Heat Treatment Furnaces Technology

HEAT TREATMENT FURNACES TECHNOLOGY
Melting copper &aluminum
BUILDING ELECTRICAL INSTALLATION DEPARTMENT
Prepared By:
Ins. Getahun Ayele
AMARO KELLE TVET COLLEGE

MAY, 2013
Acknowledgements
I wish thank the Amaro kelle Tvet college technology center for recognizing the problem and for
sponsoring the project. I also wish to thank all of the college members for their involvement in
completing surveys necessary and from outside for the advancement of my project.
First of all, in each movement of this project work time we would like to thank our ALMITHY
GOD. Next to that, there are some peoples that we like to thank them, in which they helped us by
giving a good advice to write this nice technology ins. Getahun Ayele they advised, oriented and
suggested us in a good manner on this heat treatment furnaces technology.
Finally I would like to thank for advising my research project, for his professional guidance,
support, and useful and constructive recommendations given throughout the advancement of the
project.
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Abstract
Heat treating is the controlled heating and cooling of a material to achieve certain mechanical
properties, such as hardness, strength and the reduction of residual stresses. Many heat treating
processes require the precise control of temperature over the heating cycle. The objective of this
technology work is to develop a comprehensive furnace model by improving the thermal control
Heat Treatment Planning furnaces and the improved electric furnaces operates on the principle
of electric resistance and the resistance of the heatingelement was obtained to be 6.8Ω. The
electric furnaces or oven was put to test in order to determine its function ability and
effectiveness through some pieces of copper, aluminumand oven for bread items. When the
electric furnaces or oven was tested, higher efficiency is obtained when compared with the
already existing one. Therefore, it can be deduced that the designed technology is faster and thus
tempered effectively when compared with existing one (that means furnaces for knife making
and gold house furnaces).
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Acknowledgements.....................................................................................................................................ii
Abstract......................................................................................................................................................iii
Abbreviations...........................................................................................................................................viii
CHAPTER ONE..........................................................................................................................................1
1.1 INTRUDUCTION AND BACKGROUND...........................................................................................1
1.2.Statement of the problem...................................................................................................................1
1.3.General Objective..............................................................................................................................2
1.4Specific Objective...............................................................................................................................2
1.5.Scope.................................................................................................................................................2
1.6. Limitations........................................................................................................................................2
1.7. Significance of the technology.....................................................................................................2
CHAPTER TWO.........................................................................................................................................4
LITERATURE REVIEW............................................................................................................................4
2.1 Heat treating process overview..........................................................................................................4
2.2 What is Heat Treating?......................................................................................................................4
2.3 Why Use Heat Treating ?...................................................................................................................4
2.4 Basic requirements of heat treatment process....................................................................................5
2.5 Basic requirements of furnaces..........................................................................................................6
2.6 Heat treatment processes...................................................................................................................6
2.7 Types of furnaces...............................................................................................................................6
2.8 Value chain analysis..........................................................................................................................8
CHAPTER THREE...................................................................................................................................10
METHODOLOGY....................................................................................................................................10
3.1. Method of Data Collection..............................................................................................................10
3.1.1 Primary data collection.............................................................................................................10
3.1.2 secondary data collection..........................................................................................................10
3.2 Design Methodology..................................................................................................................10
3.2.1...................................................................................................................................................10
3.2.2 Failure Theory and other possible designing concepts employed.............................................10
Loose wire........................................................................................................................................10
3.2.3 Development tools used for the heat treatment furnaces (software and equipment)..................11
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Developing this technology using proteus electrical software and solid Design auto cad..................11
Electrical equipment and material......................................................................................................11
3.4. Feasibility analyses.........................................................................................................................11
3.4.1 Technical Aspect................................................................................................................13
3.4.2 Economic Aspect...............................................................................................................13
CHAPTER FOUR.....................................................................................................................................14
THE DESIGNING PROCESS...................................................................................................................14
4. Introductions......................................................................................................................................14
4.1 Design analysis..........................................................................................................................14
4.1.1Product and Part description......................................................................................................14
4.2Material selection.............................................................................................................................14
4.3Failure analysis.................................................................................................................................15
4.4Part manufacturing process...............................................................................................................15
4.5.1Insulation...................................................................................................................................15
4.5.2Electrical....................................................................................................................................16
4.7Assembly and maintenance..............................................................................................................19
4.8. Direct material cost.........................................................................................................................20
CHAPTER FIVE.......................................................................................................................................21
CONCLUSION & RECOMMENDATION..............................................................................................21
5.1.CONCLUSION................................................................................................................................21
RECOMMENDATION.............................................................................................................................22
REFERENCES:-.......................................................................................................................................23
APPENDICES...........................................................................................................................................24
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LIST OF TABLE
Table 1Temperature conversion chart...........................................................................................12

