May. 06, 2024
Graphite can prove tricky to machine, particularly for EDM electrodes that require outstanding accuracy and structural consistency. Here are five key points to keep in mind when working with graphite:
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Graphite grades are visually difficult to distinguish, but each features unique physical characteristics and properties. Grades of graphite are grouped into six classifications by average particle size, but only the smaller three (with particles measuring 10 microns or smaller) see regular use in modern EDM. How grades rank within classifications is an indicator of potential applications and performance.
According to an article by Doug Garda (formerly of Toyo Tanso, now of SGL Carbon), roughing uses grades with particle sizes ranging from 8 to 10 microns. Less-precise finishing and detailing applications employ grades with 5- to 8-micron particle sizes. Electrodes made from these grades are often used to create forging dies and die-cast molding dies or in less-complex powdered and sintered metal applications.
Fine detailing work and smaller, more intricate features are better suited for grades with 3- to 5-micron particle sizes. Applications for electrodes in this range include wire cutting and aerospace.
Ultra-fine, precision electrodes, which employ graphite grades with particle sizes of 1 to 3 microns, are often required for exotic aerospace metal and carbide applications.
Writing for MMT, Jerry Mercer of Poco Materials identifies particle size, flexural strength, and Shore hardness as three key determinants of performance during electrode machining. However, the graphite’s microstructure is often the limiting factor in how the electrode performs during final EDM operations.
In a different article for MMT, Mercer says flexural strength should be above 13,000 psi to ensure graphite machinability into deep, thin ribs without breakage. The graphite electrode manufacturing process is lengthy and can require detailed, difficult-to-machine features, so ensuring durability like this helps to keep costs low.
Shore hardness measures the machinability of graphite grades. Mercer warns that graphite grades which are too soft can clog cutter flutes, slowing down the machining process or packing the hole with dust that can stress the hole walls. Reducing feeds and speeds in these situations can prevent errors, but this will increase machining time. Hard, small-grain graphites can also cause material at the rim of the hole to chip during machining. These materials can also be very abrasive to cutters, causing wear that impacts the integrity of the hole diameter and increases the cost of the job. Generally, avoiding deflection at high hardness values requires reducing machining feeds and speeds by 1% for each point of Shore hardness higher than 80.
Due to the way EDM produces a mirror image of the electrode in the part being machined, Mercer also notes that a tightly packed, uniform microstructure is vital for graphite electrodes. Uneven particle boundaries increase porosity, thus increasing the erosion of particles and hastening the failure of the electrode. Non-uniform microstructures also result in uneven surface finishes during initial electrode machining—a problem exacerbated on high-speed machining centers. Hard spots in graphite can also cause tool deflection, throwing the final electrode out-of-spec. This deflection can be slight enough that angled holes appear deceptively straight at the point of entry.
There are dedicated machines for graphite machining, but while these will greatly speed along production, they are not the only machines manufacturers can use. Aside from dust control (covered later in the article), past MMS articles have reported on the benefits of a machine with a fast spindle and a control with a high processing speed for graphite manufacturing. Ideally, the fast control should also have look-ahead functionality, and the user should utilize toolpath optimization software.
When impregnating graphite electrodes—that is, filling the holes of the graphite microstructure with micron-sized particles—Garda recommends using copper as it can stabilize machining of exotic, copper and nickel alloys, such as those used in aerospace applications. Copper-impregnated graphite grades create finer finishes than non-impregnated grades of the same classification. They also enable stable machining when working with unfavorable conditions such as poor flushing or inexperienced operators.
Although synthetic graphite—the kind used to fabricate EDM electrodes—is biologically inert and thus not as initially hazardous to humans as some other materials, improper ventilation can still cause problems, according to a third article from Mercer. Synthetic graphite is electrically conductive, posing issues around equipment that can short out upon contact with foreign conductive materials. Also, graphite impregnated with materials like copper and tungsten requires additional care.
Graphite dust is invisible to the human eye in small concentrations, Mercer explains, but it can still cause stinging, watering, and redness. Contact with the dust may be abrasive and mildly annoying, but absorption is unlikely. The exposure guideline for time-weighted average (TWA) for graphite dust over an 8-hour period is 10 mg/m³, which is a visible concentration that should never occur with a dust collection system in use.
Excessive exposure to graphite dust over extended periods of time can lead to inhaled particles of graphite being retained in the lungs and bronchi. This causes a serious, chronic form of pneumoconiosis called graphitosis. Graphitosis is typically associated with natural graphite, but has happened in rare circumstances with synthetic graphite.
Accumulated dust in the workplace is highly flammable. According to Mercer, it can explode under certain circumstances. Dust fires and deflagration occur when ignition meets a sufficient concentration of fine particulates suspended in air. Explosions are more likely to occur if the dust is dispersed in significant volume or is in a contained area. Controlling any one hazardous element—fuel, oxygen, ignition, dispersion, or confinement—drastically lowers the possibility of a dust explosion. Most times, the industry focuses on fuel by removing dust at the source through ventilation, but shops should consider all factors for maximum safety. Dust control equipment should also have explosion relief vents or an explosion suppression system, or be installed in an oxygen-deficient environment.
Mercer identifies two primary methods for controlling graphite dust: high-velocity air systems with dust collectors—which can be fixed or portable, depending on the application—and wet systems that saturate the area around the cutter with fluid.
Shops doing a limited amount of graphite machining can use a portable unit with a high-efficiency particulate air (HEPA) filter that can be moved from machine to machine. However, shops that machine significant amounts of graphite should generally use a fixed system. The minimum air speed for capturing dust is 500 feet per minute, with speed increasing inside the duct to a minimum of 2,000 feet per second.
