Air entraining agent, also called foaming agent in some cases, is used to entrain air or air bubbles into wet mortar or concrete so that give lighter application workability or reduce density for the hardened product. It is widely used in many types of mortar like plaster or render, lightweight mortar, skim coat or base coat and concrete to stabilize the bubbles when applied on site.
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Vermicular graphite cast iron: Quaker's new technology reduces tool wear by nearly 30%
**Part 1: Research and Overcome the Machining Challenges of Compacted Graphite Iron (CGI)**
The use of compacted graphite iron (CGI) is on the rise, especially in the automotive and truck engine industries. Engineers are increasingly turning to CGI for its superior mechanical properties, such as higher strength-to-weight ratio, better thermal conductivity, and improved wear resistance compared to traditional gray cast iron or even high ferromolybdenum iron. These advantages make CGI an ideal material for critical engine components like cylinder heads and blocks, where performance and durability are essential.
However, despite its benefits, CGI presents significant challenges during machining. Unlike conventional cast iron, CGI is more difficult to cut due to its unique graphite structure and lack of natural lubricity. When machinists use standard metalworking fluids designed for gray cast iron, tool wear increases dramatically—up to 90% faster than with regular cast iron. This leads to increased downtime, higher costs, and longer machining times. In some cases, cutting speeds and feed rates must be reduced, further impacting productivity.
So why is CGI so hard to machine? The answer lies in its microstructure. While gray cast iron has flake-like graphite that helps reduce friction and improve machinability, CGI features a more complex, worm-like or coral-shaped graphite structure. This structure gives CGI higher strength but makes it more abrasive to cutting tools. Additionally, gray cast iron often contains manganese sulfide (MnS), which acts as a natural lubricant during machining. Unfortunately, CGI typically lacks this beneficial compound, leading to poor tool protection and accelerated wear.
Understanding these differences is key to developing better machining solutions. By studying the root causes of CGI’s poor machinability, researchers have been able to design new metalworking fluids that significantly improve tool life and surface finish. These advanced fluids help reduce friction, dissipate heat, and protect cutting tools, making high-speed machining operations like boring more efficient and cost-effective.
While modern cutting fluids have made great strides in closing the performance gap between CGI and traditional cast iron, there's still room for improvement. Continued research into both fluid formulations and tooling solutions will be essential for optimizing CGI machining in the future.
If you're working with CGI, it's highly recommended to consult with your metalworking fluid and tooling suppliers. They can offer tailored recommendations based on your specific application, helping you achieve better results while minimizing costs and downtime.