Ione Exchange Plating

When steel wire is submerged in a solution of copper sulphate CuSO4 sulphuricacid H2SO4 and water the surface ions on the iron Fe steel wire surface will go into solution. As this happens the steel wire will get slightly negatively charged and attract a positively charged copper Cu ion. Hence the process name ione exchange plating. The process is commonly used in the production of copper coated MIG welding wire and office staples. It is imperative that the wire surface is clean prior to entering the plating solution. The Fig below shows the princip of an continous plating line.

In line cleaning and plating line

Plating tank courtesey of Welding Wire Machineries s.r.l.

Plating tank courtesey of Outokumpu WTT AB

Furnace Types

Fluidbed Furnaces

Used for:
Annealing, Tempering, Stress Relieving, Patenting,

Quenching Lead Furnaces

Used for:
Annealing, Tempering, Quenching, Patenting,

Muffle or Tube Furnaces

The Muffle or Tube Furnaces are built for the continuous in-line austenitizing or annealing of multiple wire strands. High velocity burners are mounted along both sides of the furnaces in a staggered pattern that produces excellent temperature uniformity. Pressure controled combustion available on some furnaces gives a high turn-down ratio and efficient multiple burner control.

Direct Fired Muffle and Tube Furnaces

Direct Fired Furnaces like the Muffle or Tube Furnaces are built for the continuous in-line austenitizing or annealing of multiple wire strands. High velocity burners are normally mounted along both sides of the furnaces in a staggered pattern in order to produce temperature uniformity. Generally used for: Austenitizing stainless steel wire

Annealing Oil Tempering Lines

Oil Tempering Lines consist of an Austenitizing Furnace, Quenching System, Tempering Furnace and Cooling and Coating Tanks. The Austenitizing Furnace can be Direct Fired, Fluidbed or Muffle Tube for atmosphere control. Following the heating section, the wires are rapidly quenched in a cooling medium of mineral based oil or water based polymer fluids.

Bell Furnaces

Bell furnace processing provides better control of the cooling process and also allows for a slower cooling period where the temperature can be held at a fixed intermediate temprature for an extended period. Bell Furnaces also allow for a more homogeneous and faster heat transfer.

Salt bath furnaces

Salt bath furnaces are used for a number of heat treatment applications such as: Preheating • Austenitizing • Martempering • Neutral Hardening • High-Speed Tool Hardening • Tempering Nitriding • Carburizing • Solution Heat Treating • Dip Brazing Modern systems offer quick ramp-up and high heating uniformity

Muffle Tube Furnace

The Muffle or Tube Furnaces.like the Direct Fired are built for the continuous in-line austenitizing or annealing of multiple wire strands. High velocity burners are mounted along both sides of the furnaces in a staggered pattern that produces excellent temperature uniformity. Pressure controled combustion available on some furnaces gives a high turn-down ratio and efficient multiple burner control. On most modern furnaces the combustion systems are arranged in multiple zones of control and can be oil, gas or dual fuel fired. Several layers of high quality refractory lining on the furnace gives efficient operation and establish low skin temperatures. The furnace shells on most modern furnaces are designed with a robust welded steel construction divided into modular units with bolted flanges.

The wires travel longitudinally through the furnace in individual protective atmosphere muffle tubes. Flow meters supply inert gasses to each special alloy tube that is supported above the refractory hearth. The burners are mounted below the tubes and effectively heat their surface by radiation, convection and conduction. The combustion chamber is sealed to insure safe operation and a high thermal efficiency. It is important that the selected components are of the highest quality to ensure a long trouble free life