August 2007

Fillers and Extenders - Consultation and Selection

For the past 85 years Composition Materials has worked with a broad cross-section of industry, worldwide, to find the right fillers and extenders to match application requirements.  If one is fabricating a new compound or material, we are an excellent resource.   An organized approach to your search, with our help, will yield the end product with the characteristics for which you are looking.

What are the steps in finding the proper filler?

First, determine the attributes you wish to impart to your end product.  For example;
          Extend without absorbing expensive active ingredients
          Reduce or increase apparent specific gravity
          Introduce “Non-slip” or texture characteristics
          Add “anti-sag” characteristics
          Increase strength
          Increase flexibility or rigidity
          Change sound absorption characteristics

Next, quantify the attributes you think are needed in the Filler or Extender.  These attributes will help identify good candidates.
          Specific Gravity
          Absorbency
          Particle shape
          Particle size
          Reactive of inert
          Sound Deadening
          Color
          Melt temperature (if any)
          Ignition temperature
          Strength
          Hardness

Some Fillers & Extenders available
          Walnut Shell Flour
          Pecan Shell Flour
          Rice Hull Ash
          Rice Hull Flour
          Rice Flour
          Wood Flour
          Wheat Flour
          Hollow Glass Beads
          Aluminum Tri-Hydrate
          Fibers
                   Cellulose  
                   Sisal
                   Ground Paper
                   Leather, ground  
                   Leather Fiber
                   Nylon
                   Cotton
                   Asbestos Substitute
                   Rayon
                   Kevlar
          Thermoset Plastic Flour
                   Urea
                   Melamine
                   “Clear-Cut” Poly-allyl Di-Glycol Carbonate
                   Phenolic
          Metal Powders
                   Zinc
                   Steel
                   Aluminum
          Rubber Dust

For more information visit http://compomat.com/home.asp

Shanghai Shidongkou Gas Making Company Doubles Gas Output with Anderol BDC 68 Polyolester Synthetic Compressor Oil

Selecting the right lubricant for machinery operations positively impacts the plant’s bottom line. By sufficiently providing processing equipment with correct lubrication, companies can extend equipment life, increase productivity and avoid unnecessary repair work related to mechanical degradation. What should companies consider when employing a lubricant?  The key is to look for a lubricant that meets the requirements of your plant operations.  Shanghai Shidongkou Gas Making Company Limited converted to Anderol BDC 68 polyolester (POE) synthetic compressor oils to reap significant performance benefits.

Shanghai Shidongkou Gas Making Co. Ltd, a subsidiary of Shanghai Fuel Gas Group, is a new air/gas supply plant built to implement the city’s five-year gas development plan for domestic and industrial gas production.  The company utilizes four York RWB II-856 twin-screw compressors, each with a discharging capacity of 6,020m3/hr at a maximum discharge pressure of 1.4 Mpa and discharge air temperature between 110°C  to 120°C. 

Throughput Concerns
During a production peak at the end of 2004, maintenance engineers noticed an abnormal reduction of compressed air capacity. The unit production volume dropped drastically from normal startup figures of 5,100 m3/hr to 5,200 m3/hr to as low as 2,000 m3/hr. With the compressor capacity reduced to less than half of its potential, Shidongkou had to operate three compressors to generate the output normally achieved by one machine. Another significant concern was the blackening of oil as a result of premature oxidation after only 300 hours of operation. Through used oil analysis testing, Anderol was able to detect this problem, which was severely undermining compressor performance.

“Detailed checks revealed that the cause of capacity fluctuation was premature thermal-oxidative breakdown of the lubricant,” said an official representative of Shanghai Fuel Gas Group. “We tried other synthetic compressor oils including products from the original manufacturer and several other lubricant companies, but unfortunately, the problem persisted.”

Solving the Problem
To solve the problem, Shidongkou approached Anderol Specialty Lubricants to implement an effective long term lubrication strategy.

“Using inappropriate synthetic compressor oil could lead to complications such as heat exchange deficiencies or compatibility issues regarding seal, gaskets and quality of discharge air.  Ignoring these problems could imply a safety threat, especially to equipment operators,” said Francis Hou, general manager, Asia Pacific, Anderol. “We had to be really selective in helping Shidongkou choose the right compressor oil.”

To maximize operational efficiency, it was necessary for Shidongkou to select a new synthetic compressor oil with qualities that promised not only enhanced performance but also safety and reliability during use.  The lubricant must have high viscosity/temperature stability, high degree of thermal oxidative stability, extended service life and excellent thermal conductivity properties. After careful matching and consideration, Anderol recommended its BDC 68 POE synthetic compressor oil, which met all of Shidongkou’s requirements.

