1.Vacuum brazing process

In the vacuum furnace, a certain vacuum is maintained, and the temperature is heated to an appropriate level to melt the solder in the weld of the base material, forming a weld zone with no pores, no looseness, and bright weld joints, which enhances the sealing of the weld joints. It is mostly used for welding fluid equipment. It is suitable for stainless steel, high-temperature alloys, especially heat-resistant alloys with high aluminum, copper, silver, and titanium content, and can obtain high-quality welding joints. It is also suitable for welding the same refractory alloys or dissimilar metals such as titanium, zirconium, molybdenum, and tungsten.

 

2.Vacuum integral quenching and tempering process for large parts

The group is equipped with super-large high vacuum furnaces (one vertical vacuum furnace with a maximum diameter of 1.6 meters and a height of 2.5 meters; one vertical vacuum furnace with a maximum diameter of 2.0 meters and a height of 1.2 meters), which are specially used for quenching and tempering processes of large precision automobile bumpers, instrument panels, and pedal molds; solution and aging processes of precision instrument parts; and diffusion tempering treatment of large leather pattern molds.

 

3.Chemical surface treatment process: nitriding process and carburizing process

1 Nitriding process: gas nitriding and ion nitriding

Gas nitriding is a chemical heat treatment process in which nitrogen-containing gas is introduced into a sealed furnace tank and heated to a certain temperature to allow nitrogen atoms to penetrate into the surface of the workpiece. Main features: low treatment temperature, suitable for many types of steel, significant strengthening effect, small distortion of the workpiece, wear resistance, corrosion resistance, and fatigue resistance. It can also improve the anti-adhesion, anti-bite and anti-melting effects of hot working molds.

This process is widely used in the final heat treatment of mechanical equipment parts, hot and cold working and plastic molds. The company is equipped with a pit nitriding furnace (maximum diameter 1.0 meters, height 8 meters) to treat shaft workpieces; the Hefeis pit nitriding furnace (maximum diameter 2.5 meters, height 5 meters) is suitable for wind power gear ring workpieces.

Ion nitriding is a process of nitriding in a nitriding atmosphere below 105 Pa (usually 10-1~10-3Pa), using the glow discharge generated between the workpiece (cathode) and the anode. Main features: Wide treatment temperature range. Even at 350°C, a certain thickness of nitriding layer can be obtained; The nitriding speed is faster than gas nitriding; The compound layer structure is easy to control; It saves gas source and ammonia consumption; It is pollution-free; Non-nitriding parts are easy to protect; It automatically removes the passivation film and is widely used in stainless steel products.

2 Carburizing process

Carburizing of steel is a chemical heat treatment process to increase the carbon content of the surface of the workpiece and form a certain carbon content gradient in it. The workpiece is heated and kept warm in a carburizing medium to allow carbon atoms to penetrate. After carburizing, quenching and tempering, the surface of the workpiece can obtain higher hardness, strength, wear resistance and fatigue strength, while the core of the workpiece still maintains a certain toughness.

Each subsidiary of the group is equipped with a Hefeis pit carburizing furnace (maximum diameter 3.5 meters, height 3 meters); the German "Stanger" carbon potential control system greatly ensures the stability and accurate execution of process parameters, and is widely used in the production of key parts of large equipment.

In the execution of carburizing and nitriding processes of large gear rings, Jiangsu Fuguan is equipped with advanced equipment and process designers in the industry, and successfully serves customers in the heat treatment of large parts such as wind power, metallurgy, and ships.

 

4.Laser surface treatment:

1 Laser quenching

Laser quenching and melting are self-excited quenching processes with rapid heating and rapid cooling. The main difference between laser hardening and traditional quenching processes is that it has a short action time and does not require a cooling medium. Compared with traditional heat treatment processes, laser hardening has the following characteristics:

(1) Extremely fast heating speed, high cooling speed, and extremely small deformation of the workpiece.

(2) Significant optimization effect of surface modification.

(3) Laser local hardening can be performed on workpieces with complex shapes.

(4) Short process cycle, good production repeatability, and stable and reliable quality.

(5) Clean and environmentally friendly process. Laser hardening is a self-excited quenching process that does not require cooling media such as water or oil, which is beneficial to environmental protection.

Compared with conventional heat treatment methods, laser hardening has its unique advantages and a very broad application prospect. However, laser hardening also has its limitations. It is only suitable for some workpieces that require local surface hardening, and the hardened layer is shallow. It is usually laser hardened for some workpieces that do not require overall hardening, have high dimensional requirements, and have complex shapes.

2 Laser Cladding (Additive)

Laser cladding, also known as laser cladding or laser melting, refers to adding selected coating materials to the surface of the substrate in different filler forms, using a high-energy density (104~106W/cm2) laser beam to melt it simultaneously with the extremely thin layer on the surface of the substrate, and then quickly solidify to form a surface coating with extremely low dilution and metallurgical bonding with the substrate, thereby improving the wear resistance, corrosion resistance, heat resistance, and oxidation resistance of the substrate surface.

