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Engineered SolutionsFor Thermal Processing

InductionHeating&Melting

2 Engineered Solutions

Steel IndustryAdvanced Heating TechnologyAjax TOCCO offers solid state induction technology along with innovative inductor designs enabling millsto dramatically improve processes such as bar and slab rolling, and strip processing.

In-Line induction heaters working in conjunction with continuous casting lines save thousand of energydollars by utilizing casting generated heat and restoring only the additional energy required to reachoptimum rolling temperature. Continuous strip heating with strategically placed heating coils thataccurately control temperature cycles using only a fraction of the space of convention heating methods.The induction quench and temper process offers superior metallurgical results and has become thepreferred method for state of the art heat treating.

The ISG Induction Strip Galvannealing, developed by Ajax TOCCO, is easily integrated with new or existingequipment. Strip heater designs present many cost cutting opportunities for applications such as stripannealing, strip dryers, and taper heating for more uniform rolling.

Melting TechnologyLarge high powered channel induction furnaces with “Jet-Flow™” inductors are used to:

Superheat blast furnace iron prior to use in a steel makingprocess. Increased yield coupled with a lower costmake the Superheater a viable alternative to conventionalpractices.

Provide a large initial charge of molten iron to arc furnacesfor the melting of steel scrap. The initial iron chargeenhances electrode life and increases the initial melt rate ofthe arc furnace.

Provide melting and holding capability to a new meltingprocess where DRI and / or fine scrap is continuously meltedto supply iron for the steelmaking process.

Ajax TOCCO ceramic lined induction coating and pre-meltpots are the industry standard in the production of coatedsteel strip and tubing.

Coreless furnace technology is used for a wide variety ofapplications in the steel industry. These include:

Heating tundishes in continuous casting processesMelting of steel alloys in mini-mill applicationsVacuum induction melting (VIM) for processing alloy steels

Ajax TOCCO’s latest design in High Power Density (HPD)furnaces has improved performance and refractory lifeover previous designs for high capacity melting operations.

Ajax TOCCO ISGsystems provide themost advanced stateof the art heatingequipment. Thesesystems offer the shortest heating lengths and the most efficientsystem in the industry. We continue to develop new ways to improvethe system to satisfy our customer's needs.

A view of a 1200 kW strip dryingAapplication. This equipment is beingused for a wide variety of coatingapplications. The equipment is designedfor horizontal or vertical installations.

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Ajax TOCCO, Transverse Flux heating is changing the wayprocessors want to heat strip. TFIH enables the user to heat awide variety of strip with the same inductor and enables ourcustomers to make adjustments to the system without shuttingdown the line. Processing costs can be cut as much as 25%,and scale formation reduced as much as 67%.

Manufacture and overhaul for vacuum melting corelessinduction furnaces.

A view of a 1200 kW strip dryingfurnace. This equipment is being usedfor a wide variety of coating applications.The equipment can be designed forhorizontal or vertical installations.

Ajax TOCCO quench and temper lines for bars and shapes are known industry wide for producingsuperior metallurgical and physical properties. These benefits are achieved with the ultra high heatingrates and temperature control possible only with induction heating.

This 1500 ton Superheater melts at the rate of33 tons per hour and superheats blast furnaceiron 400° F at the rate of 250 tons per hour.

4 Engineered Solutions

Forging IndustryAdvanced TechnologyAjax TOCCO continues to refine induction technology offering the mostefficient and flexible heating systems to the forging market.

Utilizing “cast brick” or “open coil” technology, we supply heating systems designed to meet the customer'sthermal requirements while increasing process efficiencies.

For typical heating applications, we provide increased operating efficiencies, reduction in installation costplus minimizing floor space by offering our “MONO FORGE” heating systems.

For larger applications we market our standard heating concepts, which are easily modularized to meetcustomer's specific process applications.

Power SystemsOur constant current power supplies are the proven choice. Their patented designs, operating into a 3 to 1conductance range, minimize the number of inductors required, thus reducing capital expense, insuringprocess integrity and reducing changeover time while increasing productivity and profits.

Control and monitoring of our systems is provided through our “FORGE VIEW” control packages, whichmonitor and control the power supply, billet feeding system and temperature of the billets.

Standard controls are PLC based, offering basic power and system monitoring. When processrequirements dictate more precise control and monitoring, PC based controls can be supplied withcapability to monitor and/or upgrade operating parameters via the internet allowing the user to changeproduction requirements as needed to meet their customer's needs.

FixturingWe offer billet feeding solutions via pinch wheel, pusher, and caterpillar type drive units. For specialapplications, a walking beam fixture may be considered.

