UGIMA®-X: Transforming Stainless Steel Machining with Unprecedented Efficiency and Sustainability
Swiss Steel Group has launched UGIMA®-X, the third generation of high-machinability stainless steels. With over 30 years of research and collaboration with industrial partners, UGIMA®-X sets new standards in stainless steel production, pushing the limits of productivity, tool life, and consistency in machining processes. This breakthrough results in a material that reduces operational costs, minimizes downtime, and enhances overall manufacturing performance.
New Grades: Tailored for Precision and Strength
UGIMA®-X introduces three new grades, each tailored for specific industrial needs:
• UGIMA®-X 4021: A martensitic stainless steel designed for mechanical and food/beverage applications requiring high strength and corrosion resistance. It is ideal for high-stress components and is compatible with the food industry.
• UGIMA®-X 4028: Another martensitic grade, this steel offers superior mechanical resistance and is perfect for high-precision applications. Its increased dimensional stability makes it suitable for the food and medical sectors.
• UGIMA®-X 4460: A duplex stainless steel combining high mechanical strength with exceptional resistance to corrosive environments. It excels in chip fragmentation and machining stability, making it ideal for chemical processing and mechanical industries.
Innovative Metallurgical Optimisation: Enhancing Machinability and Reducing Variability
The development of UGIMA®-X is based on advanced metallurgical processes, particularly the introduction of oxides during the melting process. These fine-tuned modifications improve chip formation, reduce tool wear, and provide uniform machining properties across different heats. One of the most notable achievements of UGIMA®-X is the significant reduction of quality variations, a long-standing challenge in stainless steel machining. This precision ensures reliable performance and consistency in production batches, increasing the material's appeal across various industries.
Superior Performance Across Key Applications
UGIMA®-X delivers significant productivity gains, with productivity improvements averaging 20% and tool life extended by up to 50%. For example, UGIMA®-X 4021 outperforms previous versions by improving machinability by 28% over UGI® 4021 and 14% over UGIMA® 4021. The grade is especially effective for the automotive, mechanical engineering, and food industries.
Similarly, UGIMA®-X 4028 offers a 12% improvement in machinability compared to UGI® 4028 and 7% over UGIMA® 4028, making it ideal for high-precision components. In the UGIMA®-X 4460 grade, duplex stainless steel technology has resulted in a 20% to 30% productivity improvement over standard 1.4460 grades, providing exceptional performance in harsh, corrosive environments.
Extended Tool Life and Reduced Operational Costs
One of the key advantages of UGIMA®-X is the extended tool life, up to 50% longer than traditional stainless steels. The material’s ability to reduce tool damage and chip hammering results in reduced machine downtime and extended intervals between tool changes. This not only optimizes productivity but also contributes to significant cost savings, making UGIMA®-X an economically attractive option for manufacturers.
Moreover, the consistency and reproducibility of UGIMA®-X performance reduce scrap rates and improve production accuracy. This level of predictability in manufacturing leads to better planning and overall operational efficiency.
Green Steel: Sustainable Manufacturing with UGIMA®-X
In line with global sustainability efforts, Swiss Steel Group offers UGIMA®-X in an environmentally friendly "Climate+" version, produced using renewable energy sources such as wind, solar, and hydropower. This “Green Steel” option significantly reduces carbon emissions in the stainless steel production process, helping companies meet their environmental goals while maintaining high performance and reliability in their machining applications.
Application-Specific Benefits and Diverse Industrial Solutions
UGIMA®-X has undergone extensive testing, involving the production of 2,000 metric tons of material and 3,000 hours of real-world testing. This research ensures that UGIMA®-X is a tailored solution for various industrial challenges. The grades are particularly effective for applications in industries like:
• Automotive and Mechanical Engineering: For high-strength components and precision parts, UGIMA®-X offers reliability and durability.
• Food and Beverage Industries: The compatibility of UGIMA®-X with food-grade applications ensures safety and precision, especially in environments requiring moderate corrosion resistance.
• Chemical Processing and Medical Sectors: The duplex stainless steel grade (UGIMA®-X 4460) offers exceptional resistance to aggressive environments, making it ideal for chemical processing and critical medical components.
Comprehensive Support and Expertise
Swiss Steel Group’s commitment to providing comprehensive support ensures customers achieve optimal results with UGIMA®-X. For over three decades, the company has been offering application-oriented consulting and technical expertise, along with detailed material data, machining guidelines, and process optimization analyses.
Key Takeaways:
• UGIMA®-X is the third generation of high-machinability stainless steels, offering significant advancements in productivity, tool life, and process reproducibility.
• The new grades UGIMA®-X 4021, UGIMA®-X 4028, and UGIMA®-X 4460 are tailored for specific industrial needs such as high-strength mechanical parts, precision components, and corrosive environments.
• Productivity Increase: UGIMA®-X increases machining productivity by up to 20%.
• Tool Life Extension: Tool life is extended by 25% to 50%, reducing machine downtime and tool replacement costs.
• Improved Machinability: Machinability has been enhanced by up to 28% compared to previous steel grades.
• Enhanced Reproducibility: UGIMA®-X ensures exceptional consistency across production batches, minimizing quality deviations.
• Sustainability: A “Climate+” version of UGIMA®-X is produced using renewable energy sources, reducing carbon emissions in production.
• Application Flexibility: UGIMA®-X is suited for industries such as automotive, food, medical, chemical processing, and mechanical engineering.
• Green Steel Option: The “Green Steel” variant enables businesses to meet sustainability goals without sacrificing performance.
UGIMA®-X is poised to redefine the landscape of stainless steel machining, offering unmatched performance, cost savings, and sustainability across a wide range of industries.