Compared with conventional surface coating processes, laser cladding has the following significant characteristics:

(1) The biggest feature of laser cladding technology is that it can selectively prepare high-performance cladding layers on the surface of cheap and easy-to-process substrate materials, and the thickness of the cladding layers is not limited; single-layer cladding or multi-layer cladding can also be performed as needed to give the coating a gradient function.

(2) Compared with general coating processes, the hardness of laser cladding coatings is generally relatively high, and the wear and corrosion resistance is also relatively good; it can even produce new performance structures, such as metastable phase, superdispersed phase, amorphous phase, etc.

(3) It can achieve local precision cladding and repair, and the subsequent processing is small.

(4) Since the heat action zone is very small, the thermal deformation of the workpiece is also relatively small, and the mechanical properties of the substrate are not damaged.

(5) The thickness of the cladding layer can be precisely controlled, and the cladding layer forms a metallurgical bond with the substrate; and the dilution rate of the cladding layer is small.

(6) The layer composition and performance are almost not affected by the composition of the base material.

(7) The processing flexibility is good, and laser cladding can be easily performed on grooves, hole walls and other parts that are difficult to process by conventional methods; the movement controllability of the laser beam is good, and the complex contour surface of the switch can be easily processed.

(8) It has the characteristics of high degree of automation, easy process control and automation, no pollution to the environment, low noise, and comfortable workpiece conditions. It is a "green" surface engineering technology.

(9) Laser cladding technology provides a new way with unique advantages for parts manufacturing.

3 Laser 3D printing (molding) technology

It is a product with a certain strength that uses computers and three-dimensional geometric modeling technology of parts to melt specific metal powder through laser heating source, and pile it into the geometric shape of the workpiece. The biggest feature is fast proofing speed and low cost. This technology has been widely used in the manufacturing fields of medical equipment parts and electronic consumer parts such as aerospace, nuclear power, etc.

 

5.Mold material sales, CNC processing, grinding processing

Taicang Kuntai Precision Mould Co., Ltd. is a subsidiary of the group company to solve the one-stop demand services for materials and CNC processing of customers within the group. It has 2 sets of mould material milling and grinding equipment, and the daily processing capacity of moulds and mechanical light plates reaches 20 tons. Among them, the effective processing stroke is .4×2 meters and 8×3.2 meters large precision grinders (accuracy 0.02mm), which effectively solve the grinding and processing problems of large mechanical equipment appearance parts. It is also equipped with 10 precision machining centers, with machining strokes ranging from 1.0 meters × 600mm to 3.2×8 meters. It is also equipped with corresponding testing tools and equipment, covering the processing of almost all hardware moulds and most mechanical equipment table plates and wall panels. Provide one-stop services from materials, processing and surface treatment for suppliers of automotive moulds, welded parts, 3C and new energy automation equipment.

Shanghai Pengtai Machinery Technology Co., Ltd. provides 45 steel, 42CrMo full-specification round steel raw materials, and helps sawing, tempering, finishing and other processing services.

 

6.Gear Pump Products

The "Shanghang brand" gear pumps independently developed and produced by Shanghai Pengtai Machinery Technology Co., Ltd. include two series: spur gear conjugate internal gear pumps and involute gear pumps. Spur gear conjugate internal gear pumps are divided into low-pressure pumps, medium-pressure pumps (including servo-specific pumps) and high-pressure pumps in terms of pressure; they are divided into single-stage pumps, multi-stage pumps (including series pumps), and double pumps (series pumps with different displacements and different pressures) in terms of structure; they can be widely used in aviation kerosene fuel filling equipment, injection molding machines, polyurethane equipment, rubber tire equipment, shearing machines, bending machines, die-casting machines, hydraulic test benches, coal machinery, mining machinery and hydraulic stations, etc.

The product has strong self-priming performance; the inner and outer rotors have the same direction, less wear and long service life; the pump speed is linearly related to the flow rate, and the speed can be appropriately changed to change the pump flow rate; it is particularly suitable for the transportation of high-viscosity media; the liquid is transported smoothly, without pulsation, small vibration and low noise; the correct selection of parts materials can transport a variety of corrosive media, and the operating temperature can reach 200°C; servo-specific pumps are energy-saving; series pumps can be used for the transportation of low-viscosity liquids; duplex pumps can be equipped with different flow rates and pressures according to needs.

The biggest feature of the product is that the company has a dedicated R&D team, all processing processes are controlled by itself, and all parts processing is not outsourced, which fundamentally solves the problem of material selection and accurate control of heat treatment processes, gives full play to the mechanical properties of materials, and performs parts finishing according to international standard tolerances. The assembly and shipment are fully inspected, and the product quality exceeds that of domestic peers, which can completely replace imported similar products.

 

7.Testing Services

The laboratory cooperates with national-level metal material quality inspectors and imported testing equipment to independently complete material composition quantitative testing, metallographic structure testing, mechanical properties testing and part failure analysis.