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COMPARISON & ADVANTAGES
 Basic Comparison :: Advantages :: Cost Savings :: Detailed Comparison
 

:: Basic Comparison :: 

CHARACTERISTIC CAST STEEL SHOTS OUR
Raw Material Basic Raw Material has far lower physical property & composition, obviously causes blowholes & porosity which makes the shots to fracture into small particle. Raw Material is of exact composition without any material defect (blow holes, porosity, shrinkage etc. ), and wears out nominally during it's use.
Dust Generation Higher Dust generation No Dust generation
Environment Friendly Deteriorates environment of work place and it's dust is considered hazardous to health Environment Friendly
Performance Consistency Consistent Performance not possible due to fast size deterioration Consistent Performance
Time Consumption Higher consumption in Shot Blasting/peening increases Working Cycle time Reduced Time for Shot Blasting/Peening
Shot Consumption Higher Consumption Consumption decreases i.e. 33% to 67% less to cast shots (case to case basis)
Inventory Cost Higher consumption requires high Inventory, more money and Space as well Lower Inventory required for the same job
Operation Cost Higher Operation Cost Lower Operation Cost
Shape Variations Shot being produced are of mixed size hence product is a mix of various spherical sizes. All shot being made out of same wire are identical, no variation of size anywhere.
Hardness Variation They have larger variation in hardness. Uniform hardness throughout
Micro-Structure In Micro-structure carbide always there Micro-structure is only Tempered martensite
Grain Size Grain size of cast shot is unstabilized Due to drawing passes grain size is stabilised

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:: Advantages :: 

 CONSISTENCY KACHSHOT exhibit highest consistency in size, shape,  density & hardness
 DURABILITY KACHSHOT has almost no internal defects (crack,  porosity ,shrinkage etc.), it's durability is many times as  it maintains the size longer and higher resistance.
 NO DUST GENERATION KACHSHOT do not fracture into small particles so does  not have any dust generation.
 LOWEST SURFACE CONTAMINATION KACHSHOT leave minimum residue on the parts surface  and produces brighter surface.
 IMPROVE PART FATIGUE RESISTANCE KACHSHOT (Conditioned) when used for shot peening  on parts, releases KACHSHOT (Conditioned) when used  for shot peening on parts, releases


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:: Cost Savings ::

Due primarily to its superior Durability and Resistance to Fracture as well as the absence of Iron Oxide coating, Cut Wire Shot provides cost savings associated in Media Consumption, Dust Generated and removal of Surface Contamination.



Photo CCW35 - 1000 cycles
Photo CS330 - 1000 cycles

Media Consumption - Durability testing can be done to measure representative media life (in cycles) or breakdown rate (in grams per cycle). By multiplying the breakdown rate (grams/cycle) by the cost of the media ($/gram), one can determine a relative cost per cycle ($/cycle)

e.g.: CCW35 - Breakdown Rate measured as 0.038 g/c, and
Cost = $0.00227/g.
Cost per cycle = 0.028 g/c x $0.00227/g=$0.000086/cycle.

CS330 - Breakdown Rate measured as 0.158 g/c, and
Cost = $0.000937/g
Cost per cycle = 0.158 g/c x $0.0009937/g=$0.000148/cycle.


                                                                  The media consumption cost of CCW 35 is 58% that of the S-330 shot.

Dust Generation -
During Durability testing, and also during use, the Dust Generation Rate (DGR) of a particular media can be determined. If 100 grams of media is tested in a life Tester, a small amount of the sample will exit the test machine as dust. The amount of dust lost divided by the Number of cycles tested gives the DGR in grams per cycle (g/c). Cut Wire Shot generates much less dust than other media, and therefore cost of dust disposal can be reduced.


e.g.: The cost in Cleveland, Ohio to dispose of one 55 gallon drum
(containing 800 pounds of non-hazardous metal dust) is about $55.00
or $0.000152/gram.

DGR of CCW35 = 0.0147 g/cycle
Cost of Dust Removal = 0.0147 g/c x $0.000152/g = $0.0000022/cycle

DGR of CS330 = 0.0254 g/cycle
Cost of Dust Removal = 0.0254 g/c x $0.000152/g = $0.0000039/cycle

                                                                  The cost of dust removal of CCW 35 would be 56% that of the S-330 shot.


Surface Contamination -
Studies have shown that the residue left on the surface of a blasted or peened part are much less (as much as 10 to 15 times less) with cut wire shot compared to cast shot. On steel parts, the residue (Iron Oxide) is not normally objectionable. But on non-ferrous parts, it should be removed. Decontamination processes (chemical decontamination is normally preferred) can be costly, dangerous to personnel, and require disposal of spent chemical solutions. With surface residue significantly reduced, decontamination time is also reduced. Exposure of personnel to potential safety hazards is lessened and replacement of spent chemical solutions is less frequent.

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:: Detailed Comparison ::


Improved Consistency -
Cut Wire Media exhibits the highest consistency from particle to particle in size, shape, density, and hardness of any commonly used metallic media.

Image Analysis was performed on various cast steel media and equivalent conditioned cut wire (CCW) sizes. The variation (Standard Deviation) in size of the cast shot shot was 1.5 times that of the Cut Wire media. Image Analysis results of shape (roundness) evaluation showed CCW media 2 times more consistent in shape than equivalent cast shot sizes. Comparing hardness specifications - cast shot normally meets an 11 point Rockwell C Hardness range (e.g.: HRC 55-65, HRC 40-50, HRC 42-52) whereas CCW media ranges are normally 6 points or less (e.g.: HRC 55-60, HRC 50-55, HRC 56-59). The density of Cut Wire Shot is the same as that of normal high carbon steel - 7.8 grams/milliliter. Due to the large number of Internal Defects may be present, specifications allow the density of cast shot to be as low as 7.0 grams/milliliter - over 10% lower than Cut Wire Media.

Highest Durability -
Because of its wrought internal structure with almost no internal defects (cracks, porosity, shrinkage, etc.), the Durability (Life) of CCW media can be many times that of cast shot of equivalent size and hardness. Life testing in Laboratory and Production equipment have measured the Life of CCW shot to be as much as 10 times that of equivalent size and Hardness cast media.

In addition to the Durability of media, the mode of breakdown is very important, especially in shot peening applications. Most media deteriorates by forming broken (fractured) particles. CCW media's mode of deterioration is wear. CCW particles tend to wear down into smaller diameter pieces rather than fracture into sharp edge broken particles.


Surface Damage
Fatigue Life vs. % Broken Shot

Dust Generation -
Since CCW media exhibits the highest Durability and Resistance to Fracture, it also exhibits the lowest dust generation rate of the commonly used media.

Lowest Surface Contamination -
All media leave a residue on the surface of the part being blasted or shot peened. Those media that fracture rapidly can leave tiny broken particles imbedded in the part surface. Other media leave a very thin smear on the part surface. CCW media does not breakdown as quickly as other media and does not tend to fracture into the tiny particles that may imbed themselves into the part surface. Finally CCW media does not have an Iron Oxide coating over the entire particle surface which rubs off on the part being processed. Therefore CCW media leaves much less (as much as 10 to 20 times less) residue on the part surface.

Improved Part Fatigue Resistance -
Fatigue tests have been performed on actual parts as well as laboratory specimens to determine if one steel media is equal to, or better than, another in terms of part life. Parts and specimens shot peened. with CCW shot exhibit higher average life and more consistent life than those peened. with equivalent cast steel shot.

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