TIG.CLINOX® LINE Cleaning / Polishing / Marking / Etching

� Stainless Steel � Surface treatments � Pickling and Passivation � TIG.Clinox Line

(a) Overview (b) Units (c) Patents (d) Electrolytes (e) Inserts & Pads

� TIG.Clinox Pro EVO : The new inverter board � Accessories

(a) Cleaning and Polishing (b) Marking and Etching

� Comparison with Abrasives and Pickling Pastes/Gels � Ecological/health and safety analyses carried out by

EC-authorised laboratories. � Clinox users � Tests and Documentation � Contacts

STAINLESS STEEL

Metals and alloys are divided into two categories: 1. Ferrous 2. Non-ferrous Ferrous alloys which are essentially Ferro-carbon alloys, include steels and cast irons. Different steels may be classified according to their chemical composition, manufacturing processes, mechanical characteristics and application. The properties and special characteristics which distinguish one steel from another are determined by two important factors: 1. chemical composition 2. type of heat treatment The term stainless steel defines those Ferro-chromium or Ferro-chromium-nickel alloys containing 12 to 30% chromium and 0 to 35% nickel. The following table provides a schematic classification of the different types of stainless steel: Stainless steel % Ni % Cr Properties Example Martensitic - 12-18 Hardness and mechanical resistance AISI 431 Ferritic - 15-30 Heat resistance AISI 446 Austenitic 7-35 12-30 Excellent machinability; most widely used AISI 304L - 316L Austenitic-Ferritic 4-8 20-25 Excellent mechanical properties SAF 2205 The main property of stainless steel is its corrosion resistance which may be attributed to its capacity to passivate in oxidising conditions. After welding or spot-welding etc., the heat-affected zone of the stainless steel is no longer corrosion-resistant and must therefore be passivated. The passive film formed on metal and in particular stainless steel, can be created either electro-chemically or chemically.

SURFACE TREATMENTS Stainless steel offers exceptional mechanical properties which make it irreplaceable. More often than not operators exercise particular care over mechanical (cutting, bending etc.) and thermal (welding, spot-welding etc.) operations, but tend to neglect the finishing treatments which are essential to restore the material’s original characteristics of durability and corrosion resistance. Of the various treatments which steel may undergo, the following are outlined below: 1. Degreasing; 2. Pickling; 3. Passivation. Degreasing This operation serves to remove all trace of dirt and grease (organic molecules and in particular carbon) from the surface of the stainless steel component before it undergoes heat treatments such as welding etc. or surface finish treatments such as satin finishing, electrolytic bath etc.

During heat treatments the carbon present in the surface may disperse inside the material, causing unsightly defects and the localised deterioration of properties, thereby making the component harder, more fragile or less resistant to corrosion. Degreasing may be performed by: 1. washing with alkaline solutions, 2. washing with organic solvents, 3. washing with diluted acid-based detergents, 4. steam jets or pressurised hot water, 5. ultra-sound cleaning.

PICKLING and PASSIVATION Pickling Due to the thermal alterations generated by welding applications etc., the chromium content of the steel in the heat-affected zone falls below the threshold of 12%. This “chromium-free” layer hence loses all its corrosion-resistant properties and must therefore be removed. Pickling removes the fine layer of “chromium-free” steel and oxide residues on the surface of the work-piece to prevent subsequent corrosion and unsightly blemishes. Only after pickling the manufactured component can be completely and uniformly passivated. Pickling may be performed by: 1. the immersion of components in chemical baths, 2. the application of pickling gels or pastes on the affected area, 3. the use of abrasives on the affected area, 4. the use of electrolytic cleaners like CLINOX units on the affected area. Passivation A treatment which forms a protective oxide film on the surface of the steel to make it corrosion-resistant. Stainless steel may also form a passive film through contact with atmospheric oxygen. However, the film formed by contact with air does not always offer full protection, and there is the possibility that, if the air is contaminated with pollutant (iron dust, several chloride etc), instead of the passive oxide layer there is the formation of rust. Air passivation is a slow and uneven process due to the variable atmospheric-ambient conditions to which the manufactured part is submitted (temperature, % of oxygen in air, atmospheric humidity etc.). In the case of pickling with abrasives, steel may often be considered passivated when in actual fact it is not because it has not been exposed to the air for a sufficient length of time after pickling. In the case of chemical or electro-chemical pickling (TIG.CLINOX system), the manufactured component is completely and uniformly passivated because the chemical agent stimulates the steel to form a film of some thickness (obtained using aggressive substances) and uniformity (obtained in the same conditions). The thickness of the passive film and hence the depth of passivation is proportional to the aggressiveness of the chemical substances used and is therefore greater in the case of chemical pickling which uses nitric acid and hydrofluoric acid (toxic) compared with electro-chemical pickling which uses ecological electrolytes (TIG.CLINOX and MIG.CLINOX system). However the uniformity of the passivation obtained by an electro-chemical pickling (TIG.CLINOX system) is much greater than the passivation obtained by a chemical pickling: all the advanced analysis made, show that the passive layer formed after the TIG.CLINOX and MIG.CLINOX

