ES1 Stainless Steel Resists Corrosion And Fatigue

NSK has developed ES1 stainless steel for use in high-humidity chemical and hygienic environments, where corrosion can impair the reliable long-term operating life of rolling bearings. ES1 provides superior corrosion resistance and rolling contact fatigue life to conventional AISI 440C steel in wet and aggressive environments; this helps to reduce maintenance, downtime and replacement-bearing costs.

Until the development of ES1, AISI 440C had been the general choice for use in bearing applications where corrosion resistance was a primary concern. Because the steel contains coarse eutectic carbides that act as crack initiators under rolling contact stress, the performance of AISI 440C had not always proven satisfactory. ES1 steel has no eutectic carbides but consists of fine carbides, nitrides and strong martensite, resulting in improved resistance to corrosion and fatigue. ES1 also has optimum nitrogen content and lower carbon content to suppress the eutectic carbides generated in conventional steel-making processes.

The operating benefits of this new material specification have been proven following extensive testing by NSK. ES1 outperformed other stainless steels in a five per cent aqueous sodium-chloride immersion test, a salt-water spray test, 5-N sulphuric acid and 5-N hydrochloride solution immersion tests and during life tests in water. In the aqueous sodium-chloride immersion test, test pieces of ES1, 13Cr stainless steel and AISI 440C were immersed in a five per cent aqueous sodium-chloride solution at room temperature for eight hours.

Before immersion in the solution, all surfaces of the test pieces were polished, then passivation treatment was applied. The test revealed that the conventional AISI 440C and 13Cr stainless steels rusted, whereas ES1 did not. Similar results were also recorded in the saltwater spray test, with both AISI 440C and 13Cr rusting considerably, while ES1 did not. Additional performance advantages were recorded for ES1 in the water-immersion test. The test bearings were 51305 thrust ball bearings with fluororesin cages and silicon-nitride balls.

They were subjected to a load of 980N (maximum contact pressure: 1470MPa) and rotating speed of 1,000rev/min, until the bearing vibration level reached about five times its initial value. Under these conditions the test results revealed that ES1 provides approximately five times longer life than AISI 440C. Because bearings manufactured from stainless steel are routinely exposed to cleaning solutions of sulphuric acid and hydrochloric acid, a further corrosion test was undertaken.

This evaluated the corrosion resistance of ES1, 13Cr stainless steel and AISI 440C in a 5-N aqueous sulphuric-acid solution and 5-N hydrochloric-acid solution. In the test, samples of each type of steel were immersed in the solutions at room temperature for 20 hours. The amount of corrosion was then measured. This revealed that ES1 is superior to both conventional stainless steels in its resistance to both sulphuric and hydrochloric acids.

Parker Replaces RSD Steel Parts With Peek Polymer

Parker Hannifin, based in Mainz-Kastel, Germany, has replaced the steel components of its RSD quick couplings with the Victrex Peek polymer. The company wanted to replace the components with one single injection-moulded part that reduced the number of components to be assembled and that controlled the overall production costs. The RSD couplings are used to connect and disconnect the hydraulic lines between a tractor and its various items of equipment (a trailer or a plough, for example) without using any tools.

The technology of the RSD coupling allows for the completely safe connection of a male connector, whether pressurised or not, under adverse conditions, such as under a maximum pressure of 250bar (3,626psi), and withstands a return flow rate that may reach 190 litres per minute (50.2 gallons per minute) and even beyond for a few seconds at a temperature close to 120C (248F). David Aragones, project manager at Parker Hannifin, said: 'Apart from the high performance demanded of the coupling, it was essential for us to control our production costs by reducing the number of metal components.

'Consequently, we sought a multipurpose material that was both highly flexible and capable of withstanding high loads over a wide range of temperatures in order to allow us to incorporate as many functions as possible in the clip,' he added. The Victrex Peek polymer valve minimises the number of components in motion during connection and disconnection. The shape of the clip and the elasticity and the fatigue resistance of the material ensure the reliable and durable connection of the pressurised male connector.