Technical Support and ServiceWith our ability to integrate billet handling systems plus offering “turn-key” installation, Ajax TOCCO has theengineering, technical, service and spare parts network in position to meet the needs of the forging industryas we meet the challenges of an ever changing global market.

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Authorized OEM for AIH, IEH, Ajax Magnethermic®, TOCCO®, Lectrotherm,Pillar, Westinghouse, and Cycle-Dyne.

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Ajax TOCCO consistently leads the way in developingnew induction heating technology providing new ideas tothe forging industry's drive to support existing customersplus capture new markets.

In this age of international competition, the key tosurvival, in a constantly changing environment, is efficientand flexible use of plant space, energy, and manpower.

Wide oval walking beamheater for 1/2" to 1 1/8"bars 8" to 18" long. Allsizes can be heated withthe same inductor.

150 kW, 10 kHzautomatic bar endheater on a unitizedbase, with dropbottom tote boxloading.

Sway bars for automobile suspensions are forged withthis Ajax TOCCO heater. Bars are continuously fedthrough five cast coils for fast scale free heating.

The first of several dual-line heaterssupplied to process in excess of12,000 pounds per hour.

6 Engineered Solutions

Foundry IndustryAdvanced TechnologyAjax TOCCO leads the way with induction melting technology allowing our customers to maintain acompetitive edge in today's worldwide market.

Pacer® PowerThe Ajax TOCCO Pacer® power supply has the ability to melt a wide range of alloys at maximum powerwithout tap changes or capacitor switching. Pacer is the only solid state power supply that utilizes fiberoptics to extend component life. Efficiency remains high at all power levels. The Pacer is available insizes to 16000 kW.

Jet-Flow™ InductorsAs the world leader in channel furnace technology, Ajax TOCCO continues to refine the design of theworld famous Jet-Flow inductor. Ajax TOCCO has not only broken the 8000 kW barrier, but can alsopoint to the successful start up of the largest channel furnaces in the world.

Melt Control SystemsThe Magne-Com melt control system enhances the overall melt system making furnace start up, dailymelting, and maintenance simpler. This system can also provide access to valuable processinformation, alarm management, troubleshooting, data logging, trending, and report generation.

Ajax TOCCO leads the industry with high powered Jet-Flow™ channel inductortechnology. This, coupled with our innovative large furnace designs, hasallowed us to create “Superheaters” for the steel industry. Superheaters aredesigned to melt scrap and superheat blast furnace iron prior to introductioninto a steel making process. Ajax TOCCO designs and manufactures theworld's largest channel induction furnaces.

The Vertiplex Channel Furnace isideal for holding, duplexing, andmelting ferrous alloys where aconstant supply of metal isrequired to meet productiondemands. The Vertiplex can pourand receive metal at the sametime. Vertiplex furnaces featureJet-Flow™ channel inductors.

The channel furnace offers a great deal of upper case designversatility to meet the demands of all casting processes. Channelfurnaces with “Jet-Flow™” inductors are used for traditional foundryapplications, up-casing, horizontal, and vertical direct chill castingprocesses.All channel furnaces are available with solid state controls.

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The heart of a channel furnace is theinductor. For optimum performance, theinductor must be extremely reliable. AjaxTOCCO leads the industry in high poweredinductor designs for both ferrous andnon-ferrous applications. Jet-Flow™inductor designs set the worldwidestandard for inductor performance.

This 90 ton vertical channel furnaceincreased gray iron pouring capacitywithout increasing energy costduring peak demand periods. It actsas a buffer between primary meltingand molding requirements providinga continuous flow oftemperature-controlled andmetallurgical constant iron.

Two 3600 kW medium frequency solid statepower supplies are used here with two 10 toncoreless furnaces to provide this foundry withthe flexibility required to meet a variety of hotmetal needs. The ruggedness of the AjaxTOCCO design provides day in and day outtrouble-free operation.

The Swinger Furnace isfast, clean and efficientfor melting non-ferrousalloys. Low metal lossesjustify this two positionmelter for thenon-ferrousfoundry.This furnaceis ideal whenbatches ofdifferent alloysare required.

Magna-Melt Furnace is a rugged design for highfrequency melting applications. Cast refractory topand bottom, stainless steel tie rods and theheavy-duty fabricated aluminum side plates forma rigid structure.

Compact packagedcoreless furnace meltingsystems drasticallyreduce installation costs.

The Steel Shell Furnace design providesmaximum strength and support for allmelting applications. Ideal for use withcharge buckets and vibratory conveyorcharge systems.

