Heat Treatment Racks/Baskets/Trays/Furnace Bottom Plates – FH, 300+ Factory Cooperation Cases, 30% Cost Reduction Soluti

In industries such as machinery manufacturing, auto parts, metallurgy and wind power equipment, heat treatment is a core process to enhance the performance of metal materials. As key heat treatment fixtures directly carrying workpieces, baskets, trays and furnace bottom plates directly determine heat treatment efficiency, product qualification rate and comprehensive production costs. Most enterprises face pain points such as easy deformation, short service life and uneven heating of workpieces with traditional heat treatment fixtures, leading to energy waste, high rework rates and soaring replacement costs. With years of experience in the heat treatment fixtures field, FH(Junteng FangHu ) has served over 300 factories with cost reduction solutions through customized technology and high-quality products, achieving a direct 30% reduction in comprehensive costs and has become a trusted heat treatment fixture partner in the industry.

Three Major Cost Pain Points of Traditional Heat Treatment Fixtures

1. Fast Heat Treatment Fixtures Wear, High Replacement Costs: Conventional heat treatment fixtures are made of ordinary heat-resistant steel, which is prone to creep and cracking under high-temperature cyclic environments of 900-1200℃, with a service life of only 1-2 years. Annual replacement costs account for more than 20% of the total cost of the heat treatment process.
2. Unstable Workpiece Quality, High Rework Costs: Irrational structural design of standardized heat treatment fixtures results in overcrowded workpiece placement and uneven stress, leading to large temperature gradient differences during heating or cooling, frequent problems such as excessive oxide scale and out-of-tolerance deformation, with rework rates as high as 15%-20%.
3. Imbalanced Energy Consumption and Efficiency, High Hidden Costs: Excessive self-weight of heat treatment fixtures increases furnace load, and poor ventilation or heat transfer design prolongs process time while wasting energy, making the energy consumption cost per workpiece 30% higher than the industry's advanced level.

FH's Core 30% Cost Reduction Solution

Centering on the three core pillars of "material upgrading, structural customization, and process coordination",FH (Junteng Fanghu) has created a full-scenario optimization solution for racks, trays, baskets and furnace bottom plates, addressing cost challenges from the source.

1. High-Performance Material Selection, Extending Service Life to Reduce Replacement Costs

• The core material adopts high-chromium-nickel austenitic heat-resistant steel such as ZG40Cr25Ni20Si2, which can withstand extreme high temperatures up to 1200℃. Through solution strengthening and carbide strengthening technologies, thermal fatigue resistance and creep resistance are improved by 40%, extending the service life of heat treatment fixtures to more than 5 years, 2-3 times that of ordinary heat treatment fixtures.
• Heavy-duty components such as furnace bottom plates adopt bimetallic composite casting technology, with the working layer hardness reaching HRC55 or above, and the base layer maintaining toughness, achieving both wear resistance and fracture resistance, directly reducing annual replacement costs by 60%.
• In the raw material procurement stage, direct-reading spectrometers are used to complete the analysis of 20 element contents within 30 seconds, with a detection accuracy of 0.001%, ensuring stable material performance and avoiding premature heat treatment fixtures scrapping due to substandard materials.

2. Customized Structural Design, Improving Quality to Reduce Rework Costs

• Heat Treatment Racks: For different workpieces such as shafts, gears, and bearings, a "layered separation + elastic support" design is adopted, with 3-5mm uniform gaps reserved to ensure full circulation of heating atmosphere, improving workpiece heating uniformity by 25% and reducing oxide scale formation by 90%.
• Heat Treatment Trays: Optimize grid spacing and support points, adopt hollow structure design to reduce workpiece contact points, avoid "soft spots" or adhesion problems, reduce self-weight by 35%, and improve furnace space utilization.
• Furnace Bottom Plates: Adopt annular radiant grid support structure to optimize thermal stress distribution, combined with anti-oxidation coating, control deformation within 0.02mm/m, ensure furnace surface flatness, stably support over 500kg/m² load capacity, and eliminate workpiece deformation caused by uneven furnace bottom.

3. Process Coordination Optimization, Saving Energy and Improving Efficiency to Reduce Hidden Costs

• Combined with finite element simulation and AI algorithms, adjust heat treatment fixtures structure according to heat treatment processes (quenching, tempering, carburizing, etc.). For example, racks for carburizing processes strengthen ventilation channels, and trays for air-cooling processes optimize heat dissipation design, shortening process time by 10%-15%.
• Adopt lightweight design concept, reduce material redundancy on the premise of ensuring load-bearing capacity, reduce the weight of a single set of heat treatment fixtures by 20%-30%, and reduce furnace energy consumption by 18%-25%.
• Optimize furnace bottom plates in coordination with heating equipment, improve structural compactness through centrifugal casting technology, increase thermal efficiency by 12% compared with traditional products, and further reduce energy consumption.

4. Full-Process Quality Control, Eliminating Invalid Costs

Comply with ISO 9001 quality certification standards, implement a "three-inspection system" in the production process, achieve 99.7% detection rate of internal casting defects through X-ray machines, and control dimensional accuracy error within ±0.02mm. Before delivery, finished heat treatment fixtures undergo 1000℃ high-temperature cycle tests to verify deformation and stability, ensuring that heat treatment fixtures meet standards upon delivery and avoiding production downtime costs caused by quality problems.

Verified by 300+ Factories: Tangible Cost Reduction Results

FH's solutions have been implemented in various industries such as automotive manufacturing, wind power equipment, and metallurgy, with remarkable results:

• After an automotive gear factory adopted customized racks, the fluctuation of gear carburizing layer depth was narrowed from ±0.2mm to ±0.05mm, the rework rate was reduced from 18% to 3%, and the annual rework cost was saved by more than 800,000 yuan.
• After a wind power equipment enterprise used FH furnace bottom plates, the annual replacement cost of a single piece of equipment was reduced from 500,000 yuan to 150,000 yuan, while heating efficiency was improved by 12%, saving 300,000 yuan in annual energy costs.
• A metallurgical enterprise achieved a 12% reduction in workpiece processing cycle, 22% reduction in unit energy consumption, and 32% annual reduction in comprehensive costs through a complete set of optimization of trays and racks, fully meeting the cost reduction target.

Conclusion
In the trend of industrial cost reduction and efficiency improvement, the "high quality" and "high cost performance" of heat treatment fixtures have become the core competitiveness of enterprises. With the practical experience of serving 300+ factories, FH (Junteng Fanghu) has achieved a significant 30% reduction in comprehensive costs by upgrading materials to extend service life, customizing designs to improve quality, and coordinating processes to reduce energy consumption. Whether for batch processing of conventional workpieces or customized needs of large heavy-duty workpieces, FH can provide full-process services from selection and design to production and delivery, becoming a reliable partner for enterprises to reduce costs and improve efficiency. In the future, FH (Junteng Fanghu) will continue to focus on technological innovation and provide more cost-effective heat treatment fixtures solutions for customers in more industries.