Autore: Alexander

Expanite, the surface hardening specialist replaces hard chrome plating at LIAG® LÄUFER INTERNATIONAL AG and solves abrasive wear and corrosion challenges in the field.

The Challenge: Abrasive wear – and long-lasting corrosion resistance to keep food safe

Even where special coatings may be applied in certain environments, heating and cooling LIAG® LÄUFER is a specialist in hygienic shutter valves and pigging systems. The products are designed to meet the highest safety demands in the food industry, and must withstand significant abrasive wear and corrosion aggressive environment. Their stainless steel cones were originally specified with hard chrome plating. Due to the potential health risks however, hard chrome plating is increasingly prohibited in the food industry. LIAG® LÄUFER needed to find an alternative. In their attempt to solve these challenges LIAG® LÄUFER tried different surface hardening solutions, which all failed, including a commonly used carburizing process, which caused corrosion after short time in use.

The solution: Expanite treatment offers surface hardness and increased corrosion resistance!

LIAG® LÄUFER finally tested Expanite and found a hardening solution that effectively reduces wear and galling, and at the same time improves corrosion resistance of the parts.

Sustainable and environmentally friendly solution

LIAG® LÄUFER is determined to offer environmentally sustainable solutions to comply with the industry demand to exclude chrome in the food industry. Expanite hardening solution is a diffusion-based process and therefore significantly more environmentally friendly and sustainable compared to other hardening methods. Lars Meesmann – Project Engineer at LIAG® LÄUFER says: “Our cooperation with Expanite was highly successful. We are very satisfied with the impressive results of the unique Expanite technology which completely meets all our demands and expectations. Expanite´s support, knowledge and experience throughout this project have been first-class”. Mr. Lars Meesmann continues: “The technology is very flexible – and applicable independent of geometry of the product. The superior corrosion properties, lead-time and even a price competitive solution enables LIAG® LÄUFER to supply customers with high end and environmentally safe products”.

The Expanite Surface hardening process

The patented Expanite process doesn’t add anything to the material (besides nitrogen and carbon), it just makes the surface harder — as much as 10 times harder. Sales Manager Dr. Holger Selg explains: “The process begins with treating stainless steel parts under certain atmospheric conditions, which diffuses nitrogen and carbon atoms into the surface of the part. It passes ASTM tests, and the resulting products meet all FDA regulations and are ISO 9001:2015 compliant. We’re only diffusing nitrogen and carbon into the surface of the workpieces, so it’s called surface hardening”.

About Liag

LIAG® offer hygienic valves and pigging systems in maximum quality and reliability for the processing of high-value media and, at the same time, represent the ideal basis for competitive production. More about Liag: https://www.laeufer-ag.de/en/

About Expanite

Expanite offers state-of-the-art solutions for surface hardening treatment of stainless steels and titanium. With Expanite’s processes, it is possible to increase the material’s surface hardness tenfold while at the same time maintaining and even increasing its corrosion resistance. Expanite is a global organization with a combined development and production facility near Copenhagen, Denmark, and hardening capacity in both US, Germany, Korea and China. Expanite’s solutions are flexible and can be introduced directly into a customer’s own production line as part of a licensing arrangement. Learn more on www.expanite.com.

 

(Articolo in inglese) Expanite – —the Danish pioneer specializing in surface hardening of stainless steel & titanium and ENPULSION the world leading manufacturer of electric propulsion systems for nano-and microsatellites collaborates successfully in solving wear and galling challenges in the production line at ENPULSION.

The Enpulsion Field-emission Electric Propulsion (FEEP) technology is an advanced electrostatic propulsion concept of an ion engine that uses liquid metal –indium -as a propellant. A FEEP drive system consists of an emitter and an accelerator electrode. A potential difference in the order ofkV is applied between the two, creating a strong electric field at the top of the metal surface which extracts ions from the apex of the cone and accelerates them to high speeds. The IFM Nano Thruster is used as a compact pre-qualified building block in order to provide customized propulsion solutions for nano-and microsatellites. By clustering the proprietary indium ion emitters, a scaled-up thruster – the IFM Micro Thruster –is created to target the even larger market of small and medium size space crafts.