Aragones continued: 'The use of this high-performance plastic has allowed us to offer an entirely innovative, patented design. 'These connectors are particularly valued for their pressure-resistant characteristics and their compactness,' he said. Didier Padey, market development manager at Victrex Europe, said: 'Victrex Peek polymer retains its mechanical properties even in aggressive environments at high temperatures.

'Apart from its outstanding thermal performance, it also presents a unique combination of properties; in this case, it is the mechanical resistance and ductility, even under the most adverse conditions, that led to the specification of the Victrex Peek polymer for the valve clip of the RSD hydraulic couplings from Parker,' he added. Parker has achieved increased design freedom and simplified implementation by injection moulding, while improving the functions of its RSD coupling.

Stainless-Steel Frame Provides Enclosure Stability

Rittal has built a range of outdoor enclosures around a central stainless-steel frame. This provides stability, and because it is made from the company's standard TS8 punched section profile it also offers an optimal mounting for any internal fitments.

Examples of easily added parts include mounting plates for heavy equipment, contractors, DIN rails for component and interconnection mounting, thermostats and cabinet heaters for climate control, and 19in profiles for standard electronic equipment.

Shelving can be fastened directly to the frame, as can telescopic slides and static slide rails to allow access to the rear of installed equipment and make installation simple. Many different 'Meccano'-style sections are available.

Demag Installs Cranes At Rainham Steel Warehouse

Demag Cranes and Components has installed two crane systems at Rainham Steel's Scunthorpe distribution centre, as part of the development of a new warehouse facility. To meet sustained expansion, Rainham Steel has developed a 75,000ft2 warehouse facility for the processing and storage of steel beams. To meet the company's materials-handling requirements, Demag installed two double-girder travelling cranes, with spans of 30.8m and 31.5m, both rated at 7 tonnes plus 7 tonnes SWL.

Both cranes are equipped with two Demag DR-Pro wire rope hoists, upon which magnets are mounted. The use of magnets for the lifting process is said to eliminate time-consuming 'slinging' of loads and improves safety by excluding operators from the lifting area. The Demag cranes have long travel speeds of 8-80m/min, cross-travel speeds of 5-25m/min and hoisting speeds of 1-16m/min.

Drive motors feature AC frequency inverters for variable speed, providing smooth movement and precise positioning accuracy in all motions. Operation of the cranes, hoists and magnets is via a user-friendly HBC radio control, which allows the operator to stand clear of the process area.

Steel Railway-Platforms Allow Quick Building

Corus Rail Products is offering a range of steel modular platforms as an alternative to concrete structures. These platforms provide a fast and inexpensive way to extend existing platforms, or create new ones without any significant traffic interruption. The commissioning of 17 platforms for the West Coast Main Line in the UK marks the beginning of European commercial development. The platforms are made from rectangular hollow-steel sections.

The objective was to provide a cost-efficient and quick method to design and install passenger platforms. Corus's modular systems can be customised with all kinds of surfaces and finishes. The use of lightweight components minimises foundation impact and avoids the need for costly and time-consuming ground-treatment measures. Specific installation material is not required, traffic is not interrupted during erection and the structure has a 75-year life span. During that period, the Corus modular system is also adjustable and can be relocated.

The modular platform-system allows a platform to be designed and installed within a few weeks. Corus has developed specific software that allows a quick customised design, starting from standard modules, whatever the width, length or curvature (convex, concave or reverse). Structural resistance, shape and weight are automatically computed. Thanks to the low weight of the individual components, the platform can be manually assembled. Each component requires only a one or two-person lift.

Pre-surfaced modular deck panels can also be proposed or a bespoke finish can be used to enable extensions to aesthetically fit in with existing structures. Modular design and low weight allow the platform to be dismantled and placed in another location. The height can be changed by altering the adjustable feet. This allows for variation in foundation levels to be readily accommodated within certain tolerances. Thanks to a cantilevered design, the platform can be installed in the green zone while the line is still open.

