Carbide is a composite material that responds to cryogenic processing. It is made up of carbide particles held together with a cobalt alloy binder and cryogenic processing affects the binder and its durability.
Pictured below are carbide inserts that were milled on the same cutter. Notice the dark area near the top of the insert which is the wear. In this test, the treated insert had to take up the slack as the untreated one wore out.
A recent doctoral thesis, research indicates that cryogenic treatment significantly alters the microstructure of tungsten carbide, causing the beta-phase particles to increase in size and quantity, while the eta-phase and γ-phase show corresponding decrease. It also found that cryogenic treatment increases the hardness of tungsten carbide tools by about 7%. It noted that keeping the carbide cool is important to maintaining the wear resistance created by the treatment.
We process many types of carbide cutters, end mills, drills, and other cutting tools.
There are a lot of different carbide companies out there making a lot of different carbides. It may take several tries to find the best processing parameters for any one item, as we usually have no indication as to the makeup of the carbide.
………Work with us and we will find the right combination
If you see these pictures on our competitors’ web sites, be advised that we did the photography.
The plastics molding industry is extremely competitive. Any advantage that can be had can make the difference between profit and loss on almost any job. You cannot allow your competition to have the advantage of greatly reduced mold wear and higher profits due to molding runs that are uninterrupted by maintenance problems.
Cryogenic processing is very successful in reducing wear on runners and in cavities, even when highly abrasive materials are being molded. Our customers typically see two to three times the life on molds, pins, and other parts.
Cryogenic processing has shown to stop the seizing of ejector pins: Our analysis is that the pins actually grow in use due to retained austenite transforming to martensite. This causes the pins to seize tightly. Cryogenic treatment prevents this from happening.
Side actions show reduced wear, and parting lines stay sharp.
One of the biggest costs of a mold is polishing. The cost of polishing is up to 30% of the total mold cost. Cryogenic processing reduces the time required to polish a mold. The process produces a more evenly hard surface that is easier to polish.
Treating pelletizer knives increases their life by an extraordinary amount. For one major household products supplier (with over 50 pelletizers at one plant), cryogenic processing increased the life of pelletizer blades and screens from two months to over two years. CPT saved the company money in labor, sharpening, purchasing and new parts costs. But, even if you only have one pelletizer, we can save you money.
We worked closely with a plant manager at the Rubbermaid Corporation sometime back. The following experiment and calculations are based on the parameters we extracted from that trial:
Cost Comparison, Cryogenically Treated vs. Non Treated Pelletizer Blades
The following is a cost comparison for the difference in total expenditures between a set of cryogenically treated knives and untreated knives for a Nelmore grinder. The blades are D2 steel. Results may vary with type of plastic and other factors. Processing costs will vary with blade size and number.
- The customer told us that untreated blades wear out after three months of service.
- The same company told us that cryogenically treated blades wear out in 24 months.
- Labor to change blades is 4 hours.
- Cost to sharpen a set of blades is $100.00.
- Untreated blade sets can be sharpened ten times.
- Cryogenic processing of the blade set costs $500.
- The blade set costs $750.
- Labor charge out costs is $50.00
- Time basis for the calculation is one year.
The total cost of using the blades:
- The cost of the set(s) used minus any residual value at the end of the year
- Sharpening Costs
- Labor Costs
Blade cost calculations:
Yearly cost of sharpening:
Labor cost for changing the blade:
The money saved by using cryogenic processing was $1216 per year /per grinder.
With over 65+ grinders in this one plastic molding plant, potential savings is over $79,000 per year. The money invested in processing the blades is returned in less than six months. More savings are available if the screens are processed.
Resistance Welding Electrodes
Resistance welding electrodes are widely used by the automobile and appliance industries.
Cryogenic processing improves the life of these items considerably. Linde Gas Division of Linde AG (a major supplier of industrial gases) says they can make them last longer by a factor of two to nine times.
It may be necessary to change some welding parameters in order to take full advantage of the gains offered by processing these parts.
Cryogenic processing has a great effect on grinding wheels, for both plated super-abrasive wheels and vitreous-bonded wheels.
Tests at automotive plants show consistent results. The wheels stay sharper, there is a reduction in tensile residual stresses induced into the piece, and the desired surface finish is easier to obtain. Plated wheels are expensive, and cryogenic processing can make them much more cost effective.
The quote below is taken from a grinding wheel manufacturer’s web site.
“Electroplated (super-abrasive) grinding wheels offer substantial benefits in grinding exotic alloy steels. Since the…crystal resists dulling much better than conventional abrasives, it provides stress-free, cool cutting action throughout its long life. The crystal tends to be self-sharpening as cutting stress increases…”
We also treated vitreous bonded wheels and again, they stay sharper longer with less need for dressing. Our process affects the crystal structure in the grinding grain, which makes it stay sharper longer.
Gear making is an expensive proposition. Hobs are costly tools and when they wear, tooth profiles change. Cryogenic processing has shown to give hobs up to five times the life. We treat hobs for some of the best gear makers around, especially in the racing industry. Treating their hobs and other cutting tools gives them a big competitive advantage over lesser companies. The cost savings transfer directly into more profit and more business.
There are few places as rough on equipment as a foundry. Foundry machines and tooling is subjected to abrasive sand. Metal slag is everywhere. All this adds up to huge costs to keep things running.
Pictured at the right is a pattern used to form the sand molds for a transmission case. This form has sand packed around it to create a mold. The sand abrades the form and can wear it out of tolerance.
These forms are very expensive. We can make them last three times as long as an untreated pattern.
Pictured Below is a pattern used in forming a mold for a crankshaft. Again, wear on this pattern creates costly problems and cryogenic processing can reduce that wear. considerably.
Pictured below are trim dies. They are used to cut metal off the casting. The castings have sand and other debris all over their surface.
Cryo can keep these in production much longer and reduce the need to sharpen or replace them.