Challenged by galling

Before Enpulsion started using the Expanite hardening process they were challenged by galling of threads on the housing which caused serious issues in the production line. Enpulsion contacted Expanite to find a better solution. “We contacted Expanite since their anti-galling SuperExpanite treatment seemed convincing in combination with the flexible production lines. We were very excited to work with the highly motivated expert team at Expanite, who supported us throughout our testing of the Expanite hardening process”, says Mr. Roman Hörbe, Supply Chain Manager at Enpulsion. “Our target was to use a treatment that prevents galling and retains corrosion properties of the austenitic stainless steel part, while maintaining the manufacturing tolerances and guarantee good weldability of the final part. Thus, a conventional coating or surface treatment was simply not an option”, says Expanite Area Sales Manager, Dr. Holger Selg. The result already after first test trail proved overwhelmingly convincing on all parameters, and most importantly, the galling phenomenon disappeared completely. “There has been no records of damaged parts ever since”, says Mr. Roman Hörbe, Supply Chain Managerat Enpulsion

About Enpulsion

The company is based in Wiener Neustadt, Austria and has a business development office in Silicon Valley, CA. In its own semi-automated production facility ENPULSION is manufacturing the IFM Thruster family, including the IFM Nano Thruster –the only compact, scalable, and modular electric propulsion system worldwide. With today ENPULSION is producing and delivering nine IFM Nano Thrusters per month to its international B2B customers

About Expanite

Expanite offers state-of-the-art solutions for surface hardening treatment of stainless steels and titanium. With Expanite’s processes, it is possible to increase the material’s surface hardness tenfold while at the same time maintaining and even increasing its corrosion resistance. Expanite is a global organization with a combined development and production facility near Copenhagen, Denmark, and hardening capacity in both US, Germany, Korea and China. Expanite’s solutions are flexible and can be introduced directly into a customer’s own production line as part of a licensing arrangement. Learn more on www.expanite.com.

 

(Articolo in inglese)

With more than 20% of the turnover coming from hard chrome replacement projects, Expanite, the Danish pioneer within surface hardening of stainless steel, is on its way to position itself as one of the most used alternatives for hard chrome plating.

Finding a replacement for hard chrome plating can be challenging, and with EU regulations lowering the limit value for hexavalent chromium, across the industrial markets, need to find alternatives. Hard chrome plating, in various forms, has been one of “the standards” to improve resistance towards wear and corrosion for stainless steel components – and as new solutions are required, Expanite’s hardening technologies has documented its effectiveness within automotive, pumps, valves and food processing equipment markets.

Sustainable solutions, diffusion vs. coatings

Unlike a hard chrome coating, where the electrolyte used during processing may contain hexavalent chromium ions (Cr⁶⁺), which are hazardous to human health and is environmentally harmful, the Expanite treatments involves only nitrogen and carbon atoms. This makes Expanite an environmentally friendly and sustainable process. Expanite effectively removes the native oxide film covering stainless steels during the first steps of the gas process without adding any aggressive chemicals, and this allows controlled diffusion of carbon and nitrogen atoms in the underlying steel hereafter.

Expanite replacing hard chrome plating

“More than 20% of the parts we are processing today with the Expanite process are replacements for hard chrome plating”, says Thomas Abel Sandholdt CEO at Expanite. Whether it’s the valve parts of a fuel injector within automotive, a bushing for marine engines or the rotor for a large pump – they have all experienced the benefits of choosing a diffusion process with no risk of coatings cracking or inhomogeneous hardening zones – and on top comes the compliance with the EU Reach program on reduction of Cr6+ as well as the fundamental decision to move towards more sustainable solutions. Talking about replacing hard chrome with Expanite, Thomas Abel Sandholdt highlights opportunities in the automotive industry with valve components. “Independently of each other, three major suppliers to the automotive industry approached Expanite. They all produce fuel injectors with valve components in ferritic stainless steel which traditionally were hard chromed plated. All three were facing issues such as wear, general quality problems and high cost – and they all found various solutions within the Expanite toolbox. The first of the three projects went into serial production in January 2020, while the two other projects are scheduled to begin serial production in 2021 and 2022,”. “As we are often our customers´ biggest secret, many will not allow us to reveal that we actually have helped them change from hard chrome plating”, Thomas Abel Sandholdt continues.