TIG.CLINOX LINE

OVERVIEW The temperature fluctuations generated during welding process cause the loss of the passivation on stainless steel, blackish oxide layers which modify both the aesthetic and functional characteristics of the component. This oxide must therefore be removed as effectively as possible. In the old times, welds can be cleaned only in two ways: ⇒ with tools (brushes, abrasive wheels etc.) which mechanically remove all trace of scale and weld bead; ⇒ with pickling pastes or gels which are applied to the weld by brush. These products generate a chemical

reaction which removes the metal layer immediately underneath the undesired oxide layer, thereby removing all trace of scale.

Both these solutions have problems for which there is no remedy! TIG.CLINOX is the perfect solution for cleaning and polishing welds and residues on stainless steel and for indelible marking and etching of the stainless steel surface. TIG.CLINOX technology and functions are based on a lot of international patents: that makes the Nitty-Gritty units unique.

UNITS Using an electrical current and specific electrolyte solutions, the TIG.CLINOX units effectively remove weld scale from stainless steel, thereby restoring its special corrosion-resistance (passivation) TIG.CLINOX is manufactured by Nitty-Gritty srl and is available in 3 versions:

SPOT CLINOX NRG Tig.CLINOX ECO* Tig.CLINOX PRO EVO Input Voltage (AC) 110 or 220/240 110 or 220/240 110 or 220/240 Output Voltage (AC) 30 (fixed) 10 � 30 (2 V step) Automatic Output Voltage (DC) / 10 � 30 (2 V step) Automatic Marking Black (AC) Yes Yes Yes Erosion White (DC) No Yes Yes Small Torch Yes Yes Yes Big Torch** No No Yes Fumes aspiration No No Yes (w. Big torch) Hours of continuous work ½ 5 - 10 24

*available from march 2013 with the new inverteboard **working speed is faster with the big torch of the Tig.Clinox PRO due to the automatic flow of the liquid

PATENTS FUMES SUCTION: solutions Environment and operator safety are our first concern! As laboratory analysis show, the fumes and vapours produced working with the Nitty-Gritty units and Bomar solutions are not dangerous, anyway everyone prefers to breath fresh air! This is why we developed the fumes suction system integrated in the unit big torch, and, best of all, we are the only that can use this kind of device!

PAD MATERIAL: The special polymer, high durable and resistant, used to produce the pads has been patented for this application.

SMALL TORCH: The way others work with electrochemical systems is the “dip and work”. It means that the user has to manage with the electrolyte solutions, has to use a bowl than dip the torch and work, stop working to dip again and again, dropping liquid everywhere, who likes working that way!? Nitty-Gritty has developed and patented a small torch with a connected tube and a pump: when the user pushes the pumping button, the liquid flows from the tube directly to the tip, to wet the pad. No drops on the floor, no liquid in contact with the operator, no stops to the working process, possibility to work in every position.

