nabalox · a defined abrasion rate will be initially induced due to the secondary grains and...
TRANSCRIPT
Pre polishing
Matting
Finishing
Solid polishing compounds
Liquid polishing compounds
NABALOX®
Polishing Aluminas
Our know-how for your safety
Specific surface area (BET)
60 - 80 m2/g 6 - 12 m2/g 0.6 - 0.9 m2/g 0.4 - 0.7 m2/g
Primary crystal size
~0.02 μm ~0.2 μm ~2 μm ~3 μm
Crystal modification
< 5 % α-AI2O3 70 - 90 % α-AI2O3 95 - 98 % α-AI2O3 > 98 % α-AI2O3
5 µm
20 µm
5 µm
20 µm
5 µm
20 µm
5 µm
20 µm
Very soft Soft Hard Very hard
Calcination temperature
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NABALOX® Aluminas
Nabaltec is a worldwide leading producer of synthetic raw materials. These are: Aluminas (NABALOX®), ready-to-press ceramic bodies (GRANALOX®), aluminas for polishing (NABALOX®) and synthetic sintered mullite (SYMULOX®). The special types of NABALOX® aluminas are successfully utilised worldwide as both abrasive and polishing media. The NABALOX® polishing oxide range offers a broad spectrum of soft and hard calcined aluminas for a variety of applications for industrial surface finishing. A multitude of NABALOX® polishing aluminas are used for the production of polishing pastes and emulsions for almost any material group, such as metals, stone, plastics, car paints, semiconductors, special glasses and many others. The properties of the agglomerates and primary crystals of the aluminas have a direct influence on the quality of the surfaces that are to be finished and are determined by the following parameters:
The primary crystal size is mainly determined by the degree of calcination of the polishing alumina. This size will influence the dimension and type of the material abrasion and is thus primarily respon-sible for the achievable surface quality. Small primary crystals lead to minor surface roughness with only minor material abrasion and therefore lead to a high surface quality. When large primary crystals are used, the surface roughness and material abrasion will be correspondingly higher.
The secondary grain represents a cluster (agglomerate) of primary crystals. During the polishing process the secondary grain will be destroyed by mechanical action, leading to the release of primary crystals which range from several hundred nanometers to micrometer size.A defined abrasion rate will be initially induced due to the secondary grains and polishing begins on release of primary grains.The initial abrasion rate is reduced by the decomposition of the agglomerate and a polishing action begins, which relates to the final surface quality. In addition to the grain size, the structure of the grain cluster will also influence the oil absorption value.
The grain size distributionreflects the distribution of the different grain size classes (fractions), relative to the secondary grains. With regard to the polishing behavior, the portion and dimension of the coarsest fraction are crucial. For applications with a low tolerance for coarse grains Nabaltec AG has developed a completely new group of soft calcined polishing aluminas. Using our innovative and state of the art processing steps we can ensure that oversized secondary grains are significantly reduced compared to other conventional polishing agents.
Our taskBy tailoring the production process it is possible to manufacture a broad spectrum of different polishing aluminas which can be readily adjusted to the various finishing requi-rements of a wide variety of materials. The following tables are intended to provide an overview of the available alumina types.
Conventional polishing alumina:
Stainless steel 20 min polished Removal 0.08 µm / min
Stainless steel 20 min polished Removal 0.04 µm / min
Conventional polishing alumina:
Sieve residue > 45 µm: approximately 2%
Sieve residue > 45 µm: approximately 0.02%
Conventional polishing alumina:
Stirred slurry Stirred slurry
NO 383
NO 383
NO 383
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The polishing process
The result of the polishing process is determined by several factors. Since the polishing tool and work piece are often defined by the customer’s needs the selection of the correct polishing grain plays a crucial role. Due to its excellent price to performance ratio the alumina is well known and is widely used as a raw material in almost all industrial applica-tions such as grinding or polishing.
NABALOX® Aluminas
The polishing result
Through a systematic development of the conventional manufacturing process for soft calcined aluminas we can achieve a further significant reduction in abrasiveness. This has resulted in the development of new high-gloss polishing aluminas NO x8x. The optimized method allows the production of high quality polishing aluminas with a grain size range of 1 - 10 microns (D50).
Agglomeration and dispersibility
Another aspect is the behavior of the alumina during the production and preparation of the polishing compounds. In particular, for highly sensitive polishing applications, such as polishing of automotive paints, a good dispersion is needed. Nabaltec’s progressive preparation methods provide the customer with raw materials of controlled, well defined and low levels of re-agglomeration. As a result, a homogeneous distribution of polishing grains on the work piece can be achieved.
