MicroSet Compounds & Applicators

MicroSet Compounds & Applicators

Amazing Fast Curing, Flexible Replicating Fluid, Ideal for Component and Surface Feature Duplication Down to Sub-Micron Level

Overview

Microset Products Ltd manufacture high-resolution replication materials for engineering inspection. We supply to the Aerospace, Nuclear, Oil, Gas and Marine engineering industries. Typical applications include surface damage and surface finish assessment, quality control of internal surfaces and dimensions, crack detection and metallography. Microset materials are used where conventional NDT methods are impractical.

Can also be used in Offshore Underwater systems to produce accurate 3D replicas of underwater steel surfaces, including replication of 'O' ring groove geometry, corrosion pitting, weld profiles and mechanical damage. 

Example of replication

Features

  • Resolution better than 0.1 microns (4 x10⁻⁶ inches)
  • Specially formulated two-part polymers, designed for high resolution replication of surface detail
  • Convenient and reliable cartridge application system
  • Replicas can be made in any shape or size, of most solid non-porous surfaces
  • Can be stored indefinitely for future reference
  • High strength elastomeric material - capable of being removed from holes, tubes and moderate re-entrant geometries without damage to the replica surface
  • Bright metallic appearance under coaxial illumination for high magnification inspection of micro-defects

Replicating with Microset

In order to use Microset replicating compounds, a simple application system is required comprising: a cartridge dispensing gun, a twin pack cartridge of Microset compound (contains both base material and catalyst) and a static mixing nozzle. A cartridge of Microset compound is dispensed using a manual, pneumatic or electric dispensing gun. Air free mixing of the base and catalyst is achieved by using a static mixing nozzle attached to the outlet of the cartridge. Three application systems are available, 50ml, 265ml and 495ml. Each application system delivers fully mixed replicating compound directly to the area of interest. The compound cures to produce a highly accurate flexible rubber replica of the surface. Microset compounds are available as either fluid or thixotropic materials and with a range of curing times to accommodate varying ambient temperatures.

High Viscosity Putty materials are also available which do not require an application system.

Fatigue pitting on a gear tooth surface SEM x100

Replica Examination

When viewed microscopically under coaxial illumination, Microset replicas have a bright metallic appearance, allowing detail such as microstructure, micro-cracking and pitting to be observed at high magnifications. These characteristics make Microset replication ideal for the assessment of defects on critical engineering surfaces. Microset replicas can be examined using various techniques including: Microscopy, Stereo Macroscopy, 3D Infinite Focus Microscopy, Scanning Electron Microscopy, Atomic Force Microscopy, White Light Interferometry, Shadowgraph Measurement and 3D Laser Measurement.

8400K Optical Depth Measuring Micrometer

The 8400K is a portable inspection microscope with depth measurement capability. It quickly and accurately measures the depth of surface damage, is easy to operate, portable and durable. The 8400K Optical Micrometer Kit, when used in conjunction with Microset compounds, provide a quick and convenient method of obtaining precise measurements of damage in hard to reach places.

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Technical Specifications

Microset 101 Fluid Replicating Compounds

Microset 101 Fluid Compounds are high resolution, two part silicone polymers designed for replication of metal surfaces. The free-flowing nature of these compounds minimizes the risk of air entrapment in the replica, and makes them easy to apply over large areas. They are suitable for replicating rough surfaces, cavities, tubes, threaded holes etc.

Microset Grade Working Life @ 25 °C Cure Time @ 25 °C Key Features Typical Applications
101RF 0.5 min 5 min General purpose fast curing fluid material Replication of horizontal or sloping surfaces. Use in low temperature conditions or where rapid results are required
101FF 4 min 30 min General purpose fluid material Replication of horizontal or sloping surfaces. Use in normal or high temperature conditions
101XF 15 min 60 min Specialist purpose fluid material Replication of horizontal or sloping surfaces
101FS 50 min 210 min Specialist purpose fluid material Replication of horizontal or sloping surfaces
General Specifications
Resolution 0.1 microns
Shelf Life 24 months
Cured Hardness 28-30 Shore A
Shrinkage Less than 0.1%
Color Black or Grey
Useable Temperature Range 14 to 356 °F (-10 to 180 °C)
Specific Gravity 1.1g/cm3
Linear Expansion Coefficient 280 x 10-6 / °C
Packaging Twin pack cartridge in three sizes – 50ml, 265ml, 495ml

 

*Working life and curing times vary with temperature – higher temperatures decrease working life and cure, lower temperatures increase working life and cure

*Quoted times may vary up to +/- 15% between batches

Microset 101 Thixotropic Replicating Compounds

Microset 101 Thixotropic Compounds are high resolution, two part silicone polymers designed for replication of metal surfaces. The thixotropic nature of these compounds allows them to be applied on vertical and overhead surfaces without the compound dripping or flowing away from the area of interest.

