An In-Depth Look at Ni Excel Resin and Its Powerful Properties

An Introduction to Ni Excel Resin

Resin materials have become increasingly popular in recent years for use in a variety of applications. One type that has generated significant interest is ni excel resin. This unique material offers some advantages over other resin options on the market today.

In this article, we will provide an in-depth look at ni excel resin. We will explore what it is, its key properties and characteristics, how it is used, and the main benefits it can provide. Whether you are familiar with resin materials or completely new to them, this guide will help give you a strong understanding of this specific type and its capabilities.

What Is Ni Excel Resin?

Ni excel resin is a patented nickel-filled epoxy system that is manufactured by Freeman Manufacturing and Supply Company. It consists of a two-part epoxy resin that is mixed with nickel powder prior to curing. The nickel filler gives the material its unique properties and advantages.

This resin was initially designed for tooling applications in the aerospace industry. It provides an affordable alternative to traditional steel tools while still maintaining dimensional stability. As its popularity grew, ni excel resin began being used for a wider range of industrial applications.

The nickel filler contained in the resin can make up 40-50% of its total weight. This high nickel content gives the cured material enhanced thermal conductivity, impact and abrasion resistance, and low coefficient of friction.

Key Properties of Ni Excel Resin

Let's take a closer look at some of the standout properties that ni excel resin possesses:

• High strength - The cured resin has a flexural strength of 10,000-15,000 psi and a compressive strength of 30,000-35,000 psi. This gives it the strength required for demanding production applications.
• Temperature resistance - Ni excel resin maintains its properties at temperatures up to 400°F. This makes it suitable for use in high temperature tooling.
• Thermal conductivity - With a thermal conductivity rating of about 4 W/m-K, ni excel resin conducts heat much better than standard epoxies. This allows for faster production cycles.
• Impact resistance - The nickel filler boosts impact resistance, allowing the resin to withstand repeated shock, vibration, and loading.
• Abrasion resistance - Ni excel resin demonstrates better abrasion resistance than steel tools, reducing wear over time.
• Dimensional stability - The material exhibits minimal shrinkage, excellent stability, and high precision with intricate geometries.

These properties make ni excel resin suitable for use in production and tooling applications where high strength, heat resistance, stability, and wear resistance are critical requirements.

Typical Applications

Thanks to its specialized set of properties, ni excel resin is a problem-solving material for several industrial uses. Some of the top applications include:

• Composite tooling - Ni excel resin is widely used to create molds, forming tools, and other production tooling for composite parts and structures.
• Injection molds - It serves as an affordable alternative to machined steel molds for short run injection molding jobs.
• Production fixtures - The resin allows for fabrication of high strength jigs, fixtures, and workholding devices.
• Checking fixtures - Its dimensional accuracy makes ni excel suitable for intricate checking fixtures.
• Vacuum forming - It can be used to manufacture vacuum forming molds for thermoforming applications.
• Patterns & Models - Prototypes, patterns for castings, and master models can all be constructed from ni excel resin.

These represent just a sampling of the many production applications where ni excel resin provides an advantage. Its unique property set enables it to improve performance and efficiency across a range of manufacturing processes.

Benefits of Ni Excel Resin

There are several key benefits associated with selecting ni excel resin for industrial projects and applications:

• Lower production costs - Ni excel resin tooling can cost 50-75% less than steel tools. This saves significantly on total project costs.
• Faster turnaround - Lead times for ni excel tools are measured in days or weeks rather than months.
• Lighter weight - Lighter resin tools reduce shipping costs and make handling easier.
• Rapid modifications - Design changes and modifications can be made quickly without needing to scrap tools.
• Improved quality - The high accuracy and stability ensures production quality remains high over tool life.
• Long service life - Ni excel resin provides extended service life thanks to its outstanding wear resistance.

For manufacturers looking for ways to accelerate and optimize production, ni excel resin presents an innovative solution. The time and cost savings it provides are substantial while still delivering exceptional performance.

Working with Ni Excel Resin

While ni excel resin offers some clear advantages, there are some important factors to consider when working with this material. Understanding how to properly handle, process, and utilize it will ensure optimal results.