Competitive cost

From the first look, Expanite hardening technology might seem costly compared to hard chromium plating, but Thomas Abel Sandholdt is convinced the price difference will equalize, once total life cycle cost and performance is taken into account. The proof lies in the decisions made by so many of Expanite’s customers.

About Expanite

Expanite offers state-of-the-art solutions for surface hardening treatment of stainless steels and titanium. With Expanite’s processes, it is possible to increase the material’s surface hardness tenfold while at the same time maintaining and even increasing its corrosion resistance. Expanite is a global organization with a combined development and production facility near Copenhagen, Denmark, and hardening capacity in both US, Germany, Korea and China. Expanite’s solutions are flexible and can be introduced directly into a customer’s own production line as part of a licensing arrangement. Learn more on www.expanite.com.

 

Expanite – The technology of the Danish pioneer for surface hardening of stainless steel and titanium is used more and more frequently when it comes to alternatives to classic fluoroplastic coatings such as Teflon®, Halar® or Xylan®. In addition to technical and commercial advantages, the environmental compatibility and sustainability of the Expanite process are playing an increasingly important role for customers.

After the discovery of PTFE (polytetrafluoroethylene) – also known as Teflon® – in 1938, some time passed before technically usable applications for the highly inert material paved their way. Today, coatings based on per- and polyfluoroalkyl substances (PFASs), known by their trade names such as Teflon®, Halar® or Xylan® or more generally referred to by the abbreviations ECTFE, PFA, FEP, ETFE, PVDF etc., are applied in many areas to optimize the sliding and non-stick properties as well as wear and corrosion resistance of components. In addition to the well-known disadvantages of coatings, i.e. inhomogeneous layer thicknesses, layer detachment and increased corrosion attack if the coating is damaged, PFAS-based products have another substantial deficit: the highly stable and therefore not completely degradable carbon-fluorine compounds are harmful not only for humans but also to the environment and can cause cancer, among other things. Accordingly, there has been a trend towards avoiding the use of these materials since the early 2000s, and especially when it comes to improving wear and corrosion resistance, Expanite surface hardening offers a cost-effective and sustainable alternative. The Expanite technology is based on a gas process in which carbon and nitrogen are diffused in the component surface. The otherwise comparable soft and wear-prone stainless steel material hardens by a factor of up to 10 and while classic diffusion processes impacting corrosion resistance of the material, the Expanite processes generally improve the corrosion properties of the component.

Sustainable against wear and galling

Besides the elimination of carcinogenic substances, Expanite’s gas-based diffusion process is significantly more energy-efficient and environmentally friendly than comparable wear protection processes, and thanks to the treatment in a vacuum, no time-consuming cleaning of the parts, e.g., with aggressive chemicals, is necessary after hardening. “The different cases in which Expanite is used as an alternative to such plastic coatings are widely spread and can be found, for example, in the areas of pumps and valves, food & beverage or general industrial applications,” explains Dr. Holger Selg, application expert and Expanite Sales Director DACH, and continues: “First and foremost, we increase the wear and galling resistance of stainless steel components. By hardening the surface, the sliding properties are improved at the same time and, depending on the application, offer an adequate replacement for fluoroplastic coatings.” The Expanite technology, specially developed for corrosion-resistant materials, offers a solution for austenitic, martensitic, ferritic, and duplex stainless steels as well as for expensive nickel-based alloys such as Inconel and Hastelloy. Moreover, ExpaniteHard-Ti, which the Expanite team of experts has developed to market maturity in recent years, is used for titanium grades.

About Expanite

Expanite offers state-of-the-art solutions for surface hardening treatment of stainless steels and titanium. With Expanite’s processes, it is possible to increase the material’s surface hardness tenfold while at the same time maintaining and even increasing its corrosion resistance. Expanite is a global organization with a combined development and production facility near Copenhagen, Denmark, and hardening capacity in both US, Germany, Korea and China. Expanite’s solutions are flexible and can be introduced directly into a customer’s own production line as part of a licensing arrangement. Learn more on www.expanite.com.

