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TF-4000

The cost-effective tilting furnace TF-4000

The „small“ TF machines have been developed with the focus on least possible energy consumption and on safe and ergonomic handling. The melting unit and crucible can be tilted and locked in position by the user at multiple angles for gentler filling. Such “soft pouring” also prevents damage to the crucible. Pouring off is continuous and gradual, using a pivot lever. The operator is forced to stand to the side of the machine – away from the dangers of the pouring area. In the rare event of a crucible breaking, the machine is not damaged – all of the assemblies are covered by a separate protective housing, and every model has a large collecting tray under the smelting unit to prevent potential loss of metal.

The TF 2000 and TF 4000 models, which like their predecessors are used both in the jewelery industry and in refineries, are completely new developments. They are equipped with new high-performance induction generators, which ensure that the melting temperature is reached much faster and ensure that the melt is thoroughly mixed and homogenized. Depending on the model, the capacity ranges from 2,000 ccm to 4,000 ccm crucible volume, which corresponds to approx. 60 kg gold 18.

Data Overview of TF-4000

■ standard equipment, ○ optional, - not available
TF-2000 TF-Series TF-4000 TF-4000 HTC TF-6000 TF-Series TF-12000 TF-12000 HTC TF-28000
Power
Temperature max. 1500° C 1850° C 1500° C 1850° C 1500° C 1850° C 1500° C 1850° C 1500° C
Power max. / electrical connection 20 kW (3x400 V) 20 kW (3x400 V) 30 kW (3x400 V) 30 kW (3x400 V) 40 kW (3x400 V) 40 kW (3x400 V) 40 kW (3x400 V) 60 kW (3x400 V) 60 kW (3x400 V)
Operation and Control
Control system by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readout
Programs 20 20 20 20 100 100 100 100 100
Tilting by lever ■ ■ ■ ■ - - - - -
Tilting with motor drive (remote control) - - - - ■ ■ ■ ■ ■
Temp. measurement by thermocouple ■ ■ ■ ■ ■ ■ ■ ■ ■
Temperature measurement equipped with an optical pyrometer ○ ○ ○ ○ ○ ○ ○ ○ ○
Quality Assurance
RS 232, Ethernet, USB interface, diagnostic system ■ ■ ■ ■ ■ ■ ■ ■ ■
GSM-modem for remote service ○ ○ ○ ○ ■ ■ ■ ■ ■
DMS
■ ■ ■ ■ ■ ■ ■ ■ ■
InduthermCloud ○ ○ ○ ○ ○ ○ ○ ○ ○
iThermControl ○ ○ ○ ○ ○ ○ ○ ○ ○
Accesories
Protective gas flush to avoid oxidation ○ ○ ○ ○ ○ ○ ○ ○ ○
Vacuum pump ○ ○ ○ ○ ○ ○ ○ ○ ○
Moveable table (with customized molds) ○ ○ ○ ○ ○ ○ ○ ○ ○
Hood for smoke vent ○ ○ ○ ○ ○ ○ ○ ○ ○

*real capacity for casting / useful volume

Other Advantages of TF-4000

Approximate duration of process: 5 min.

The DDP system is ensuring a constant and controllable metal mass flow, and therewith gas-to-metal ratio, independent from the melt level in the crucible.

The bar casting kit is developed for casting defined quantities of your alloy into ingot molds or into any other molds. The program control recognizes the applicated equipment and provides the suited parameter settings on the display.

Longer consumable life can be achieved by reducing frequent temperature changes and exposure to oxygen as much as possible. For this reason, we offer filling devices for numerous system models that enable recharging without loss of temperature and without contact with oxygen.

Very sharp separation. Wide classifying range, e.g. separation of steel or bronze from ~4 to ~120 kg/h bronze/stell (depending on version, separation at 10 µm), adjustable by the material feed.

With the sintering unit processes can take place under a vacuum, which is important for alloys with a manganese component.

Footprint of just a few square meters including infrastructure

Our self-developed generators and induction heating systems tailored to the intended use ensure maximum energy efficiency. They not only reduce power consumption, but also increase the heating speed and the maximum temperature. They also reduce electromagnetic emissions with regard to the EMC directive. Efficient encapsulation ensures that the induction generated is used with as little loss as possible for rapid melting of the metal. The thermal insulation around the inductor and crucible protects against heat radiation. This high use of energy also reduces the energy consumption for water recooling in the machine and for any air conditioning that may be necessary in the foundry.

The user-oriented and modular structure of the systems ensures optimum accessibility for all work as well as for inspection and maintenance. This construction principle also ensures short installation and training periods.

Polished stainless steel surfaces prevent powder adhesions in spray chamber, cyclone and collector – all parts are easy to clean without any residues.

Excellent mould filling thanks to high overpressure and vibration system.

Reliable production of metal powder with narrow particle size distribution and high process yield Ideal for small to medium amounts

Short training period, easy and reliable handling. Optimum accessibility for inspection and maintenance, low cleaning effort. Minimum metal loss and cross-contamination. High process stability.

