dr. fritsch pst-overview_english_2014.pdf

Overview

POWDER SHAPING TECHNOLOGIES

Powder Shaping Technologies

FAST-Direct-Hot-Pressing / Granulating / Mixing

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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

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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.


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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:

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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

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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


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


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


2 and 5 % H

2, Ar)



- Precise measurement of temperature and pressure

- Up to three thermocouples connectable, two of them for control

of exchange parts

Options


- Electronic stroke control system to show the compression


- Rack for up to eight thermocouples, two of them for control

of exchange parts

- Temperature control with pyrometer


- Active suction


- 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


DSP 507Sintering Press

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Sintering

- Suitable for high quantities resp. large sintering parts

- Large graphite electrodes with large opening height


2 and 5 % H

2, Ar)



- 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



- 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


- Fine vacuum 0,05 mbar

- Active suction


- 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


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

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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

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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


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Technical data and design subject to modification.

www.directhotpressing.com

Vers

ion

_01_

2014

Dr. Fritsch contact

Dr. Fritsch worldwide


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]

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