Microset Grade Working Life @ 25 °C Cure Time @ 25 °C Key Features Typical Applications
101RT 0.5 min 5 min Fast curing thixotropic material Replication of vertical or overhead surfaces. Use in low temperature conditions or where rapid results are required
101TH 3 min 20 min General purpose thixotropic material Replication of vertical or overhead surfaces. Use in normal or high temperature conditions
101THS 7 min 30 min Specialist purpose thixotropic material Replication of vertical or overhead surfaces
101XFT 15 min 60 min Specialist purpose thixotropic material Replication of vertical or overhead surfaces
General Specifications
Resolution 0.1 microns
Shelf Life 15 months
Cured Hardness 28-30 Shore A
Shrinkage Less than 0.1%
Color Black or Grey
Useable Temperature Range 14 to 356 °F (-10 to 180 °C)
Specific Gravity 1.1g/cm3
Linear Expansion Coefficient 280 x 10-6 / °C
Packaging Twin pack cartridge in three sizes – 50ml, 265ml, 495ml

 

*Working life and curing times vary with temperature – higher temperatures decrease working life and cure, lower temperatures increase working life and cure

*Quoted times may vary up to +/- 15% between batches

Microset 202

Microset 202 Fluid Compounds are high resolution, two part silicone polymers designed for replication of metal surfaces. They have a resolution of 0.05 microns making them ideal for metallography. The free-flowing nature of these compounds minimizes the risk of air entrapment in the replica, and makes them easy to apply over large areas. Microset 202 compounds cure harder and are less flexible than 101 compounds and are prone to tearing and damage when removed from surfaces with complex geometry or significant re-entrant surface detail. They are suitable for replicating metallurgical microstructure, rough surfaces, cavities, tubes, thread profile etc.

Microset Grade Working Life @ 25 °C Cure Time @ 25 °C Key Features Typical Applications
202 2 min 7 min Fast curing, two part compound, 0.05 micron resolution, low viscosity fluid Suitable for microstructure examination and surface finish measurement
General Specifications
Resolution 0.05 microns
Shelf Life 24 months
Cured Hardness 45 Shore A
Shrinkage Less than 0.1%
Color Black
Useable Temperature Range 14 to 356 °F (-10 to 180 °C)
Specific Gravity 1.1g/cm3
Linear Expansion Coefficient 280 x 10-6 / °C
Packaging Twin pack cartridge in three sizes – 50ml, 265ml, 495ml

 

*Working life and curing times vary with temperature – higher temperatures decrease working life and cure, lower temperatures increase working life and cure

*Quoted times may vary up to +/- 15% between batches

Purchasing Details

In order to use Microset replicating compounds, a simple application system is required comprising:

  • Dispensing Gun
  • Cartridge of Microset compound (contains both base material and catalyst)
  • Nozzle

**Microset Compound Cartridges are available in Black or Grey formulations. Black is supplied unless otherwise specified. Grey is special order and not typically in stock.

Application Systems

50ml System

50ml System

General purpose system for small to medium replication and molding applications. Fluid and thixotropic compounds are available.

Photo Description Part Number
50ml Manual Dispensing Gun
Hand operated, plastic reusable tool for dispensing 50 ml cartridges
DG50

50ml Microset Compound Cartridge
Black or Grey Formulations

Come in the following grades:
Fluid Grades: RF, FF, XF, FS
Thixotropic Grades: RT, TH, THS, XFT

MC50 (+ grade + color)
50ml Nozzles - 10 Pack
Pack of 10 static mixing nozzles required for air-free mixing of Microset compounds
NP10
50ml Nozzles - 50 Pack
Pack of 10 static mixing nozzles required for air-free mixing of Microset compounds
NP50
265ml System

265ml System

General purpose system for medium to large replication and molding applications. Fluid and thixotropic compounds are available.

Photo Description Part Number
265ml Manual Dispensing Gun
Manually hand operated, reusable tool for dispensing 265ml cartridges
DG265M
265ml Pneumatic Dispensing Gun
Pneumatically operated, reusable tool for dispensing 265ml cartridges
DG265P
265ml Electric Dispenser
Electronically operated, rechargeable tool for dispensing 265 ml cartridges
DG265E

Twin Pack 265ml Microset Compound Cartridge
Sold separately. Black or Grey formulations.