Table 2Direct material cost............................................................................................................20
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LIST OF FINGURE
Figure 1 furnaces type.....................................................................................................................7
Figure 2 value chain as is.................................................................................................................9
Figure 3 value chain TO BE............................................................................................................9
Figure 4 value chain GAP................................................................................................................9
Figure 5 fire bricks(gypsum model ).............................................................................................14
Figure 6 PID temperature controller Door frame angle iron.........................................................15
Figure 7 heating element (resistor )...............................................................................................15
Figure 8 Switch brackets and door hinge .....................................................................................15
Figure 9 mechanicaly asembled main body part...........................................................................17
Figure 10 control box.....................................................................................................................18
Figure 11 Fig software simulation on proteus...............................................................................19
Figure 12 lay out of the pid design................................................................................................19
Figure 13 wiring diagram of temperature control.........................................................................20
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Abbreviations
PID…………………………………..proportional integral derivative
Ac…………………………………….Alternating current
A………………………………………ampere
p……………………………………power
R……………………………………..resistance
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CHAPTER ONE
1.1 INTRUDUCTION AND BACKGROUND
Heat treating is the controlled heating and cooling of a material to achieve certain mechanical
properties, such as hardness, strength, flexibility, and the reduction of residual stresses. Many
heat treating processes require the precise control of temperature over the heating cycle. Heat
treating is used extensively in metals production, and in the tempering and annealing of copper
molded and aluminum molded products.These furnaces are made up of an assortment of different
materials; sheetmetal ,angle iron ,pid thermal control ,resistor and gypsum composites are used
to create furnace parts and fixtures. The purpose with this technology was to evaluate the control
of the temperature in an annealing furnace, both the existing control and possibly new control
strategies. That means (PID) Proportional Integral Derivative control system ,which is essentially
"lots of gas when you are getting up to speed and less gas when you get are at the desired speed."
In this case, the heating stays steady as the oven is warming up and then reduced as the kiln
interior gets closer to the target temperature. One benefit of a PID type controller is that as you
get close to the target temperature, it doesn't "overshoot" and push the temperature too high;
which can be the case with a conventional open/close heating circuit that is slow to respond.
1.2 Statement of the problem

1. Now days, we can see the demand on making a suitable metal for some condition. For
example they will be used in home appliances that means for beauty purpose and cutting (knife)
purpose or construction where they required a metal that can stand with certain condition at the
low cost of manufacturing process. And previously working heat treatment on manually and high
cost of charcoal (cutting of trees) .that economic impact and air pollution on our country.
2. And secondly there are no heat treatment furnaces for the gold house and there is no home
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beauty furnaces that melting copper and aluminum
1.3.General Objective
The objective of this technology to develop a heat treatment furnace model byimproving the
temperature controlled or pid system based furnace model.Can also be used to obtain certain
manufacturing objectives like
 To improve machining & formability
 To restore ductility
 To recover grain size etc.
 Known as Process Heat Treatment
1.4Specific Objective
Heat treatment done for one of the following specific objective:
 Hardening
 Softening
 Property modification
1.5.Scope
The scopes of this project are :
 Design the furnaces working electrical heating element to keep the heat on the crucible
 This project focused on melting copper ,aluminum, knife making steelmetal and oven for
bread only.
1.6. Limitations
Some of the limitations of the proposed work in this research are the availability of experimental
data. The thermal gradient model is based on experimental data and is not possible to represent
the gradients, unless a few experiments are conducted at several locations in thefurnaces
1.7. Significance of the technology

