2019 EN Solutions for the plastics industry
CERATIZIT is a high-tech engineering groupspecialized in tooling and hard material technologies.
Tooling the Future
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Stephane Claude Wear Protection Line Manager Specially developed for you: as your expert partner we create made-to-measure carbide solutions.
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Carbide solutions for the plastics industry
As a producer of plastic components or tool In the nature of things, cemented carbide has manufacturer for such components, you great dimensional stability and is extremely represent a growing market. Ever more wear-resistant. But it offers even more advantages. companies need more and more plastic For the plastics industry, thermal conductivity materials in an increasing number of and corrosion resistance are crucial additional industrial sectors. In Europe, 60,000 parameters. There is no need to tell you that enterprises with more than 1.5 million your products are only as good as the tool used employees generate almost 350 billions of to produce them. With products from CERATIZIT Euros – and the trend is on the rise. you can count on reliability – the reliability you would expect from an internationally leading Along with this growing demand, requirements carbide expert. You can benefit from our many relating to the material and its properties are years of experience in the development of rising as well. Hard Material Solutions by specific solutions which set standards in the CERATIZIT delivers customised carbide plastics industry. CERATIZIT’s achievements have solutions of premium requisites for many made an impression on many prestigious sectors of the plastics industry. You can order customers, seeing that we command the entire nozzles and mould cores for Metal Injection process chain of carbide production from the raw Moulding (MIM) as well as dies and knife blades material to the finished product. Thanks to this or rotor knives for pelletizing. Everything from a unique expertise we can provide you with your single source! own individual solution ensuring the maximum service life of your assembly groups.
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Advantages and benefits
Advantages Benefits
Optimised carbide grades for working Maximum tool life, higher productivity, more temperatures even over 400°C: rigid, process reliability dimensionally stable, wear-resistant, corrosion-resistant and heat-resistant, very good heat-conducting properties
Highly precise versatile production procedures: High production speed, optimal product quality minimum tolerances, optimal surfaces, maximum precision
Individual solutions based on the specific needs Design specially geared to the given application of the customer – e.g. also ceramic and titanium- zirconium-molybdenum solutions can be provided, as we are part of the CERATIZIT and Plansee Group
Technical advice on site: A contact person for every challenge and sales representatives and product managers innovation, rapid response when needed with technical know-how of the sector
More than 60 company sites worldwide There is always a contact person nearby
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Premium products for all applications
We offer carbide solutions for various applica- ▲ Hot runner systems, tions and process steps in the plastics industry, ▲ Mould-making for injection e.g. for: moulding ▲ Injection moulding machines ▲ Pelletizing technology
The cycle of of plastics products
Starting granulate Heating + mixing + homogenisation
Recycling Pelletizing
Injection Molding
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Cemented carbide for hot runner systems
For the production of hot runner systems Hard separated from the remaining components. Material Solutions by CERATIZIT delivers both The hot runner nozzles are of decisive nozzle tips for hot runner nozzles as well as importance in this process as the critical shut-off needles. interface between the cavity and the machine, since they represent the plastification unit. Process efficiency with all materials Carbide nozzles ensure good transport, master Whether you process thermoplastics, elastomer the transmission superbly while also ensuring or thermosetting plastics, metals or ceramics excellent thermal stability. (MIM, CIM) or whatever – solutions from CERATIZIT always ensure a homogeneous For all systems and stable injection moulding process. Valve gate nozzles allow carbide to show its This is particularly important for sophisticated strengths: excellent heat conductivity, maximum components which have to be produced in high wear protection with abrasive plastics and quantities. In this case hot runner systems are abrasion of the shut-off needle. We supply almost always used. components for all hot runner systems, whether open or valve gate systems. In the first case Ideal nozzles there are different types of nozzle tips, with Such a system connects the entrance of the one or more openings. plastification unit with the mould of the injection moulding tool (the cavity) and is thermally
Advantages Benefits
Optimised carbide grades Very good heat transmission, optimal Very high thermal conductivity, high wear flow properties in the hot runner nozzles, resistance and corrosion resistance with homogeneous final products, maximum working temperatures even over 400°C tool life, highest process reliability
Versatile production Individual geometries can be provided at any Almost every execution can be made to time, innovation can always be looked into customer’s request, highly precise manufacture for minimum tolerances
Manufacturer’s expertise Innovative partner on your level, on site Advice for every application from our sales presence in next to no time representatives and product manager staff, detailed technical expertise in dealing with materials, processes and products
