ZELL GRID: Distortion-free workpiece carriers for component hardening up to 1,200 °C

When hardening metal components - for example in toolmaking, aviation or medical technology - the focus is on one thing: dimensional accuracy despite heat and stress. In hardening ovens with temperatures of up to 1,200 °C, conventional carrier systems quickly become a risk factor. They warp, lose their shape or cause heat shading - with direct consequences for component quality, rework and rejects.

This is precisely where the ZELL GRID system comes in: a modular, high-temperature-resistant workpiece carrier system that has been specially developed for hardening processes in which conventional racks fail.

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🔥 Typical problem: Deformed hardening racks - high reject rate, high cost

Many customers - such as the internationally active fastener manufacturer SFS - turn to ZELL when existing carrier systems regularly become the subject of complaints:

• Parts lose their exact position due to distortion at >1,000 °C
• Components tilt, weld together or are hardened unevenly
• Repeatable processes are no longer guaranteed
• The service life of the carriers decreases drastically - sometimes after less than 50 cycles

In these cases, ZELL is often called in as a specialist to provide a dimensionally stable, thermally resilient and durable alternative.

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🧩 ZELL GRID - high-temperature beams with a system

The ZELL GRID is based on a robust, modular grid concept. Depending on the application, the construction is made of high-temperature-resistant stainless steel (e.g. 1.4841 / AISI 314), Inconel or special cast alloys with long-term strength >1,200 °C.

Technical features:

• Temperature-resistant up to 1,200 °C in continuous operation
• Load capacity per grid surface up to 30 kg (depending on configuration)
• Distortion-free design thanks to defined expansion zones in the frame
• Modular configuration: customizable retaining bolts, support pins, fixing shells
• Optimum heat distribution due to open grid design, minimal shadow formation

The carriers can be loaded manually or automatically (e.g. by robot). Cleaning, tracking and reuse are possible without any problems.

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🛠️ Typical application examples

1. hardening of precision tools (e.g. cutting punches, dies)

• Avoidance of hardening cracks thanks to precise, tension-free support
• Multiple use >200 cycles without dimensional change

2. heat treatment of titanium components for implants

• Material combination: heat-resistant carrier + ceramic-based insulators
• No discoloration or reaction layers at contact points

3. annealing processes in the aviation industry (e.g. structural components)

• Load-bearing support structures for components with complex geometries
• Process validation according to AMS2750, CQI-9 supported by stable support

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📈 Economic added value for hardening shops & manufacturing companies

• Significantly longer service life compared to standard racks: documented >200 uses without distortion
• Less waste & rework: thanks to reliable component positioning and uniform temperature distribution
• Reduced set-up times thanks to modular quick-change elements
• Lower lifetime investment costs: support structure is retained, only mounts can be replaced
• Reliable integration into automated processes thanks to grid standard, optionally with RFID/DMC for batch tracing

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✅ Conclusion: When standard beams fail, the ZELL GRID begins

The ZELL GRID is more than a support system - it is the answer to a common problem in heat treatment: distortion, component loss and process uncertainty due to inadequate racks. With over 30 years of experience and customers like SFS, ZELL delivers precise, resilient and economical solutions for industrial hardening practice - ready for extreme temperatures and tight tolerances.

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