DYNAMIC-CERAMIC

Applications of Applications of Advanced CeramicsAdvanced Ceramics

By Mitch RozenDynamic-Ceramic Limited

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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)

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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?