray Diffraction (XRD) Analyze phase composition (e.g., whether corrosion products are Fe₃O₄ or Fe₂O₃) Corrosion, high-temperature oxidation Transmission Electron Microscopy (TEM) Observe atomic-level structure (e.g., dislocations, precipitates) Failure caused by material microscopic defects (e.g., abnormal alloy precipitates) Example: Microscopic Judgment of Fracture Failure If SEM observes a large number of "dimples" (pit-like features) on the fracture, it indicates ductile fracture, which may be caused by overload (load exceeding the material’s yield strength); If the fracture has "cleavage planes" (flat small crystal planes) or "intergranular fracture" (cracks propagating along grain boundaries), it indicates brittle fracture, which may be caused by low temperature, material inclusions, or intergranular corrosion; If the fracture has "fatigue striations" (parallel stripes), it indicates fatigue fracture, which may be caused by repeated alternating loads (e.g., rotational vibration of a shaft) or surface crack sources (e.g., machining scratches). IV. Determination of Failure Mechanism: Link Phenomenon and Essence The failure mechanism refers to the "physical/chemical process leading to part failure". It is necessary to combine macroscopic + microscopic analysis results to clarify the core cause of failure. Common failure mechanisms and corresponding scenarios are as follows: Mechanical Failure Mechanisms Overload fracture: Load exceeds the material’s ultimate strength, with dimples on the fracture; Fatigue fracture: Repeated alternating loads, with fatigue striations + crack sources on the fracture; Plastic deformation: Load exceeds the material’s yield limit, or material softening at high temperatures; Wear: Material loss due to surface contact friction (abrasive wear, adhesive wear, contact fatigue wear). Chemical Failure Mechanisms Corrosion: Chemical reaction between metal and environmental medium (e.g., carbon steel rusting in humid environments, stainless steel pitting in Cl⁻ environments); Oxidation: Reaction between metal and oxygen at high temperatures (e.g., steel forming oxide scale above 800℃, leading to reduced dimensional accuracy). Thermal Failure Mechanisms Thermal softening: High temperatures cause a decrease in material strength/hardness, leading to deformation or fracture; Thermal fatigue: Repeated heating-cooling cycles cause thermal stress cycles and crack formation (e.g., boiler pipes, engine blocks). V. Root Cause Tracing: Investigate Responsible Links in the Full Life Cycle Based on the failure mechanism, further investigate the root cause from 5 links: "design, material, manufacturing, use, maintenance", avoiding stopping at "phenomenon description": Design Link Defects: Stress concentration design (e.g., excessively small fillet radius), insufficient safety factor (load calculation error), improper material selection (e.g., using ordinary carbon steel instead of stainless steel in corrosive environments); Example: A chemical pipeline using Q235 steel (not acid-resistant) to transport hydrochloric acid resulted in corrosion leakage, with the root cause being "incorrect material selection". Material Link Defects: Substandard material composition (e.g., insufficient alloying element content), internal inclusions (e.g., sulfide inclusions in steel), metallurgical defects (e.g., casting porosity, forging cracks); Example: A gear made of 20CrMnTi steel fractured at the tooth root due to excessive sulfur content during smelting, leading to inclusions. Manufacturing Link Defects: Incorrect heat treatment process (e.g., insufficient hardness due to low quenching temperature), improper welding process (e.g., incomplete penetration, pores), surface processing defects (e.g., turning scratches leading to fatigue crack sources); Example: A shaft part cracked on its own during storage due to excessive internal stress caused by not tempering in time after quenching. Use Link Defects: Overload operation (e.g., crane overload), operation beyond temperature/pressure limits (e.g., boiler pressure exceeding design value), abnormal environment (e.g., no rust prevention in humid environments); Example: A motor shaft suffered fatigue fracture due to excessive alternating loads caused by excessive equipment vibration. Maintenance Link Defects: Insufficient lubrication (accelerating bearing wear), failure to clean corrosive media in time (e.g., unremoved scale on pipeline inner walls, intensifying corrosion), improper repair (e.g., introducing new cracks during welding repair). VI. Propose Improvement Solutions: Avoid Recurrence of Failure The ultimate goal of analysis is to solve the problem. Targeted and implementable improvement measures should be proposed based on the root cause, with common directions as follows:

