Applied Process Inc. has collaborated with AFC-Holcroft to produce a Monster Parts™ furnace for a new plant that Applied Process is establishing in Oshkosh, Wis. The new plant is in response to growing demand for Austempered Ductile Iron (ADI), Carbidic Austempered Ductile Iron (CADI™), Austempered Gray Iron (AGI), Austempered Steel and Carbo-Austempered™ Steel components and for applications that consolidate many steel or aluminum weldments, forgings, castings or assemblies into a single, large, elegant ductile iron design not previously feasible. The unique universal batch quench-austemper (UBQA) design will have a working envelope of 84 inches x 96 inches x 56 inches and a maximum gross load of 20,000 pounds. The unit integrates a controlled atmosphere furnace with an oversized nitrate/nitrite salt quench with transfer from the furnace accomplished safely, automatically and under atmosphere.

The new heat-treating facility, Applied Process’ Monster Parts Division, will be housed in a purpose-built, 15,000-square-foot building in Oshkosh. The furnace will employ strategically placed natural-gas-fired radiant tubes and is designed to meet the stringent temperature uniformity requirements of various new international standards. It will utilize an endothermic gas atmosphere with natural gas addition. The heat and atmosphere will be uniformly circulated in the furnace with the aid of four alloy fans. A raised pier design in the furnace will allow both the sight lines necessary for efficient radiant heat transfer and the smooth flow of atmosphere circulation. A special direct gear drive handling system was developed by AFC-Holcroft for this furnace. The system is designed to smoothly accelerate and decelerate the load quickly, without the rough, jerking motions that can plague conventional transfer systems.