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Mill Mates Plus
PDF: English
Ceramic Dispersion and Milling Media
Based Upon Ceria (Ce) Stabilized TZP*
Evolution in mill design and production requirements across a range of viscosities and particle sizes demand a superior media. Mill Mates Plus, from Zircoa, are engineered to satisfy these needs.
Formulations up to 50,000 cps and particle sizes less than 1µm are routinely processed and achieved with very low media and mill wear.
*TZP is an acronym for Tetragonal Zirconia Polycrystals, a form of Zirconium Oxide.
Highly Engineered Performance
Mill Mates Plus are based on Tetragonal Zirconia Polycrystals (TZP). The superior micro-structure makes possible a dispersion media with a higher fracture toughness, density and hardness.
Compared to the closest competing product(s), Mill Mates Plus last longer and require fewer re-charges. Using Mill Mates Plus will reduce mill wear and lessen downtime for maintenance, while it speeds processing time.
For a Wide Range of Formulations
Mill Mates Plus' highly engineered microstructure results in a bead that is fracture and wear resistant, extremely round, tough and dense. Mill Mates Plus become highly polished, resulting in very low friction and abrasive qualities.
Mill Mates Plus… the ultimate in Ceria Stabilized TZP technology. The best dispersion value for your most demanding needs.
Features & Benefits of Mill Mates Plus
| Features | Benefits |
| Tetragonal Zirconia Polycrystal (TZP) ................ |
Extremely wear resistant, low contamination |
| Controlled, consistent microstructure .................... |
Predictable media performance, favorable hardness and toughness combination |
| Excellent roundness and size distribution control ... |
Maximum shear for increased efficiency in horizontal milling |
| Smooth surface .............................. |
Low mill wear, easily washed between formulations |
| High density .............................. |
Maximum throughput in recirculation grinding |
Applications and Industries Served by Mill Mates Plus
- Automotive and Industrial Coating
- Inks, Dyes and Pigments
- Frits, Glazes and Ceramics
- Minerals
- Magnetic Materials, Coatings and Dielectrics
- Foodstuffs, Pharmaceuticals and Cosmetics
Optimizing Mill Performance, Reducing Wear
Shear - Extensive testing confirms that shear is the predominant dispersion mechanism in fine media milling. Mill Mates Plus’ tight size distribution and extremely uniform size facilitates and intensifies this effect, delivering more shear during processing.
Product Feed Rate - Dense, smooth, and round media, which are uniform in size, allow for increased feed rates. Mill Mates Plus deliver all these features, minimizing the risk of hydraulic packing.
Particle Size Reduction Rate - Mill Mates Plus uniform size distribution, results in superior dispersion (compared to higher-priced media) reducing the time required to achieve a given particle size.
Mill Component Wear Rate - Laboratory and case studies demonstrate that Mill Mates Plus' low friction coefficient (associated with its smooth surface) results in very low wear on the mill, screen and other components.
| Property/ Characteristic |
Units | Mg-PSZ | Ce-TZP Mill Mates Plus |
Y-TZP |
| Bead Wear Rate (1 hour under Hydraulic Packing) |
% |
8.4 |
0.1 |
0.04 |
| Impeller Wear Rate | % | 0.29 | 0.01 | 0.07 |
Calculating the Correct Amount of Mill Mates Plus
| Horizontal Mill Size (Void Volume) |
Mill Mates Plus (1mm) for 85% Charge |
|
| liters | lbs | kgs |
| 15 20 45 100 200 |
110 148 333 740 1480 |
50 67 151 336 673 |
Specifications
Mechanical Properties - Mill Mates Plus
| Property | Units | Mill Mates Plus |
|---|---|---|
| Composition | - - | (Ce-TZP) |
| Density | g/cm3 | 6.25 |
| Hardness (HV) | GPa | 11.3 |
| Fracture Toughness, K1C |
MPa*m1/2 | 11.0 |
| Elongation | - - | 0.96 |
| Crush Strength |
lbs. force | 200 |
| Wear Rate* Bead Impeller |
% % |
0.1 0.01 |
| Surface | - - | Smooth, becoming highly polished with use |
| Color | - - | Dark Grey |
*1 hour under Hydraulic Packing
Nominal Sizes - Mill Mates Plus
| Nominal Size* | Range (mm) | Packing Density | |
| kgs/L | lbs/L | ||
| .5 mm .7 mm 1.0 mm 1.5 mm 2.0 mm |
.4 - .6 mm .6 - .85 mm .85 – 1.18 mm 1.4 – 1.7 mm 1.7 - 2.3 mm |
3.777 3.906 3.938 4.028 4.063 |
8.33 8.61 8.68 8.88 8.96 |
* Other sizes available upon request.
Typical Properties Comparison - Mill Mates Plus
| Media | Density g/cm3 |
Primary Material |
Crushing Strength lbs/grain (a) |
| Mill Mates Plus | 6.25 | CeO2 - ZrO2 | 150 – 300 |
| Zirbeads | 5.5 | MgO - ZrO2 | 105 - 220 |
| Zircon beads | 3.7 | ZrO2 - SiO2 | 105 – 160 |
| Alumina beads | 3.5 | Al2O3 | 125 – 220 |
| Glass beads | 2.8 | SiO2 | 40 – 70 |
(a) ASTM D1213-54