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Thermal solutions for challenging applications

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article image Heated parts offer numerous advantages.

WATLOW 's Batavia, Illinois facility is the company's thermal solutions supplier specialising in design and manufacturing of thermal assemblies based on cast aluminum, precision-machined and interference fit construction (IFC) techniques.

Watlow's thermal assemblies are used in some of the most challenging industrial applications.

The facility offers many advantages including precision manufacturing equipment and processes, clean room assembly and a strong support structure while working with its customers to minimise product development cycles.

Heated parts are designed to meet the customer's mechanical and temperature specifications. For lower temperature applications, the thermal assembly will typically use a formed cable or tubular heater, cast into aluminum or flexible heater mounted into a precision assembly.

For high-temperature applications, Batavia also offers IFC-designed parts, using proprietary processes to uniformly assemble heater elements and cool tubes into stainless steel or other heated parts.

Heated parts offer numerous advantages, including durability, long life and custom design. But the main advantage is the machining tolerance for flatness, perpendicularity and superb temperature uniformity, which is due to an optimised heater layout and precision mould design.

Watlow Batavia’s resources include include state-of-the-art CNC machines, which guarantee precision machining and repeatable result. The company also has lapping machines for extremely flat and smooth surfaces.

It has a high-tech lab, which conducts ongoing product and process research as well as temperature uniformity testing and validation, heating and cooling ramp rates, structural characteristics and coating performance.

Batavia uses these and other resources to offer CAD/CAM design and solid modelling, application of E-beam welding to manufacture sandwich heated assemblies, application of vacuum brazing to create three-dimensional heated parts and the application of special coatings such as Teflon, anodising and electroless nickel plating.

It also offers X-ray techniques to check for porosity-free castings and validation of heater positioning. It offers services such as finite element analysis (FEA) and additional treatment of heated parts, such as chemical cleaning and packaging for clean room acceptance. The compnay has a Class 10,000 clean room and specially-designed packaging.

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