 Heat treating is the controlled heating and cooling of a material to achieve certain
mechanical properties, such as hardness, strength, flexibility, and the reduction of
residual stresses.
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 The process of heat treatment involves the use of heating or cooling, usually to extreme
temperatures to achieve the desired result. It is a very important manufacturing process that can
not only help the manufacturing process but can also improve product, its performance, and its
characteristics in many ways.
 This technology is many significant for example molten aluminum ,copper then we get
molded copper and aluminum for home beauty stand and some pieces of steel to melt
then we get knifes.
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CHAPTER TWO
LITERATURE REVIEW
2.1 Heat treating process overview
Heat Treatment may be defined as heating and cooling operations applied to metals and alloys in
solid state so as to obtain the desired properties. Heat treatment is sometimes done inadvertently
due to manufacturing processes that either heat or cool the metal such as welding or forming.
Heat treatment is often associated with increasing the strength of material, but it can also be used
to refine the grain size, relieve internal stress, to improve machine ability and formability and to
restore ductility after a cold working process. Some of the objectives of heat treatment are
summarized as follows:
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• Improvement in ductility •Relieving internal stresses • Refinement of grain size • Increasing

hardness or tensile strength • Improvement in mach inability • Alteration in magnetic properties
• Modification of electrical conductivity • Improvement in toughness
2.2 What is Heat Treating?

Heat Treatment
• process of controlled heating and cooling of metals • Alter their physical and mechanical properties •
without changing the product shape • sometimes takes place inadvertently due to manufacturing processes
that either heat or cool the metal such as welding or forming.
Controlled Heating And Cooling of Metal to Change Its Properties and Performance.
Through:
•Change in Microstructure
•Change in Chemistry or Composition
Heat Treatment
• Heat treatment done for one of the following objective:
–Hardening. –Softening. –Property modification.
2.3 Why Use Heat Treating?

In simple Terms
•Soften a Part That Is Too Hard.
•Harden a Part That Is Not Hard Enough.
•Make Good Magnets Out of Ordinary Material.
•Make Selective Property Changes Within Parts.
Electrical Heating Systems Electrical Heating Systems for Heat Treating
•Resistance Electrical Heating Systems
Electrically Heated Conventional Furnaces
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Figure 1electrical heating system
Major Components of an Electrical Heating System

•Heating Elements
•Power Supply Power Supply
•Power Control System Connected with the Furnace Temperature Control System
•Water Cooling System
2.4 Basic requirements of heat treatment process

The main requirement of the heat treatment process is the accurate control of thetemperature
profile. And also soaking/holding at specified temperature for obtaininguniform cross section
temperature across load and work piece is another basicrequirement of the heat treatment
process. In processes like carburizing once the loadreaches the soaking temperature the enriching
hydrocarbon gas is added to the furnaceand the load is held at the carburizing temperature for the
carbon diffusion to occur untilthe required case depth is achieved. And the cooling cycle is
determined by the requiredmicrostructure desired. And the cooling can be either liquid or gas
cooling depending onthe furnace.
2.5 Basic requirements of furnaces

The main requirement of the furnaces in the heat treatment process is to provide the necessary
heat input for the load/work piece. The furnace also requires a control system to control the
temperature in the furnace accurately. Also a uniform temperature distribution is desired inside
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the furnace. Apart from the temperature controller there are also several atmosphere controllers
and material handling controllers required based on the type of furnaces.
2.6 Heat treatment processes

There are several different types of heat treatment processes. By controlling the soak temperature
and the cool down rate of the steel, we can determine the process to be accomplished. Those
processes include,
• Annealing
• Normalizing
• Stress relieving
• Hardening
• Tempering
Annealing
Annealing is the process of heating the steel to a particular temperature in the austenite region
and cooling down the steel very slowly.
Normalizing
Normalizing is a process that makes the grain size normal. This process is usually carried out
after forging, extrusion, drawing or heavy bending operations.
Stress relieving
Stress relieving is an intermediate heat treatment procedure to reduce induced residual stresses as
a result of machining, fabrication and welding.
2.7 Types of furnaces

The furnaces used in the heat treating process can be classified in several different
ways. The most popular classification method is shown in Fig. 2.3.
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Figure 1furnaces type
2.2.1 Classification based on energy used method