Variable-Capacity Bogie Hearth Furnace 2025-08-29 Variable-Capacity Bogie Hearth Furnace The Variable-Capacity Bogie Hearth Furnace is a batch-type industrial heating equipment with flexibly adjustable furnace chamber volume. Its core feature lies in enabling workpiece loading and unloading via a movable bogie, combined with a detachable/telescopic furnace structure (such as movable furnace doors and segmented furnace walls) to adapt to the heating needs of workpieces of different sizes and batches. It is widely used in metal heat treatment (e.g., annealing, quenching, normalizing), forging heating, and casting aging treatment, and is particularly suitable for the "multi-variety, small-batch" production scenarios of small and medium-sized manufacturing enterprises. I. Core Design Highlights: Dual Advantages of "Variable Capacity" and "Bogie-Type Structure" 1. Variable-Capacity Design: On-Demand Adjustment for Energy Conservation Traditional bogie hearth furnaces have a fixed chamber volume, which often leads to the problem of "using a large furnace for small workpieces" when heating small-sized workpieces—this results in low space utilization inside the furnace and severe heat waste (energy consumption can be 30% or more higher). The variable-capacity bogie hearth furnace achieves volume adjustment through the following structures: Segmented Furnace Walls/Movable Insulation Modules: The side walls or top of the furnace are equipped with detachable/sliding insulation modules (e.g., lightweight refractory fiber boards), which can reduce the ineffective space inside the furnace according to the height and width of the workpiece (e.g., reducing a 10m³ furnace chamber to 5m³); Liftable Furnace Top/Side Walls: Some high-end models adjust the height of the furnace top and the spacing of the side walls via hydraulic or electric devices to adapt to the heating needs of long-axis workpieces and special-shaped parts (e.g., machine tool spindles, large gears); Multi-Zone Independent Temperature Control: The furnace chamber is divided into multiple heating zones (e.g., left, middle, right). Only the heating system in the zone where the workpiece is located is activated, while the unused zones are kept at a low temperature or turned off to further reduce energy consumption. 2. Bogie-Type Structure: Convenient Loading/Unloading for Heavy/Large Workpieces Movable Bogie: The bogie carries the workpiece in and out of the furnace along rails, eliminating the need for manual handling. It is especially suitable for heavy workpieces weighing over 10 tons (e.g., forged steel parts, cast steel joints); the bogie table is paved with high-temperature-resistant refractory bricks or insulation materials to avoid local overheating caused by direct contact between the workpiece and the bogie; Sealing and Positioning: The joint between the bogie and the furnace body adopts a "labyrinth seal" or "pneumatic sealing strip" to reduce heat leakage; the bogie is accurately aligned with the furnace body via positioning pins to ensure uniform heating. II. Core Structural Composition: Synergy of 6 Systems Based on the structure of traditional bogie hearth furnaces, the variable-capacity bogie hearth furnace enhances the "volume adjustment" and "sealing insulation" designs, mainly including the following components: System Name Core Components Functional Role Furnace Body & Variable-Capacity Mechanism Fixed furnace shell, movable insulation modules, hydraulic/electric adjustment devices Forms the heating chamber and adjusts the furnace volume via movable modules; the furnace shell is made of steel structure + refractory castable to ensure high-temperature resistance and airtightness. Bogie System Bogie body, rails, driving device (motor/hydraulic) Carries workpieces in and out of the furnace; the driving device enables automatic positioning of the bogie (accuracy ±5mm) to avoid manual operation errors. Heating System Heating elements (resistance wires, silicon carbide rods, gas burners), zoned temperature controllers Provides heating sources; zoned temperature controllers independently adjust the temperature of each zone (temperature control accuracy ±5℃) to meet the heating needs after volume adjustment. Insulation System Lightweight refractory fibers, high-alumina bricks, sealing strips Reduces heat loss inside the furnace (the outer wall temperature ≤60℃, much lower than the 100℃+ of traditional furnace bodies); sealing strips enhance the joint sealing between the bogie and the furnace body. Smoke Exhaust/Cooling System Smoke exhaust fan, flue, water-cooled jacket (optional) Discharges waste gas generated during heating (e.g., volatile substances from workpiece degreasing); the cooling system is used for furnace body cooling or workpiece quenching cooling. Control System PLC, touch screen, temperature recorder, alarm module Sets heating curves (heating rate, holding time, cooling method), monitors furnace temperature and bogie position in real time; triggers sound and light alarms in case of abnormalities (over-temperature, bogie misalignment). III. Core Technical Parameters: Key Indicators for Selection When selecting a model, focus on parameters related to "process requirements" and "energy-saving effects": Temperature