Ceramic beads for impact surface treatments

1 Ceramic beads for impact surface treatments Enhanced work piece quality and surface finish Lower production costs Support from a competent teamI/ Zirblast and Zirshot beadsenhance work parts quality andsurface finishThree main factors contribute to thesequalitative improvements:1/ no contamination of treated surfaces Ceramic beads do not contaminate treating parts by embed-ment of reactive particles. Their exceptional mechanicalproperties (toughness, impact resistance, hardness, elasticproperties) allow them to maintain their initial shape withoutshattering and without being subject to strain hardening, evenafter being used for a long period of uniform, reproducible treatment qualityThe results are uniform over the entire surface of the all, treatment quality is consistent and reproducible,part after part.

2 surface finish is of consistent quality fromone production run to the of their elastic properties, Ceramic beads reboundseveral times during the blasting process. This propertymakes them ideal for treating parts of complex geometry andareas that are inaccessible using conventional no damage to the partsTheir relative density is optimal: higher than that of glass beads ,for higher treatment intensity, lower than that of steel high rate of coverage ofceramic media makes it possibletotreat only the necessary surfaceswith no damage to the rest of thepart. For example, the edges andmarkings of glassmaking molds orthe pattern of tire molds finish condition (after cleaning,descaling or stress relieving ofwelds) is impact surface treatmentsZirblast and ZirshotCompressed Air Stainless steel samplesRoughness measurementsGlass beadsZirblastCeramic beads70-125 m (B120)5 bars80-150 m5 mSoci t Europ enne des Produits R fractaires (SEPR)manufactures Zirblast and Zirshot Ceramic beads for impact surface treatment applications by a uniquefusion process of oxides at very high addition to giving superior treatment quality with lowerproduction costs, these beads offer enhanced operatingconditions and greater versatility.

3 They are equally effective whether used in air blast (dry or wet) or wheel-blast systems. II/ SEPR Ceramic beads reduceoperating costsCost reduction is a key priority for production managers,and the feedback from our customers is unanimous: the use of SEPR Ceramic beads drives down production consumption of Ceramic media is one-tenth that of glass mediaBecause of their high toughness, ceramicbeads do not break into small particles duringuse, thereby minimizing the use of the dust col-lection system. Moreover, the beads them-selves can be recycled more times, extendingtheir service enhanced working conditions boostoperator productivityFreedom from dust ensures excellent visibilityinside or outside the blast rooms and keepsbeads flowing smoothly. As a result, operatorsspend less time on each work piece and onmachinery equipment lasts longerThe dust generated by traditional media creates a highlyaggressive environment for machinery.

4 With Ceramic media,the reduction or elimination of dust means longer service lifefor the equipment. Wear parts last longer, making for morestreamlined maintenance steel shot, Zirblast and Zirshot beads keep theirsmooth, spherical shape during treatment. These stableproperties help reduce wear on machinery and tooling,especially in wheel-blast energy consumption is reducedThe low relative density and optimal effectiveness of ceramicbeads, when delivered even at low velocities, allow the use oflower air pressure in air blast systems or a lower powerrequirement in wheel-blast systems. These savings are cou-pled with enhanced treatment quality and higher waste production is limitedThis feature is the direct result of the lower bead consump-tion and reduced production of dust, which usually requirescostly cycles10 cycles40 cyclesCERAMIC BEADSGLASS BEADSBead behavior during identical operating conditions, glass beads aredestroyed after 40 treatment cycles (turned into dust), while nearly all Ceramic beads remain use of Ceramic beads (left) vs.

5 Steel shot (right) leads to a significant difference in abrasive wear on consumption (amperage) can be reduced whilestill improving treatment Technical support: a vitalcomponent of the SEPR offeringThe use of SEPR Ceramic beads in an existing installation ora new machine ispreceded by trialsto determine themost appropriateoperating condi-tions. SEPR pro-vides technical sup-port during pilot(pre-production)testing to deter-mine the main set-tings and parame-ters. The user is then given a copy of the testing procedureor can arrange to have assistance on necessary, full-scale tests can be conducted at the SEPR showroom, in the company's plant near Avignon at Le Pontet(France). the customer or potential user may send a representativetoattend the testing and thus acquire all information and dataneeded for the use of Ceramic beads in his application, or tests can be conducted according to a program definedjointly with the customer, to be followed up by the issuanceof a test report and recommendations for by its experience in the field of impact surface treat-ment, SEPR has a highly selective testing policy, formulatingproposals only for tests likely to prove technically successfuland pave the way for economic also offers the support of a Research Center where thetechnical means are concentrated: scanning electronicmicroscope, Zirblast and Zirshot.

