Zirblast & Zirshot Ceramic Beads for Surface Treatment. April 2006

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Aubrey McDonald
6 years ago
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1 Zirblast & Zirshot Ceramic Beads for Surface Treatment April

2 Summary 1 Zirblast & Zirshot ceramic beads characteristics 2 Behavior in industrial use 3 Benefits in use 4 Applications 5 Testing facilities 2

3 Zirblast & Zirshot Ceramic Beads Characteristics 3

4 Chemical composition and structure ZrO2 67% SiO2 31% Misc. < 3% (Typical values) Thanks to their very fine micro structure ZIRBLAST & ZIRSHOT are showing very good wear and impact resistance. 4

60 GPa Poisson s coefficient 0.27 (Typical values) Zirblast Zirshot ZirPro ceramic beads are fine and hard.

5 Physical Characteristics & aspect Density 3.76 Steel shot 7.6 Glass beads 2.5 Bulk density 2.3 kg/l Vickers micro-hardness 700 HV1 Young s modulus 330 GPa Spring steel 220 Gpa Aluminium oxyde 390 Gpa Glass 60 GPa Poisson s coefficient 0.27 (Typical values) Zirblast Zirshot ZirPro ceramic beads are fine and hard. They show a spherical shape. Thanks to their smooth surface, ceramic beads are gentle with the work part, blasting machine and tooling. 5

6 Available bead sizes & qualities Zirblast : basic product for current applications Bead size (µm) B205 B120 B60 B40 B30 B20 B125 Zirshot : improved for high performance applications Narrower size range, controlled shape and satellites, conditioned to avoid initial breakage Z100 Z150 Z210 Z300 Z425 Z600 Z850 6

7 Zirblast & Zirshot Ceramic Beads Specific Advantages Are: Density in the middle of the range between glass and steel: process versatility, Smooth surface: not abrasive, Round shape: high peening ability, Chemically inert: no contamination, High mechanical strength and hardness level: high impact efficiency, weak consumption rate, High grade version Zirshot: High performance guaranties. Summary 7

8 Zirblast & Zirshot Behavior in Industrial Use 8

High impact strength versus glass beads Ceramic beads are breaking into pieces, but not

They produce no dust and keep their initial size, shape, hardness and smoothness.

explode and generate dust which is sticking to the beads.

9 High impact strength versus glass beads Ceramic beads are breaking into pieces, but not wearing. They produce no dust and keep their initial size, shape, hardness and smoothness. Ceramic beads New product After cycles cycles cycles cycles Glass beads explode and generate dust which is sticking to the beads. After 10 cycles, only glass Glass beads CETIM Tests, compressed air, pressure 4 bars, Aluminum target dust is remaining.. In the meantime, this dust is sticking to the beads, and they become aggressive. 9

10 High impact strength versus glass beads Influence of impingement angle and target hardness Target Soft steel Soft steel AG5 Alloy Bead size: 300/425 µm Pressure : 4 bars Dry process (Venturi gun) Angle Glass Beads Ceramic Beads Breakage (%) after 20 cycles 70.6 % 2.6 % 44.6 % 2.3 % 40.1 % 2.1 % R = 27 R = 19 R = 19 In practise, most of the users are consuming at least 8 to 10 times less Zirblast versus their past consumption of glass beads. R = breakage ratio glass beads / ceramic beads 10

High impact strength versus steel shot Ceramic

cycles 10 cycles 40 cycles 60 cycles Steel

11 High impact strength versus steel shot Ceramic beads are breaking into pieces, but not wearing. They produce no dust and keep their initial size, shape, hardness and smoothness. Steel shot Ceramic beads New product After 5 cycles 10 cycles 40 cycles 60 cycles Steel shot is wearing and breaking according to its hardness, generating dust. Hardness, shape and size are not consistent during life time. CETIM Tests, compressed air, pressure 4 bars, Aluminum target 11

12 Good Resistance to Projection by Wheel Turbine ERVIN Test ZIRBLAST in WHEEL TURBINE LIFE DURATION TEST Designed for steel shot testing, Ervin test allows to compare the life time of different blasting medias. Usable fraction % Mean life time 2,600 cycles Parameters Zirblast B40 Size range µm Throwing velocity 50 m/s Almen intensity N number of cycles Result Life time comparable with the one of cast steel shot. 12

Good Recycling Ability Dust collector Wasted dust (almost no Zirblast) Wasted broken beads Air entrance Turbine feeding Note: Air washer separator is the most suitable recycling

Standard Air Wind Separator Dirty mix is brought to the head of the separator where the flow is regulated to make a curtain of media to be recycled.