ELECTROLYTES TIG.CLINOX solutions are called “BOMAR”, and they are available in 3 different versions:

NEUTRAL

BOMAR TIG BOMAR BRILL BOMAR

COLOR Blue Green Red ACID CONTENT 0% <20% >50% AC CLEANING Yes Yes Yes DC POLISHING No No Yes Weld meters per liter * * 150/200 150/200 150/200 **depending on the weld quality

INSERTS & PADS

TUNGSTEN INSERT + STANDARD BOND BIG TORCH (TIG.CLINOX PRO EVO)

TUNGSTEN INSERT + TIG BOND BIG TORCH (TIG.CLINOX PRO EVO)

GRAPHITE INSERT + TIG BOND SMALL TORCH (TIG.CLINOX PRO EVO, TIG.CLINOX ECO, SPOT NRG)

STAINLESS STEEL INSERT + TIG BOND

SMALL TORCH (TIG.CLINOX PRO EVO, TIG.CLINOX ECO, SPOT NRG)

TUNGSTEN INSERT + TIG BOND SMALL TORCH (TIG.CLINOX PRO EVO, TIG.CLINOX ECO, SPOT NRG)

TIG.CLINOX PRO EVO : THE NEW INVERTER BOARD The new generation electronics offer a lot of advantages in terms of:

• POWER: more than 50% output power!! (in comparison to the old generations inverter)

• CONSUPTION: the improved electronics reduces the peaks and better control the current flow.

• PRODUCTIVITY: the automatic voltage control allows the user to work in every condition (flat, corners, etc) without stop to manually set the voltage. Simply set the output power (minimum – medium – maximum) and start working, the machine will do the rest!

• P.F.C.: the Power Factor Control is a component which controls and reduces the ‘nosie’ on the electrical line; it will be soon required by law in all the European countries: we are ready from now!

• NEW ACCESSORIES: with the new inverter board there is the possibility to use different accessories like the brush and larger pads.

New inverter board logic (TIG.CLINOX PRO EVO)

ACCESSORIES

CLEANING and POLISHING

CLEANING - BIG TORCH (TIG.CLINOX PRO EVO)

POLISHING - BIG TORCH (TIG.CLINOX PRO EVO)

CLEANING - SMALL TORCH (TIG.CLINOX PRO EVO, TIG. CLINOX ECO, SPOT NRG)

POLISHING - SMALL TORCH (TIG.CLINOX PRO EVO, TIG.CLINOX ECO)

CLEANING - BRUSH (TIG.CLINOX PRO EVO , TIG.CLINOX ECO)

POLISHING - BRUSH (TIG.CLINOX PRO EVO , TIG.CLINOX ECO)

CLEANING – BIG PAD (TIG.CLINOX PRO EVO)

MARKING and ETCHING

MARKING (TIG.CLINOX PRO EVO, TIG.CLINOX ECO, SPOT NRG)

ETCHING (TIG.CLINOX PRO EVO, TIG.CLINOX ECO)

It is possible to realize marking and etching by tw o technologies: GREEN SCREENS: It can be used up to 1000 times, is produced by Nitty-Gritty following the graphic request of the customer

PAPER SCREENS: Disposable screen, created directly by the customer using the Printer-Kit with the special paper to make the marking screen; suitable for: � Data matrix � Barcodes � Serial numbers � Logos � Machinery plates � Variable informations

PRINTER KIT

Example of the Printer Unit connected to a PC

COMPARISON WITH ABRASIVES AND PICKLING PASTES/GELS

Mechanical pickling with abrasives Mechanical removal by abrasives is the only method available for the mechanical removal of weld beads. It also offers a viable alternative to pickling gels and electrolytic cleaners when removing welding scale from manufactured components, but only when it doesn’t matter if the surface is damaged by scratching during pickling. The abrasives used may pollute the surface of the stainless steel and cause corrosion. Moreover, mechanical pickling entails high costs due the abrasive consumables used and the production times involved. Neither does it passivate completely and uniformly. In qualitative terms the main problems are as follows:

⇒ visible damage to surface of manufactured part; ⇒ pollutes stainless steel; ⇒ does NOT guarantee total and uniform passivation; ⇒ high costs incurred by abrasive materials and production times.

In health and safety terms the main problems are as follows:

⇒ exposure of operators to metal particle emissions (e.g.: aluminium); ⇒ presence of moving parts which may injure the operator.