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Product overview
Nozzle tips Standard types Individual solutions ▲ Ready-to-use products: finish-ground nozzle ▲ Design according to customer drawing tips with a surface quality up to Ra 0.02 µm, ▲ For any type of assembly situation (e.g. polished, for open systems (hole as sintered) specific threads and forms of the outer and shut-off needle systems (ground exit profile) hole) ▲ Complicated hole geometries for special ▲ Semi-finished products: as sintered nozzles components with preground areas, exactly ▲ Nozzle tips are available as hybrid and tailored to your needs and the possibilities composite parts. CERATIZIT is the only of your production department carbide manufacturer worldwide who offers ▲ Blanks: sintered parts with a surface components made of steel, TZM or ceramic roughness of Ra 0.8 µm and a dimensional produced within the Group. accuracy of +-1 %
Shut-off needles CERATIZIT provides extrusion-pressed blanks, ▲ Surface quality up to Ra 0.1 µm preground rods and ready-to-use ground shut-off ▲ Dimensional and geometrical tolerances in needles the µm range ▲ Valve needles with axial slots and complicated geometries possible
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Valve gate nozzles
▲ Sintered pressed/formed inner profiles ▲ Complex outer profiles of the blank: hexagonal, wrench flat, threads ▲ Ground guide holes ▲ Virtually all grinding operations possible
Nozzles for open systems
▲ Sintered formed inner profiles ▲ Wide design latitude in relation to the exit holes ▲ Fastening thread / fine thread on the outer profile ▲ Entirely ground outer profile ▲ Virtually all grinding operations possible
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Ready-to-use assembly groups
Numerous high-performance materials from Finishing possibilities a single source ▲ Technical coating ▲ Tumbling/blasting Benefit from a virtually unlimited selection of high-performance materials: Joining procedures ▲ Screw connections Directly from the CERATIZIT/Plansee Group: ▲ Brazing ▲ Cemented carbide ▲ Shrinking (tungsten carbide – cobalt – nickel) ▲ Pressing ▲ TZM (titanium – zirconium – molybdenum) ▲ Gluing (special materials) ▲ Ceramic (silicon nitride)
Outsourced materials: ▲ High-performance steels ▲ Stainless steels ▲ Copper composite materials ▲ Many others available upon request
Optimised carbide grades for hot runner technology
Our recommendation: CTC25A ▲ High thermal conductivity up to ▲ Good thermal resistance 150 W/(m*K) ▲ Good corrosion resistance ▲ Optimal wear resistance (12 % cobalt-content)
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Mould cores in cemented carbide
If you produce injection moulding parts with corrosion stress occurs. The high thermal cavities, the quality of the mould core is crucial. conductivity of our cemented carbide means Any injection moulding expert is aware that you can count on shorter process times due to the final product is only as good as the tool faster cooling down, especially when producing used to produce them. This is because the small parts where because of the size no injection mould part is the exact negative of the coolant hole can be used in the mould. mould. Injection mould parts with cavities The material of choice Mould cores are used for a variety of products, As a material for the mould core, cemented e.g. for pipette tips, test tubes, measuring cups carbide has proved its worth on grounds of for medical use or cartridge tips, buckets and its numerous excellent properties. Neither drinking bottles. The variety of final products abrasive wear, which results when the parts is matched by the versatility of CERATIZIT are removed, nor thermal impact with working mould cores. These are suitable for production temperatures of 200-400°C, present any processes with various materials, from thermo- problem for Hard Material Solutions by plastics to elastomer or thermosetting plastics, CERATIZIT. The tool remains extremely metal (MIM) or ceramic (CIM), guaranteeing robust, tough and heat-resistant over the maximum precision in component production. entire service life, even when additional
Advantages Benefits
Optimised carbide grades Excellent heat transmission for quick cooling of High thermal conductivity, rigidity, wear the injection mould parts, low thermal expansion resistance and corrosion resistance with and high rigidity resulting in maximum precision working temperatures even over 400°C
Highly precise production High precision in the manufacture and low Minimum tolerances, optimal surfaces adhesion of the final products on the tool
Manufacturer’s expertise Innovative partner on your level, on site presence Advice for every application from our sales in next to no time representatives and product manager staff, detailed technical expertise in dealing with materials, processes and products
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Product overview
CERATIZIT offers blanks, semi-finished Finish products and ready-to-use ground mould ▲ Rotationally symmetrical, straight or cores where the outer profile is characterised ▲ Helical (several holes) by optimal surface quality and minimum tolerances over the entire length. Hard Material Solutions by CERATIZIT supplies coolant holes as a standard in sintered condition Base variants with a surface quality of approx. Ra 0.8 µm ▲ On the mould core as a solid carbide step RZ16. All other surfaces are polished to a ▲ As a steel mounting base (for brazing, quality of Ra 0.02 µm upon request. gluing, shrinking or screw connection)
Coolant To ensure speed of production, the mould cores generally come with coolant holes inside.