One of the popular methods of classifying the furnaces is based upon the heatingor energy input
method. And it can be divided into combustion based heating and electricheating methods.
Combustion-based (Fuel-based) Process Heating
Heat is generated by the combustion of solid, liquid, or gaseous fuels, and transferredeither
directly or indirectly to the material. Common fuel types are fossil fuels (e.g. oil, natural gas,
coal) The combustion gases can be eitherin contact with the material (direct heating), or be
confined and thus be separated from the material (indirect heating; e.g., radiant burner tube,
radiant panel, muffle).
Electric process heating (Electro technologies)
Electric currents or electromagnetic fields are used to heat the material. Direct heatingmethods
generate heat within the work piece, by either
(1) Passing an electrical currentthrough the material,
(2) Inducing an electrical current (“eddy current”) into the material,
(3) By exciting atoms/molecules within the material with electromagnetic radiation(e.g.
microwave).
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Indirect heating methods use one of these three methods to heat aheating element or subsector,
and transfer the heat either by conduction, convection,radiation or a combination of these to the
work piece.
2.8 Value chain analysis
Input Preparation Packaging andTransportation

Hardware implementation storage Marketing
Testing Finished
Research the Selectin product
and Direct
electrical g in Delivery
developme
compone selling
nt material
Making worksho
ntsIdentify p
furnaces
needed
body
Design software
for the andelect S IS
design
Layout rical a inA
c h
Material
process design
Testing
a lue
selection
for final V
urnaces circuit
design
Figure 2value chain as is
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Input Preparation
Hardware implementation
Packaging and storage
Transportation Marketing
Selecting
Research Testing
material Packing
and the Whole
circuit Finished Delivery
developme componen selling
Selecting design and
Making product
nt ts
the best control
furnaces
Design software Standard
body Retailing
for the storage
Simulation andelectric
design Inspection
al design Quality
Material by auto Servicing
and testing control
selection cad and Repairing
Layout final (display
poteus Training
process for product room)
furnaces
design
Furnaces Value chain TO BE
body part
Figure 3value chain TO BE
Input Hardware implementation

Preparation Packaging and storage
Transportation Marketing
Research Testing Selecting

and the material Packing
Whole
developme componen circuit Finished Delivery
selling
nt Selecting
ts design and product
the best Making
control
Design software furnaces Standard
for the body Retailing
storage
design
Simulation andelectric
Material by al design
selection Inspection Quality
MULTISM Servicing
Simulation and testing control
Repairing
by auto final (display
Training
Furnac
cad and
poteus
product room)
es Value chain GAP

body
part
Figure 4value chain GAP
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CHAPTER THREE
METHODOLOGY
3.1. Method of Data Collection
3.1.1 Primary data collection
I was able to get to suitable heat treatment furnaces on our are (kelle town) and our country there
is no good furnaces on this area and that they advised new design for this heat treatment soak
temperature for almost all the knife steels ,melting copper and aluminum could want. i did have
to set the target "pid " temperature higher than what i wanted. because of this I am thinking the
oven was approaching its maximum temperature limit. Works for me!
3.1.2 secondary data collection
another one for data gathering for this heat treatment furnaces technology secondary data
collection this means collecting from source of internet, wikipedia and other books from the
basic heat treatment.
3.2 Design Methodology

3.2.1Consider the possible mechanisms: The following instructions describe the design
and construction of a simple but effective heat treatment furnace suitable for the treating
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copper ,steel ,aluminum and bread oven
All measurements for the body of the furnace are given as a guide only, you are free to make
yours as large as you want but making it smaller will cause problems in installing your
elements. The inner volume of the furnaces casing measures ( 310 mm wide x 300 mm high
x 410mm deep )
3.2.2 Failure Theory and other possible designing concepts employed
Loose wire.
Over time, the vibration that results from the furnace running can cause internal wires to
become loose. Eventually, a wire gets so loose that it causes a short, leaving you with an
electric furnace that’s not heating. It may take some time to find the problematic wire, but
fixing or replacing the loose wire will take care of this problem. To prevent this problem in
the future, make sure you have your system regularly inspected and tuned up, to keep those
wires tightened and prevent shorts.
3.2.3 Development tools used for the heat treatment furnaces (software and
equipment)
Developing this technology using proteus electrical software and solid Design auto cad
Electrical equipment and material
 Fire bricks
 heating element(resistor)
 Improved electric Heat treatment furnaces oven was designed and fabricated. It
consists of (PID)
 breaker, wire
 thermostat
 housing unit
 light indicator
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 Timer and heating element and interlock switches.