NO 383
is part of a new and pioneering family of soft calcined polishing aluminas with reprodu-cible processing properties, which enable our customers to develop sustainable products for new, high-quality applications.
Polishing tool
• Material (Brush, sponge, ...)• Hardness• Speed• Pressure
Work piece
• Material• Hardness• Surface quality
Polishing compound
• Aggregate state• Hardness/viscosity• Wettening effects• Abrasive grain
Polishing grain AI2O3
• Hardness 9(α-Phase)• Grain size 1µm – 80 µm (-distribution) ~• Grainshape ~
polis
hing
effe
ct
grain/particle size
Schematic correlation between grain size and polishing effect
cut
gloss
NO 205 G
NO 295
NO 183
50 µm50 µm 10 µm
Hard-coarse
• High cut on all materials• Rough grinding of metals,
natural stone, glass• mattening
Hard-medium
• High cut on all materials• Precise pregrinding of metals• Mattening
Soft-advanced
• High cut combined with high gloss
• Blue shine finish on stainless steel• Car paint polish
Hard-fine
• High cut on soft materials• Pregrinding of non-iron metals• Polishing of stone and ceramics
Soft-milled
• High cut on soft materials• Pregrinding of plastics and coatings• Household polishers• Household cleanders
Stereoscopic pictures:
rough surface, 50x - objective
X = 325 μm Y = 326 μm Z = 1.42 nm
polished surface with scratches, 50x - objective
X = 325 μm Y = 326 μm Z = 216 nm
finished surface, 50x - objective
X = 325 μm Y = 326 μm Z = 83 nm
20 µm 20 µm20 µm
Soft-coarse
• High cut on soft materials• Low cut on hard materials• Gloss on iron and steel• Polishing of stone
WhiteLightInterferomety3Dprofiles
Polished surfaces of stainless steel
Optical Photographies
NO 183NO 283NO 383NO 483NO 683NO 783
NO 202 II
NO 221-30
NO 481NO 681
NO 384NO 484NO 684
NO 205-71NO 205 G NO 255 F
NO 245NO 255NO 250
NO 230NO 255NO 295
NO 115-71NO 275
NO 235
NO 275NO 115-G
NO 201NO 265NO 212NO 313
NO 221-40
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Hard calcined Definedmeasurementofsurfacefinishingqualities (White Light Interferometry)
Interferometry enables 3D-profiling of (polished) surfaces up to highest resolutions (300 nm laterally and 0.1 nm vertically). Polishing properties of different abrasives can be compared with high accuracy. Development of customer specific abrasives is our mission.
Soft calcined
NABALOX® Different grades of polishing aluminas
Very hard calcined aluminas
α-AI2O31): > 98 % · Primary crystal size2) : 3 – 5 μm, platelets
Abrasivity3)
D50 [μm]4)
D90 [μm]4)
BET [m2/g]
5)
Oil absorption [%]6)
NO 205-71 ***** 55 90 0.6 35 - 45NO 230 **** 8 45 0.6 15 - 25NO 115-71 *** 6 30 0.7 15 - 25NO 235 ** 4 10 0.8 10 - 20
Hard calcined aluminas
α-AI2O31): 95 – 98 % · Primary crystal size2) : 1 – 2 μm
Abrasivity3)
D50 [μm]4)
D90 [μm]4)
BET [m2/g]
5)
Oil absorption [%]6)
NO 205 G **** 80 120 0.7 30 - 40NO 255 *** 70 110 0.8 30 - 40NO 255 F *** 60 95 0.8 30 - 40NO 250 ** 50 80 0.8 30 - 40NO 225 ** 8 35 0.8 20 - 30NO 275 ** 6 30 0.8 15 - 25NO 295 ** 5 25 0.9 15 - 25NO 215 G ** 5 15 0.9 15 - 25NO 215 * 4 15 0.9 10 - 20
Soft calcined aluminas
α-AI2O31): 70 - 90 % · Primary crystal size2) : 0.1 - 0.5 μm
Abrasivity3)
D50 [μm]4)
D90 [μm]4)
BET [m2/g]
5)
Oil absorption [%]6)
NO 202 II *** 80 120 7 40 - 50NO 265 ** 6 40 8 25 - 35NO 212 ** 5 35 9 25 - 35NO 313 * 2.5 20 11 20 - 30
Very soft calcined aluminas
