The Thermal Processing Divisions of VAC AERO International have provided repair services for damaged components from land-based and aerospace gas turbine engines. Engine manufacturers, operators, overhaul centers and commercial airlines are just a few of the customers that depend on these services. Many hot section engine components are fabricated from nickel-based superalloys. These materials cannot be repaired by traditional techniques, such as welding, without causing significant reductions in mechanical properties. As a result, VAC AERO developed proprietary vacuum brazing techniques to repair cracks, wear and other service-induced damage. By Jeff Pritchard - Vac Aero International Inc.

As with any piece of equipment, proper maintenance at regular intervals is essential for long service life and trouble free operation.

The mechanical components in a vacuum furnace require standard maintenance practices (ie. cleaning, lubrication, etc.). However, successful use of a vacuum furnace depends on the purity and reliability of its vacuum. Additional maintenance activities are required to ensure good vacuum levels in the system. Leaks in joints and contamination of furnace internals will greatly affect operating vacuum levels and the quality of the processing.  Leaks are the most time-consuming and troublesome of the maintenance items.

This is the first in a series of four articles on Vacuum Furnace Maintenance due to appear over the next three months.

Most base metals typically brazed in vacuum furnaces have a natural oxide “coating” that can inhibit the flow of brazing filler metals. 

The oxides of the less reactive metals like iron, nickel and cobalt tend to dissociate (break down) under low pressure and high temperature. Therefore, alloys such as the 300 and 400 series stainless steels, carbon steels and many tool steels can be successfully brazed in vacuum at relatively high pressures (1 to 50 microns).

This is the first in a series of four articles on Vacuum Brazing Tecniques due to appear over the next three months.

All furnace equipment used for heat treating should be properly instrumented and periodically tested for uniformity.

The temperature uniformity within the furnace must be regularly surveyed. The frequency of surveying is largely dependent on the type of equipment in use and its previous history in accuracy and reliability. Exact survey frequencies should be determined from applicable processing specifications. However, quarterly temperature uniformity surveys are fairly standard. The purpose of the uniformity survey is to determine the range of temperatures present at different locations in the furnace under normal operating conditions. A furnace is normally qualified through an initial comprehensive survey.

In any heat treating cycle, there are two important considerations concerning temperature: the temperature of the furnace hot zone which is generating the heat input, and the temperature of the actual workload.

Heating by direct radiation, the main heating mechanism in vacuum, tends to be a slower process than other heating mechanisms such as convection or conduction. As a result, there are times in the heat treating cycle, particularly during heat up, when the load will be at a lower temperature than the furnace hot zone. This is known as temperature lag.

The purchase of a vacuum furnace involves a considerable capital investment. As a result, the question of buying a used furnace at a lower cost than a new furnace is a fairly common one. However, there are a number of potential issues with used equipment that should underscore the warning “buyer beware”. To begin with, good used vacuum furnaces are a rare commodity. When they do appear on the market, they don’t last long. Many of the best are purchased through industry networking and never reach the general market. Still, there are numerous dealers of used furnace equipment with inventories posted on their websites.

Once a good fixture design has been developed, careful consideration should next be given to the loading of the workpieces.

Heating in a vacuum depends mostly on the transfer of energy through radiation from the elements to the load.  For uniform heating and cooling, it is important that the workpieces are not shielded by one another.  Pieces within the load should be evenly spaced to ensure even exposure to radiation.  The size, shape and high temperature strength of the workpiece should also be considered during loading.  Alloys with complex shapes and relatively low strength at heat treating temperatures may distort during processing.  In some cases, it may be necessary to support these components with specially designed fixtures.