Specialized Turning Blog

What Does it Take to Machine Zeron 100

Posted by Chip Holm on Jun 19, 2019 10:10:10 AM

Specialized Turning Now Has Zeron 100 Machining Capability

In need of a super performer for your machined material requirements? We have you covered! Specialized Turning recently added the ability to machine Zeron® 100 to our list of capabilities. Zeron 100, a super duplex stainless steel, is excellent for sub-sea applications due to its high-strength and corrosive-resistance properties. The material is well renowned for the toll it takes on the tooling and its heat and corrosion-resistance properties, so having us do the machining for you is well worth it!

Zeron 100 is in high demand in industries where there is extreme pressure and a caustic environment, such as (but not limited to):

Machining Zeron 100
  • Petrochemical
  • Chemical
  • Oil and gas
  • Pollution control
  • Pulp and paper
  • Pharmaceutical
  • Mining
  • Marine industries

Zeron 100’s most valuable attributes include resistance to acids—such as sulfuric, phosphoric, nitric, and hydrochloric. It’s almost completely free from chloride-induced stress corrosion cracking and has high strength (80,000 psi minimum yield strength). This allows for outstanding resistance to pitting, crevice corrosion, and intercrystallite corrosion.

Specific characteristics include:

  • Guaranteed corrosion performance (PREn ≥ 40)
  • Resistance to acids, such as sulfuric, phosphoric, nitric, and hydrochloric
  • Outstanding resistance to pitting, crevice corrosion and intercrystalline
  • Almost completely free from chloride-induced stress corrosion cracking
  • High strength (80,000 psi minimum yield strength)
  • High resistance to erosion corrosion and corrosion fatigue
  • Excellent mechanical properties and good weldability
  • Possibility for weight reduction over austenitic, standard duplex and nickel base alloys

High Price of Machining Zeron 100

A few factors that contribute to the high cost of Zeron 100 include the high amount of energy needed to separate the metal due to its high strength properties and its ductile or gummy nature, which creates difficult-to-control chip nests.

At Specialized Turning, we are well-versed in how to handle this tough metal and maximize our machining efficiency. We’re experts at navigating the challenging variables Zeron 100 presents when working with it. When machining Zeron 100, we must consider some tough restrictions on machining parameters that can affect:

  • Metal removal rates
  • Surface finish quality
  • Dimensional accuracy
  • Tool life (premature tool change vs. expense of regrind)
  • Run time (as compared to machining other types of alloys)
  • General maintenance of machines

Zeron 100’s Machinability

While finished precision Zeron 100 components may have attractive features, some of the properties of Zeron 100 that impact its performance when being machined give credence to its classification as being tough to work with. Factors that influence Zeron 100’s machinability are its:

  • High strength characteristics, which cause excessive tool wear and chip nesting, especially on internal machining operations
  • Chemical reactivity, which causes galling, welding,and smearing, all leading to compromising the cutting tool
  • Precise speeds and feeds required to mitigate Zeron 100’s high strength qualities that tend to distort key features, especially any thin cross-sections of the part. The exact speeds and feeds are usually specific to the geometry of the part, sharp cutting tools, and general system rigidity

The good news for our customers is that we are experts in machining Zeron 100 alloys to produce the best possible quality andvalue. We use only state-of-the art tooling geometries and coatings to ensure the most economical stock removal rates at the highest speeds possible for economical machining. With our extensive inventory of tooling upfront costs and order processing, costs are minimized.

Leave the hard stuff to us. How can we help you with your next Zeron 100 project?

Contact Us

Topics: Machining Zeron 100