But before integrating the new compressor oil into the production process, Anderol assisted Shidongkou in the changeover procedure to eliminate residual oil, carbon deposit and rust inside the compressor system to ensure equipment cleanliness.

The Right Lubricant Saves the Day
The Anderol BDC 68 synthetic base oil, made from technical grade PE-polyolester, was highly compatible with Shidongkou’s consumable parts. Exhibiting high thermal stability, the oil was especially suitable for use in screw compressors operating under high discharged air temperatures above 95°C.  After application of the Anderol BDC 68 onto all of Shidongkou’s four compressor units, it was found that all of them were able to consistently operate at a smooth air discharging capacity of 5,000 m3/hr to 5,300 m3/hr. 

“The outstanding thermal oxidative stability of the BDC 68 virtually eliminated the deleterious by-product of oxidation, resulting in extended service life of our equipment,” explains an official representative of Shanghai Fuel Gas Group “This led to substantial cost savings on our resources.  Effectively, we were able to do more for less.”

On top of these benefits, the ANDEROL BDC 68’s natural detergency and dispersing capabilities not only remove internal deposits to ensure smooth functioning, but also help keep the system clean.  While its biodegradable properties make Anderol BDC an environmentally friendly product, its high flash point ensures a higher level of operational safety.

The combination of the right lubricant and proper maintenance strategies has proved to be fruitful for Shidongkou.  After application, Shidongkou was able to increase production efficiency and double it’s gas pressure output capacity from 2,000 m3/hr to 5,000-5,300 m3/hr.

“Anderol BDC 68’s high quality viscometrics, high-temperature stability and sealing capabilities have brought out the best performance in our compressors,” affirms Shanghai Fuel Gas Group’s official representative. “We know that Anderol has helped customers achieve business goals for many years. It’s great to see that success replicated with Shidongkou air compressors.”

Electrically Conductive Adhesive Supplied in Bubble Packs, Kits and Syringes

Mereco Metaduct 1202 Silver Adhesive is a silver-filled, electrically conductive epoxy that is designed for lead attachment cold soldering, chip bonding and lead frame bonding applications. This adhesive cures at room temperature. It is supplied in plastic bubble packs from 2 grams to 200 grams, five kits from 2 oz. to 32 oz. and pre-mixed and frozen syringes.

Solvent-free, non-bleeding, and thixotropic, Mereco Metaduct 1202 Silver Adhesive is compliant with NASA’s outgassing specification.  It has a volume resistivity at 25°C of 10-4 Ohm-cm, 800 psi lap shear strength and exhibits 80 D Shore hardness. Typical applications include manufacturing, assembly and repair of heat-sensitive components where hot solder is impractical.

New Victrex T-Series Compound Delivers Enhanced Performance at High Temperatures

Victrex, a manufacturer of high performance materials, released a new Victrex T-Series compound called TF-60C, a proprietary blend of Victrex Peek polymer, Celazole polybenzimidazole (PBI) and carbon fiber reinforcement. The new carbon fiber product delivers high strength, high modulus, low creep and is suited for the most demanding applications in the semiconductor/electronics industries including soldering tools, cassettes, wafer transportation and chamber parts in spin coating, etching and PVD.

Victrex T-Series products are high performing melt processable thermoplastics for use in applications requiring physical property retention and wear resistance at elevated temperatures. Offering excellent mechanical performance at high temperatures up to 300°C (572°F), they are a suited replacement option for metals and non-melt processable high temperature plastics such as polyimides. 
 
Key features of the TF-60C compound include high temperature resistance, compressive strength as well as tensile and flexural performance. Other features include tribology and resistance to a range of extreme environments that degrade most plastics.  

Concrete Repair Alternative Offers High Early Strength Gains for Rapid Vehicle Reload

Ceratech, Inc. recently introduced its Pavemend SLQ, a rapid-hardening, high early-strength material for patching and long term repair of concrete, masonry and structural asphalt surfaces. It was developed for urgent infrastructure repair scenarios where a one hour return to service is important.

Pavemend SLQ was engineered to address many of the constraints posed by traditional construction materials, including extreme weather applications, rapid return to service, ease of use, shrinkage, resistance to thermal expansion/contraction and long term durability. It offers aggressive bonding characteristics along with one-hour compressive strengths exceeding 3400 PSI, enabling repairs to be reloaded by wheeled vehicles in one hour and foot traffic in 20 minutes.  These features make SLQ suited for the repair of roads and bridges, airport runways and tarmacs, warehouses, manufacturing and industrial floors, post tension cable repairs and form and pour projects, among others.

Packaged in five gallon buckets to facilitate easy mixing, Pavemend SLQ is a single component powder that is water activated. Once activated, itbecomes a slurry mix that, when poured into the area to be repaired, bonds tenaciously to most construction materials, including steel. Unlike most repair products, it will bond to itself with no surface preparation, allowing for indefinite layering without cold joints.