Software:-AutoCAD, protease draw
Hand tools and machine grander
3.4. Feasibility analyses
Feasibility analysis
This technology (electric heat treatment furnaces)operates on the principle of electric resistance.
Due to the resistance to current flow, the heating element was heated up and the voltage indicator
shows a green light confirming the presence of current. Once the switch is turned on, the
indicator shows red indicating that the oven is in operation. The basic operational principle of
the electricHeat treatment furnaces oven is the process of heat transfer. Heat transfer through
conduction, convection and radiation, tends to occur whenever there is a temperature difference
Temperature conversion chart
Degree Celsius degree faranait

Water freezes 0 32
Copper melt 1084 1983
Aluminum melt 660 1220
Water boils 100 212
Iron melt 1530 2786
Tin melt 232 450
Lead melt 328 621
Table 1Temperature conversion chart
Formula for calculating resistive heating is:
P = I2 x R
Where P is the power, I is the current, and R is the resistance. This equation could be
derived from the first one by substituting I .R for V (according to Ohm’s law). This
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second formula is more frequently used in practice to calculate resistive heating,

whereas the first formula has other, more general applications.
. P = I2 x R ……p= 2600W,i=20amp then calculating resistance
R= P/ I2
R=2600/ (20*20)amp
=6.5Ω
3.4.1 Technical Aspect
On this technology there are technical aspect that are documented to working this heat treatment
developed what the advantage on the technology energy consumption offices and all of the benefits of furnaces
that means for melting copper that modification for some machine equipment and model for oven of bread
3.4.2 Economic Aspect
Looking at the economics of owning your own heat treatment furnaces oven, I am computing it's
a big plus! My heat treatment service more advantage on new furnaces because on old melting
iron working manually and this one is working on electric system that is not more costy than the
previous one and on another hand working time is economic aspect
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CHAPTER FOUR
THE DESIGNING PROCESS

4. Introductions
The overall circuit consists of a 220VAC 20A supplied electric heating element. My target
total resistance is 6.6 ohms and thus the current draw from the heater itself is around 18A at
220VAC. This works out to about 2600W, which is ideal for a small space like the one I am
going for. My survey of off the shelf heat treating ovens from Even heat range are typically
3500 to 7200 watts per cubic foot.
4.1 Design analysis
4.1.1Product and Part description
Product requirements are defined

When doing this technology (heat treatment furnaces ) many product and material are required
that are suitable for the projectthat main or basic product are :-molted fire bricks gypsum,
pid ,breaker and angle iron
4.2Materialselection
The factors considered in the selection of materials include; mechanical properties such as
strength, hardness, durability; cost, availability, and electrical properties.
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Figure 5fire bricks(gypsum model )
Electric wire 2.5 Figure 6PID temperature controller Door frame angle iron
Figure 7HEATING ELEMENT (RESISTOR )
Figure 8Switch brackets and door hinge ,
Furnaces Frame(angle iron ),Control panel or box
LEDs and Element Off switch,Red and green 220v,Single phase Beaker
4.3Failure analysis
- Find allowable stress: Heating Electrical Connections
The two heating elements in this design are in parallel, which means I need to have six leads
coming from inside to the outside. These will then be connected two N (Neutral) sides
together and two L (Line) sides together..overOverall, thinking I can improve on the heating
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curve by increasing the temperature in certain areas(furnaces)floor. The target is 1500°C ,the
machine is woring at tis temperature the reisistancefalurity is happened or loose
4. Productionmanual process
4.5.1Insulation
These bricks are soft, lightweight and super easy to cut, shape, drill, scrape or however we
want to work with them. The dust is a hazard, so always wear some safety glasses, gloves
and particle respirator when cutting, sanding or drilling. Keep a vacuum handy.to build a
front door kiln with a fairly small volume. I decided based in the bricks that a interior size of
280mm (long) x 300mm (wide) x 410 (high) would suffice for almost any steel ,copper and
oven for bread
4.5.2Electrical
The overall circuit consists of a 220VAC 20A supplied electric heating element. My target total
resistance is 6.8ohms and thus the current draw from the heater itself is around 20A at 220VAC. This
works out to about 2160W, which is ideal for a small space like the one I am going for. My survey of
off the shelf heat treating ovens from Even heat range is typically
3500to7200wattspercubicfoot.started by placing the fire bricks in a variety of different ways to create
a suitable interior dimensions for heating small parts. Once I have the arrangement, I planned where
the heating elements are going to be routed on the inside.
By using a pencil attached to various blocks of wood, I could draw parallel lines for the
heating element grooves. A compass can help with the bends.
Heating Electrical Connections
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The three heating elements in this design are in parallel, which means I need to have six leads
coming from inside to the outside. These will then be connected three N (Neutral) sides
together and three L (Line) sides together.
The process of installing the elements is quite simple. Twist about 3" of lead on each end of
the element and feed the lead through the hole and staple the element into place with U
shaped staples I made from carbon steel welding wire. My Kanthalcomes wound pretty
consistent and I made the groove size to fit, so not too many staples are required. Say 1 staple
every 4 to 6 inches. More may be needed if your heating wire doesn't friction fit as tight. Use
some needle nose pliers and push the staples in at about a 45 degree angle to secure the
heating elements
Mechanical Assembly
After the heating circuits are wired in, we need to put the brick panels all together and
mechanically secure them so everything fits tight. There also needs to be a hinge and a
Figure 9mechanicalyasembled main body part
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frame to hold the door on. An idea for a corner frame made with flat bar, ready-rod, a few
pieces of angle iron and a little bit of welding came to mind.
Control box
The PID controller needs a square so I drilled the corner holes so the jig saw blade could get
started. Clamped down to the bench I cut the square out rough
Figure 10control box
Rear panel. This needs holes for the following: Main power cable, Fuse 1 (main power) and F2 (control
power), Thermocouple, door switch and output to the heating circuitthe front panel layout. Clockwise
from PID controller: 1: Oven On LED, 2: Door Open LED, 3 - Elements Off LED, 5: Elements Switch, 6:
Main Power Switch, 7: Main Power On LED. On the underside of the oven I have a momentary NO/NC
switch installed.The thermocouple is fitted to a piece of Plastic and cemented in with high temperature
mortar from the bottom. The probe extends up into the centre of the oven.This is away from the elements
and where the steel is going to beheating.
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On the left side is the main power switch along with the LEDs and Element Off switch. The right side
(back of the enclosure) contains the SSR, power fuses and I/O strain reliefs. Note that it's a good idea to
put some thermal compound on the SSR when mounting it. This helps dissipate the heat.
4.6 Software Simulation of each part (optional)