In ecological terms the main problem is as follows:

⇒ emission of metal particles (e.g.: aluminium) into the atmosphere. Chemical Pickling with Pickling Pastes or Gels

Chemical pickling with pastes or gels offers a wide range of applications but involves a number of significant problems of an environmental/health and aesthetic nature. Pickling pastes and gels are in fact highly toxic and therefore dangerous and leave a white halo on the surface of the manufactured component. By using solutions with a low acid concentration which are still however toxic and corrosive, the cleaning times are considerably lengthened by a number of hours. Extremely powerful solutions containing nitric acid, hydrofluoric acid and sulphuric acid are therefore required to effectively clean components within an acceptable time (30-40 minutes). Legal limits only allow for an extremely low percentage of nitric acid and hydrofluoric acid to be used in pickling pastes (max.1%), thereby only making it possible to use solutions with a low acid concentration which, although still toxic, are not very efficient. Many manufacturers however, skirt legal requirements by using substances such as fluoride and nitrate salts etc. for which there are no recognised limits and which when used, react with the air to form hydrofluoric and nitric acid and are thus extremely toxic and hazardous to both the user and environment. Moreover, pickling pastes and gels are designed to fix to the component being cleaned to maximise their efficiency, and are hence very difficult to remove. The component must in fact be thoroughly washed with special machines like the “Pulivapor” which in turn means that the polluted waste water generated must be treated using expensive purification systems (more than 100.000,00 €) Many companies dispose of large quantities of polluted water directly in the main sewers (1 HL per 5 m. of weld), thereby causing serious pollution. Such action is prohibited by law and carries the risk of prosecution for the Head of Safety. If the pickling paste or gel is not completely removed, the component will start to corrode. If, however, the paste or gel is removed too early, the component will only be partially pickled, while, if it is removed too late the aggressive action of the paste or gel will cause the component to start corroding. The entire process must therefore be carefully monitored by the person in charge. This involves a great deal of time and cannot even then guarantee an acceptable result. The operating times of the pickling paste or gel also vary according to the atmospheric temperature: the colder the ambient temperature is, the slower the pickling process. In ecological terms the main problems are the :

⇒ emission of toxic vapours generated by banned products (Nitric and Hydrofluoric acid) into the atmosphere;

⇒ disposal of large quantities of polluted water (containing toxic acids such as Nitric and Hydrofluoric acid, and heavy metals such as Chromium and Nickel). This polluted waste is usually disposed of in the main sewers (100 litres per 5 metres of weld) due to the exorbitant costs required to install the necessary water purification plants.

⇒ risk of prosecution for Head of Safety. In health and safety terms the main problem is as follows:

⇒ exposure of operators to toxic vapours generated by strong acid reactions (Nitric and Hydrofluoric acid).

In qualitative terms the main problems are as follows:

⇒ formation of white halos which damage the component surface; ⇒ unfavourable working conditions due to the need to work outside the workshop; ⇒ a long work process requiring constant monitoring and offering unreliable results; it is not practical

to pickle a single piece at a time; if the pickling paste or gel is removed too early it does not guarantee full and uniform passivation and if removed too late, it causes corrosion.

In short, TIG.CLINOX offers a number of advantages compared with conventional mechanical pickling using abrasives:

⇒ it does not damage the surface finish of the material; ⇒ it does not release metal particles (aluminium and others) into the atmosphere; ⇒ it does not pollute the material; ⇒ it cleans and passivates uniformly;

⇒ it reduces the cost of consumables; ⇒ it improves working conditions; ⇒ fewer hazards due to the absence of moving parts which may injure the operator;

chemical pickling using pickling pastes or gels:

⇒ much faster process; ⇒ immediate verification of final result; ⇒ improved working conditions; the user can operate:

⇒ inside the building; ⇒ on a single piece at a time;

⇒ it does not damage the surface finish of the material (no haloes); ⇒ it does not generate vapours harmful to both the operator and environment (only in the case of

TIG.CLINOX PRO EVO; the TIG.CLINOX ECO model must instead be used in conjunction with an extractor hood).

