PACE Technologies' composite grinding disks offer long-lasting, rigid support for consistent surface planarity and aggressive material removal during metallographic sample preparation. These innovative disks are precharged with diamond abrasives to eliminate manual charging steps and reduce variability, making them ideal for high-volume sample preparation.
Apply diamond or alumina suspensions during grinding for enhanced removal rates and surface finish control, even though the disks are precharged.
Rinse and clean the disk surface between stages to prevent contamination and wear artifacts that can affect sample quality.
Choose between PSA or magnetic backing depending on your platen system and ease of disk changes for optimal workflow efficiency.
Composite grinding disks provide an innovative solution for intermediate grinding and polishing stages in metallographic sample preparation. PACE Technologies offers two advanced composite disk systems: the ORION and SIRIUS, both engineered for high material removal rates, surface uniformity, and extended disk life.
Unlike traditional consumables, these disks are precharged with diamond abrasives to eliminate manual charging steps and reduce variability. The ORION disk is embedded with 3-micron diamond for fine grinding/rough polishing, while the SIRIUS disk utilizes 9-micron diamond for coarser, aggressive grinding, equivalent to replacing conventional 320-600 grit SiC grinding steps.
Composite disks operate through a combination of fixed abrasive grinding and controlled surface wear. As the disk rotates, the precharged diamond abrasives interact with the specimen surface, achieving material removal while minimizing subsurface deformation. These disks are ideal for reducing preparation time while maintaining high flatness and reproducibility.
Their rigid construction makes them compatible with both manual and semi-automatic grinding systems, particularly in labs preparing a high volume of samples for microstructural analysis, hardness testing, or failure analysis.
| Description | Size | Catalog Number | Product Image |
|---|---|---|---|
| ORION Composite Disk precharged with 3 µm diamond (magnetic steel backing) | 8-inch 10-inch 12-inch |
ORION-MD08 ORION-MD10 ORION-MD12 |
|
| SIRIUS Composite Disk precharged with 9 µm diamond (magnetic steel backing) | 8-inch 10-inch 12-inch |
SIRIUS-MD08 SIRIUS-MD10 SIRIUS-MD12 |
|
| Symptom | Cause | Corrective Action |
|---|---|---|
| Uneven grinding or sample tilt | Disk wear or improper mounting | Replace the disk and ensure platen surface is flat and clean |
| Excessive scratching or pitting | Disk contamination or incorrect abrasive size | Flush with water, use proper micron suspension, or replace disk if heavily worn |
| Short disk life | Excessive pressure or lack of lubrication | Reduce force, ensure water flow, and avoid dry grinding |
The NFZ System integrates NANO manual polishers, FEMTO autopolishing heads, ZETA automated dispensers, and RC recirculating filter systems into a complete grinding and polishing workflow for composite disk preparation.
Common questions about composite grinding disks
ORION disks are precharged with 3-micron diamond and are used for fine grinding and rough polishing stages. SIRIUS disks contain 9-micron diamond for more aggressive grinding, replacing conventional 320-600 grit SiC papers. SIRIUS is ideal for initial planar grinding, while ORION provides a smoother intermediate finish before final polishing.
Composite disks are precharged with diamond, so additional suspension is not required. However, for extended grinding sessions or to maintain cutting efficiency, you can optionally apply additional diamond suspension. Always use water or grinding lubricant to flush debris and prevent overheating.
Disk life depends on material hardness, grinding pressure, and lubrication. With proper use (light to moderate pressure, adequate water flow, and regular cleaning), composite disks can process hundreds of samples. Replace disks when grinding performance decreases significantly, excessive scratching occurs, or visible wear is apparent on the disk surface.
Composite disks require a compatible magnetic steel receiver wheel or platen. They work with most manual and semi-automatic grinding systems that accept 8-inch, 10-inch, or 12-inch magnetic-backed consumables. Verify your equipment has the proper magnetic platen before ordering. PSA-backed versions may be available for non-magnetic systems.
Use light to moderate pressure, typically 20-40 N depending on sample material and size. Excessive pressure reduces disk life, increases heat generation, and can cause sample deformation. Start with lighter pressure and increase only if material removal is too slow. Always ensure adequate water flow during grinding.
Rinse disks thoroughly with water after each use to remove debris and swarf. Allow them to dry completely before storage to prevent corrosion of the magnetic backing and maintain surface integrity. Store disks flat in a clean, dry location away from contaminants. Regular cleaning extends disk life and ensures consistent grinding performance.