The Table Top Furnace is ideal for assaydetermination, precious metals, smallmelting requirements and laboratoryprojects. The hand tilted interchangeablebody provides maximum flexibility.

8 Engineered Solutions

Heat Treating IndustryDynamic Variable FrequencyAjax TOCCO has developed power supplies that free the user of the one frequency, one jobsyndrome. Ajax TOCCO's solid state power supplies were specifically developed for inductionapplications. They enable the user to accommodate part variations and patterns with very littleeffort. Ajax TOCCO's variable dynamic frequency approach provides the user with the capability totune to a specific load, enhance pattern development and improve the production flexibility of anyinduction system.

Standard Equipment and CustomAutomationIndustry demands system designs that are cost effective and contribute to the bottom line. To meetthese challenges, Ajax TOCCO has developed computer control systems to speed change-over,improve quality and set new reliability standards. Many systems are self monitoring andautomatically adjust for minor variations. The use of lean manufacturing cells with automated pickand place fixtures, robotics, and built-in quality control provides the means of handling a widervariety of parts with the same equipment.

PerformancePerformance and reliability are only as good as the effort designed and built into the system beforeit is shipped to the customer. Ajax TOCCO makes the extra effort. Our metallurgical testingfacilities, complete with our staff metallurgist, assure process parameters are satisfied beforeequipment shipment.

Dual frequency heating of sprockets provides uniformroot and tip temperatures required for hardening. Theprogrammable lift fixture is designed to harden sprocketsup to 25" diameter using up to 1000 kW.

Chrome shafts and cylinder rodsare continuous or skip hardened onhorizontal scanners designed andbuilt by Ajax TOCCO. The servo driveand computer provide precise controlof recipe information.

Robots load and unloadheavy truck axle tubeassemblies into a heavyduty single spindlevertical scanner forhardening andtempering.

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This track pin harden andquench system for off-highwayequipment is fully automated andcomputerized. The user gainsexact repeatability and flexiblescheduling.

Yoke shafts and flanged axlesare induction hardened andtempered at rates up to 50parts per hour on dual spindlescanners. Scan speeds andpower levels are preciselycontrolled and monitored withservo drives and computeroperator interfaces.

Factory cell and pick and placesystems such as this AjaxTOCCO designed hubhardening unit are completelyself-contained and shippedready for utility hook up. Theyare ideal for achievingconsistent high quality andreducing labor costs.

Stems of CV joint componentsand wheel spindles arehardened on a variety ofstandard and custom designedlift and rotate systems.

Single shot hardening of driveshafts, transmission shafts andaxles are provided utilizinghorizontal and vertical systems.

It's tough to dominate an industry. Yetwhen other companies cut their researchbudgets, Ajax TOCCO continues todevelop programs which lead to betterways of putting induction heat treatingtechnology to work; ways that challengetraditional induction heating concepts.

10 Engineered Solutions

Pipe and Tube IndustryPipe and Tube TechnologyAjax TOCCO has a global commitment in developing new induction heating technology for tubularproducts. As a result, induction furnaces are in use that process up to 120 tons of high quality pipe andcasing per hour with consistent quality and ovality.

Induction heating equipment supplies heat where you want it, when you want it, with flexibility, control andreliability. Ajax TOCCO converters provide that flexibility with a patented, wide operating window. Thisability allows a larger range of sizes to be processed in one induction coil size without the need forcapacitor or voltage switching.

Converting barrel furnaces to induction heating, enables the use of existing handling equipment and theadvantage of fast, controllable, energy saving induction heating. The results are a dramatic savings inspace, reduced energy consumption, improved quality and the benefit of recipe control.

Ajax TOCCO is at the forefront of API pipe production for the oil and gas industry. Because casing drillpipe and line drill pipe reliability is critical, you can depend on the experience of Ajax TOCCO to supplysystems to harden and temper pipe, casing and couplings to full API specifications.

With the skilled specialists of Ajax TOCCO on your team you can expect a wealth of experience to assistyou in your pipe and tube heating requirements. Let Ajax TOCCO provide you with a full “turn-key”installation tailored to meet your individual requirements.

Ajax TOCCO is the industry expert for pipe and tube heating specializing in:Seam annealingSolution annealingBright annealingFBE CoatingBending and FormingEnd heating for upsettingCuringQuench and TemperGalvanizing

Heating both seamless and ERW tube prior to enteringthe stretch reducing mill, zone weld annealing,complete hardening and tempering lines, pipe coating,pipe forming and bending, solution annealing, internalhardening, and much more are produced and designedby Ajax TOCCO.