On this technology used proteus software for design analysis
Figure 11Fig
software simulation on proteus
Figure 12lay out of the pid design
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Figure 13wiring diagram of temperature control
4.7Assembling manual
I decided based in the bricks that a interior size of 90mm (long) x 280mm(wide) x 310mm(high)
would suffice for almost any knife i would be heat treating.
Construction
I started by placing the fire bricks in a variety of different ways to create a suitable interior
dimensions for heating small parts. Once I have the arrangement, I planned where the heating
elements are going to be routed on the inside.
By using a pencil attached to various blocks of wood, I could draw parallel lines for the heating
element grooves. A compass can help with the bends.
This will be the inside of the ceiling blocks with the power coming in on the right side.
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I went over the pencil lines with a permanent marker.then after that intering heating element into
the box of fire brich and out to the control box of the plug of resistor yhen after design the
control system or pid of temperature controller
Drive mechanisms (user manual)

1. First plug in power supply (single phase from the socket outlet)
2. Secondly checking control box switch in on or off button and power on to the furnaces
3. Lastly checking thermometer that means degree Celsius up to 1200
WARNING:
I am offering this information for entertainment purposes only. I will not be liable
for any use or misuse of this information. This project deals with hazardous
voltages, temperatures and substances that you must understand and work with
at your own risk. If you are not knowledgeable about electricity consult with a
qualified electrician
maintenance
Overall, I am thinking I can improve on the heating curve by increasing the insulation in
certain areas e.g. gaps in door seal,. The target is 1200°C but unfortunately increasing the
degree Celsius that damage the heating resistance and loose heat resistance, and on that case
maintenance is occurred and renewed design and interringinsulating resistor on the furnaces
and all of the maintenance equipment are or accessory are in market .
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4.8. Direct material cost

No. Technical
Item description specification Unit Qty Unit Total price
price
1. Single phase breaker Ac single phase 25A 1 120 120
2. thermostat PID), Temperature 220v 1 2500 1500

controller
3 light indicator Red and yellow 220v 2 100 200
4 resistor heating element 1.02 ohm 2 200 400
5 electric wire 1.5 flexible flexible 1.5 1 200 200
6 electric wire 2.5 flexible flexible 2.5 1 250 250
7 Angle iron 2mm 3 350 800
8 door hinge 1 30 30
9 Door Switch brackets 1 45 45
10 Gypsum pc 4 120 480
11 Cement Mugger o.5 1 100 100
12 Sheet metal 0.8mm 1 200 200
Total cost=3900 birr
Table 2Direct material cost
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CHAPTER FIVE
CONCLUSION & RECOMMENDATION