Pavemend SLQ is used by US military forces worldwide for numerous strategic purposes, including force protection, aircraft runway and infrastructure repair applications.  Roadway potholes and craters created from IED’s (Improvised Explosive Devices) are quickly filled and eliminated as potential hiding places for new IEDs placed by insurgents. The extreme rapid hardening capabilities minimize the exposure to military personnel by reducing the time required to stand guard over “soft” repairs from hours to just minutes.

“From US Military operations in Iraq and Afghanistan, to state DOT’s across the country, urgent infrastructure repair scenarios constantly demand one hour returns to service,” said Jon Hyman, Chief Executive Officer, CERATECH, Inc.  “Pavemend SLQ, and all our Pavemend products, are answering that demand and redefining today’s longstanding industry standards.”

New PPG brochure highlights Certified Fabricator Program

PPG Industries’ performance glazings business has published a new brochure highlighting the Certified Fabricator Program (PPG/CFP) – a group of glass fabricators certified by PPG to provide a full range of high-performance PPG glass products, including Solarban 70XL, Solarban z50 and Solarban 60 glasses.

The brochure includes a map of PPG/CFP member locations as well as contact information for each. It also details the benefits PPG/CFP members offer to their customers, such as priority access to select high-performance PPG glass products, as well as accelerated lead times, in-stock replacement glass and regional sourcing.

The brochure also includes information about five additional Certified Fabricator Program groups for glass products ranging from commercial windows to laminated glass. The new derivations of the PPG/CFP program are as follows:

• The Certified Commercial Window Fabricator (PPG/CCWF) Program offers architects and building owners the benefits of PPG high-performance glass in a manufactured window.
• The Certified Laminator Program (PPG/CLP) includes a select group of glass laminating partners supplying laminated, solar control, low-emissivity glass for overhead skylights, safety and security glazing applications.
• The International Certified Fabricator Program (PPG/ICFP) upholds the standards of the North American Certified Fabricator Program on a global scale.
• The International Certified Laminator Program (PPG/ICLP) supplies laminated, solar control, low-e glass for overhead skylights, safety and security glazing applications in several other countries.

Liquiguard Technologies Releases Liquiguard Conformal Coating for Electronic and Electrical Industry

Liquiguard Technologies has introduced its Liquiguard, conformal coating developed to protect electronic devices and printed circuit assemblies from damage when exposed to moisture, water, beverages, non-corrosive liquids and even mild solvents.

More than a moisture repellant, Liquiguard will continue to protect a powered up electronic device in case the device accidentally becomes fully immersed in water or other non-corrosive liquid. Liquiguard bonds tenaciously with the PC board and its components. Its ability to safeguard the PCB with a 1 mil film has the added advantage of heat dissipation and ease of repair without prior removal of the coating. Due to its weathering and aging properties, Liquiguard can also be used to protect electrical assemblies exposed to the elements.

Liquiguard is manufactured in the US and sold in aerosol cans, pint, quart, gallon, five gallon and fifty gallon packing. It can be applied via dipping, spraying or brushing. Liquiguard is a water-based non-toxic, non hazardous and environmentally safe product.

Unique Quantum Effect Found in Silicon Nanocrystals Quantum Dot Materials May Improve Efficiency of Silicon Solar Cells

Researchers at the US Department of Energy’s National Renewable Energy Laboratory (NREL), collaborating with Innovalight, Inc., have shown that a new and important effect called Multiple Exciton Generation (MEG) occurs efficiently in silicon nanocrystals. MEG results in the formation of more than one electron per absorbed photon.

Silicon is the dominant semiconductor material used in present day solar cells, representing more than 93 percent of the photovoltaic cell market. Until this discovery, MEG had been reported over the past two years to occur only in nanocrystals (also called quantum dots) of semiconductor materials that are not presently used in commercial solar cells, and which contained environmentally harmful materials (such as lead). The new result opens the door to the potential application of MEG for greatly enhancing the conversion efficiency of solar cells based on silicon because more of the sun’s energy is converted to electricity.  This is a key step toward making solar energy more cost-competitive with conventional power sources.

An NREL team reported that silicon nanocrystals, or quantum dots, obtained from Innovalight can produce more than one electron from single photons of sunlight that have wavelengths less than 420 nm. When today’s photovoltaic solar cells absorb a photon of sunlight, about 50 percent of the incident energy is lost as heat. MEG provides a way to convert some of this energy lost as heat into additional electricity.

