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DYNAMIC-CERAMIC
Applications of Applications of Advanced CeramicsAdvanced Ceramics
By Mitch RozenDynamic-Ceramic Limited
DYNAMIC-CERAMIC
Material Types Dynamic-Ceramic Material Types Dynamic-Ceramic ProvidesProvides
Zirconia (Technox)– Partially Stabilised Zirconia (PSZ)– Tetragonal Zirconia Polycrystals (TZP)– critical applications– not suited to large surface area applications
Alumina (Dynallox)– 94 - 99.9% Purity
Silicon Nitride– Reaction Bonded Silicon Nitride (RBSN)– Sintered Silicon Nitride (SSN)
DYNAMIC-CERAMIC
Manufacturing RouteManufacturing Route
precision machining
firing/sintering
green machining
Powder Raw Materials
inspection
Pressing (Die/Isostatic) Casting or Moulding
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Raw MaterialsRaw Materials Highly purified and refined ceramic
raw materials The powder raw materials are in
the region of 1000 times smaller than conventional clay based ceramics
Particle sizes of around 70nm
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Die PressingDie Pressing
Raw Materials are compacted using die pressing techniques at pressures up to 30,000 p.s.i.
Top Tool
Bottom Tool
powdercompact
MouldBody
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Fluid
Iso-Pressing OutlineIso-Pressing OutlineFlexible
Bag
Bungs
Steel Mandrel
PowderApplied Pressure
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Wet Bag Isostatic PressingWet Bag Isostatic PressingCold Isostatic Pressing (CIP) is a method of compacting powders into green bodies and near net shapes in a pressure vessel. The powder is sealed in a flexible mold shaped like the end product. High pressure is used–30,000 psi). A high and uniform density is achieved, resulting in easier handling, easier machining and even and predictable shrinking during sintering.
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Fluid
Dry- Bag Iso-PressingDry- Bag Iso-Pressing
Bungs
Steel Mandrel
PowderApplied Pressure
Inner Flexible
Bag
Outer Flexible
Bag
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Green MachiningGreen Machining
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SinteringSintering The machined
powder compact is fired or sintered in furnaces at temperatures up to 1800°C.
During the sintering process the powder compact shrinks ≈ 25%.
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Precision MachiningPrecision Machining
• Once sintered the advanced ceramic component is extremely hard and can only be machined with diamond. Dimensional tolerances of less than 1/100 of the thickness of a human hair are possible
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InspectionInspection
All common inspection techniques can be used
Difficult to detect defects within the component - good processing required
Crack detection performed on surface.
Remember Ceramics have “elephant like” memories
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MicrostructureMicrostructure
Fine, uniform & homogeneous microstructure (Technox 2000)
Toughened by “Transformation Toughening”
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0
500
1000
1500
2000
2500
3000
Temperature (C)
5 10 15
Mol % Yttria
Liquid (L)
Cubic (F)
L+F
TransformableTetragonal (T)
T+FM+T
Monoclinic (M)
Non-TransformableTetragonal (T') Cubic
1600 C Tie Line
1400 C Tie Line
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Crystal StructureCrystal Structure
Monoclinic Tetragonal
Cubic
1172o
C2370o
C
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Martensitic TransformationMartensitic Transformation
Tetragonal Grains
Monoclinic Grain
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Transformation TougheningTransformation Toughening
Advancingcrack Tip
TetragonalParticles
TransformedMonoclinicParticles+ 4%
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Strength (MPa)Strength (MPa)
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Test Bar FractureTest Bar Fracture
Tortuous failure mode
Does not shatter
Usually a clean break
1 mm
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Weak, K1c~3 Large radial cracks
Tough, K1c~10-15
Implications for wear behaviour
Vickers indent
Radial Cracks
Identical Vickers indents on polished surfaces
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The RealityThe Reality
The Combination of Strength & Toughness with defect free processing
Impact resistance into the regime of metallics
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Performance in Aggressive Performance in Aggressive EnvironmentsEnvironments
Erosive Wear Tests High Pressure Sand & Water
– 25 m/s, 90° against direction of impact for 30 minutes.
Volume lost is compared to a Standard Stainless Steel control pin
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Erosive WearErosive Wear
0
20
40
60
80
100
Technox WC Alumina S/Steel
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Corrosion ResistanceCorrosion Resistance
0
102030405060708090
100
H2SO4 (96%) HCl (35%) NaOH (50%)
Technox
SSN
SiC
WC-Co
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ApplicationsApplications Wear Resistant
– sliding wear– erosive– cavitation
Corrosion Resistant
Thermal Protection
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Process IndustriesProcess Industries
Mixer Bladesonly use the ceramicwhere it is required
ball valves
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PumpingPumping
Chemical Pump Body
Mag-Drive Pumps
Corrosion Resistance
Non-Metallic Non-Magnetic
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Flow ControlFlow Control
Flow control valves and chokes
Reduce cavitation and erosion
steel ceramic assemblies
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Cutting EdgesCutting Edges Technox
zirconia blades last up to 1000 times longer than steel blades.
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Oil & Gas ExplorationOil & Gas Exploration Solid Technox
3000 pump body Located sub-sea
and pumps un-filtered sea water
“innovation award” winner
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NEW AREAS OF PETROLEUM NEW AREAS OF PETROLEUM EXPLORATION FOR DYNAMICEXPLORATION FOR DYNAMIC
Ceramic Cutting Inserts (a.k.a. buttons) for Heads –(Not yet being manufactured presently)
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Other Deep Water Alternatives Other Deep Water Alternatives for Future Ceramic Developmentfor Future Ceramic Development
Split Shot Covers Ceramic Pipe
Components Gaskets in BOP
Annular Preventers
Liners
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HydrocyclonesHydrocyclones
Slip cast alumina bowls
Large Diameters– 1m
Bonding and installation important
25cm
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Bearings - Screw ConveyorsBearings - Screw Conveyors
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Solids HandlingSolids Handling
Hanger Bearings Used in journals of screw conveyors Have replaced WC/ Stellite in many applicationsUsed in aggressiveenvironments; Cement Industry Quarries Power Generation Metal Refineries
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Silicon Nitride PartsSilicon Nitride Parts Wear Resistance Chemical
Resistance Electrical Insulating Non-Magnetic Electrical Resistivity
@ 25°C =3 x 1010
Ω·cm Density,ρ, = 3.25
g /cc
Low Coefficient of Thermal Expansion, α = 3 x 10-6 /°C
Metal FormingAutomotive Parts
SiN Valve Sleeves
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Mechanical EngineeringMechanical Engineering Engines
Rocker Bushes
3000 hrs in a running engine
minimal lubrication
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Gear Pump PartsGear Pump Parts
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The new stone age?The new stone age?