For us, solutions which can be achieved by using our functional fillers have a big importance. It is first and foremost to create a beneficial application of our products. We develop these solutions in internal R&D projects as well as together with universities or with customers at their site to achieve a targeted use of our products.
Case Study 1
Micronized MIOX® and active pigments in corrosion protection coatings
Topic
In corrosion protection coatings, especially in prime layers, active pigments like Zink dust or Zinc Phosphate play an important role. Due to increased environmental requirements and raw material costs in production, coatings companies try more and more to reduce Zinc based products or even get rid of them. Especially the volatile pricing of Zinc based products is an additional stimulus to reformulate.
Our solution
With our micronized MIOX® grades Zinc dust can be partially replaced in Zinc Rich Prime coatings, by keeping or even increasing the coatings performance. Also in combination with Zinc phosphate based coatings, an increased performance can be achieved. As a consequence beside the technical advantages, also cost savings can be generated. Constant raw material costs also contribute strongly to a better planning process.
Case Study 2
Foundry industry – Veining problems with casted gearboxes
Topic
A midsized German foundry is casting gearboxes (GJL-200) for a well-respected player. This foundry has been continuously facing the same problem. Although they used an expensive anti veining additive (dosage level 5.2 %), the results had been still negative as partially veining and poor surface quality occured. During the foundry process, smoke was generated caused by incomplete incineration and phenolic in the additive. In spite of using an expensive additive, the cores had to be coated.
Our solution
Adding 1.7 % MIOX® as anti-veining additie leads to casted parts which are completely veining-free and show an excellent surface quality. MIOX® is a completely inorganic substrance and free of Phenolic.
Additionally cores need not to be coated any more and the binder content can be reduced from 0.7 % to 0.55 % which provides economic advantages and reduces the emissions.
Case Study 3
Fight warpage with MICA
Topic
A German compounding company produces compound for automotive applications. One compound should be used in injection moulding to produce an engine cover for a well-respected German automotive manufacturer. As typical under the hood application, the compound consist of glass fiber reinforced polymer to achieve the desired mechanical reinforcement. Unfortunately the glass fiber filled, Polyamide based parts are out of dimensional specs because of warpage caused by the glass fiber orientation in the moulding process. Therefore this compound cannot be used in this application.
Our solution
Additionally to glass fiber, the compound will be filled with Mica HLP 100 by replacing 50 % of the glass fiber in a one to one ratio. The predominantly platy shape of the Mica particles implement a two dimensional component which prevents the orientation of the glass fibers and therefore the strong anisotropic shrinkage of the part. The shrinkage “in machine” and “cross machine” direction will become more isotropic, this also reduces the warpage and the part dimensions are within the specifications. This partial replacement is also cost neutral because of comparable raw material costs.
