To create mini pellets using a 7 mm diameter die, the typical operational load is 2.0 tonnes. This specific load generates a pressure of approximately 500 MPa within the die, which is generally sufficient to form a stable, high-quality pellet for analysis.
Core Insight: Pressure is the result of force applied over a specific area, meaning smaller dies require significantly less load to achieve the same compression. Applying "standard" loads to a mini die will result in excessive pressure that can destroy the die or ruin the sample.
The Mechanics of Mini Pellet Creation
Specific Values for 7 mm Dies
According to standard protocols for mini pellets, you should utilize a 7 mm diameter die.
When using this size, the target load should be set to 2.0 tonnes. This inputs enough force to compress the powder without exceeding the mechanical limits of the smaller die surface.
Resulting Pressure
At a load of 2.0 tonnes, the material inside a 7 mm die experiences a pressure of 500 MPa.
This pressure level is the critical factor that causes the sample powder (often mixed with a binder like KBr) to fuse into a solid, transparent disc.
Comparing Mini vs. Standard Pellets
The Impact of Surface Area
It is vital to understand that the required load does not scale linearly with diameter, but rather with the surface area of the die face.
Because a 7 mm die has a much smaller surface area than a standard die, it concentrates the force much more intensely.
Values for Standard 13 mm Dies
For comparison, a standard 13 mm diameter die typically requires a load of 10 tonnes.
This higher load results in a pressure of 739 MPa. Note that while the load is 5 times higher (10 tonnes vs. 2 tonnes), the resulting pressure is relatively comparable because the 13 mm die distributes that force over a larger area.
Understanding the Trade-offs
The Danger of Over-Loading
A common mistake is applying the standard 10-tonne load to a 7 mm mini die.
Doing so would generate massive internal pressures far exceeding 500 MPa, likely causing the die to fracture or explode.
Sample Consistency
While 500 MPa (Mini) and 739 MPa (Standard) are different, both are generally sufficient for pellet formation.
However, if your specific application requires higher density, you may need to adjust the load slightly, provided you stay within the safe working limits of your specific 7 mm die.
Making the Right Choice for Your Goal
To ensure equipment longevity and sample quality, verify your die size before applying force.
- If your primary focus is creating 7 mm Mini Pellets: Set your press to a maximum of 2.0 tonnes to achieve the target 500 MPa pressure.
- If your primary focus is creating 13 mm Standard Pellets: You can safely increase the load to 10 tonnes to achieve approximately 739 MPa.
Always calculate the specific pressure rating for your die assembly to avoid catastrophic failure.
Summary Table:
| Die Diameter | Recommended Load | Resulting Pressure | Common Use Case |
|---|---|---|---|
| 7 mm (Mini) | 2.0 Tonnes | ~500 MPa | Mini pellets / KBr discs |
| 13 mm (Standard) | 10.0 Tonnes | ~739 MPa | Standard XRF/FTIR pellets |
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