The silicon nanocrystals produced by Innovalight, Inc., a thin-film solar cell developer, were studied at NREL as part of a collaboration between NREL and Innovalight scientists. The NREL team consisted of Matthew C. Beard, Kelly P. Knutsen, Joseph M. Luther, Qing Song, Wyatt Metzger, Randy J. Ellingson and Arthur J. Nozik.

The findings represent an important extension of the range of semiconductor materials that exhibit MEG and are a further confirmation of pioneering work by Nozik, who in 1997 predicted that semiconductor quantum dots could exhibit efficient electron multiplication and hence increase the efficiency of solar cells.

To date, all experiments showing the production of more than one electron per absorbed photon have been based on various types of optical spectroscopy.  In a solar cell device it is necessary to extract the electrons produced in the quantum dots and pass them through an external circuit to generate electrical power.  Such experiments are currently underway at NREL, Innovalight and other laboratories to demonstrate that MEG can indeed lead to enhanced solar cell efficiencies. Calculations at NREL by Mark Hanna and Nozik have shown that the maximum theoretical efficiency of quantum dot solar cells exhibiting optimal MEG is about 44 percent with normal unconcentrated sunlight and 68 percent with sunlight concentrated by a factor of 500 with special lenses or mirrors.  Today’s conventional solar cells that produce one electron per photon have maximum efficiencies of 33 percent and 40 percent, respectively, under the same solar conditions.

In addition to efficiently extracting the electrons from the quantum dots in solar cells, future research is directed toward producing MEG at wavelengths that have a greater overlap with the solar spectrum, as well as producing a much sharper onset of the MEG processes with decreasing wavelength of the photons.

NREL is the US Department of Energy's primary national laboratory for renewable energy and energy efficiency research and development. The NREL research was funded by DOE’s Office of Science, Office of Basic Energy Sciences, Division of Chemical Sciences, Geosciences, and Biosciences. NREL is operated for DOE by Midwest Research Institute and Battelle. 

Ceradyne, Inc. Receives $78 Million Ceramic Body Armor Order for US Army

Ceradyne, Inc. received a $78 million delivery order for ESAPI (Enhanced Small Arms Protective Inserts) from the US Army. This new delivery order is scheduled to be shipped beginning September 2007 through December 2007. This delivery order will be shipped against a larger indefinite delivery/indefinite quantity (ID/IQ) contract. The Company records as firm orders only delivery orders, such as the above, that have firm scheduled delivery dates.

Keithley Enters Joint Development Partnership with French CEA Leti Laboratory to Pursue Advanced Nanotechnology and Semiconductor Materials Research

Keithley Instruments, Inc., a company focused on solutions for emerging measurement needs, has entered into a Joint Development Partnership (JDP) surrounding semiconductor device material testing technology with CEA Leti, a semiconductor development laboratories. The JDP calls for Keithley and CEA Leti to research methods for characterizing advanced semiconductor materials and devices that support DC, high frequency and RF-level signals on both micro- and nano-level structures. CEA Leti will use Keithley RF-enabled semiconductor test equipment as part of its broad portfolio of research projects in order to expand and enhance understanding of the performance of semiconductor devices that perform at the highest levels.

“As semiconductor technology pushes the upper limits to achieving RF-level signals and device miniaturization to nano levels, measurement technology must not only keep pace but even lead researchers’ ability to build and test these devices,” said Mark Hoersten, Keithley vice president, business management. “Our partnership with CEA Leti is a unique opportunity to create new measurement technology at the point where many of our customers’ technologies converge – semiconductor, RF/wireless and nanotechnology.”

LM Glasfiber Releases Plans for New Blade Plant in Arkansas

The Little Rock plant will be LM Glasfiber’s third North American production facility, effectively doubling the capacity of the existing factories in Grand Forks, N.D. and Gaspé, Quebec.

Zero Downtime 2007
November 6 - 7, 2007
Scottsdale, Ariz.

Zero Downtime 2007, Nov. 6-7 in Scottsdale, Ariz., is a two-day conference focused on the latest advancements in protecting electronic equipment for data centers, communication and control networks, 24X7 industrial and facility systems, infrastructure and emergency service operations and other mission-critical electronic systems.
Topics discussed will include new developments in power protection and reliability including UPS, surge and circuit protection; thermal protection including controls, sensors, heating, cooling and environmental mitigation; condition monitoring and control including predictive and reliability capabilities, preventative maintenance; EMI shielding; and electronics packaging solutions such as enclosures shelters, cabinets and cases.
This November event will be organized to provide numerous opportunities for networking, discussion sessions, daily luncheons, a cocktail reception, and a large, co-located exhibit (co-located with Remote Monitoring and Networking 2007 and Onsite Power 2007) with dedicated hours and exhibit only passes for industry attendees.
Register today at www.EquipmentProtectionMagazine.com/zero07_reg.htm or call 800-803-9488.