Improved Consistency - Cut Wire Media exhibits the highest consistency from particle to particle in size, shape, density, and hardness of any commonly used metallic media. Image Analysis was performed on various cast steel media and equivalent conditioned cut wire (CCW) sizes. The variation (Standard Deviation) in size of the cast shot shot was 1.5 times that of the Cut Wire media. Image Analysis results of shape (roundness) evaluation showed CCW media 2 times more consistent in shape than equivalent cast shot sizes. Comparing hardness specifications - cast shot normally meets an 11 point Rockwell C Hardness range (e.g.: HRC 55-65, HRC 40-50, HRC 42-52) whereas CCW media ranges are normally 6 points or less (e.g.: HRC 55-60, HRC 50-55, HRC 56-59). The density of Cut Wire Shot is the same as that of normal high carbon steel - 7.8 grams/milliliter. Due to the large number of Internal Defects may be present, specifications allow the density of cast shot to be as low as 7.0 grams/milliliter - over 10% lower than Cut Wire Media.
Highest Durability - Because of its wrought internal structure with almost no internal defects (cracks, porosity, shrinkage, etc.), the Durability (Life) of CCW media can be many times that of cast shot of equivalent size and hardness. Life testing in Laboratory and Production equipment have measured the Life of CCW shot to be as much as 10 times that of equivalent size and Hardness cast media.
In addition to the Durability of media, the mode of breakdown is very important, especially in shot peening applications. Most media deteriorates by forming broken (fractured) particles. CCW media's mode of deterioration is wear. CCW particles tend to wear down into smaller diameter pieces rather than fracture into sharp edge broken particles.
Dust Generation - Since CCW media exhibits the highest Durability and Resistance to Fracture, it also exhibits the lowest dust generation rate of the commonly used media.
Lowest Surface Contamination - All media leave a residue on the surface of the part being blasted or shot peened. Those media that fracture rapidly can leave tiny broken particles imbedded in the part surface. Other media leave a very thin smear on the part surface. CCW media does not breakdown as quickly as other media and does not tend to fracture into the tiny particles that may imbed themselves into the part surface. Finally CCW media does not have an Iron Oxide coating over the entire particle surface which rubs off on the part being processed. Therefore CCW media leaves much less (as much as 10 to 20 times less) residue on the part surface.
Improved Part Fatigue Resistance - Fatigue tests have been performed on actual parts as well as laboratory specimens to determine if one steel media is equal to, or better than, another in terms of part life. Parts and specimens shot peened. with CCW shot exhibit higher average life and more consistent life than those peened. with equivalent cast steel shot.
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