dr. fritsch powder shaping technologies english catalogue
DESCRIPTION
Product catalogue displaying an overview of the Technologies which Dr. Fritsch has to offer: FAST Direct Hot-Pressing, Granulation, Mixing. Main focus is on the manufacturing of friction materials, sputter targets, heat sinks and machines for R&D ( universities, etc.).TRANSCRIPT
Overview
POWDER SHAPING TECHNOLOGIES
Powder Shaping Technologies
FAST-Direct-Hot-Pressing / Granulating / Mixing
2
Since the foundation of the company over 60 years ago,
Dr. Fritsch has continuously been setting milestones in
the sintering technology. Our self-developed FAST-Direct-
Hot-Pressing has triggered a little revolution in the
industry. Finally it was possible to significantly shorten
the sintering cycle. This not only lowered production
costs at higher productivity, but also allowed the
development of new materials and products with
considerably improved properties.
The early beginnings of Dr. Fritsch started in the diamond
tool industry. In this sector Dr. Fritsch holds a market
share of about 50 % and the FAST-Direct-Hot-Pressing
has become a standard. Meanwhile many other indus-
tries benefit from customized sintering solutions. Beside
the manufacturing of diamond tools, the Dr. Fritsch
sintering presses are also used for the production of
brakes and clutches, heat sinks, sputter targets, in the
hard metal industry as well as at universities and research
institutes. In addition to these innovative sintering
presses, Dr. Fritsch offers field-tested solutions for mixing
and granulation of metal and ceramic powders.
Our customers are the center of our business – that is
what nearly 100 employees in our German and Indian
companies as well as a global sales network with
representatives all over the world stand for. Our highly
qualified service technicians guarantee a comprehensive
and competent support on site. The close interdiscipli-
nary cooperation of our construction teams allows the
development of individual solutions and also complete
production lines according to your requirements.
In our Application Center we offer extensive test
possibilities on nearly all machines from our product
range. Upon request, we also provide assistance in the
field of mold design. Since we are exclusively focused on
machine production without any final product manu-
facturing you can always rely on our confidentiality
regarding your R&D activities.
Dr. Fritsch would like to contribute to your success with
experience, innovative technologies, highest quality and
first-class service.
We look forward to cooperating with you!
Yours DR. FRITSCH team
Over 60 years of milestones in the sintering technology
3
Technology
FAST stands for Field Assisted Sintering Technique.
This refers to the heating of a mold by means of cur-
rent flow. The unit is not heated from outside as usual
in a furnace (indirect), but from inside (direct).
Dr. Fritsch applies a self-developed direct current pro-
cess (FAST-Direct-Hot-Pressing). This process can also
be used with electrical non-conductors such as various
ceramics.
In this case heating occurs through the sintering mold
and therefore much closer to the sinter part than with
conventional heating technologies.
This heating technology has significant advantages:
● The very short sintering cycles reduce the unit costs
at a higher productivity
● The significant reduction of the grain growth
improves the property of the material
● The attainable densities are considerably higher
than with conventional sintering methods
● The temperature control is very precise due to the
direct resistance heating
● The development time for new materials can be
substantially shortened
● New material combinations can be manufactured,
for example FGMs (Functionally Graded Materials),
which cannot, or only with great difficulty be pro-
cessed with conventional methods
● Parts can be produced at near net shape
● Expensive production steps can be skipped; for
example the application of adhesive and solder
between the backing plate and the friction material
and also the final calibration. Even the copper
plating of the carrier might be omitted.
POWDER SHAPING TECHNOLOGIES
4
Sputter Targets
During the sputtering process planar
targets are used for the coating of surfaces,
which are bombarded with ions. As a result,
particles are released from the target and
become deposited on the surface to be
coated.
Usually the targets are made of highly pure
materials and have to be sintered to the
highest possible density in order to obtain
an even surface coating.
This process is widely used for the coating
of tools, data carriers, glass surfaces, flat
screens and many other industrial applica-
tions.
Some of the largest and most powerful
FAST-Direct-Hot-Presses are used in this
industry.
Friction Material Industry
Sintered brake and clutch pads are a rapidly
growing segment in the friction lining
industry. These type of friction linings are
used, for example, at high speed and freight
trains, wind turbines, motorcycles and pla-
nes, in motor sport as well as marine gear
units, trucks and for industrial applications.