⇒ with TIG.CLINOX, the excess BOMAR solution need only be removed with a rag soaked in water. The component does not have to be washed which means that NO toxic waste is produced (100 L per 5 metres of weld). NEITHER therefore does the Head of Safety run the risk of prosecution.

ECOLOGICAL/HEALTH AND SAFETY ANALYSES CARRIED OUT BY EC-AUTHORISED LABORATORIES.

TIG.CLINOX: 1. effectively passivates components; 2. offers a qualitatively superior result; 3. significantly reduces the environmental problems associated with conventional pickling. The above advantages may be attributed to the use of a non aggressive chemical product, the low pollution content of the special waste generated, the minimal amount of special waste generated and the extraction of vapours emitted. The enclosed technical literature describes in detail the following points: ⇒ Chemical solution ⇒ Special waste ⇒ Vapour emissions ⇒ Chemical solution With TIG.CLINOX, the excess of BOMAR solution need only be removed from the pickled component with a

rag soaked in water or using the INOX.FIT spray. The component does not have to be washed which in turn means that NO special liquid waste is produced.

⇒ Vapour emissions The integrated vapour extraction system guarantees maximum operator safety; moreover the vapours

emitted by TIG.CLINOX do NOT need to be filtered. • TIG.CLINOX application The TIG.CLINOX electrolytic cleaner offers superior pickling quality in terms of:

⇒ surface finish, ⇒ working conditions, ⇒ environment and health safety.

It is suitable for STAINLESS steel light-weight structural components (with satin finish, polished finish, scotch brite finish, satin flower finish etc.) made using the following welding techniques:

⇒ SPOT-WELDING, ⇒ TIG welding, ⇒ MIG pulse arc welding ⇒ PLASMA welding, ⇒ LASER welding, ⇒ RESISTANCE welding, ⇒ ORBITAL welding.

In the case of protected steel, remove any glue residues prior to welding to prevent the formation of black haloes (caused by glue heated during welding) which TIG.CLINOX CANNOT remove.

CLINOX USERS Food industry ⇒ Wine-making machines ⇒ Distillery machines ⇒ Bottling plants ⇒ Bar/restaurant furnishings ⇒ Industrial kitchens (NOT AISI 430 hoods) ⇒ Finishes for food-grade tanks ⇒ Pasta-making machines ⇒ Wheat grinding machines (flour) ⇒ Ice-cream making machines ⇒ Piping for food industry ⇒ Stainless steel food-grade liquid pumps ⇒ Dairy industry: cheese-making machines ⇒ Iced-tea and slushed-ice drink machines etc. ⇒ Bread ovens ⇒ Pans Other industries ⇒ Stainless steel electric panels ⇒ Stainless steel flues ⇒ Air conditioning and heating ducts ⇒ Automatic dispensers ⇒ Boat interior fittings and yacht finishes ⇒ Paint plants ⇒ Water purification plants ⇒ Car and motorbike silencers ⇒ Stainless steel filters for pharmaceutical industry ⇒ Automatic photo developing machines ⇒ Chemical analysis plants ⇒ Cold rooms ⇒ Stainless steel furnishings (changing rooms) for food and pharmaceutical industries ⇒ Flow-meters for chemical and food industries ⇒ Stainless steel ducts for electrical systems ⇒ Stainless steel fittings for food industry ⇒ Air conditioning systems ⇒ Stainless steel sculptors ⇒ Pharmaceutical plants (construction) ⇒ Stainless steel window and door frames ⇒ Stainless steel interior fittings for lorries

TESTS and DOCUMENTATION

⇒ SDS and TDS of all the products ⇒ Corrosion resistance test after cleaning (salt spray) ⇒ Corrosion resistance test before/after cleaning (polarization curves) ⇒ Corrosion resistance test before/after marking (polarization curves) ⇒ Corrosion resistance test before/after etching (polarization curves) ⇒ Food alimentary compliance for cleaning/marking

CONTACTS Nitty-Gritty srl, Via dei Marmorari 36, 41057 – Spilamberto (MO) – Italy

Tel: +39 059785210 - Fax: +39 0597861612 - info@nitty-gritty.it