 

(Articolo in inglese)

The processes for surface hardening of stainless steel from the Danish pioneer Expanite, has in recent years been used more and more frequently when it comes to improving galling and corrosion resistance of stainless steel fittings. The results of a long-term corrosion test show in particular the superiority of the Expanite technology over traditional methods.

About Expanite

Expanite offers state-of-the-art solutions for surface hardening treatment of stainless steels and titanium. With Expanite’s processes, it is possible to increase the material’s surface hardness tenfold while at the same time maintaining and even increasing its corrosion resistance. Expanite is a global organization with a combined development and production facility near Copenhagen, Denmark, and hardening capacity in both US, Germany, Korea and China. Expanite’s solutions are flexible and can be introduced directly into a customer’s own production line as part of a licensing arrangement. Learn more on www.expanite.com.

 

Expanite surface hardening on stainless steel passes critical test for food contact with exceptional results. Superior wear resistance can now be combined with safety in relation to food contact!

Expanite, the leading provider of sustainable surface hardening and heat treatment on stainless steel and titanium, reaches outstanding results with the SuperExpanite® hardening of AISI316/1.4404 stainless steel for metallic food contact material. The tests, performed in accordance with the European Committee CM/Res(2013)9 Resolution, focuses on repeated food contact scenarios, and Expanite surface hardening is thereby concluded safe to use in stainless steel food contact applications.

The test

The tests was conducted in accordance with the Council of Europe Resolution CM/Res(2013)9, focusing on repeated food contact scenarios – and the possible migration of substances from metallic components into food. In the test, performed for Expanite in October 2023 by an independent laboratory, coupons of stainless steel were treated with Expanite surface hardening (SuperExpanite®) and hereafter exposed to the testing media. Results from the test are expressed in terms of migration levels of various elements into the testing medium, in essence food. Overall aim is to limit migration and stay below the limits expressed in the resolution. The details of the test, were as follows:

• Material: AISI316/1.4404 stainless steel
• Expanite treatment: SuperExpanite20 NC
• Testing medium: 0.5% citric acid
• Temperature: 70 degrees Celsius
• Duration: 2 hours

The test results

Basically, Expanite-treated components passed the migration criteria for all relevant substances. The tests showed exceptional performance achieved through Expanite’s surface hardening on stainless steel – the treated AISI316 stainless steel exhibited remarkable resistance and compliance with the stringent conditions outlined in the CM/Res(2013)9 test. In the larger perspective, it means that it can be considered safe to apply Expanite surface hardening to on stainless steel for food applications – and thereby combining safety with superior wear resistance. The surface hardening and heat treatment applied by Expanite not only meet but exceed the expectations for materials used in repeated food contact applications. The enhanced properties of the treated stainless steel make it an ideal choice for various industries, including those requiring compliance with strict regulatory standards.

About Expanite

Expanite offers state-of-the-art solutions for surface hardening treatment of stainless steels and titanium. With Expanite’s processes, it is possible to increase the material’s surface hardness tenfold while at the same time maintaining and even increasing its corrosion resistance. Expanite is a global organization with a combined development and production facility near Copenhagen, Denmark, and hardening capacity in both US, Germany, Korea and China. Expanite’s solutions are flexible and can be introduced directly into a customer’s own production line as part of a licensing arrangement. Learn more on www.expanite.com.

Expanite® receives Master File for Devices (MAF) acknowledgment letter from FDA on their patented process for surface hardening of stainless steel in medical devices applications. and solving some of their challenges with wear on the titanium parts in their racing car.

Expanite announces it has submitted a Master File for Devices (MAF) to the United States Food & Drug Administration (FDA) and has now been issued the submission number MAF3078. Expanite has successfully submitted a Master File for Devices (MAF) to the Center for Devices and Radiological Health (CDRH) at the FDA for SuperExpanite®, their patented process for surface hardening of stainless steel and received an Acknowledgment letter from FDA confirming submission filing. The MAF covers necessary information such as technology, production processes and facility information, as well as test data and more. The SuperExpanite Master File has been issued submission document control number MAF3078. “We are very pleased to have achieved this significant milestone. The FDA registration makes it easier for our U.S. customers to obtain approval for new medical products that use Expanite surface hardening. Expanite is now able to provide a signed and named Authorization letter to our customers on their request, for the purpose of their product registrations at FDA. This is the first of many MAFs to come” says Expanite CEO, Thomas Abel Sandholdt.

