Fighting wear, corrosion, galling and fatigueon stainless steel and titanium alloys

Expanite®: Who we are

Expanite® Processes: How we do it

Wear and Corrosion after… Testing Expanite®

Expanite® in Food, Beverage & Packaging industry

Agenda

From research to business

• Expanite® founded in 2010

…but development goes back to 2000!

• First major customer early 2012

• Company culture driven by being a game-changer on the following parameters

• Speed -> Costs

• Tailoring

• Cleanliness

• Expanite® today

• Approx. 30 employees

• Treatment centers in

Denmark, Germany, USA, China & Korea

University 2009

Hillerød 2012

Expanite® Processes:

How we do it

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

Product portfolio

• Tailoring of four core processes

• ExpaniteHigh-T

• ExpaniteLow-T

• SuperExpanite® = ExpaniteHigh-T + ExpaniteLow-T

• ExpaniteHard-Ti

• Other services include

• Material recommendation/selection

• Implementation & quality control of Expanite

Patent families:SuperExpanite® WO2012146254ExpaniteLow-T WO2011009463

The processes

Temperature in vacuum: 1000-1200°CFast gas quenchAdds nitrogenDK: 400 x 400 x 600 mmDE: 400 x 400 x 1000 mm

350

400

450

500

550

600

650

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: 750 HV0.3

ExpaniteHigh-T process – martensitic exampleAISI 410 / 1.400612.5Cr-0.12C-(1.5Mn+1.0Si max)

The processes

Temperature in atmospheric environment: 380 – 470°CAdds nitrogen and carbon in solid solutionDK: 600 x 600 x 1.000 mmDE: 400 x 400 x 1.000 mm

The ExpaniteLow-T process

CrN

Too high temperature– corrosion resistance lost!

Expanded austenite

Low temperature– supersaturated solid

solution

The processes

ExpaniteHard-Ti

• Temperatures in vacuum: < 800°C

• Diffusion process without titanium nitrides

• Application possibilities:

• Alloyed titanium e.g. Grade 5

• Pure titanium e.g. Grade 2

• Surface hardness: ca. 1.000 HV

• Case depth: 10-50µm

Wear and Corrosion after…..

Testing Expanite®

Improved wear resistance

Duplex 2205

Knifes used to cut enzyme powder

Accelerated wear without Expanite® hardening

Unused knife

Used knife without Expanite

Used knife with Expanite®

What’s unique -> 125x wear resistance

9h June 2015 AT n° CET0111600_PV_01_a Page 21/23

Final

“SuperExpanite” tests: worn plane surfaces

Figure 17 : Worn surface on “SuperExpanite” plane – test #1.

µm

0

1

2

3

4

5

6

7

8

9

10

11

12

13

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15

16

Longueur = 3.99 mm Pt = 4.19 µm Echelle = 10.0 µm

0 0.5 1 1.5 2 2.5 3 3.5 mm

µm

-6

-5

-4

-3

-2

-1

0

1

2

3

Profondeur maximum 3.38 µm Surface du trou 664 µm²

Hauteur maximum 0.306 µm Surface repoussée 2.39 µm²

Un treated reference

SuperExpanite hardened

ASTM G133 wear test on AISI316

9h June 2015 AT n° CET0111600_PV_01_a Page 20/23

Final

Figure 15 : Figure 16 : Worn surface on reference stainless steel plane – test #3.

µm

0

10

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50

60

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90

100

110

120

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Longueur = 3.00 mm Pt = 144 µm Echelle = 200 µm

0 0.5 1 1.5 2 2.5 mm

µm

-100

-75

-50

-25

0

25

50

75

Profondeur maximum 135 µm Surface du trou 153411 µm²

Hauteur maximum 1.59 µm

Conclusion: 125 times less wear on SuperExpanite treated plane surface

What’s unique -> new standards in galling resistance

OwnerofBudLabs:“ ..hasneverseenanythingperformsowellon316inhis15yearsoftribologytesting”

Untreatedvs.untreated

34bar 68bar 138bar2758bar 344bar 138bar

SuperExpanitevs.SuperExpanite

Aboveyieldstrength!

ASTM G98 galling test on AISI316

-500

-300

-100

100

300

500

700

900

1100

1300

1500

1E-08 0.00000010.000001 0.00001 0.0001 0.001 0.01 0.1 1 10 100

AISI316

Annealed

EN 1.4401 (AISI 316)Pitting resistance in seawater

SuperExpanite

ExpaniteHigh-T 316 reference annealedPitting potential increase: 400 mV

Improved corrosion resistanceVoltage

[mV]

Current[A]

Expanite® Treatment in

Food, Beverage & Packaging industry

Expanite Treatment in Various Industries

OIL & GAS AUTOMOTIVE MEDICAL INDUSTRIAL

PUMPS & VALVES

CONSUMER GOODS

MARINE FOOD & BEVERAGE

• At this point, Expanite has attracted customers within the following segments of the food and beverage processing industry:

• Beverage equipment especially capping and filling equipment

• Bakery machines

• Chocolate processing & packaging

• Ice-cream processing & packaging

• Dairy processing

• Meat processing incl. slicing machines

• Pumps for food incl. positive displacement pumps and screw pumps

capping machine

bakery

ice-cream processing & packaging

screw pumps

filling machine

Food, beverage & packaging

• Nuts and bolts

• Knives

• Shafts

• Valves

• Bushings

• Pistons

• Sealings

• Filler parts

• Pump rotors, housings, screws

Typical parts Typical materials

• AISI 316L / 1.4404

• AISI 304L / 1.4301

• Duplex grades / 1.4462

• AISI 420 / 1.4034

• AISI 440 B / 1.4112

Certification & Approvals

Approval from the U.S. Federal Food & Drug Administration

Certification from independent Danish Technological Institute for

usage as food contact material

What Expanite® can be used for…

• Generally increase wear, galling or corrosion resistance of stainless steel and titanium!

• More specifically for austenitic and duplex stainless steel:

• Replace known processes such as Kolsterising® from Bodycote. Typically outcome; faster lead-time, cost reduction and improved corrosion resistance.

• Replace hard-chrome plating/coatings. Typically outcome; replace the coatings with diffusion -> no issues with spalling & in-homogenous layers, better environmental compliance.

• Replace plasma nitriding. Typically outcome; improved corrosion resistance.

• More specifically for ferritic and martensitic stainless steel:

• Replace conventional heat treatment / vacuum hardening. Typically outcome; significant increase in wear and corrosion resistance.

Goes beyond the surface to reduce lead time and costs

What’s next?

• Upcoming webinars

• Next round of webinars already in planning, i.e. watch your mailbox and follow us on LinkedIn

• Contact us

Dr. Holger Selg Florian KrügerArea Sales Manager Area Sales Manager hs@expanite.com fk@expanite.comOffice: +49 7022 20 80 038 Mobile: +49 151 50980956Mobile: +49 176 234 935 74

Expanite A/Shttp://www.linkedin.com/company/expanite-a-s/

www.expanite.com