Given the horizontal press design enabling one-directional material flow, the available range of large vessel volumes and existing automation solutions of our integration partners, the throughput of a high-volume production line will not be bottlenecked by the Warm Isostatic Pressing (WIP) process if sized correctly.
HIP is used to consolidate powders, solids and combinations thereof. Materials range from ceramics to metals and composite materials. Light-weight materials, high speed steels, tool steels and super alloys all use HIP, and new generations of materials such as high entropy alloys are also developed using this process.
In discussion with Quintus, you will be able to optimise the footprint in your facility to ensure that productivity is ensured. We help in layout discussions and can arrange the machine layout to make best use of your space. This ensures good planning of civil work, transportation and installation. We help you to get up and running so that you can increase the return on your investment.
As the high-pressure gas is working isotopically on all exposed surfaces of the treated components, the general shape of the parts does not change from the HIP process making it possible to treat any component shape if the surfaces are gas-tight.
Castings, MIM, sintered powder compacts, and AM parts are all possible to HIP, and canned powders are formed into solid components (processes called PM HIP or PM NNS (Near Net Shape)).
From the two vessel technologies, mono-block and wire-wound, the wire-wound technology systems can be scaled up to a cylinder volume of 2000 L.
Modern standard HIP equipment operates up to 2000 °C and 200 MPa pressure from argon or nitrogen gas. The parameters chosen are always material-specific, keeping in mind that the elevated pressure will lower the temperature needed to achieve the same effect in a pressureless environment. This can be utilized for e.g., minimizing grain growth in sintering, avoiding part surfaces sticking, controlling microstructures, etc.
Beside the final part quality, the main perceived benefit is the low fabrication cost. This due to the low tool cost involved. The process also allows for several tools and parts to be produced in one and the same forming operation. 50-90% of conventional 2-piece tool cost may typically be saved by using the Flexform technology.
From thin foil up to ~10 mm sheet metal may be formed, typically however thicknesses of 1-5 mm are used, including traditional aerospace aluminum alloys, stainless and most mild steel alloys. Tough alloys such as Inconel and titanium may also be formed.
Within the aerospace industry the use of high-pressure typically reduce, or even eliminate, the need for labor hand correction and the need for intermediate heat treatments.
In all applications the high-pressure support forming of complex and intricate shapes, at excellent repeatability and part quality.
The flexible diaphragm in the fluid cell press allows most kind of forming in block dies, cavity dies and expansion dies. Shallow/small tools may be mixed with high/large tools in one and the same forming operation. Undercuts, intricate shapes, as well as trimming and cutting may be performed by the fluid cell technology. The fluid cell press provides full pressure all over the tool surface, contrary to the rubber pad process where the pressure drops dramatically in the lower section of for example a block tool.
A failure is typically detected because the cycle time and the pressurization time is extended, causing a small leakage only. At worst, at a major failure, the tray may be filled by oil, but this is extremely unusual. The press will automatically decompress and evacuate the oil in the system to the tank. The operator can then close a manual valve at the main oil tank. A worn-out diaphragm is typically changed within four hours, having all replacement parts at hand.
Most commonly the warm isostatic processing step is located after pouching and sealing of the cell, enabling the press to be located outside of dry room conditions.
Although the battery industry is focused on pressing complete multilayer cells, it is also possible to press electrodes and solid electrolytes by themselves before stacking.
The cost of warm isostatic cell processing in GWh scale production is projected to be in the lower EUR cent area per kWh.
Please discover our latest findings in our white paper for more detailed information on cost aspects:
Whitepaper | Throughput and cost analysis of solid-state battery production | Quintus Technologies
While we are open to different approaches and chemistries, the current focus is on sulfide solid electrolyte cells and the pouch cell format as these appear to have highest industrialization momentum.
Concepts such as “anode-free” designs, lithium metal anodes and dry-coated electrodes are very interesting for us on a production level of testing.
The Quintus warm isostatic battery presses are able to deliver pressures up to 600 MPa and temperatures of up to 145 °C.
We support the customers throughout the complete HPP development process. From recipes to packaging to designing and providing in-house validation services. Our comprehensive evaluation and support is geared for getting your product in the market quickly.
Our Quintus ® Care Program reflects our culture of true partnership, as witnessed by near three quarters of a century pioneering pressure technologies. Your immediate and long term benefits of Quintus ® Care includes controlling ongoing operational costs, guaranteed access to parts, regular technical reviews and remedial training, application support, as well as opportunities to participate in ongoing educational seminars
During HPP the pressure reaches up to 6,000 bar (87,000 psi). At this pressure, products will compress approximately 15% of their volume, meaning that HPP packaging must be waterproof, hermetically sealed, and include materials which are flexible to withstand compressions of at least 15%. For these reasons, different plastic materials have traditionally been a popular choice for HPP since many of these are flexible enough to allow containers to compress without breaking and elastic enough to retake their original shapes after the process. Additionally, several sustainable alternatives can be used with HPP such as rPET, PP, PLA and other biodegradable solutions.
Commonly used packaging and materials for HPP include bottles, cups, pouches, trays, in combination with various types of films or closures. Sealing surfaces for films need to be relatively wide, uniform and preferably flat. Sealability (heat seal strength) is an important element for packaging that is subjected to HPP. Cross-hatched patterns are not suitable as they can allow oxygen diffusion into the packages that will contribute to oxidative deterioration of products.
Definitely. HPP guarantees food safety and achieves an increased shelf life, while maintaining the optimum attributes of fresh products. In addition, HPP is highly recognized by numerous food safety authorities (FDA, EFSA…). Food safety is achieved by inactivating vegetative pathogens, including bacteria, viruses, molds, yeasts and parasites by applying 400 MPa (4000 bar/58,000 psi) to 600 MPa (6000 bar/87,000 psi), for a few seconds to around 6 minutes.
As a science based technology, HPP is not only fully recognized by global regulatory bodies as an antimicrobial process with superior capabilities for inactivating many food pathogens of concern, but also for slowing down the growth of spoilage bacteria, thereby extending refrigerated shelf life between 2-10 times longer than unprocessed foods. Both these benefits alone can have a significant
impact on the global challenges of food safety and food waste.
Most conventional food processing methods such as heat and/or chemicals have negative effects on health and nutrition. Consumers are demanding high nutritional values in foods, particularly those present in fresh, raw, or minimally processed varieties. HPP does not affect nutritional components in foods largely because it has no effects on covalent bonds so HPP products maintain their vitamins and bioactive compounds.
Manufacturers using HPP eliminate chemical preservatives used to control microbial growth and reduce the frequency of food safety testing, thus satisfying the demand from customers for preservative-free foods, while reducing operational costs, hence delivering higher company values. HPP has thus become the process of choice among non-thermal food processing technologies. The
assurance of inactivating foodborne pathogens, post packaging, provides food and beverage manufacturers the business-critical food safety confidence for protecting their consumers, as well as ensuring that their brands and company reputations remain untarnished.
With over 70 years of expertise, we are the global leader. Many of our machines operate reliably after more than 40 years. However, even the most advanced technology can occasionally face challenges.
Discussion with our support team helps to ensure any potential problems are addressed promptly and efficiently. We can help you minimize downtime and maintain optimal performance. The applied strategy for uptime is:
Studies shows that maintenance cost for a normal machine within the Industrial sector is around 6-7%/year of the investment and our full fledge Quintus Care is normally well below that. The full fledge SLA allows you to control all the cost for the material. Whereas the base agreement leaves the material portion open for sourcing to Quintus on need basis, or towards other suppliers.
Over the years we have developed our service level agreements; Quintus care in two main offers.
The base offer gives you support priority, remote tech support, application support (some countries this cannot be offered to), annual f2f trainings and annual maintenance, safety and reliability inspection.
Quintus care full additionally to the base also includes all spare parts for preventative maintenance, as well as covering spare parts if something unexpected happens (with some exceptions).
Being proactive about maintenance with a Quintus care contract keeps your costs planned and secures the best possible uptime for your system.
Share your concerns with your dedicated account manager or through the Quintus customer web portal. This can help address specific issues and improve the service.
Ask for a review of the SLA terms to see if adjustments can be made to better meet your needs.
This your choice. Some customers believes that they have a stronger negotiation position if they finalize SLA discussion prior to investment. Some appreciate to get guaranteed uptime also during the warranty period. Others wants to avoid establishing a spare stock and avoid to expend internal organization by signing a SLA early. The warranty in general covers issues during warranty. Preventative maintenance is still needed to start directly and go on also during the warranty period.
Do not hesitate to contact us. We are always ready to answer your questions.