Benefits of MAF implementation

The advantages of the MAF being submitted at FDA for the manufacturers who utilize Expanite surface hardening technology and register their products at FDA are many e.g.:

• • Expanite, individually, invested time to search and understand the FDA requirements for MAF submission

• • Documentation compiled, as required, and submission confirmed by FDA.

• • Surface hardening technology documentation available for FDA’s review as of now.

• • Eliminates communication time and effort between manufacturer and Expanite on MAF build and requirements.

• • Expanite responsible to maintain MAF up to date, as appropriate.

Master File for Devices now available

For the manufacturer ‘s medical devices registrations purposes, the SuperExpanite Master File for Devices is now available for reference and review at FDA. Expanite shall provide MAF Authorization letter on customer requests to make Expanite technical documentation available for FDA’s review in context of their product registration. Please contact Thomas Abel Sandholdt to hear more about the FDA Master File for Devices, SuperExpanite MAF content and request a signed and named Authorization letter for your product registrations.

About Expanite

Expanite offers state-of-the-art solutions for surface hardening treatment of stainless steels and titanium. With Expanite’s processes, it is possible to increase the material’s surface hardness tenfold while at the same time maintaining and even increasing its corrosion resistance. Expanite is a global organization with a combined development and production facility near Copenhagen, Denmark, and hardening capacity in both US, Germany, Korea and China. Expanite’s solutions are flexible and can be introduced directly into a customer’s own production line as part of a licensing arrangement. Learn more on www.expanite.com

 

Expanite, the Danish pioneer within surface hardening of stainless steel and titanium has successfully been ISO9001:2015 certified. In parallel with this certification, Expanite’s quality management system is now also complying with the CQI-9 standard for heat treatment within automotive.

ISO9001:2015 cover the production in all locations

Expanite originally achieved the ISO 9001:2008 certificate in 2013 for its Danish headquarter but with the recertification to the ISO 9001:2015 the scope is extended to cover the production, laboratory, shipping and office facilities in all locations; Germany, US and Denmark. “We are very proud of being among the first companies to reach the ISO certification according to the 9001:2015 edition. The recertification to the new standard for all our locations marks an important milestone for Expanite; with the certification, our customers can be confident that Expanite is dedicated and committed to maintaining the same high quality in processes, services and procedures no matter where customers are being serviced. Our motivation to obtain the certifications is driven by a desire to meet customer needs and continue to improve customer satisfaction”, says CEO, Thomas Abel Sandholdt.

ISO9001:2008 vs 9001:2015

The most noticeable change to the standard is its new structure is:

• The emphasis on leadership
• The focus on risk management
• Emphasis on objectives measurement and change
• Communication and awareness
• Fewer prescriptive requirements

About Expanite

Expanite offers state-of-the-art solutions for surface hardening treatment of stainless steels and titanium. With Expanite’s processes, it is possible to increase the material’s surface hardness tenfold while at the same time maintaining and even increasing its corrosion resistance. Expanite is a global organization with a combined development and production facility near Copenhagen, Denmark, and hardening capacity in both US, Germany, Korea and China. Expanite’s solutions are flexible and can be introduced directly into a customer’s own production line as part of a licensing arrangement. Learn more on www.expanite.com

 

Expanite, the Danish specialist in heat treatment and surface hardening of stainless steel and titanium, is thrilled to announce the addition of Thorsten Schild as Business Development Manager. With 25+ years expertise within the field, the appointment of Thorsten Schild will further strengthen Expanite’s commercial and technical service, and thereby support the company’s ambitious growth strategy.