Next time you are sitting in an Intercity Ex-
press or TGV, pay attention to the enormous
braking power. Possibly, the brake lining
has been produced on a Dr. Fritsch FAST-
Direct-Hot-Press.
Nearly all leading manufacturers of sintered
friction linings are using Dr. Fritsch ma-
chines. It is the largest application outside
the diamond tool industry.
ApplicationsDr. Fritsch has more than 60 years of expe-
rience in the production of FAST-Direct-
Hot-Presses for industrial applications.
The machines are designed for a daily
3-shift operation, all reasonable work pro-
cesses are automated and easy to operate.
The equipment is arranged in a compact
housing. The risk of operating errors is re-
duced due to the intelligent programming
and not freely accessible components.
In co-operation with our customers and
due to continuous development and
optimization we succeed to enter into new
application areas.
Today, our machines are used in the follow-
ing areas:
5
Heat Sinks
Heat sinks are used to protect sensitive
(electronic) components from overheating
by dissipating the heat.
During the last years the requirements and
the range of application has enormously
increased. Due to the conversion to LED
lighting and the increased use of high-per-
formance laser a great future is predicted
to this technology.
Sintered heat sinks usually consist of a
copper matrix with an even distribution of
fine diamonds. Dr. Fritsch has more than
sixty years of sintering experience gained
from the diamond tool industry. Therefore,
Dr. Fritsch might be the most experienced
partner in the world with regard to the
development and manufacturing of high-
performance heat sinks.
Research and Development
Worldwide a great number of universities
and research laboratories are working with
Dr. Fritsch FAST-Direct-Hot-Presses. With
these machines new materials in the
powder metallurgy are researched and
brought to series production. Particularly
the short cycle times are of interest to the
researchers. The significant reduction of
granular growth and the par tially binder
free sintering allows the production of
brand new material combinations resp.
materials with improved properties.
The short cycle time are speeding up the
research process. Sometimes the cycle time
can be reduced from 24 hours to 1 hour.
This means, that the sintering result can be
analyzed several times a day and re-tested
in an optimized cycle.
An up-to-date topic in research and
development are thermo-electrical mate-
rials. Especially with these materials a fast
sintering process, suitable for industrial use,
is absolutely essential.
Materials
- hard metals, especially tungsten carbide
and pure tungsten
- Functionally Graded Materials (FGM), such
as combinations of steel and tungsten
carbide
- steel, for example stainless steel for filters
- ceramics, such as AlN, B4C, SiC, SiN, Al
2O
3,
etc.
- metal-diamond-bonds
- precious metals, such as gold and silver
- rare earths, such as ruthenium
- infiltrated materials
- direct sintering without using solder or
adhesives
6
Mixing
Capacity 2 l
- Sieving of granules to ensure an uniform grain size
- Improved distribution of the granules in the cold press die to
provide an uniform density in the segment
- Adjustable vibration frequency
Sieve size
Upper sieve 0,8 – 1,4 mm
Lower sieve 0,315 – 0,63 mm
- Continuously adjustable rotating
speed
- Particularly suitable for dry
powder mixtures
- Timer
- Particularly suitable for wet
powder mixtures
- Preparation of the powder for
granulation
Option
- Underframe with rolls
PM 2Mixer
Capacity 19 l
- Continuously adjustable rotating
speed
- Particularly suitable for dry
powder mixtures
- Timer
PM 10Mixer
Granules Sieving DeviceMixer
Capacity 20 l
- Particularly suitable for wet
powder mixtures
- Preparation of the powder for
granulation
Mixer
Capacity 6,7 l
KMM 750
GM 400 GRS 140
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Granulating
- Very high output
- Production of granules with very good flowability
- Easy access for cleaning and maintenance
- Efficient suction system
- Powder storage (storage hopper) allows unattended
operation, capacitiy approx. 28 l
- For economical use of batch sizes from 500 g or more
- Powder transporting parts can be exchanged quickly and
cleaned outside the machine.