6 A widerange of applicationsElectrofused Ceramic beads are now used in many sectorsof industry, such as: Vessel construction: specially for stainless steel and alu-minum components and assemblies for the textile, food,nuclear, chemical and other industries. The beads are used for: cleaning and finishing of surfaces stress-relieving of welds shot-peening of reactor vessels to prevent and reducethe spread of cracks as well as stress corrosion Glass-making, tire-making and extrusion of lightweight alloysor plastics. beads are used to clean molds, dies and tools. Foundry: deburring of thin and fragile parts cleaning of molds, core boxes and tools finishing of parts made of metal alloys treatment of hard-to-reach zones ( , engine blockcooling circuits) Cryogenic deburring of plastic parts, compacting of plasmacoatings, cleaning, surface preparation of mechanical parts,aluminum cylinder heads, surgical instruments, medicalprosthesis, eyeglass frames.

7 Automotive industry: scale-removal: universal joints, welds, etc. polishing or repair of surfaces: alloy wheels refurbishment: alternators shot peening: springs, pinion gearsV/ Ceramic beads for both air-blastand wheel-blast systemsZirblast and Zirshot Ceramic beads enhance the performanceof each projection systems:Wheel-blast systemsWhen introduced into the center, the media is first acceler-ated by an auxiliary turbine then distributed through a controlcage to the main blades. The beads are then accelerated bycentrifugal force, and move along the blades to the end,where they are hurled against the parts. Optimal perfor-mance of Zirblast and Zirshot Ceramic beads is achievedusing a low delivery velocity coupled with the right media flowrate, and the smallest bead size : the use of a high flow rate of small beads at a lowprojection velocity increases the number of impacts per unitof surface area (cover-age), thereby improvingthe quality of the sur-face treatment whilereducing the beads can beused with most existingwheel-blast systems,including relatively oldmodels.

8 The best per-formance can beachieved using recentmodels designed withtight tolerances, especially when using the smallest systemsDry process with direct pressure systems(sandblasting-type system)The media is channeled through a pipe and then acceleratedthrough a nozzle. There is a wide adjustment range for themedia flow rate, which is fairly independent of the com-pressed air : by increasing the nozzle and pipe diameters andreducing pressure to ensure a constant rate of air consump-tion, the bead flow rate is increased substantially, leading inturn to higher productivity. Wear is also reduced because thebead delivery velocity is process with venturi guns (Giffard suction effect)After fluidization in an air stream, the beads are sucked up intoa pipe at the nozzle inlet, then accelerated through the is little possibility of adjusting the media flow ratebecause it is directly correlated to the air injection.

9 The small size and smooth surface of SEPR ceramicmedia reduce wear of the air injector and nozzle componentsand allows an increase of the or semi-wet process, using venturi guns with orwithout force-feed pump or direct pressure systemsWet processes work on a principle similar to that of dry air-blast systems, except that the media is mixed with water,either continuously or in a batch mode (metering water andmedia) for each blast these processes, optimal performance of Zirblast andZirshot is achieved by increasing the concentration of beadsin the processes allow for gentler treatment and generate farless dust than dry air-blast systems using fragile or Zirshot beads in a dry air-blast process, however,enable the higher costs of wet processes to be : Zirblast and Zirshot Ceramic beads offer: enhanced productivity through rapid sedimentation andrinsing, low wear of force-feed pumps and mixing pumps, evenusing a high concentration of beads in water, no wetting agent, rust inhibitor or emulsifier is necessary,even for the smallest Ceramic and cleaning systemsAll recycling and cleaning systems are compatible withceramic beads .

10 The parameters and settings must beadjusted based on the relative density of Ceramic beads ,namely: air separators adjusted to reduced air flow velocity, widerair stream and enlarged expansion pot, no air inlet at the base of cyclone separators, spiral-type classifiers are not essential for peeningapplications, adaptations in the size, the vibration frequency and ampli-tude of is rarely necessary to provide a cast-iron casing for shot-peening cabinets; austenitic manganese steel plates in themost exposed areas are adequate. A polymer lining offerssuitable protection for zones of indirect impactVI/ Proof through testingThe SEPR showroom offers an extensive range of and potential users of Zirblast and Zirshot ceramicbeads can contact: the sales manager, who initiates the test program andaccompanies the customer to industrial implementation ofthe product, or the application engineer, who monitors testing, using thelaboratory's analytical and monitoring equipment at the showroom is designed to simulateindustrial conditions as closely as possible.