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Industrial IPSEN chamber furnace and quenching system used in heat-treatment processes for metal components.

Improved surface quality in IPSEN chamber furnace

Black deposits on small-sized quenched parts caused defective goods after the quenching process in an IPSEN chamber furnace. After installing a CJC™ Fine Filter, the deposits vanished within 1½ weeks, surface quality improved significantly, and the amount of rejected parts was reduced.


Application Snapshot

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Industry:

Industry

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Country:

Germany

Droplet icon representing the type of oil used in the application.
Oil type:

Mineral oil-based quenching oil

Executive summary

After the quenching process, black deposits covered small-sized quenched parts (valve covers). The deposits originated from the contaminated quench bath and could not be removed despite extensive after-treatment. Due to optical flaws, the parts were sorted out as defective goods during quality control.


To remove contamination from the quenching oil and improve surface quality, a CJC™ Fine Filter HDU 38/100 was installed with 4 × F 38/20 inserts (3 µm absolute) and a pump flow of 270 L/h.

Only 1½ weeks after installation, the surfaces of the quenched parts were significantly cleaner. The black deposits vanished, sandblasting in the after-treatment could be omitted, and the amount of defective goods was reduced. Following the successful test period, the company decided to purchase the CJC™ Fine Filter.


A CJC® Fluid Care System 27/27 was installed directly on the tank in an offline circuit. Varnish and other oil degradation products, as well as moisture and particles, were continuously removed 24/7. Oil analysis including varnish potential (MPC index) was implemented to ensure valid comparability under operating conditions.

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Droplet icon representing contaminated quench oil being cleaned through filtration.

Contaminated quench oil cleaned

The CJC™ Fine Filter removed contamination from the quenching bath using 3 µm absolute filtration.

Checkmark shield icon representing reduced rejected parts and improved product quality.

Reduced defective goods and omitted sandblasting

The amount of rejected parts was reduced and sandblasting in after-treatment could be omitted.

Valve icon representing removal of black deposits from components in the quenching system.

Black deposits eliminated

After 1½ weeks, black deposits on valve covers vanished and surface quality improved significantly.

Industrial component icon representing improved consistency and quality in the quenching process.

Improved consistency in quenching process

Cleaner quenching oil improved the quality consistency of hardened parts.

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Client brief

DURA Automotive Systems Rotenburg GmbH, Germany, is one of the largest suppliers to the international car and caravan industry and manufactures metal, cold-formed, and fine-blanked parts as well as valve spring plates.

Engineer holding two oil sample bottles comparing contaminated and cleaner oil.

Challenge

After quenching, small-sized valve covers were covered with black deposits originating from contaminated quenching oil. These deposits could not be removed despite extensive after-treatment. Because of these optical flaws, parts were classified as defective during quality control.

Production line with stacked cylindrical filter inserts used in industrial oil filtration systems.

Solution

A CJC™ Fine Filter HDU 38/100 equipped with 4 × F 38/20 inserts (3 µm absolute) was installed with a pump flow of 270 L/h. The system has a dirt holding capacity of approximately 15 kg and a water absorption capacity of approximately 8.5 litres.

Close-up of oil droplets suspended in liquid representing oil condition and contamination analysis.

Measured oil and process improvement

Oil samples taken before and after filtration showed a clear reduction in contamination. The improved oil condition resulted in visibly cleaner quenched parts.


Only 1½ weeks after installation, the surfaces of hardened parts were significantly cleaner compared to parts treated in unfiltered oil.

Results and operational impact

Following installation of the CJC™ Fine Filter, the black deposits on the quenched valve covers vanished within 1½ weeks. As a result, sandblasting in the after-treatment process could be omitted. The improved surface quality led to a reduction in defective goods identified during quality control.


Due to these convincing results during the test period, the company decided to purchase the CJC™ Fine Filter for permanent operation.












“We have clearly seen the efficiency of the CJC™ Fine Filter on the quenched parts. This result has convinced us.”
- Maintenance Manager, Mr. Riebesell


Person reviewing filtration system data and performance results on a tablet device.

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