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Carbide for pelletizing technology
The pelletizing process calls for dies, knife Wear-resistant on principle blades or rotor knives; for maximum efficiency Whatever the process you use, carbide of pelletizing, you can count on Hard Material solutions from CERATIZIT make wear Solutions by CERATIZIT as carbide cutting resistance a top priority: this means not only tools offer the reliability you require. Our maximum tool life, but also resistance to carbide solutions with nickel or cobalt binder process water and extraordinary heat resistance provide strength, toughness, corrosion giving carbide products a leading position in resistance and thermal resistance – important the quality scale. properties for important processes, whether you use classic extrusion pelletizing or underwater pelletizing.
Standing up to reinforced plastics Maximum wear resistance of all components is crucial, as fibre-reinforced plastics are frequently used in the pelletizing process. This increases wear for all components.
Advantages Benefits
Optimised carbide grades/innovative Long tool life, very good economic efficiency steel-carbide combinations: thanks to low acquisition costs of the composite High wear resistance, corrosion resistance solutions and thermal resistance
Highly precise manufacture & mounting: Granulate without burrs, high speed thanks to Minimum tolerances, optimal surfaces; application-specific design Various joining processes for the production of composite parts
Manufacturer’s expertise Innovative partner on your level, on site presence Advice for every application from our sales in next to no time representatives and product manager staff, detailed technical expertise in dealing with materials, processes and products
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Product overview
Hard Material Solutions by CERATIZIT offers you ▲ Cutting rotor blades for extrusion pelletizing facilities ▲ Pelletizing dies for underwater pelletizing
Decisively better: rotor blades Best performance: cutting strips The blades of cutting rotor blades face In order to separate the granulate effectively, enormous wear which is why they are produced cutting strips are required. CERATIZIT offers in carbide. They are brazed, mounted with you all types and lengths of strips, which can screws or clamped. Blades from CERATIZIT be made either in solid carbide or in a can be ground quickly and easily to the combination of steel and carbide. The desired cutting angle (from -3 up to +15°). thickness or the blade can be ground in keeping with your requirements, so as to achieve optimum parallelism and maximum sharpness.
Massive meets filigree: pelletizing dies For underwater pelletizing CERATIZIT supplies pelletizing dies in solid carbide or for steel-carbide composite parts: the latter ones consist of a perforated steel plate which is brazed onto the carbide segments. Both variants need to be provided with micro-holes to a diameter of 0.1 mm.
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Cemented carbide for injection moulding systems
Plastic manufacturers are interested in either made of carbide or provided with a maximum strength of the material, which is carbide plating. Corrosion-protected grades why glass and carbon fibres may be integrated with various hardness and strength levels give into the material to reinforce the granulate. In you a wide range of individual choice. With our order to improve fire resistance, highly corrosive many years of expertise, we can recommend flame inhibitors are also used in addition. It the ideal material combination, whatever the follows that for all components which come into component requirements. CERATIZIT delivers contact with plastic injection moulding systems maximum service life! maximum wear and corrosion resistance is a must! Only then can maintenance be kept to Always guaranteed individuality a minimum throughout the tool life. Your machine is geared to your needs – so it follows that components must also be High selection for high demands specifically made to measure. You can count At CERATIZIT you can find components for on always getting the best individual non-return valves like cochlea tips, shut-off and solution, which is designed on the basis of pressure rings, components for the plastification your technical drawing. unit such as cylinders, cochleas and bushes as well as machine nozzles and shut-off needles for your specific application. The products are
Advantages Benefits
Optimised carbide grades Notably longer service life of the components and Very high wear resistance, corrosion resistance systems, less maintenance work and downtimes, and thermal conductivity with working tempera- higher process reliability, better product quality tures even over 400°C
Versatile production Any geometry is possible, innovations can be put Almost every execution can be made to into practice at any time customer’s request, highly precise manufacture for minimum tolerances
Manufacturer’s expertise Innovative partner on your level, on site presence Advice for every application from our sales in next to no time representatives and product manager staff, detailed technical expertise in dealing with materials, processes and products
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Product overview
