Stc overview (pre brd)


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  • STC began in New York/ New Jersey. The plant was the first building in the St. Albans Industrial park in 1974, it was commissioned in 1975. 80,000 square feet of production and office space. There have been 4 expansions.
  • STC 2, located across the street in the Industrial Park, has 55,000 sq ft of manufacturing space.
  • Ceramics are used in a variety of markets. STC has a diverse customer base.
  • STC is one of a few companies in the US with rights to import Lava. Grade A lava only comes from one place on Earth -- South Africa.
  • This is an overview of the major manufacturing steps that STC takes in order to make products. Emphasize the variety of forming methods & expertise in green machining.
  • ST purchases over 75 different Raw materials. Every material has to pass our Raw Materials Qualification (RMQ) testing in order to be used for production. This testing is conducted in house by our lab. Raw materials are qualified before use in wet mixes or spray dried powders. All batched materials are tested again for quality and processing characteristics Specific surface area analyzer & Laser Particle size analyzers characterize the powders before compaction. Pill pressing and test fires determine shrinkages of powder, density, and other properties of final product Dry pressing and iso-pressing require powder feedstock that has been ball milled and spray dried Each forming method requires different organic additives in order to form green blanks. The raw materials are mixed with binders and plasticizers in a ball mill or pan mixer
  • Quantities and geometries dictate the forming method used. Each method has advantages and disadvantages depending on cost and volume. An advantage of STC is the ability to mix and match forming and finishing processes based upon geometry and volume.
  • Wet-bag isopressing is for low run, large, or custom jobs. Dry-bag isopressing is for high volume jobs.
  • CNC equipment is also a more repeatable process than non-CNC equipment. STC will use both methods depending on volume or delivery timelines. Dust collection is an important aspect of green machining. The part is in a chalk-like state that can be turned, milled, and ground with conventional tooling. Material removal rate is 10 times greater than when the part is fired.
  • STC has small and large kilns. Kiln cycles can last from one day to a week or more. