Comprehensive Guide to Super Duplex Zeron 100
Imagine a material that offers unparalleled corrosion resistance, exceptional strength, and versatility across a range of demanding industries. Super Duplex…
In the world of industrial fasteners, durability and resistance to harsh environments are paramount. Enter Zeron 100 fasteners, the unsung heroes crafted from super duplex steel, designed to withstand the most demanding conditions. Whether you’re working in the petrochemical, marine, or aerospace industries, these fasteners promise unparalleled strength and corrosion resistance. But what makes Zeron 100 fasteners stand out from the rest? This article delves into their material composition, examines their wide range of applications, and provides a comprehensive pricing guide. By the end, you’ll understand why Zeron 100 fasteners are the go-to choice for engineers and procurement managers alike. Dive in to discover the specifications that make these fasteners exceptional, the diverse environments they thrive in, and how they can be the perfect fit for your next project.
Zeron 100: The Ultimate Super Duplex Stainless Steel
Zeron 100, also known as UNS S32760, is a super duplex stainless steel celebrated for its outstanding strength and corrosion resistance. Its unique composition ensures it stands out in demanding environments.
Zeron 100 comprises 24.0-26.0% Chromium, 6.0-8.0% Nickel, 3.0-4.0% Molybdenum, and other elements including Tungsten, Copper, Nitrogen, Manganese, Silicon, Phosphorous, and Sulfur, with Iron making up the balance.
Zeron 100 excels in resisting various types of corrosion, making it ideal for harsh environments. Its high chromium, molybdenum, and nitrogen content provide excellent resistance to pitting, crevice corrosion, and stress corrosion cracking, especially in chloride-rich and sour environments. Additionally, it offers outstanding resistance to non-oxidizing acids like hydrochloric and sulfuric acids, as well as strong alkalis.
Zeron 100 fasteners are known for their high tensile strength (minimum 750 MPa), yield strength (minimum 550 MPa), 25% elongation, and Rockwell C hardness. These properties make them suitable for high-stress applications.
Zeron 100’s duplex structure combines the benefits of austenitic and ferritic stainless steels. However, it should not be used above 572°F (300°C) due to reduced toughness. It also offers good weldability, allowing for easy fabrication and assembly.
Zeron 100 fasteners offer enhanced strength, superior corrosion resistance, high ductility and toughness, and versatile applications in industries like marine, chemical processing, and petrochemical. These attributes make Zeron 100 an indispensable material for challenging industrial applications.
In the petrochemical and chemical processing industries, Zeron 100 fasteners are a top choice due to their exceptional resistance to pitting, crevice corrosion, and stress corrosion cracking. Their exceptional resistance to various forms of corrosion makes them ideal for environments exposed to harsh chemicals, such as in the production of chemicals, nitric acid processes, and the manufacture of polypropylene and PVC. This ensures long-lasting performance and reliability in these demanding applications.
The oil and gas industry requires materials that can endure highly corrosive environments, particularly in offshore drilling rigs and production platforms. Zeron 100 fasteners are ideal for these applications due to their robust mechanical properties and superior corrosion resistance. They can effectively resist the corrosive effects of saltwater and sour gases, which are prevalent in oil and gas extraction and processing operations. This makes them indispensable in the construction and maintenance of oil rigs, pipelines, and other critical infrastructure.
In marine and offshore environments, materials are constantly exposed to corrosive seawater and harsh weather conditions. Zeron 100 fasteners are highly valued in these settings for their outstanding resistance to seawater corrosion and biofouling, making them essential in the construction of ships, submarines, offshore platforms, and various marine equipment. Their durability and strength ensure the integrity and safety of marine installations, even under the most demanding conditions.
The aerospace industry demands materials that offer high strength and excellent corrosion resistance. Zeron 100 fasteners meet these requirements, making them suitable for various aerospace applications. Their ability to maintain structural integrity under extreme stress and corrosive environments makes them ideal for aircraft components, including engine parts, structural fasteners, and other critical hardware. Using Zeron 100 fasteners in aerospace technology enhances the reliability and longevity of aircraft.
In the food processing industry, hygiene and corrosion resistance are crucial. Zeron 100 fasteners are used in equipment and facilities where cleanliness and resistance to aggressive cleaning agents are essential, such as in the processing of corn, vegetables, and other food products. Their ability to withstand corrosive substances, including acids and alkalis used in cleaning processes, ensures that food processing equipment remains safe and operational.
Sewage treatment plants operate in environments with highly corrosive substances and harsh conditions. Zeron 100 fasteners are ideal for these facilities due to their exceptional resistance to corrosion and wear. They are used in various components of sewage treatment systems, including pumps, valves, and structural supports. The durability of Zeron 100 fasteners ensures the reliable operation of sewage treatment plants, contributing to the efficient processing and management of wastewater.
Heavy-duty engineering applications often involve high-stress conditions and exposure to corrosive environments, making Zeron 100 fasteners essential for various heavy-duty machinery and equipment. They are employed in industries such as mining, construction, and manufacturing, where reliable fastening solutions are critical for safety and performance. Using Zeron 100 fasteners in heavy-duty engineering ensures the longevity and efficiency of machinery and infrastructure.
Zeron 100 bolts, celebrated for their high strength and exceptional corrosion resistance, are ideal for challenging environments. These bolts, available as heavy hex bolts, flange bolts, and lag bolts, are commonly used in pipeline systems and structural applications where secure fastening is crucial.
Zeron 100 nuts, crafted to pair perfectly with Zeron 100 bolts, ensure a tight and secure fit. Offered in various dimensions and standards, they are indispensable in applications demanding high strength and corrosion resistance, particularly in harsh chemical environments.
Zeron 100 screws, including round head, self-tapping, and set screws, deliver precise fastening and superior corrosion resistance. These screws are perfect for applications where accuracy and durability are essential, such as chemical processing and marine environments.
Zeron 100 stud bolts are designed for heavy-duty applications requiring high tensile strength. Available in various lengths and sizes, they are ideal for environments that demand robust and reliable fastening, such as petrochemical processing and offshore drilling.
Zeron 100 washers, including square types, offer additional support and sealing in fastening systems. They distribute the load and prevent surface damage, ensuring long-lasting performance in harsh environments, which is vital for many industrial applications.
Zeron 100 pins and anchors are engineered for specialized applications needing specific holding power and corrosion resistance. Essential for secure fastening in marine construction and offshore platforms, their durability ensures the integrity and safety of the structures.
Zeron 100 fasteners, crafted from super duplex stainless steel (UNS S32760), are available in various grades. Each grade is tailored for specific industrial needs, offering different specifications, applications, and manufacturing processes.
The solution annealed form is the most cost-effective grade for headed fasteners. This involves forging the fastener, followed by solution annealing.
The FG grade is produced through controlled strain hardening, which increases yield and tensile strength to meet ASTM A193 Grade B7 standards. These fasteners are machined from bar stock for consistent performance.
The FLT grade offers similar high yield and tensile strength as the FG grade. These fasteners are also machined from bar stock and are used in high-stress environments. Selection depends on specific engineering requirements.
Zeron 100 fasteners maintain a consistent material composition, combining elements like chromium, molybdenum, nickel, and nitrogen for superior corrosion resistance and strength. They comply with standards such as DIN 931, DIN 933, BS 1768, ISO 4014, and ISO 4017.
The cost of Zeron 100 fasteners is influenced by several key factors.
Zeron 100 fasteners are made from Super Duplex Stainless Steel (UNS S32760), a high-alloy material known for its superior corrosion resistance and mechanical strength. The alloy contains chromium, nickel, molybdenum, and nitrogen, which enhance its performance but also raise the material cost.
The dimensions and specifications of Zeron 100 fasteners, which range from M02 to M30 or 3/6 inches to 2 inches and include types like bolts, nuts, screws, studs, and washers, significantly influence their pricing. Meeting international standards like ASTM, DIN, and ISO ensures high quality and material consistency, which can impact the cost.
The manufacturing process is another crucial factor in determining the price of Zeron 100 fasteners. They can be produced through hot forging, cold forging, and bar stock machining. Each method has different costs. For example, the FG grade, which requires controlled strain hardening, is more expensive to produce than the solution annealed form because of the extra processing steps.
Demand across various industries also affects the pricing of Zeron 100 fasteners. These fasteners are used in heavy-duty applications such as petrochemical processing, chemical production, aerospace technology, offshore drilling, oil and gas production, and marine equipment. High demand in these sectors can drive up prices due to the specialized material and manufacturing process.
Although exact prices are not usually disclosed, several indicators can help estimate the cost:
For exact pricing, contact suppliers directly, as many provide quotes based on specific requirements and quantities. Working with suppliers allows for tailored pricing based on your specifications and order volume.
Zeron 100 fasteners are crafted from Super Duplex Stainless Steel (UNS S32760), renowned for its high levels of chromium, molybdenum, and nitrogen. This composition guarantees outstanding corrosion resistance and robust mechanical strength.
Zeron 100 fasteners conform to several key international standards, ensuring their reliability and performance:
Zeron 100 fasteners are manufactured in compliance with stringent industry regulations and standards:
These fasteners are produced by companies certified under the Pressure Equipment Directive (PED). This certification ensures they meet essential European safety standards for pressure equipment, ensuring reliable performance in critical applications.
Zeron 100 fasteners come with EN 10204 3.1/3.2 certification. This certification provides comprehensive documentation detailing their chemical and mechanical properties, ensuring traceability and maintaining stringent quality control.
Zeron 100 fasteners are employed in a variety of demanding environments where high corrosion resistance and strength are essential:
Petrochemical and Chemical Processing:
Ideal for environments with corrosive fluids, such as nitric acid processes.
Used in the production of polypropylene and PVC.
Offshore and Oil & Gas:
Suitable for offshore drilling rigs.
Used in oil & gas production facilities, withstanding seawater corrosion.
Subsea and Marine:
Employed in subsea applications like securing buoyancy modules.
Used in marine environments, including attaching rubber fenders to docks.
Sewage Treatment and Heavy-Duty Engineering:
Applied in sewage treatment plants.
Utilized in tunnel linings and other heavy-duty engineering applications requiring durability and corrosion resistance.
Zeron 100 fasteners are available in various forms to meet different requirements:
Solution Annealed, FG, and FLT Grades:
These grades vary in yield and tensile strength.
FG and FLT grades offer higher strength, suitable for high-stress environments.
Manufacturing Processes:
Produced through hot forging, cold forging, and bar stock machining.
The choice of process depends on the order quantity and specific application needs.
Zeron 100 fasteners are essential for industries demanding high durability and exceptional corrosion resistance. Their compliance with international standards and certifications ensures their reliability and effectiveness in the most challenging environments.
Below are answers to some frequently asked questions:
Zeron 100 fasteners are made from a super duplex stainless steel alloy known as UNS S32760. This alloy comprises high percentages of chromium (24% minimum), nickel (6% minimum), molybdenum (3% minimum), and copper (0.5% minimum), along with nitrogen, which enhances its strength and corrosion resistance. The key properties of Zeron 100 fasteners include high tensile strength, excellent ductility, impact strength, and superior resistance to stress corrosion cracking, pitting, and crevice corrosion. Additionally, they possess low magnetic permeability, strong weldability, and a low thermal expansion coefficient, making them suitable for various industrial applications.
Zeron 100 fasteners are typically used in industries that require high strength and excellent corrosion resistance. These include the oil and gas industry (offshore drilling rigs and production), marine industries (boats and ships), chemical and pharmaceutical plants, petrochemical processing, power generation and pollution control systems, pulp and paper industry, desalination plants, mining and mineral industries, sewage treatment plants, and food processing facilities.
The cost of Zeron 100 fasteners varies based on the type, size, and quantity. Generally, Zeron 100 bolts range from $1 to $100 per piece, nuts from $0.0002 to $0.005 per piece, screws from $0.08 to $1 per piece, washers from $0.1 to $5 per piece, and stud bolts from $0.1 to $10 per piece. These prices reflect the diverse applications and specifications of the fasteners.
Zeron 100 fasteners offer significant benefits in corrosive environments due to their exceptional resistance to a wide range of corrosive substances, including chlorides, acids, and alkaline solutions. This resistance is attributed to their high chromium, molybdenum, and nitrogen content, which provides superior protection against pitting, crevice corrosion, and stress corrosion cracking. Additionally, these fasteners are twice as strong as austenitic stainless steel, offering high tensile strength and durability even in extreme temperatures. Their low magnetic permeability makes them suitable for sensitive electrical equipment, and they have strong weldability and thermal stability, ensuring easy installation and structural integrity. Compliance with various international standards further ensures their quality and reliability in demanding applications.
Zeron 100 fasteners are available in a variety of types to suit different industrial and engineering applications. These include hex bolts, round head bolts, hex nuts, various screw types (such as round head and flat head screws), threaded rods, single and double-ended stud bolts, flat washers, spring washers, pins, anchors, tie rods, and tie bars. Each type serves specific purposes, offering high strength and excellent corrosion resistance, making them suitable for demanding environments.