In that security area, workers can operate while trains are running. Possessions are therefore only required to gauge the platform and lay the final surfacing. The modular system can also be used on existing platforms to increase the height, making it suitable for the handicapped or elderly.

Autodrill Develops Structural Steel Drill

Autodrill has designed a drill that uses annular cutters and a positive plug ejection system for structural steel operations. By automating the stroke and retract sequences, the operator of the equipment is kept at a safe distance from the machine and any debris created during the process.

Environmentally safe cutting fluids and materials can be incorporated into the process for drilling holes in beams, channel, tube and most other flat- or curved-surface structural products. The units are also capable of drilling in aluminium, stainless steel, plastics and other materials. All the equipment is rated for continuous duty production work.

Coupling Incorporates Stainless-Steel Bellow

MK1 bellows couplings from R & W Coupling Technology allow for increased bore diameter within a given coupling size through the use of radial set screws with dismounting grooves. Ideal for use in precision encoders and linear actuators, the MK1 range can help adapt between shafts with a large difference in size.

The coupling incorporates a stainless-steel bellow that compensates for axial, lateral and angular shaft misalignments simultaneously, while operating with zero backlash and high torsion resistance. Miniature metal bellows couplings are available for a torque range of 0.05-10Nm (0.4-88.5in/lb) and bore sizes from 1-28mm.

Sound Dead Steel Reduces Gas Pipeline Noise

Sound Dead Steel (SDS) was contacted by the Industrial Noise and Vibration Centre (INVC) to assist with a noise reduction programme for Scottish Power. The power station's main gas pipe work is 400mm diameter, with a reduction to 150mm at the metering section Close microphone measurements indicated noise levels as high as 100 to 110dB(A) with the dominant energy at frequencies >500Hz. SDS clad the pipeline with Sonphonon sound dead steel, fabricated and fitted split boxes to encase the valves.

After the final snagging was completed, the attached noise survey was carried out to determine the overall noise reduction for this project. The average noise reduction achieved within the GRF compound was approximately 8dB(A). The maximum reduction achieved was 16dB(A); this was adjacent the metering flow meter area. INVC noted that noise from adjacent cooling fans masked the full noise reduction benefits.

Noise reductions on plain pipeline measured 19dB(A), which clearly shows the effectiveness of the SDS cladding on standard pipe sections. Reductions of 7 to 8dB(A) were measured mid, up and downstream of the metering section using close microphone measurements. The reductions would have been greater, but pipe joint flanges have to be left open in case leakage occurs resulting in explosive conditions.

Stainless Steel Housings Protect Proximity Sensors

The new additions to IFM Electronic's efector T series are probably the only all-stainless steel sensors with an operating temperature as high as 100C. FM Electronic has released inductive proximity sensors with housings made from stainless steel, including the sensing face. They suit the food industry, as they can be used in wet areas and survive aggressive cleaning and high temperatures

The new additions to IFM Electronic's efector T series are probably the only all-stainless steel sensors with an operating temperature as high as 100C. The IFM devices suit true flush-mounting and normal spacing between sensors.

Complemented by the IFM EVT range of M12 stainless steel food-grade connectors, these stainless steel sensors are available in M12, M18 and M30 versions with sensing ranges optimised on stainless steel targets of 3, 5 and 10mm respectively. These food-grade sensors carry IP ratings of both 68 and 69K.

Adjustable Levers Come In Stainless Steel

JW Winco has expanded its line of inch and metric stainless steel adjustable levers. These adjustable levers feature a solid, all stainless steel handle with a sand blasted satin finish. Inserts, screws and springs are also stainless steel. The all-stainless steel construction makes this lever appropriate for applications in the food processing and chemical industries.

Levers are available in a variety of sizes, in tapped, blind bore and threaded stud types. Special bores, threads, and stud lengths are available on request.