High Vacuum News
Tips and Hints to Keep your Pumps Running Strong
October, 2011 - Vol 2, Issue 2
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| Greetings! |
We want you to be better informed and get more from your vacuum processing system. We also want to let you know what is happening at Metallurgical High Vacuum so we may be of service.
That's why we are sending you this newsletter that will let us keep in contact.
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President's Corner
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| Geoff Humberstone |
President's Corner
After 30 years in operation, Metallurgical High Vacuum is still going stronger than ever, thanks to loyal customers who supported us and still do. We continue to support customers and they reward us with their business, and recommendations.
There are many issues when it comes to vacuum pumping whether in a heat treat shop or coating operation, and we are committed to helping out in every way we can. One area that seems to come up is the selection and use of vacuum pump oil.
In particular on rotary piston pumps, you should use the recommended oil viscosity and grade for vacuum pump service, such as MHV Formula "F" oil. This is a highly refined grade of oil with the correct lubricity and viscosity; anti-foaming agents; detergent to hold contaminants in suspension; anti-corrosive additives and low vapor pressure so you can attain proper vacuum levels.
We've seen pumps gummed up with sludge deposits resulting from contamination or eaten up with acids (HF and HCL) resulting from processes like brazing and sintering that can create them. We are able to make recommendations that can mitigate those problems, and suggest using inline traps or other solutions like filtration. Basically, bring those problems to us and we can help.
Our unique capabilities allow us to go further in balancing out pump vibrations, better than even the original manufacturer. Click Here to Read more
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| Tips & Techniques: Change Filters with Pump in Use |
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| Pump Oil Filters |
We designed an oil filtration system that can be constantly used on a pump, yet allows swapping the filters even while it is operating. We call this a "hot swap" filter and it solved a problem for this customer who can't afford to shut it down for servicing the filters.
The Hot Swap Filter is an exclusive MHV design and enables the user to swap out filter cartridges with the pump operating. You simply switch over the valve to the new filters, then remove and replace the old filters. This unit is designed for a Model 412H11 pump with a full pressure alumina-type acid filter in the quad filter setup.
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| New Tool Makes Quality Parts |
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MHV Adds Numerical Controlled Lathe
The shop recently added a precision, automated Mazatrol Nexus 350II CNC tool. This has added to MHV's capabilities for producing high quality parts in-house with a fast turnaround time. It affords a wide range capacity with its 12-inch chuck and 60-inches between centers. It is equipped with the Mazatrol Matrix CNC control that can handle the toughest machining jobs. The manufacturing facilities at Metallurgical High Vacuum include the latest metal machining and welding facilities, engineering technology software and systems, material handling capabilities, extensive testing and quality control equipment and systems.
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| CNC Lathe Performs Multiple Operations |
The new lathe will make production faster on shafts, cams and similar parts we need to manufacture for our customers.
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| Unit Holds Up To 12 Tools |
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| Slide Pins |
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| Application Spotlight--Production Coating Systems |
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MAKING AUTOMOTIVE LIGHTS BRIGHTER, MORE EFFICIENT
Valeo Sylvania, LLC produces lighting products at their Indiana plant for automotive use, and has several vacuum coating systems used for Physical Vapor Deposition (PVD). In operation, plastic components are first loaded into fixtures that position the parts adjacent to the vapor metallizing source within the vacuum chamber. After closing the chamber door, it is pumped down using a combination of high vacuum pumps. A metallizing cycle is started to apply the reflective coating to the parts. This plant manufactures a wide range of products ranging from main headlamps with LED, xenon or halogen technology, daytime running lights with LEDs or traditional bulbs; rear lights and high-mounted stop lamps with LEDs or traditional bulbs; fog lights and auxiliary lights.
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| Vergason VTI-4000 Unit Coats Automotive Headlamps |
A key to the coating system's performance and reliability are the vacuum pumps which are relied upon to keep the systems operating on multiple shifts.
Mr. Tom Nolan, Senior Manufacturing Engineer, is responsible to keep production running at peak performance and uses Metallurgical High Vacuum for rebuilding and maintaining the vacuum blowers and piston pumps that keep the systems running.
He noted: "We use a mixture of pumps on our various coaters, such as Edwards 412 piston pumps and 615 blowers, Leybold 630's and Varian pumps." Click here to read more
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Heat Treating Conference and EXPO
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The ASM Heat Treating Society and the American Gear Manufacturers Association are partnering to create an exciting mix of education, technology, networking and exposition opportunities - all at the 26th ASM Heat Treating Conference and Exposition and Gear Expo.