Prior to joining Expanite, Thorsten Schild worked for Bodycote’s S3P division as group sales director, and he was one of co-founders of BorTec-SMT. All-in-all, Thorsten Schild can in many ways be regarded as one the most experienced people within sales and marketing of stainless steel surface hardening. Over more than 25 years, he has assisted countless customers across many industries globally on finding solutions for wear and galling on stainless steel. As Business Development Manager within Expanite, Thorsten will play a key role in expanding Expanite’s reach and solidifying the position as a leader in surface hardening solutions. With his extensive industry knowledge and network, he will contribute to the company’s strategic initiatives and drive business growth. “We are delighted to welcome Thorsten to the Expanite team,” says Thomas Abel Sandholdt, CEO at Expanite. “Combining his proven sales expertise with Expanite’s unique process-related benefits in surface hardening of stainless steel makes it a perfect match. The appointment will reinforce our commitment to deliver cutting-edge solutions and services for all sectors requiring increase protection against wear, galling and corrosion.” Thorsten Schild already started his role as Business Development Manager at Expanite. and will collaborate closely with the existing team to drive innovation, strengthen customer relationships, and identify new business opportunities.

About Expanite

Expanite offers state-of-the-art solutions for surface hardening treatment of stainless steels and titanium. With Expanite’s processes, it is possible to increase the material’s surface hardness tenfold while at the same time maintaining and even increasing its corrosion resistance. Expanite is a global organization with a combined development and production facility near Copenhagen, Denmark, and hardening capacity in both US, Germany, Korea and China. Expanite’s solutions are flexible and can be introduced directly into a customer’s own production line as part of a licensing arrangement. Learn more on www.expanite.com

 

(Articolo in inglese)

We’re proud to announce that Expanite – the Danish specialist within surface hardening and heat treatment of stainless steel and titanium – has achieved the ISO 14001 certification.

ISO 14001 has become the international standard for designing and implementing an environmental management system. Companies that achieve the certification have proper procedures in place to measure, reduce and manage their environmental impact. Audited by TÜV Nord, one the world’s largest inspection, certification and testing organization, Expanite demonstrated that our environmental management system meets the requirements of ISO 14001.

An important milestone for Expanite

The certification requires Expanite to consider all environmental issues relevant to the business, to have a strategy for managing issues, and to continually improve. Since the foundation of Expanite, sustainability and environmental aspects hereof has been a part of our company DNA. Expanite is the leader in sustainable surface hardening solutions – and in this light, the ISO14001 is a very important milestone. “Sustainability and reducing the environmental impact are important guiding principles of Expanite, principles that we work hard to live up to. We are committed to sustainability and have a responsibility to the communities in which we operate. The completion of the global ISO 14001 certification process is a strong testament to that commitment”, says CEO Thomas Abel Sandholdt.

What is ISO 14004

Any organisation that achieves ISO 14001 certification must consider a wide variety of potential environmental impacts, including air pollution, water and sewage issues, waste management, soil contamination, climate change mitigation and adaptation, resource use and efficiency. ISO 14001 certification is a guarantee for quality in the environmental management system, and the company’s compliance can be audited. This means anyone doing business with Expanite can be reassured we have procedures in place to measure, reduce and manage our environmental impact.

Setting targets for Expanite’s environmental impact

At Expanite, certification and the active management of our environment management system will ensure that we among other topics will focus on:

• A reduction in the use of resources and materials
• Less waste production (and therefore reduced costs for waste management)
• An increase in the share of renewable resources
• Improve our internal structures to guarantee efficient performance resulting in sustainability
• Pushing the standards for our industry

Finally, the ISO14001 certification is an opportunity to demonstrate to our team, our customers, and the community that we´re committed to the environment. Expanite also holds ISO 9001 certification, and we believe that both ISO certificates reflect our commitment and dedication to working to the highest possible standards in every aspect of our business.

About Expanite

Expanite offers state-of-the-art solutions for surface hardening treatment of stainless steels and titanium. With Expanite’s processes, it is possible to increase the material’s surface hardness tenfold while at the same time maintaining and even increasing its corrosion resistance. Expanite is a global organization with a combined development and production facility near Copenhagen, Denmark, and hardening capacity in both US, Germany, Korea and China. Expanite’s solutions are flexible and can be introduced directly into a customer’s own production line as part of a licensing arrangement. Learn more on www.expanite.com