Output rate up to 5 kg / hour
Sieve size 0,6 – 1,2 mm
Granulating Machines
- Very versatile machines as they can be used for granulating
metal and ceramic bonds with / without diamond
- Prerequisite for volumetric cold-pressing
- Optimum ratio between productivity and set-up time
The use of granules
- reduces the die wear
- improves the distribution of powder in the segment
- reduces metal powder dust in the air
Output rate approx. 20 kg / hour
Sieve size 0,4 – 1,2 mm
Granulating Machine
- Passing unit with continuously adjustable passing wing and
stainless steel sieve for the production of pre-granules, capacity
approx. 1,5 l
Output rate up to 10 kg / hour
Sieve size 0,6 – 1,2 mm
Granulating Machine Granulating Machine
GA 270 GA 300
GGM 120
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Sintering
- For production as well as for research and development
- Vacuum (20 mbar) and inert gas (N2; 95 % N
2 and 5 % H
2, Ar)
- Offers all the advantages of short cycle times by FAST-Direct-Hot-
Pressing (see page 3)
- Precise measurement of temperature, pressure and stroke with
display of the compression
- Up to three thermocouples connectable, two of them for control
of exchange parts
Options
- Different pressure ranges
- Process documentation by PC-connection
- Rack for up to eight thermocouples, two of them for control of
exchange parts
- Temperature control with pyrometer by upper hydraulic cylinder
- Additional temperature control with pyrometer
- Sintering temperature up to 2.400 °C
- Fine vacuum 0,05 mbar
- Active suction
- USV (uninterrupted power supply) for control
- Barcode reader
- Suitable for automation
- Special colours
Total electric power approx. 110 / 155 kVA DC
Pressing force up to 600 kN
Size of graphite electrodes 180 x 180 mm, 200 x 200 mmor 220 x 220 mm
Max. opening height 145 mm
Temperature measurement thermocouple / pyrometer
DSP 510/515Sintering Press
- For research and development as well as production
- Vacuum (20 mbar) and inert gas (N2; 95 % N
2 and 5 % H
2, Ar)
- Offers all the advantages of short cycle times by FAST-Direct-Hot-
Pressing (see page 3)
- Precise measurement of temperature and pressure
- Up to three thermocouples connectable, two of them for control
of exchange parts
Options
- Different pressure ranges
- Electronic stroke control system to show the compression
- Process documentation by PC-connection
- Rack for up to eight thermocouples, two of them for control
of exchange parts
- Temperature control with pyrometer
- Sintering temperature up to 2.400 °C
- Active suction
- USV (uninterrupted power supply) for control
- Barcode reader
- Special colours
Total electric power approx. 81 kVA DC
Pressing force up to 259 kN
Size of graphite electrodes 165 x 140 mm or 200 x 200 mm
Max. opening height 150 mm, at temperature > 1.100 °C 145 mm
Temperature measurement thermocouple / pyrometer
DSP 507Sintering Press
9
Sintering
- Suitable for high quantities resp. large sintering parts
- Large graphite electrodes with large opening height
- Vacuum (20 mbar) and inert gas (N2; 95 % N
2 and 5 % H
2, Ar)
- Offers all the advantages of short cycle times by FAST-Direct-Hot-
Pressing (see page 3)
- Precise measurement of temperature, pressure and stroke with
display of the compression
- Up to three thermocouples connectable, two of them for control of
exchange parts
Options
- Different pressure ranges
- Process documentation by PC-connection
- Rack for up to eight thermocouples, two of them for control of
exchange parts
- Temperature control with pyrometer by upper hydraulic cylinder
- Additional temperature control with pyrometer
- Sintering temperature up to 2.400 °C
- Fine vacuum 0,05 mbar
- Active suction
- USV (uninterrupted power supply) for control
- Barcode reader
- Suitable for automation
- Special colours
Total electric power approx. 200 / 370 kVA DC
Pressing force up to 2.073 kN
Size of graphite electrodes 350 x 350 mm
Max. opening height 325 mm
Temperature measurement thermocouple / pyrometer
DSP 520/535Sintering Press
Automation
On request Dr. Fritsch develops an automated solution that is
tailored to your individual requirements. The station of mold pre-
paration is connected with the sintering press by a central transport
module, if subsequently needed also with several cooling stations
and the mold discharge station. The design and the flexible control
allow an installation of more sintering presses in this fully-automatic
production process.
At Dr. Fritsch all components come from a single source and are
perfectly matched to each other.
- Unmanned operation process, for example during the night shift
- Consequently automatic sintering of different materials and
dimensions
- Safe handling of very hot resp. heavy loads
- Simple expandability due to a modular construction
- Sector-specific solutions
- Higher productivity by cooling of the molds outside the machine
- Complete CE-conform protection with monitoring sensors
- Adaption to your structural conditions on site
- Whole sintering process from one single source and only one
contact person for all matters
- On request mold-tracking and connection to your IT
- Perfect matching of the single components
- Field-tested and solid construction
10
Software
PC-Connection of Dr. Fritsch Sintering Presses
Visualization software and process management
Software is updated regularly. Therefore the pictures shown are for illustrative purposes only.