Metallurgical High Vacuum will be in Booth #2315 on November 1-2. Stop by and see our latest developments. Contact us by phone or e-mail if you need complimentary EXPO passes.
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Metal Laser Cutting Systems
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Laser cutting systems are found throughout the metals industry, and can range from small units that cut intricate patterns for electronic parts to very large lasers for cutting structural metals.
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| Laser Cuts Accurately |
MHV knows downtime is critical for laser operations, which is why we specialize in rebuilding Laser Blowers that can stand up to rugged use and last longer. We remanufacture Oerlikon Leybold® blowers (WSLF 1001 and 2001 models) that are used throughout the laser metals industry to the tightest specifications, so they will run "like new".
MHV has a lot of demanding customers whose blowers are vital to their lasers running efficiently, with a low cost of ownership.
Shown below is a Leybold® blower on final test. We run it with air at 70 torr, (100 hectopascals), to closely approximate conditions in the laser. MHV tests and balances each blower to assure they have a total vibration less than 0.12 inches/second using our FFT analyzer.
A high quality MHV remanufactured blower can add years to a laser's life without breaking the bank.
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| Leybold® Laser Blower Under Testing |
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Tips and Techniques: Saving Energy and Lowering Costs
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Being energy smart can save $$$ every year.
We often do not think about the utilities being consumed by the vacuum pumping systems which can be considerable when viewed over a long period. For example, the electric motors can draw prodigious amounts of energy in a year. If you are using motors that are over 15 -- 20 years old, you could be burning 30 to 35% more energy than more energy-efficient designs of today's motors. For example, MHV new Survivor pumps use Reliance "XEX" motors which are its most energy efficient model. These units offer substantial reduction in motor watts losses and can reduce power consumption, since they typical operate at over 90% efficiency.
When you consider the lifetime operating (20-year utility) cost of a motor is far greater (typically 97%) than its initial cost, why wouldn't you opt for greater efficiency?
In addition, cooling water usage can be substantial, and to assure the pumps are operating at the right temperature, MHV includes a "Water Miser" temperature valve that reduces water consumption and helps maintain a warmer oil temperature that reduces internal friction losses.
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| Low Base Pressure Performance |
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How important is low base pressure on a mechanical pump?
I am often asked to explain if the key performance factor in vacuum pumps is low blank-off pressure, as that can be impacted by many things from worn parts, leaky seals, contaminated oil, etc...
Low base pressure (blank off) on a mechanical pump only makes sense if the pump is used without a blower; say on a vacuum mass spectrometer. In that application, you would like to evacuate the spectrometer to under 10 millitorr so base pressure is all important. A similar application is the holding pump on a diffusion pump. Here you would like a low base at blank-off because there will be significant hot oil outgas loads and possible high vacuum poppet leaks to contend with that will bump the hold vacuum level way up even with a decent base vacuum on the hold pump.
On applications that have a booster (rotary lobe blower) between the pump and the vessel, base pressure of the combination is important. Typically you would want under 10 millitorr at the booster inlet under blank-off conditions. At blank-off, the compression ratio on then booster is at least 10/1 so a 10 millitorr base at the blower inlet would mean about a 100 millitorr base on the mechanical pump. If the mechanical pump base is higher, say 200-500 millitorr due to water in the oil or a bad shaft seal, then you would see a 20- 50 millitorr base on the blower inlet and that might be unacceptable.
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| SPECIALS |
Buy two rebuild kits and get 50% off the third.
One of our most popular parts kits is for Stokes 412 maintenance parts. Part Number SK-412H-MNC.
Kits are vacuum packed so all of the springs, gaskets, and pieces are kept together in one neat package. These are ready for immediate delivery "off the shelf".
These offers are valid through November 30, 2011.
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Contact us for quotes and more information: (877) 787-9880
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Call or write us with your questions, and let us know any suggestions and ideas you may have about the newsletter. Click to E-mail
Feel free to call on our team at MHV to help with your vacuum needs. You'll find we can respond quickly to your requests.
Sincerely,
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Geoff Humberstone
Metallurgical High Vacuum Corporation
6708 124th Avenue, Fennville, MI 49408-9632
Copyright (c) 2011--Metallurgical High Vacuum Corp. All rights reserved
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