13 Good Recycling Ability Dust collector Wasted dust (almost no Zirblast) Wasted broken beads Air entrance Turbine feeding Note: Air washer separator is the most suitable recycling system. Nevertheless sieving or cyclone separator are also working with ceramic beads. Standard Air Wind Separator Dirty mix is brought to the head of the separator where the flow is regulated to make a curtain of media to be recycled. Good beads are not deviated and then fall down straightly. The air wind, generated by the dust collector fan, brings away broken beads and dust. Dust is evacuated to the dust collector by the air stream. Broken beads fall down in the trash bin by the effect or air expansion and slowing down. 13

14 Good Recycling Ability Example of Shot peening equipment Equipment for aircraft engine blade peening 12 Venturi guns Air suction Reclaim system Dust and broken beads elimination by cyclone Size selection by sieving 14

15 Stable Aspect in Industrial Use Recycling by air wind separator New Zirblast After 85 hours 175 hours 250 hours ZIRBLAST B120 ( µm), free air blasting room, 4 bars hours Beads are keeping their round shape, cleanliness and smooth surface, by replacing, little by little, the consumption with new beads (max. 5% of the working mix). 15

16 Stable in Industrial Use During 1,000 blasting hours, mean size variation < 7% retenu (%) Diamètre médian (µm) Origine durée de grenaillage en nombre d'heures tamis <63µm tamis µm tamis >125µm Diamètre médian 0 ZIRBLAST B120 ( µm), free air blasting room, 4 bars Follow up by sieving size analysis 16

17 Steel Shot Compared with Zirblast Used Zirblast is showing a Working Mix 100 tight size range of 125 µm, with a low D 50 of 175 µm. Bead surface is smooth, their Steel shot S110 ZIRBLAST B Tranche µm D50 = 500 µm tranche µm D50 = 175 µm Cumul Retenu (% ) Cumul Retenu ( % ) shape is round. No dust has been detected. Steel shot S110 extracted from a true working mix is showing a wider size range of 275 µm, and a D 50 of 500 µm. Their surface is showing facets, due to deformation and pitting wear. More than 3% of metallic dust have been removed during the first blasting cycles. Dimension de bille (µm) 17

Steel Shot Compared with Zirblast Steel shot S110 ZIRBLAST B60 Wastes refused at the air wind separator Broken and unshaped beads. Some round beads, but in a very little amount.

18 Steel Shot Compared with Zirblast Steel shot S110 ZIRBLAST B60 Wastes refused at the air wind separator Broken and unshaped beads. Some round beads, but in a very little amount. If we consider the waste of ZIRBLAST refused at the air wind separator as base = 1 For a given amount of blasting time, the mass of refused steel shot S110 is 5 times the one Zirblast I.e; 2.5 times in bulk volume. Note: The Media price is settled by kg, and Zirblast is working 8 to 10 times faster than steel shot S110 for the present descaling application. Large amount of unshaped beads, hollow and looking like coffee grains". 18

Steel Shot Compared with Zirblast Steel shot S110 ZIRBLAST B60 Wastes refused at the dust collector Zirblast beads are not wearing, but breaking into

Note : during the test, only a little amount of oxide has been removed from the work part.

19 Steel Shot Compared with Zirblast Steel shot S110 ZIRBLAST B60 Wastes refused at the dust collector Zirblast beads are not wearing, but breaking into pieces. The finer of these are sucked to the dust collector in a very little amount. Note : during the test, only a little amount of oxide has been removed from the work part. In a true industrial blasting situation, the portion coming from the steel shot would become a minority versus the amount coming from the work parts. Steel shot are generating wearing scales which are sucked to the dust collector, with the oxide removed from the work parts. 19

20 Zirblast & Zirshot Ceramic Beads Behavior Advantages Are: Breaking instead of wearing and bursting No dust generation Less final wastes High wheel turbine process compatibility Process versatility Industrial efficiency Summary Easy recycling with conventional means Usable with standard equipment Stable in shape, aspect and size all along life time Consistent results 20

