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Surface hardening of stainless steel in the Food Processing Industry
BEYOND THE SURFACE
Agenda
Why use Stainless Steel in Food Processing Industry
Key factors
Challenges
Options
Expanite processes. This is how we do it
Expanite Introduction
Expanite Treatment in the Food Industry
Next generation surface treatment technology
Why use Stainless Steel in
Food Processing Industry
BEYOND THE SURFACE
Corrosion resistant
Migration – Approved to have Food contact
Hygienic - Clean ability
Mechanical properties
Key Factors
BEYOND THE SURFACE
Stainless steel has good corrosion properties
- but it suffers from poor wear resistancegiving several challenges
BEYOND THE SURFACE
Wear
Corrosion
And the increased focus on:
Lifetime cycle
Maintenance and Service
Cleaning
Production efficiency
Food safety.
What are the Challenges
BEYOND THE SURFACE
What are the options
Do nothing – and live with wearCoatings – and live with risk of spalling:
Hard Crome PlatingPVD/DLC
Diffusion:PlasmaSalt-bathGas
We believe the future is gas!
Expanite treatment improve the surface hardening while maintaining and/or even improving the corrosion resistance
What happens with wear and corrosion after
Expanite
BEYOND THE SURFACE
The pain…and the solution!
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WeightLoss[mg]
Time[min]
Materialloss-accelerated
Untreated
ExpaniteHighT
SuperExpanite
BEYOND THE SURFACE
Improved wear resistance
Alloy: duplex 2205
Knifes used to cut enzyme powder
Accelerated wear without Expanite hardening
Unused knife
Used knife withoutExpanite
Used knife with Expanite
BEYOND THE SURFACE
ASTM G133 wear test performed on AISI 316 stainless steel with and without “SuperExpanite” surface hardening treatment
Lubrication: noneCeramic silicon nitride ballForce: 25NTotal sliding distance: 100m
9h June 2015 AT n° CET0111600_PV_01_a Page 13/23
Final
Friction force The friction force is measured by a piezoelectric sensor attached between the machine frame and the support of the fixed specimen.
Figure 7 : Tribometer PLINT TE-77.
Figure 8 : General overview of tribometer PLINT TE77.
BEYOND THE SURFACE
Findings – worn surface trace profiles
Main conclusion: 125 times less wear on SuperExpanitetreated plane surface
BEYOND THE SURFACE
ASTM G98 galling resistance test on AISI 316 stainless Non-treated 316 vs. 316 reference SuperExpanite vs. SuperExpanite
Non-treated Expanite-treated
0.5 ksi + no
1 ksi + no
2 ksi + no
5 ksi + no
… … …
40 ksi + no
BEYOND THE SURFACE
“I haven’t seen such a solution to galling on 316 in my 15+ years of tribology testing”
–Steven Budinski Owner/ Bud Labs
Dont just take our words for it
BEYOND THE SURFACE
-500
-300
-100
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1100
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1E-08 0.00000010.000001 0.00001 0.0001 0.001 0.01 0.1 1 10 100
AISI316
Annealed
*AISI 316 –Pitting resistance in seawater
SuperExpaniteExpaniteHigh-T
ReferencePitting potential increase: 400mV
Improved corrosion resistance Voltage
Current
BEYOND THE SURFACE
Improved corrosion resistance
-400
-200
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1E-08 0.00000010.0000010.00001 0.0001 0.001 0.01 0.1 1 10 100
AISI316Annealed
AISI304Annealed
AISI304ExpaniteHighTV1
316 reference
304 reference
304 ExpaniteHigh-T
*AISI 316/304 –Pitting resistance in seawater
Voltage
Current
EXPANITEEnhancing the properties in
the stainless steel
This is how we do it
BEYOND THE SURFACE
What is Expanite?
A technology =
process/recipe =
time + temperature + pressure + gas flow + surface physics & chemistry in a furnace=
a gas-based diffusion process
N+Cnotabletopenetrateoxidelayer
Expanitegasprocessremovesoxidelayer
N+Cisnowabletoentermaterial
BEYOND THE SURFACE
What’s unique?
150
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950
1050
1150
0 50 100
Hardness[HV0.01]
Distancefromsurface[µm]
Micrographs & hardness profile of part in AISI316
ISO9227 168hr salt spray
Improving hardness and in the same time improving/restoring corrosion resistance beyond what the market previously has seen
BEYOND THE SURFACE
What’s unique?
Accurate control• Tailoring• Scalable• Clean• Fast & Cost effective
Bulk-ware treatment• Homogenous hardening• No post cleaning• Bulk treatment
. . .
Identical temperature and time – only increasing gas potential
BEYOND THE SURFACE
The processesTemperature in vacuum: 1000-1200CFast gas quenchAdds nitrogenDK: 400x400x600 DE: 400x400x1000
BEYOND THE SURFACE
The processesTemperature in atmospheric environment: 380-470CAdds nitrogen and carbon in solid solutionDK: 600x600x1000DE: 800x800x1100
BEYOND THE SURFACE
The processes
BEYOND THE SURFACE
Martensitic stainless steel
ExpaniteHigh-T Hardness and corrosion resistance increase!
Duplex stainless steel
Austenite + ferrite
Expanded austenite
Carbon martensite
Nitrogen martensite
BEYOND THE SURFACE
Martensitic stainless steel
350
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550
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700
750
0 0.4 0.8 1.2 1.6 2
Hardness[HV0.3]
Distancefromsurface[mm]
Treatment: ExpaniteHigh-TCase Depth High-T: 0.55 mmSurface hardness: 950 HV0.3
12.5Cr-0.12C-(1.5Mn+1.0Si max)
Expanite Introduction
BEYOND THE SURFACE
Established 2010 based on ongoing research since 2000HQ in Hillerød 8 furnaces doing running production R&D and production facility incl. laboratory and five experimental furnacesISO9001 certifiedLocated: DK, US and Germany
Expanite – the company
Goes beyond the surface to reduce leadtime and costs
BEYOND THE SURFACE
Expanite Treatment in the Food Industry
BEYOND THE SURFACE
Typical segments in food processing industry
Beverage equipment especially capping and filling equipment Bakery machines Chocolate processing & packagingIce-cream processing & packagingDairy processingMeat processing incl. slicing machinesPumps for food incl. positive displacement pumps and screw pumps
BEYOND THE SURFACE
Typical products in Food Processing Industry
BEYOND THE SURFACE
BEYOND THE SURFACE
BEYOND THE SURFACE
BEYOND THE SURFACE
BEYOND THE SURFACE
Next generation
BEYOND THE SURFACE
The future is gas
Why.?
Short process timeCleanerBulk wearCost effectiveHigher QualityImproving hardness and in the same time
improving/restoring corrosion resistance
BEYOND THE SURFACE
Expanite Hardening of Titanium - Why.?
Our technology works on it
It’s a alloy in growth and use
It’s a soft material
Thank you
www.expanite.com
