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

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

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

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🔥 Typical problem: Deformed hardening racks – high scrap rate, high effort

Many customers – such as the international 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 safely guaranteed
• The lifespan of the carriers decreases drastically – sometimes after fewer than 50 cycles

In these instances, ZELL is often consulted as a specialist to provide a dimensionally stable, thermally resistant, and durable alternative.

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🧩 ZELL GRID – High-Temperature Carrier with System

The ZELL GRID is based on a robust, modular grid concept. Depending on the application, the construction consists 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 properties:

• Temperature resistant up to 1,200  °C in continuous operation
• Load capacity per grid area up to 30 kg (depending on configuration)
• Distortion-free design thanks to defined expansion zones in the frame
• Modular configurable: adaptable retaining bolts, support pins, fixing shells
• Optimal Heat Distribution due to open grid design, minimal shadowing

The carriers can be manually equipped or automatically loaded (e.g. by robot). Cleaning, tracking and reuse are easily possible.

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🛠️ Typical application examples

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

• Prevention of hardening cracks due to exact, stress-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 aerospace industry (e.g., structural components)

• Load-bearing holding structures for components with complex geometry
• 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: due to process-reliable component positioning and uniform temperature distribution
• Reduced setup times thanks to modular quick-change elements
• Lower investment costs over the service life: Carrier structure is retained, only fixtures are exchangeable
• Secure integration into automated processes thanks to grid standard, optionally with RFID/DMC for batch tracking

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✅ In conclusion: When standard carriers fail, the ZELL GRID begins

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

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