As the diffusion process is very critical and in some cases very small wires have to be processed, two reliable solutions are proposed according to the product to handle.
The diffusion fluidized bed has the great advantage to work with a simple control of the temperature of the sand in which the wires are processed. As all the wires will not be able to go above that temperature there is no risk of creating dangerous beta phase even for different diameters or carbon contents processed at the same time.
Sparks may not take place such as in Joule diffusion or overheating of the wires due to different magnetic permeability in the case of induction technology.
Induction diffusion is however considered in the framework of thin wires such as sawing wire. The system is then designed to allow a full control of the diffusion kinetic while also minimizing the maintenance aspects of the cooling water and making the mastering of the process parameters easy.
The system has been developed jointly by a well-established company in induction technology following the stringent requirements and experience of the process mastered by FIB Belgium.
Our solution is focused on minimizing the pollution of the hydrochloric pickling liquor, on the comfort of the operators and on the acid consumption.
The cooling system allows avoiding the pollution of the pickling bath by lubricants or cracked soaps saving consequently neutralization costs.
Special technologies embedded in the pickling tank avoid the dilution of the acid or the pollution of the sealing water when crossed wires happen or super high-speeds are used. This technology has proved to save a lot of neutralization costs.
For the comfort of the operators the purging of the upper tray may be done in safe conditions and specific sensors avoid the destruction of the pumps if liquid is missing.
Care is also especially brought to rinsing to avoid further zinc dross formation.
A threading system for mono-wire (or multiple wires upon request) is foreseen to facilitate the operating of the line while keeping the workers in full safe conditions. As rinsing is very critical, optimization of the use of water with a high efficiency of the operation has driven to specific solutions applied in our equipment
The technology does not require any use of scrubber saving consequently a lot of water and operating costs.