Range: Conventional models range from 300℃ to 1200℃ (suitable for heat treatment of steel and cast iron parts), while high-temperature models can reach up to 1600℃ (suitable for heating superalloys and ceramic parts); Volume Adjustment Range: For example, "5~15m³", meaning the minimum volume can be reduced to 5m³ and the maximum expanded to 15m³. It needs to match the size range of workpieces commonly processed by the enterprise; Heating Power & Energy Consumption: Taking a 10m³ furnace chamber as an example, the power is usually 50~100kW. The variable-capacity design can reduce energy consumption by 20%~40% under small-volume working conditions; Bogie Load Capacity: Conventional capacity ranges from 5 to 50 tons, and heavy-duty models can reach over 100 tons. It should be selected according to the maximum weight of the workpiece; Temperature Control Accuracy & Uniformity: The temperature control accuracy is ±3~±5℃, and the temperature uniformity inside the furnace is ≤±10℃ (in accordance with GB/T 9452 standard) to ensure no local temperature difference in workpiece heating. IV. Typical Application Scenarios: Adapting to "Multi-Variety, Variable-Batch" Production Machinery Manufacturing Industry: Preheating and normalizing of small and medium-sized forgings (e.g., flanges, shafts); Annealing and quenching-tempering of machine tool parts (e.g., gears, lead screws). The variable-capacity design adapts to the batch heating of parts of different specifications; Automotive Parts Industry: Stress relief annealing of welded parts such as automobile rear axle housings and drive shafts. The furnace volume can be adjusted according to the order batch to avoid no-load energy consumption; Hardware Tool Industry: Quenching of tools such as wrenches and pliers. The furnace chamber is reduced during small-batch production to lower the energy consumption per workpiece; Special Materials Industry: Heat treatment of small-batch superalloy samples. The combination of multi-zone temperature control and variable capacity ensures uniform heating of samples. V. Precautions for Use and Maintenance Operational Specifications for Volume Adjustment: Before adjusting movable insulation modules or furnace dimensions, ensure the temperature inside the furnace drops below 200℃ to avoid damage to insulation materials or scalding caused by high-temperature operations; After adjustment, check the sealing status of the furnace body (e.g., using a smoke test for sealing gaps) to prevent heat leakage from affecting heating efficiency. Maintenance of Bogie and Sealing: After each bogie movement, clean up debris (e.g., scale, scraps) at the joint between the bogie and the furnace body, and replace sealing strips regularly (inspection is recommended every 6 months); The bogie rails need regular lubrication (using high-temperature grease) to prevent rail wear from causing bogie positioning deviations. Maintenance of Heating Elements: Regularly check whether heating elements (e.g., resistance wires) are broken or deformed, and replace them promptly if problems are found to avoid uneven local heating; For multi-zone heating systems, calibrate the temperature controllers of each zone regularly to ensure temperature accuracy meets standards. Safety Protection: Reserve a safe distance (≥1.5m) around the furnace body and prohibit stacking flammable materials; Equip safety devices such as over-temperature alarms and bogie misalignment emergency stops, and test their effectiveness regularly. VI. Industry Development Trends: Intelligent and Green Upgrading Intelligent Adjustment: Introduce AI algorithms to automatically calculate the optimal furnace volume and heating curve based on workpiece size and material, reducing manual operations; realize remote monitoring of furnace temperature and bogie status through the Internet of Things (IoT) to improve operation and maintenance efficiency; Energy-Saving Technology Optimization: Adopt a "regenerative combustion system" (for gas-fired furnaces) or "high-efficiency resistance heating elements", combined with variable-capacity design to further reduce energy consumption; Waste heat recovery and utilization: Recover heat dissipated from the furnace body for workshop heating or workpiece preheating to improve energy efficiency; Environmental Protection Upgrading: For gas-fired furnaces, add nitrogen oxide (NOₓ) treatment devices to meet ultra-low emission standards; waste gas inside the furnace (e.g., degreasing volatiles) is discharged after adsorption by activated carbon to reduce environmental pollution. In conclusion, with the core advantages of "flexible adaptation and energy conservation", the variable-capacity bogie hearth furnace solves the pain points of "large furnace for small use and high energy consumption" of traditional fixed-volume bogie hearth furnaces. It is an ideal heating equipment for small and medium-sized manufacturing enterprises to achieve "flexible production" and "cost control".

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