Program control system for fast and certified casting processes. Thanks to the control panel with full text LCD display, all programs and parameters are very easy and convenient to set. The semi-automatic machines offer temperature programs. The fully automatic machines have a program control system involving all parameters. Up to 100 casting programs guarantee fast operation and consistent casting results. Parameters are pre-programmed for all major alloys, e.g. for AGS, Alpha Plus, Heraeus, Legor and Pandora alloys. In practice this means: from the first mold, you can expect good casting results without carrying out expensive pre-tests. The program control and the integrated data printer ensure a high level of safety and the possibility of precise process documentation (important for certified casting processes).

Möglichkeit der Oxidations-Vermeidung in der geschlossenen Anlage durch Entgasung und durch gezielte Schutzgasführung

Increase of powder quality by gas flow optimisation in the spray chamber (avoidance of satellites)

All Indutherm VC machines have separate lock systems for the melting chamber and mold chamber. This allows time to be saved by “overlapping” casting: while the mold remains in the vaccuum chamber for several minutes after the casting, you may fill in and heat up the next charge.

The AU machines offer the possibility of oxidation-free processing in the closed-chamber machine by means of de-gassing, vacuum and protective gas features.

Processes can take place under inert gas.

Depending on the thickness of the rings, up to 6 rings or bangles can be processed simultaneously.

without any satellites for the highest powder fluidity and bulk density. Could be basically used as well for non-metallic materials (certain fluidity required).

due to precise control of the melting temperature via a crucible based induction heating system, while evaporation of alloy ingredients like Zn, Cr etc. is a common issue during plasma-assisted atomization.

The filling device means there is no need to open the melting chamber for refilling. This way, the melting chamber temperature remains high and unnecessary loss of energy is avoided. Most importantly: No oxygen enters the melting chamber so the chamber does not need to be evacuated again and refilled with inert gas. The advantages: lower personnel costs, more consistent casting quality, better process stability, less waste, optimised overlapping casting, up to 20 casting cycles per hour, high energy efficiency, longer service lives for consumables, minimised metal loss, replenishment without loss of pressure.

Numerous measures in our casting systems reduce metal losses during the casting process to an absolute minimum. These include, among other things, the sophisticated overpressure and vacuum controls, the anti-oxidation system, the vibration system and, last but not least, the high-quality materials of the crucibles and sealing rods.

No need for complex and expensive wire production as feedstock material for atomizing, which is time-consuming and requires additional infrastructure like continuous casting machines, a drawing bench etc.

Remote control function available. Optional upgrade features like gates for powder supply and the conveying of powder, special filter systems and interfaces to connect to your powder receivers.

for evaporated alloy ingredients otherwise caused by plasma melting

Up to 20 casting cycles per hour thanks to programmable overlapping casting and optional automatic feeding devices.

Sintering/diffusion bonding is the optimum process for producing multi-coloured rings, mostly sold as wedding rings, or bracelets. Metals are processed under pressure and at temperatures below the solidification point. The pressure is generated pneumatically and not mechanically via a threaded spindle. This means that there is no risk of graphite parts breaking as a result of heat expansion. The fusion between layers has the same durability as the metal itself. The sintering kit is ideal for the occasional diffusion bonding job and for smaller series production.

All process parameters can be set individually and saved for repeated castings.

zur Vermeidung von Metallverlusten oder Querkontamination

Straightforward installation/removal of the rings.

Very simple and safe to operate, short training periods.

The easy to install granulation tank makes each CC machine even more versatile. CC 400 and VCC 400 are furthermore offering a third application possibility: with the sintering kit you can use this machine for diffusion bonding,e.g. for the production of multi-layer rings.

In development: e.g. larger version offering a crucible volume of 1.5 l

Yield for example for Bronze d50= 40-60 µm. Bronze throughput up to several kg/h.Very small batch sizes down to ~100 g technically and financially viable.

Alloying with a good stirring/mixing effect due to strong medium- frequency induction generator with simultaneous high heating efficiency. Melting under vacuum or inert gas atmosphere and atomizing under inert gas atmosphere.

by use of different atomisation nozzles and optional use of hot spray gas Modular availability of free fall as well as close coupled atomisation nozzles to obtain specific metal powder characteristics. Fast and easy nozzle change.

Find out more about TF-4000

The cost-effective tilting furnaces TF 2000 and TF 4000

The „small“ TF machines have been developed with the focus on least possible energy consumption and on safe and ergonomic handling. The melting unit and crucible can be tilted and locked in position by the user at multiple angles for gentler filling. Such “soft pouring” also prevents damage to the crucible. Pouring off is continuous and gradual, using a pivot lever. The operator is forced to stand to the side of the machine – away from the dangers of the pouring area. In the rare event of a crucible breaking, the machine is not damaged – all of the assemblies are covered by a separate protective housing, and every model has a large collecting tray under the smelting unit to prevent potential loss of metal.

TF 6000, TF 12000 and TF 28000 – the giants among the tilting furnaces

The large crucible volumes of 6,000, 12,000 or 28,000 ccm gives these machines an enormous capacity. Because of the potentially large weight, the inductor/ crucible unit is not tilted manually – it uses a motor drive with a stable shaft. Use of a joystick enables the tilting process to be controlled easily and sensitively

More Informations about TF-4000

Download catalogue (pdf)

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