Wet systems flush away dust at the risk of the fluid "wicking" (being absorbed) into the electrode material. Not removing the fluid prior to placing the electrode in the EDM can result in contamination of the dielectric oil. Operators should use water-based solutions, as these wick less easily than oil-based solutions. Drying the electrode before EDM use typically involves placing the material in a convection oven for about one hour at a temperature slightly exceeding the vaporization point of the solution. The temperature should never exceed 400 degrees, as this makes material oxidize and erode. Operators should also never use compressed air to dry the electrode, as the air pressure merely forces the fluid deeper into the electrode structure.
Graphite electrodes are crucial components in devices that help the brain, heart, and nervous system function properly. From smartphones to pacemakers, they are an integral part of the modern world. A graphite electrode is a type of battery that utilizes dispersed material, purposely added to an electrode in order to increase its surface area so as to continue absorbing more material.
Graphite electrodes are gaining popularity all over the world because of their role in many industrial applications and benefits to users. As the demand for graphite electrodes rises, so does the number of companies involved in this industry and hence, the flourishing business of graphite electrodes.
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Uses and Application of Graphite Electrodes
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Graphite electrodes are used in industry as a popular option for heating because they are chemically inert and do not react with the material. They are also suitable for use in high temperatures, making them an excellent option for industries that need to heat their materials quickly. Graphite electrodes are used primarily in electric arc furnace steel manufacturing. Graphite electrodes can provide high levels of electrical conductivity and the capability of sustaining the extremely high levels of generated heat. Graphite electrodes are also used in the refinement of steel and similar smelting processes. Carbon-graphite electrodes are also used in gouging operations such as in the forming of a bevel or groove, removing defects in castings or weldments by an arc or gas process. Arc gouging removes material by melting it with the heat of an arc struck between a carbon-graphite electrode and the base metal. Compressed air or nitrogen simultaneously blows the molten metal away.
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Benefits of Starting Graphite Electrodes Business
The rising demand for graphite electrodes in steel-oriented sectors such as construction, automotive, infrastructure, aerospace, and defense is a key factor driving the market. The increasing requirement of anti-corrosive products for oil and petroleum wells and pipelines in the oil and gas sector has further enhanced the use of EAF, and subsequently catalyzed the demand for these electrodes. Additionally, the increasing requirement for Ultra-High Power (UHP) graphite electrodes is another market trend that is projected to drive the market. UHP has a higher thermal and electrical conductivity and can swiftly melt scrap to manufacture steel. It is therefore highly preferred by steel manufacturers, and its demand is expected to grow substantially in the coming years.
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Manufacturing of Graphite Electrodes
To begin the process, the raw materials are ground together. Next, they mix with a liquid pitch. Pitch is a tar-type resin, and when mixed with the raw materials, it forms a graphite mixture which is then placed into molds. The molds are then vibrated at high speeds to compact the mixture. The electrodes turn into pitch coke and bake, creating a solid electrode. To improve the texture, the electrodes enter an autoclave where they soak up the liquid pitch. After soaking, they bake again to solidify their composition. By baking the electrodes at 3000 degrees Celsius, they become graphite.
Indian Market Outlook of Graphite Electrodes Business
The graphite electrode market was valued at USD 8,791.65 million in 2021, and it is projected to register a CAGR of 4.6% during the forecast period (2022-2027). Graphite electrodes are one of the most common materials for metal smelting in India. For a long time, it was produced solely in Europe, China, and the United States. But nowadays as manufacturers gear up to meet ever-growing demands, business ventures and partnerships have been established with counterparts in Africa and Latin America. Prices of graphite electrodes have skyrocketed. Existing investors and entrepreneurs are considering this investment opportunity seriously now that they see that the market is only getting bigger! Indian Government Schemes Helping Fuel the Graphite Electrode Industry
The Indian government has been working on improving conditions in rural areas and establishing new industries where employment opportunities will be available to people living there. In an effort to improve the lives of these people, the Ministry of New & Renewable Energy (MNRE) has started programs aimed at creating demand for graphite electrodes among small-scale industries such as those found in rural areas. As a result, many businesses are looking into expanding their production capabilities to meet the rising need.
The largest consumers of graphite electrodes are zinc producers followed by copper producers and steel producers. However, during the last few years, iron and manganese producers have also begun using them in large quantities.
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Global Market Outlook of Graphite Electrodes Business
The global market for Graphite Electrodes, estimated at US$10.8 Billion in the year 2020, is projected to reach a revised size of US$14.5 Billion by 2026, growing at a CAGR of 5.2% over the analysis period. The Graphite Electrodes market in the U.S. is estimated at US$1.6 Billion in the year 2021. China, the world’s second-largest economy, is forecast to reach a projected market size of US$2.5 Billion by the year 2026, trailing a CAGR of 6.2% over the analysis period. Among the other noteworthy geographic markets are Japan and Canada, each forecast to grow at 3.6% and 3.9% respectively over the analysis period. Within Europe, Germany is forecast to grow at approximately 4.6% CAGR.
In the global Regular Power segment, USA, Canada, Japan, China, and Europe will drive the 3.6% CAGR estimated for this segment. These regional markets accounting for a combined market size of US$768.4 Million in the year 2020 will reach a projected size of US$982.4 Million by the close of the analysis period. China will remain among the fastest growing in this cluster of regional markets. Led by countries such as Australia, India, and South Korea, the market in Asia-Pacific is forecast to reach US$479 Million by the year 2026, while Latin America will expand at a 3.9% CAGR through the analysis period.
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