Seamless and ERW pipeand casing is hardened atproduction rates up to 120tons per hour.

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Ajax TOCCO supplies systems that provide the mostadvanced state of the art technology available. Lessspace, greater efficiency and continual designdevelopment are just some of the ways we strive tosatisfy our customer's needs.

Ajax TOCCO pioneered induction quench and temper lines for oilcountry line pipe and casings.

Nine megawatts of power are used to preheat tubing for stretchreducing. Induction heating advantages include fast start andstop capabilities, low scale formation, better surface quality,speed and scheduling flexibility.

Close tolerance pipe coating with good bonding characteristicsmake induction heating the ideal method of pre-heating line pipe.Equipment is available to handle a wide range of pipe sizes.

12 Engineered Solutions

Custom ApplicationsThe Custom Applications Team was formed with the task of exploring new areas of use forlow power induction heating. Our goal is to bring the many benefits of induction to everyapplication where thermal enhancement is required.

Our team is composed of engineers and technicians with a "can do" attitude, excited totackle opportunities that have been unthinkable with the induction process in the past. Oursuccess has been possible due to the many new advances in power supply and electricalcontrol technology. Backed by Ajax TOCCO's experience, and the support of the entire AjaxTOCCO staff, we are capable of accurately evaluating each new process. We work closelywith the customer to ensure exact process results are achieved.

The Custom Applications Team specializes in low power applications from 1kW to 50kWs.We offer both air cooled and water cooled, self tuning power supplies that have a frequencyrange of 10 kHz to 450 kHz. The Custom Applications Team gives Ajax TOCCO the addedflexibility to tackle any process from brazing fine jewelry to forging.

A 5kW TOCCOtron® AC powersource is shown within theconfines of a NASA space shuttle.This 100% air-cooled system isused to braze critical fuel andhydraulic lines. Its lightweight andsmall size allow it to be placedmost anywhere within the orbiter.

Hand held induction coils as shownin this photo have facilitated thereplacement of gas torches inmany applications. Inductionheating by Ajax TOCCO providesmany advantages, such asincreased production, improvedquality and repeatability, and lessimpact to our environment.

No more welds! Today's automobilepanels are increasingly being assembledwith heat sensitive adhesives, makingwelding and other mechanical assemblymethods obsolete. Ajax TOCCO offers anoff the shelf, 100% air cooled inductionhem bonding system that assists infacilitating this process at majorautomotive plants around the world.

Ajax TOCCO can provide turn key systemsfor the entire fastener industry. Hot heading,thread rolling, and systems for curing offastener coatings. Production rates forcuring systems can be as high as, but notlimited to, 3600 parts per hour.

Many of the products we use every dayare processed with induction heatingsystems developed by the CustomApplications Team at Ajax TOCCO.Affordable designs and unmatchedversatility are the reasons manyconsumer products companies chooseAjax TOCCO.

Induction Bondhead to shaft

Induction Heatshaft for forming

Induction Curingof adhesives used tobond grip to shaft

Induction Forgehead of club

Induction Brazeeyeglass frames

Induction Hardenhip and shoulderjoint replacements

Induction Meltingfor casting

Induction Preheatingof molds to form golf balls

Induction Hardengolf spikes

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Ovens

DevelopmentCenter

Ovens by Ajax TOCCO Magnethermic

The oven division of ATM has over 90 years experience in custom ovendesigns. We specialize in unique applications, with the exclusive capability ofcombining ATM Induction with Convection Oven technology to deliver themost efficient and precise heat process systems.

Ovens by Ajax TOCCO Magnethermic include specially designed dry andcure ovens for the Metal Decorating Industry. This industry includes roadsigns, “thin plate” advertising, and food and beverage containers.Lithography on various base materials requires a dry and cure cycle of veryprecise uniformity.

Process Development Expertise /Meeting Critical Timing ObjectivesAjax TOCCO provides the metallurgical, technical and productexpertise to develop the design of experiment, tooling andprocess that will meet your product performance objectives intoday's fast paced environment. Tooling can be manufacturedand modified within days and the Induction Laboratory has over450 inductors ready for immediate trials.

Experience and SkillsThe rapid heating cycles that make induction so attractive alsooffer new challenges for the metallurgist and process engineer.Ajax TOCCO development and process-engineering group hasthe induction knowledge only gained by experience. As materialsadvance and near net shapes become the hottest trend, we'realready looking beyond historical methodologies to advance ourcustomers to the front of the technological edge by developingthe most robust processes available in the industry.

The three ovens pictured above temper parts for CV jointson front wheel drive vehicles. In each oven 240 parts perhour are heated to 450 degrees F for one hour, thencooled to room temperature in less than 20 minutes.