- Installation of the software on PC or Laptop
- The Dr. Fritsch direct hot-press is connected to the PC
- With a suitable connection via your network the process control
and regulation can take place not only on-site but also at other
locations.
- The software allows display and recording of process curves and
data
- Individual configuration, access to the selected process parameters
- Troubles are displayed and recorded
Process data display:
Display as curve diagram, e.g. pressure and
temperature curves, error messages
Graphic display of set points
Process administration:
Jobs of the connected machines (left)
Processes of the selected jobs (right)
Set of parameters
- Set up of direct data connection is possible
- The process data can be exported to Excel or SAP for further
evaluation
- User-friendly design and administration of parameter sets
at the PC
- Database to copy, edit, delete and file the sets of parameters
- Data transfer of the parameter sets from PC to the machine and
vice versa
- Printout of the parameter sets
11
Service
For immediate disposal we have up to 3.500 different spare and wear parts in our stock.
Our understanding of service is not only commissioning and machine repairs but also
intensive advice, targeted trainings and transfer of know-how.
Our service offers:
SER VICE
Customized service contracts – Benefits for our Customers
Parts & Logistics
- Original parts and
equipment
- Safe packing
- Shipment
- Insurance
After-sales service
- Repair
- Installation
- Maintenance
- Inspection
- Machine removals
Training
- Operation
- Maintenance
- Application
Improvement/
Adaption
- Modification
- Software update
- Program optimization
Performance/
Quality
- Factory layout
- Consulting
- Analysis
- Remote services
Dr. Fritsch Servicemobil
UMTS
Customer network
Dr. Fritsch Serviceoffice
Dr. Fritschconnect
VPN-connection
Internet
Technology
Many of our machines are
already designed for remote
diagnostics. A suitable hardware
can easily be retrofitted. For
data transfers our customers
can use their own network or
radio transmission via UMTS.
Dr.Fritsch connect
Remote Services
Pricing
If you choose Dr. Fritsch connect we offer you the
necessary hardware including five hours of remote
service for free.
Then you can opt for a flatrate, a calculation in 30-minutes-
intervals or a support & hotline agreement including the
remote service.
Please feel free to contact us.
Advantages
• Effectivetrouble-
shooting
• Reductionofrepair,labour
and travel expenses
• Onlinedataacquisitionandanalysis
• Reductionofmaintenancecosts
• Increaseofmachineavailability
• Moreefficientproduction
• Valueretentionofthemachine
POWDER SHAPING TECHNOLOGIES
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Technical data and design subject to modification.
www.directhotpressing.com
Vers
ion
_01_
2014
Dr. Fritsch contact
Dr. Fritsch worldwide
POWDER SHAPING TECHNOLOGIES
Dr. FritschSondermaschinen GmbHDieselstr. 870736 Fellbach (Germany)Phone +49 -(0)711 5 18 32-0Fax +49 -(0)711 5 18 32-10E-Mail [email protected]
Powder salesE-Mail [email protected]
Technical servicePhone +49 -(0)711 5 18 32-139E-Mail [email protected]
Spare part servicePhone +49 -(0)711 5 18 32-131 /-132E-Mail [email protected]
BrazilStella & Viegas Muniz Rep. Com. Ltda.Telefon +55-11 9 8173 0382 +55-11 9 8173 0215Telefax +55-11 3926 4655E-Mail [email protected] [email protected]
China, Taiwan, KoreaAnglo Sterling Ltd.Phone +852 -2882 6311 Fax +852 -2882 9006E-Mail [email protected]
IndiaDr. Fritsch Machines & Powders Pvt. Ltd.Phone +91 -80 4127 2678Fax +91 -80 4127 2679E-Mail [email protected]
JapanKY Corporation Phone +81 -3 3435 8161 Fax +81 -3 3435 8163 E-Mail [email protected]
Mexico and Central AmericaTelek GlobalPhone +1 -832 228 7649 E-Mail [email protected]
RussiaIntech Diamant Co.Phone +7 -495-952-69-16 Fax +7 -495-952-80-13E-Mail [email protected]
TurkeyS.K.C. KarbonPhone +90 -212-624-9204Fax +90 -212-580-3907E-Mail [email protected]