21 Zirblast & Zirshot Benefits in Use 21

22 Process Speeding up Coverage on Almen strips Up to 20 times faster than with steel cut wire Base = 1 0 SCW 800 Z300 Z150 22

Less Wearing of the Equipment Steel cut wire 800 µm Compared impacts on bakelite samples for the same blasting time Due to its rough surface and high density, steel cut wire is wearing the target

23 Less Wearing of the Equipment Steel cut wire 800 µm Compared impacts on bakelite samples for the same blasting time Due to its rough surface and high density, steel cut wire is wearing the target material both by abrasion and pitting wear. The finer is the steel media, the faster is the abrasion wear of spare parts. Note : The depth of abrasion governs the replacement of spare parts. ZIRBLAST B40 Thanks to their smooth surface and low density, ZIRBLAST beads are not producing abrasion wear. Only slow pitting erosion wear is happening. The print is 10 times less deep. The mass loss is 7 times lower. The finer is the Zirblast, the lower is the pitting wear of spare parts. 23

24 Improved Energetic Efficiency Only half of the electrical amperage is necessary M e d ia F lo w ( k g / m n ) Steel shot S110 ZIRBLAST B Hole diameter (mm) Electrical Amperage (A) 6 S110 (A) 5 B60 (A) 4 ZIRBLAST B60 3 ACIER S Media flow (l / min) Due to the density difference in favor of ZIRBLAST, electrical amperage is divided by two for the same amount of bulk media thrown through the wheel turbine. 24

25 Zirblast & Zirshot Ceramic Beads Advantages in Use Are: Process speeding up Improvement of industrial efficiency Investment cost saving Summary Significant reduction of machine wear Running cost saving Improvement of machine involvement in production Lower energy consumption Running cost saving 25

26 Some Zirblast & Zirshot Applications 26

injection dies Other tool types Plastic or aluminum extrusion

27 Applications in Tool Cleaning Mould Cleaning For glass bottles, tires, aluminum casting dies, stamping matrixes, plastic injection dies Other tool types Plastic or aluminum extrusion dies, handling tools for painting, metallization, coating, brazing... 27

Applications in Surface Preparation & Finishing Stainless steel finishing Surface improvement by smoothening, hardening homogenizing in order to

profiles of stainless or special steels between hot and cold milling or extrusion. Forged or machined mechanical parts after heat treatment.

28 Applications in Surface Preparation & Finishing Stainless steel finishing Surface improvement by smoothening, hardening homogenizing in order to obtain an optimal clean ability for food or pharmaceutical equipments, transport or storage containers Difficult descaling Coils, wires, bars and profiles of stainless or special steels between hot and cold milling or extrusion. Forged or machined mechanical parts after heat treatment. The use of ceramic blasting is then saving chemical pickling operations. Others Casts or extruded aluminum finishing, surface preparation before coating 28

Applications in Shot Peening High strength steel Providing high level of compressive stress and smooth

solicitations of elastic mechanical parts such as spring, gears, power train and transmission parts, shafts

aluminum, titanium, and non ferrous alloys, providing far higher fatigue enhancement and saving

29 Applications in Shot Peening High strength steel Providing high level of compressive stress and smooth surface condition, Zirshot allows significant improvement in fatigue, pitting erosion or combined solicitations of elastic mechanical parts such as spring, gears, power train and transmission parts, shafts Light alloys Ideal elastic and non contaminant media, Zirshot is particularly suitable for shot peening of aluminum, titanium, and non ferrous alloys, providing far higher fatigue enhancement and saving decontamination and polishing operations on titanium fan blades for ex. Corrosion fighting and prevention Chemical and petrochemical reactors 29

30 Zirblast & Zirshot Testing Facilities 30

31 Demonstration Facility in France Air pressure cabinets direct pressure or Venturi system CCD camera for surface inspection & media control Wheel turbine machine Vertical moving nozzle, Rotary table Electronic roughness measurement 4 kw; 1.4m rotary table 31

Solid Carbide Tools. Composite Tools. Performance by Design. ISO 9001 Certified Company

Solid Carbide Tools. Composite Tools. Performance by Design. ISO 9001 Certified Company Solid Carbide Tools Composite Tools Performance by Design ISO 9001 Certified Company As one of the world s largest manufacturers of solid carbide rotary cutting tools, SGS Tool Company has pioneered some