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| Application: | Refractory, Structure Ceramic, Industrial Ceramic |
| Material: | Alumina, Alumina Ceramic |
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Precision Ceramic Alumina Aluminum Oxide Machined Ceramics Al2O3 Structural Components
Introduction to Structural Ceramics
Advanced ceramics can be divided into two categories according to their characteristics and uses: structural ceramics and functional ceramics.
Structural ceramics are ceramics that can be used as engineering structural materials. It has high strength, high hardness, high elastic modulus, high temperature / wear / corrosion / oxidation / thermal shock resistance and other characteristics.
Structural ceramics are roughly divided into oxide-based, non-oxide-based, and structural ceramic matrix composites. The oxide-based ceramics is represented by alumina ceramics and magnesia ceramics, the non-oxide ceramics is represented by silicon nitride ceramics and silicon carbide ceramics, and the structural ceramic matrix composites is represented by zirconia.
Advantages of Alumina Ceramic Structural Parts
1. High hardness
The Rockwell hardness is HRA 80-90, which is second only to diamond, far exceeding wear-resistant steel and stainless steel.
2. Excellent wear resistance
According to the measurement of professional research institutions, its wear resistance is equivalent to 266 times that of manganese steel and 171.5 times that of high-soldering cast iron. Under the same working conditions, the service life of equipment can be extended by more than 10 times.
3. Light weight
Its density is only half that of steel, which can greatly reduce the load on equipment.
Our product production is mainly divided into 3 steps, forming - finishing - metallization. The production flow chart is shown below.
1. Forming Method
We will choose the most suitable forming method on the basis of saving costs and ensuring quality.
| Forming Method | Features |
| Dry Pressing | 1. High production efficiency, suitable for mass production. 2. High product density and high mechanical strength. 3. Especially suitable for making ceramic products with flat shapes and small cross-sectional thickness. 4. More mold wear, complex processing and high cost. |
| Hot Pressing | 1. High dimensional accuracy. 2. Less mold wear and relatively low production cost. 3. High production efficiency, suitable for mass production. 4. Especially suitable for making engineering ceramic parts with complex shapes. 5. Low product density, relatively more internal defects and poorer mechanical properties and performance stability. 6. Not suitable for making thick-walled or large-sized ceramic products. |
| Isostatic Pressing | 1. Highest density and uniform distribution, high mechanical strength. 2. Less mold wear and relatively lower cost. 3. Able to make large-scale ceramic products with concave, slender and other complex shapes. 4. Not easy to control the size and shape accurately. 5. Low productivity, not easy to realize automation. |
| Ceramic Injection Molding (CIM) |
1. High degree of mechanization and automation, suitable for mass production. 2. Uniform density and compactness, high geometric precision and surface finish. 3. Able to make ceramic products with high dimensional accuracy and complex shape. 4. High equipment investment and processing costs. |
2. Finishing Process
In order to achieve the precision of the product, most ceramic structural parts need further finishing treatment after the sintering process.
| Finishing Process | Features |
| Machining | In order to achieve a smoother surface and better finish, as well as to meet the dimensional tolerances required by customers, we can perform machining processes such as lapping and polishing on the ceramic structural parts. |
| Glazing | A glaze coating can achieve an excellent surface finish, minimize dirt and grease build-up to avoid surface leakage and flashovers, and increase the strength and imperviousness of the ceramic surface. |
| Common Metallization Process | Process Description | Advantages | Disadvantages |
| Electroless Nickel Plating Method | Ceramic Body + Electroless Ni Plating | 1. Uniform coating and small pinholes. 2. Low cost, suitable for mass production. |
Low bonding strength |
| Silver Firing Method | Ceramic Body + Ag Coating | 1. Silver has strong electrical conductivity and good oxidation resistance. 2. The fired silver layer is firmly bonded, and the thermal stability is good. 3. The process is simple and easy to implement. |
1. Thin, discontinuous and uneven film layer. 2. Higher cost. |
| Mo-Mn Method | Ceramic Body + Mo-Mn Metallization + Electroplating or electroless Ni plating | 1. The most important one in the metal powder sintering methods. 2. Mature and stable process, and high bonding strength. 3. To prevent oxidation and improve wettability, after the metallized Mo layer is sintered, a Ni layer can be plated on it. |
The film layer is discontinuous, uneven, and rough. |
| W-Au Method | Ceramic Body + W Metallization + Au Plating | 1. Tungsten metallization has the advantages of simple formula, and can meet some special requirements, such as alkali metal vapor resistance. 2. The gold layer is highly conductive and protects against oxidation and increased contact resistance. |
The film density is not high. |
| Category | Property | Unit | 99.8% Al2O3 |
99.5% Al2O3 |
99% Al2O3 |
95% Al2O3 |
94.4% Al2O3 |
| Mechanical | Density | g/cm3 | ≥3.95 | ≥3.90 | ≥3.85 | ≥3.65 | ≥3.60 |
| Water absorption | % | 0 | 0 | 0 | 0 | 0 | |
| Vickers hardness | HV | 1700 | 1700 | 1700 | 1500 | 1500 | |
| Flexural strength | Mpa | ≥ 390 | ≥ 379 | ≥ 338 | ≥ 320 | ≥ 312 | |
| Compressive strength | Mpa | ≥ 2650 | ≥ 2240 | ≥ 2240 | ≥ 2000 | ≥ 2000 | |
| Fracture toughness | Mpam1/2 | 4-5 | 4-5 | 4-5 | 3-4 | 3-4 | |
| Thermal | Max. Service temperature (non-loading) |
ºC | 1750 | 1675 | 1600 | 1500 | 1500 |
| CTE (Coefficient of thermal expansion) 20-800ºC |
1×10-6/ºC | 6.5-8.2 | 6.5-8.0 | 6.2-8.0 | 5.0-8.0 | 5.0-8.0 | |
| Thermal shock | T (ºC) | ≥ 200 | ≥ 200 | ≥ 200 | ≥ 220 | ≥ 220 | |
| Thermal conductivity 25ºC |
W/(m·k) | 31 | 30 | 29 | 24 | 22.4 | |
| Specific heat | 1×103J/(kg·k) | 0.78 | 0.78 | 0.78 | 0.78 | 0.78 | |
| Electrical | Volume resistivity 25ºC |
ohm·cm | > 1×1014 | > 1×1014 | > 1×1014 | > 1×1014 | > 1×1014 |
| 300ºC | 1×1012 | 1×1012 | 8×1011 | 1012-1013 | 1012-1013 | ||
| 500ºC | 2×1012 | 5×1010 | 2×109 | 1×109 | 1×109 | ||
| Dielectric strength | KV/mm | 20 | 19 | 18 | 18 | 18 | |
| Dielectric constant (1Mhz) | (E) | 9.8 | 9.7 | 9.5 | 9.5 | 9.5 |
Jinghui has accumulated more than ten years of experience in the field of metallized ceramic structural parts, and can produce various specifications of metallized ceramic structural parts according to customers' drawings, with reliable quality and superior performance.
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