The portfolio of Hard Material Solutions by For all these and other products you can benefit CERATIZIT includes the following products: from customised wear parts for injection ▲ Components for non-return valves: cochlea moulding systems manufactured based on your tips, shut-off and pressure rings drawing in proven carbide grades by CERATIZIT. ▲ Components for the plastification unit: bushes, cylinders and cochleas ▲ Machine nozzles and shut-off needles
Cochlea tips with plating Innovations for cylinders and cochleas For the non-return valves of your injection Cylinder linings and solid carbide cochlea moulding machine you can order cochlea tips blanks also form part of our portfolio. Bushes which are provided with a carbide plating. from Hard Material Solutions by CERATIZIT are Grooves, pockets or holes are milled into the the ideal choice when cylinder manufacturers steel cochleas and carbide plates, and cylinders need to give their products the best possible or pins are brazed onto them. This carbide-steel lining so as to minimise wear. composite part is ground on an external Ready-to-use steel cylinders with carbide cylindrical grinding machine before it is ground plating will also be available in the future – to the desired surface quality (up to Ra 0.1 µm). please contact us with your individual enquiry at any time!
Shut-off and pressure rings as reliable seals Optimal transmission with carbide machine Solid carbide shut-off and pressure rings nozzles reliably seal the non-return valve thanks to high Machine nozzles, always a large-size component, wear resistance over a long service life. When complete the CERATIZIT premium range. We designing these parts your specifications are will make your individual nozzle using our own the top priority: with its long-standing expertise, production facilities. And should you need CERATIZIT is able to develop the best individual shut-off needles, you can of course find them solution for you – from the blank to the in our wide product assortment. ready-to-use part.
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The right grade for every application
In the table below you can find all the carbide production from the raw material all the way to grades we recommend for applications in the the final product, from metallurgy to composition plastics industry. and development. Top-quality carbide grades adapted to your individual specifications – that If you are looking for a customer-specific is what we promise and what you can count on. product, simply get in touch with us: we are Premium solutions withstanding maximum happy to develop exactly your solution! stress and convincing in every aspect, with stability, toughness, thermal conductivity One value creation – one supplier – one as well as thermal and corrosion resistance – promise together with durability that sets new standards for You can trust our unique expertise: CERATIZIT the service life of your applications. is one of the few suppliers worldwide who masters the entire process chain of carbide
Thermal Hard- Transverse expansion CERATIZIT Binder Density ness rupture strength Heat resist. coefficient grade code [m%] [g/cm³] [HV10] [MPa] [Wm-1K-1] [10-6K-1]
CTC25A 12.0 14.25 1080 3100 135 5.4
CTF12D 6.0 14.90 1750 2500 100 4.8
CF-H20P 10.0 14.31 1300 2800 95 5.2
CTS20L 10.0 14.40 1650 4000 85 5.5
CTF30D 15.0 13.75 1130 3300 80 5.7
Transverse Thermal Hard- rupture expansion CERATIZIT Binder Density ness strength K1C value Heat resist. coefficient grade code [m%] [g/cm³] [HV10] [MPa] [MPa*m1/2] [Wm-1K-1] [10-6K-1]
CF-S12Z 6.0 14.83 1860 3600 9.0 90 5.1
CF-S18Z 9.0 14.48 1630 3500 11.0 95 5.2
CF-H40S+ 12.0 14.15 1400 3200 12.5 90 5.4
CF-F35Z 17.5 13.58 1200 3300 15.6 85 6.0
CTU12R 6.0 14.82 1750 2600 7.0 100 5.1
CTS17R 8.5 14.51 1600 2800 8.7 100 5.1
CTF16R 8,0 14,58 1480 2900 11,4 85 5,1
CTF21R 10,5 14,35 1300 3100 10,0 80 5,5
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The right partner for many industries
Carbide solutions from CERATIZIT optimise the ▲ Mechanical engineering processes of plastic production, whether your ▲ Automotive industry parts are produced by injection moulding, ▲ Aerospace industry extrusion pressing or deep drawing. ▲ Sanitary industry ▲ Medical and laboratory technology The final products are used in the following ▲ Packaging industry economy sectors:
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Hard Material Solutions by CERATIZIT Wear protection for all applications and industries
Individual carbide Tools for metal forming High-performance solutions for your components for tool application construction
Extract from our product portfolio
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The CERATIZIT Group
For over 95 years, CERATIZIT has been a The CERATIZIT Group is the global market pioneer developing exceptional hard material leader in several wear part application areas, products for cutting tools and wear protection. and successfully develops new types of cemented carbide, cermet and ceramic grades which are The privately owned company, based in Mamer, used for instance in the wood, metal and stone Luxembourg, develops and manufactures highly working industries. specialised carbide cutting tools, inserts and rods made of hard materials as well as wear parts.