Comes in following grades:
Fluid: RF, FF, XF, FS
Thixotropic: RT, TH, THS, XFT

MC265 (+ grade + color)
265ml Nozzles Pack
Pack of 10 mixing nozzles, (8mm diameter). Required for air-free mixing of Microset compounds
NP8A
495ml System

495ml System

General purpose system for medium to large replication and molding applications. Fluid and thixotropic compounds are available.

Photo Description Part Number
495ml Manual Dispensing Gun
Manually hand operated, reusable tool for dispensing 495ml cartridges
DG495M
495ml Pneumatic Dispensing Gun
Pneumatically operated, reusable tool for dispensing 495 ml cartridges
DG495P

Twin Pack 495ml Microset Compound Cartridge
Sold separately. Black or grey formulations

Comes in the following grades:
Fluid: RF, FF, XF, FS
Thixotropic: RT, TH, THS, XFT

MC495 (+ grade + colour)
495ml Nozzle Packs
Pack of 10 mixing nozzles (8mm and 10mm diameter). Required for air-free mixing of Microset compound

NP8A (8 mm)

NP10A (10 mm)

Optional Accessories

Optional Accessories for all Systems

Photo Description Part Number

Backing Slides

Backing slides bond to Microset replicas and facilitate labelling, handling and inspection. Dimensions: 60mm x 40mm. Pack of 10 or 50.

BS10 (10 pack)

BS50 (50 pack)

Backing Paper

Backing paper bonds to Microset replicas and facilitate labelling, handling and inspection. Backing paper also allows thin film replicas of curved surfaces to be taped flat on slides for microscopic inspection. Dimensions: 70mm x 60mm. Pack of 100

BP70x60

Backing Paper A4

Backing paper bonds to Microset replicas and facilitate labelling, handling and inspection. Backing paper also allows thin film replicas of curved surfaces to be taped flat on slides for microscopic inspection. Dimensions: A4. Pack of 10.

BPA4

Spreaders for 50ml System

Fan tailed spreader attachment for 50ml nozzle. Pack of 10

SP10

Luer Needle Attachment for 50ml System

Needle size: 1.26mm OD (18 gauge) x 38mm long. Pack of 5

LN5

Flexible Hose Attachment for 50ml System

Reusable flexible tube extension for 50ml nozzle. Tube size 6mm OD x 100mm long. Pack of 5

FH105

Microset Tilting Stage

Precision engineered tilting microscope stage for replica examination

TS1

Carrying Case

Hard wearing plastic carry case for 50ml Microset system

CC50

Note: There is a small order fee of $25 for orders less than $50

Description Part # Saved Price Select Option Add to

Microset 50ml System

Microset Replication Dispensing Gun (50ml) (specify model)
Model #
MS-DG50-1 $102.00
Microset Replication Cartridges (50ml) (specify material)
Model #
MS-MC50-101RF-1 $62.00
Microset Nozzle Packs (50ml) (specify QTY)
Model #
MS-NP10-1 $25.00
Microset LN5 Luer Needle Attachment - 5 Pack (50ml) MS-LN5 $11.00
Microset FH105 Hose Attachment - 5 Pack (50ml) MS-FH105 $11.00
Microset SP10 Spreaders - 10 Pack (50ml) MS-SP10 $18.00
Microset CC50 Carrying Case (50ml) MS-CC50 $90.00

Microset 265ml System

Microset Replication Dispensing Gun (265ml) (specify model)
Model #
MS-DG265M-1 $389.00
Microset Replication Cartridge (265ml) (specify material)
Model #
MS-MC265-101RF-1 $216.00
Microset Nozzle Pack (265ml) (specify size)
Model #
MS-NP265-8-1 $35.00

Microset 495ml System

Microset Replication Dispensing Gun (495ml) (specify model)
Model #
MS-DG495M-1 $487.00
Microset Replication Cartridge (495ml) (specify material)
Model #
MS-MC495-101RF-1 $331.00
Microset Nozzle Pack (495ml) (specify size)
Model #
MS-NP495-8-1 $35.00

Optional Accessories

Microset BPA4 Backing Paper - 10 Sheets (A4 Size) MS-BPA4 $23.00
Microset BP70X60 Backing Paper - 100 pieces (70mm x 60mm) MS-BP70X60 $27.00
Microset BS10 Backing Slides - 10 Sheets ( 60mm x 40mm) MS-BS10 $14.00
Microset BS50 Backing Slides - 50 sheets (60mm x 40mm) MS-BS50 $72.00
Microset TS1 Tilting Microscope Stage MS-TS1 $448.00