5.1.CONCLUSION
It is significant that the use of heat treatment for manufacturing different copper alloys
with various functions has been applied in different historical periods. This indicates ancient
metalworkers’ understanding of copper and its alloys properties and heat treatments effects
on their improvement and alteration as well. Based on this investigation, two particular kinds
of heat treatment could be characterized: annealing and quenching which have been frequently
used from ancient times. According to the results, three different structures have been observed
in samples including steel melting ,copper melting and aluminum melting which imply cold
working followedby annealing as heat treatment. Annealing applied as a main heat treatment
process has been carried out on a metal or alloy, usually to improve.
Workability and remove stress in structure to allow further deformation. I changed the magnet
for a more positive closure system. This is a bolt welded on a piece of pipe. The female part at
the oven in threaded. The wood is only a handle to crank the door closed.
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RECOMMENDATION
- The recommended future work for the project is the incorporation of a load optimization
routine. Such a routine enables the furnace utilization and improves furnace efficiency. Also
models specifically developed to different processes enable more accurate prediction of thermal
Profiles and also useful for process optimization. Another recommendation is creating furnace
specific models for different kinds of furnaces instead of two general models this means for
bothpurpose heating and medical oven purpose.
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REFERENCES:-
1. “Roadmap for Process Heating Technology Priority Research & Development Goals and
Near-Term Non-Research Goals To Improve Industrial Process Heating”, Industrial Heating
Equipment Association, U.S. Department of Energy Office of Industrial Technologies, Capital
Surini Group International, Inc., Energetics, Incorporated, March 16, 2001.
2. Improving Process Heating System Performance: A Sourcebook for Industry is a development
KELLE TVET COLLEGE Page xxxiv

of the Best Practices initiative under the U.S. Department of Energy (DOE) Industrial
Technologies Program (ITP) and the Industrial Heating Equipment Association (IHEA)
3. Heat Treating, ASM Handbook -Volume
4, 1991 4. H. Ramamurthy, S. Ramadhyani, and R. Viskanta, "A Thermal System Model for a
Radiant-Tube Continuous Reheating Furnace", Journal of Materials Engineering and
Performance, Volume 4(5), 519-531, October 1995
APPENDICES (ALL part drawing and detail drawing)
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Dr by GetahunAyele
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Dr by Getahun Ayele
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Heat Treatment Furnaces Technology

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HEAT TREATMENT FURNACES TECHNOLOGY

Melting copper &aluminum

BUILDING ELECTRICAL INSTALLATION DEPARTMENT

AMARO KELLE TVET COLLEGE

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Table 1Temperature conversion chart...........................................................................................12

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1.1 INTRUDUCTION AND BACKGROUND

1.2 Statement of the problem

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beauty furnaces that melting copper and aluminum

1.7. Significance of the technology

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• Improvement in ductility •Relieving internal stresses • Refinement of grain size • Increasing

2.2 What is Heat Treating?

•Change in Chemistry or Composition

• Heat treatment done for one of the following objective:

–Hardening. –Softening. –Property modification.

2.3 Why Use Heat Treating?

•Soften a Part That Is Too Hard.

•Harden a Part That Is Not Hard Enough.

•Make Good Magnets Out of Ordinary Material.

•Make Selective Property Changes Within Parts.

Electrical Heating Systems Electrical Heating Systems for Heat Treating

•Resistance Electrical Heating Systems

Electrically Heated Conventional Furnaces

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Figure 1electrical heating system

Major Components of an Electrical Heating System

•Power Supply Power Supply

•Water Cooling System

2.4 Basic requirements of heat treatment process

2.5 Basic requirements of furnaces

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2.6 Heat treatment processes

2.7 Types of furnaces

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Figure 1furnaces type

2.2.1 Classification based on energy used method

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2.8 Value chain analysis

Input Preparation Packaging andTransportation

Figure 2value chain as is

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Figure 3value chain TO BE

Input Hardware implementation

Research Testing Selecting

es Value chain GAP

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3.1.1 Primary data collection

3.1.2 secondary data collection

3.2 Design Methodology

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copper ,steel ,aluminum and bread oven

3.2.2 Failure Theory and other possible designing concepts employed

Electrical equipment and material