Facts and figures
1 headquarters 34 > 70 Mamer, Luxembourg production sites sales subsidiaries
> 9,000 > 100,000 > 1,000 employees different products patents and utility models
> 200 > 10 30 % employees in R&D innovation awards of products developed in the last 5 years
www.ceratizit.com www.ceratizit.com E. T. Mamer LU-8232 CERATIZIT S.A. Headquarters E. T. DE-29456 Hitzacker CERATIZIT Hitzacker GmbH E. T. Empfingen DE-72186 CERATIZITGmbH Empfingen Germany E. T. Mamer LU-8232 r.l. S.à Luxembourg CERATIZIT France/Luxembourg/Belgium E. T. Velké 01 Meziříčí CZ-594 Republic Czech CERATIZIT Office RepublicCzech /Slovak Republic E. T. Xiamen CN-361022 Xiamen CB-CERATIZIT China E. T. BG-5301 Gabrovo AG Bulgaria CERATIZIT Bulgaria E. T. Brazil São PauloBR-Campinas, 13069-310 / Ltda. Latina América CERATIZIT Brazil E. T. Reutte AT-6600 CERATIZIT Austria GmbH Austria Sales +352 31 20 85-1 31 20 +352 +49 5862 969 100 969 5862 +49 0 99802 7485 +49 85-1 31 20 +352 1000 666 592 +86 812 66 206 +359 19 3115 +55 9500 200-0 5672 +43 [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] +420 566 520 341 520 566 +420 E. T. (CO) Alserio IT-22040 CERATIZIT Como S.p.A Italy T. Bekasi ID-17530 Indonesia CB-CERATIZIT Indonesia E. T. 411018IN-Pune Ltd. Pvt. India CERATIZIT E. T. IN-Gurgaon 122002 Ltd. Pvt. India CERATIZIT E. T. 641009 IN-Coimbatore Ltd. Pvt. India CERATIZIT E. T. 600037 IN-Chennai Ltd. Pvt. India CERATIZIT E. T. IN-Bengaluru 560099 Ltd. Pvt. India CERATIZIT India E. T. HU-1138 Budapest CERATIZIT Hungary Office Hungary E. T. /4878 4877 048 Toll 0800 Free S91XU UK-Sheffield UK Office CERATIZIT Britain Great +39 031 6349 211 6349 031 +39 +62-21-2961-2351 0628 6529 20 +91 124 +91 481 4018 373 273 4224 +91 4350 4269 44 +91 1262 4043 80 +91 0930 1437 +36 161 261 1925 +44 [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] E. T. Toll free +1-800-783-2280 US-Warren, MI 48089-1833 CERATIZIT Inc. USA, /Canada USA E. T. İstanbul Kartal, TR-34870 CERATIZIT Turkey Turkey T. TW-25152-Tamsui TamsuiCB-CERATIZIT Taiwan T. 2552 CH-Orpund AG Schweiz CERATIZIT Switzerland E. T. Boadilla Monte del (Madrid) ES-28660 CERATIZIT Ibérica S.L. /Portugal Spain E. T. PL-30-443 Kraków CERATIZIT Poland Office Poland E. T. ATNL-4707 Roosendaal CERATIZIT B.V. Nederland Netherlands E. T. MX-76040 Querétaro, QRO C.V. de S.A. México, CERATIZIT Mexico E. T. Mizuho, Suruga-ku JP-3-13-9, Ltd. Co., Japan CERATIZIT Japan +1-586-759-2280 43 66 216 353 +90 1668 22622 +886 93 93 344 +41 32 0609 351 91 +34 12 8591 252 +48 00 08 55 165 +31 9173 225 442 +52 1060 268 54 +81 [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected]
7003461 MA-PRO-0761-EN-12/18 We reserve the right to make technical changes for improvement of the product.