α-AI2O31): 0 – 5 % · Primary crystal size2) : 0.01 – 0.05 μm
Abrasivity3)
D50 [μm]4)
D90 [μm]4)
BET [m2/g]
5)
Oil absorption [%]6)
NO 201 *** 80 120 75 50 - 60NO 221-40 ** 40 70 75 45 - 55NO 221-30 * 30 50 75 40 - 50
1)XRD | 2)SEM | 3)comparative polishing test | 4)Laser granulometry Cilas 1064 | 5)DIN ISO 9277 | 6)DIN EN ISO 787 Part 5
Typical grain size distributions
Grain size [μm]
Grain size [μm]
Grain size [μm]
Grain size [μm]
Dist
ribut
ion
[%]
Dist
ribut
ion
[%]
Dist
ribut
ion
[%]
Dist
ribut
ion
[%]
0
20
40
60
80
100
NO 250
1001010.1
0
20
40
60
80
100
NO 215
1001010.1
0
20
40
60
80
100
NO 212
1001010.1
0
20
40
60
80
100
NO 221-30
1001010.1
NABALOX®
Formula Al2O3 CAS No. 1344-28-1 EINECS No. 215-691-6
Harmonized tariff No. 281820
Typical chemical analysis: [%]
AI2O3 > 99SiO2 0.04Fe2O3 0.03
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NABALOX® Polishing aluminas survey of types
Soft calcined aluminas
α-AI2O31): 70 – 90 % · Primary crystal size2) : 0.1 – 0.5 μm
D10 [μm]3)
D50 [μm]3)
D90 [μm]3)
Sieve Ø [μm] Residue [%] BET [m2/g]
5)
Oil absorption [%]6)
NO 183 0.5 9.3 50 75 2.00 10 30NO 283 0.8 4.5 26 63 0.04 10 25NO 383 0.7 3.2 12 45 0.01 11 25NO 483 0.6 2.1 7.2 45 0.01 11 25NO 683 0.4 1.2 3.8 45 0.01 11 22NO 783 0.2 0.8 2.2 32 0.01 11 22
1)XRD | 2)REM | 3)Comparative polishing test | 4)Laser granulometry Cilas 1064 | 5)DIN ISO 9277 | 6)DIN EN ISO 787 Part 5
Grain size [μm]
Grain size [μm]
Grain size [μm]
Grain size [μm]
Dist
ribut
ion
[%]
Dist
ribut
ion
[%]
Dist
ribut
ion
[%]
Dist
ribut
ion
[%]
0
20
40
60
80
100
NO 183
1001010.1
0
20
40
60
80
100
NO 683
1001010.1
0
20
40
60
80
100
NO 383
1001010.1
0
20
40
60
80
100
NO 783
1001010.1
Typical grain size distributions
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NABALOX® Advanced polishing aluminas Nabaltec® FamilyISO 50001
ISO 14001 OHSAS 1800
1
ISO 9001
APYRAL®NABALOX®
Aluminium Oxides, for the production of Ceramic and Refractory Products
Aluminium Hydroxides, as flame retardant filler in Plastic and Ceramic Components
APYRAL®AOH
Boehmite, as flame retardant filler as well as functional component for the catalyst industry
APYMAG®
GRANALOX®
Ceramic Bodies, for the production of engineering ceramics
Magnesium Hydroxides, as flame retardant filler for thermoplastic applications
SYMULOX®
NABACAST®
An alternative no-cement-binder system based on reactive α-alumina and magnesia (NC-Binder).
Synthetic Sintered Mullite, for the production of e.g. Refractory Products
1514
Nabaltec® Worldwide
Nabaltec maintains a global presence, with locations in Germany and the US and a network of international agencies
SchwandorfBavaria, Germany
Corpus ChristiTexas, USA
Further information:
Nabaltec AGP.O. Box 1860 · 92409 SchwandorfTel +49 943153-0 Fax +49 943161557www.nabaltec.de [email protected]
Customer ServiceTel +49 9431 53 [email protected]
Technical ServiceTel +49 9431 53 [email protected]
All data listed in this brochure are reference values and subject to production tolerances. These values are exclusive to the product description and no guarantee is placed on the properties. It remains the responsibility of the users to test the suitability of the product for their application.
Nabaltec AGP.O. Box 1860 · 92409 SchwandorfTel +49 943153-0 Fax +49 943161557www.nabaltec.de [email protected]