Mixing & Preparation

Ni excel resin starts as a two-part epoxy resin system. The base resin material must be thoroughly mixed with a matching hardener to initiate the curing process. Prior to mixing, the nickel powder filler is added to the base resin at a ratio of 4-5 parts nickel to 1 part resin by weight.

The nickel must be mixed in very thoroughly to achieve a uniform consistency throughout the resin. Care should also be taken to avoid introducing air bubbles during mixing. Vacuum degassing is recommended to completely eliminate trapped air.

The working life of the mixed resin system is approximately 3 hours at 70°F. As expected, higher temperatures will shorten the working time. The material will begin to gel and harden once the working life has been exceeded.

Curing & Post-Curing

Full cure of ni excel resin is achieved through a two-step process. First, the resin undergoes an initial 24 hour curing period at room temperature after it has been cast or formed into shape. This solidifies the material into a workable state.

The second step is a post-cure heat treatment. The resin must be slowly heated to 300-350°F and held at that peak temperature for approximately 5 hours. This post-cure removes any residual volatiles and completes the cross-linking process to reach full properties and performance.

Cooling should be performed gradually after post-cure to prevent cracking or warping issues. In addition, the resin surface may need light sanding after curing to smooth out any nicks or imperfections.

Machining

One advantage of ni excel resin is its machinability compared to other filled polymer materials. It can be readily drilled, tapped, and machined using high speed steel or carbide cutters. Feeds, speeds, and tools should be adjusted to account for the hardness and abrasion resistance of the nickel filler.

The resin cuts very cleanly with minimal burring. Precise machining makes it feasible to use ni excel resin for sophisticated geometries and intricate finished parts. Lathes, mills, and grinders are commonly used for successful machining results.

Where to Buy Ni Excel Resin

For those looking to utilize ni excel resin, sourcing it through a qualified supplier is the recommended route. The resin and nickel filler are sold as a paired system to ensure optimal properties and performance. Trying to formulate and mix materials independently can lead to disappointing results.

Freeman Manufacturing not only developed ni excel resin, but remains the sole manufacturing source for the material. They can provide the resin and nickel filler together in properly matched formulations.

In addition, Freeman has extensive technical expertise working with the material. They can provide guidance on optimal processing methods and best practices to follow when incorporating ni excel resin into a project. This support can be invaluable for ensuring successful outcomes.

R&D laboratories, universities, and industries ranging from aerospace to motorsports rely on Freeman as a specialized supplier of ni excel resin. With years of experience and unmatched technical knowledge, they are an ideal resource for anyone exploring the use of this unique material.

The Bottom Line

With its strong mechanical properties, heat resistance, dimensional stability, and affordability, ni excel resin can provide game-changing advantages for certain manufacturing applications. With proper handling and processing, it is a proven problem-solver for tools, molds, fixtures, and other production solutions.

Understanding where it excels, how to work with it, and the benefits it brings allows engineers and designers to take full advantage. For the right applications, ni excel resin can be the difference-maker in boosting quality, reducing costs, and accelerating delivery times.

FAQs

What is ni excel resin?

Ni excel resin is a patented nickel-filled epoxy system consisting of an epoxy resin filled with 40-50% nickel powder. It was developed by Freeman Manufacturing. The nickel filler gives it enhanced properties like higher strength, heat resistance, and wear resistance.

What industries use ni excel resin?

The aerospace industry was the initial user of ni excel resin for tooling applications. It is now widely used across many manufacturing industries including automotive, marine, wind power, motorsports, and more. It serves well for molds, tooling, fixtures, and other production applications.

What are the main benefits of ni excel resin?

The key benefits include lower costs, faster production times, improved tool life, dimensional stability, high precision, light weight for easier handling, and the ability to modify tools more quickly than with steel. It offers significant time and cost savings.

Does ni excel resin require any special processing?

Yes, ni excel involves uniformly mixing the two-part resin and nickel powder. Degassing is recommended. It also requires a room temperature cure followed by a post-cure heat treatment to achieve full material properties. Gradually cooling after post-cure is also important.

Where can I purchase ni excel resin?

Freeman Manufacturing is the sole producer and recommended supplier of properly matched ni excel resin and nickel filler. Their technical expertise is invaluable for learning how to work with this material successfully.