This “Pin Oven” dries and cures inks on the outsideof beverage cans. Typical speeds of these ovensare 2000 cans per minute.

Full line of metallurgicalpreparation and inspectionequipment including digitalimaging staffed byqualified metallurgists.

14 Engineered Solutions

ny brand,Induction system parts, field service, maintenance, repairs

ny brand,ny brand, type or applicationInduction system parts, field service, maintenance, repairs

Aftermarket SupportSpare PartsAjax TOCCO offers an extensive computerized inventory of factory certified replacement parts forour induction heating and melting equipment to assure quick turn around. We also offer replacementparts for all other makes of induction equipment. Our commitment to customer support means AjaxTOCCO is available to handle emergencies any time of the day and any day of the week.

Repair CentersStrategically located facilities are geared to meet the repair requirements of all induction users. Ourskilled workforce assures the customer's peace of mind in knowing that their job will benefit from thelatest technological advances in state-of-the-art materials, components, and craftsmanship.

ServiceTechnical assistance is available any time of the day or night using our 24 hour hot line. Ourexperienced service team is strategically located to provide quick response to our customerswherever they are located.

Customer Support

Replacement power units designed to replace all makes and models.Solid State contactors designed to replace the electromechanical devices.Infrared imaging for locating extraordinary sources of heat in induction equipment.Induction Power Supply Maintenance and Troubleshooting Schools.Pre-packaged set of tools for equipment maintenance.MAGNE-CLEAN water system flushing service.MAGNE-FIELD electromagnetic field mapping of induction equipment.

InstallationInstallation of induction equipment performedtimely and accurately is critical to the financialsuccess of a project. Ajax TOCCO offers completeturn-key installation service on all equipment.

Total Support Beyond /Commercial Heat TreatingOnly Ajax TOCCO enhances a successfullaboratory development with fine productionequipment and also offers a certified productionheat treating division capable of producingthousands of parts a day. Being there when youneed us is our commitment to our customers.

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Well equipped workshop facilities provide skilled services for therepair, refurbishment and upgrade of most types of heating andmelting equipment.

Ajax TOCCO has heavily-invested in facilities dedicated forthe sole purpose of repairing and reconditioning electroniccontrol boards and components. Using exclusive electronicsimulators that duplicate actual operating conditions we areable to pin-point problems quickly and to speed repairs.

New or repaired, every step of the way, you can rely on Ajax TOCCOquality – and at reasonable costs too. That's because Ajax TOCCO hasnever been closer to our present and future customers. You can besure that, regardless of the type and make of equipment, Ajax TOCCOstands behind every repair.

The Ajax TOCCO Magnethermic Service Departmentoffers a full line of services to our customers. Theseservices include our Customer Care Program, InfraredImaging, Induction Power Supply Maintenance andTroubleshooting Schools, and much more!

Ajax TOCCOcommissioning and serviceengineers are involvedwith many of ourcustomer's mainequipment contracts –from commencement ofmanufacturing through tofinal on-sitecommissioning.Technical assistance fromnumerous engineers isavailable to solve the mostcomplex of problems, andto offer suggestions forperformanceimprovements andreliability.

AjaxTOCCO Magnethermic® CorporationThe Global Force in Induction Technology

World Headquarters1745 Overland Ave.Warren, OH 44483330-372-8511330-372-8608 (FAX)

GenBR#4/411/3M-grx-og

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World HeadquartersWarren, OH 330-372-8511Customer Service 800-547-1527Boaz, AL 256-593-7770Wickliffe, OH 440-833-0386North Canton, OH 330-818-8080Longview, TX 903-297-2526Madison Heights, MI 248-399-8601Sterling Heights, MI 586-254-8470Brookfield, WI 262-317-5300Ajax, Ontario, Canada 905-683-4980Shanghai, China 86-21-6800-9546Birmingham, England 44-121-322-8000Tokyo, Japan 81-3-3647-7661Queretaro, Mexico 52-44-2221-5415Seoul, Korea 82-2-837-0413LeRoeulx, Belgium 32-64-67-37-77Hirschhorn, Germany 49-6272-9217-500Hemer, Germany 49-2372-55980Poznan, Poland 48-61-826-8136Bangkok, Thailand 66-2-625-3045

Call 1-800-547-1527, 24/7 for Service Assistance.

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Authorized OEM for AIH, IEH, Ajax Magnethermic®, TOCCO®, Lectrotherm, Pillar,Westinghouse, and Cycle-Dyne.

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InductionHeating&Melting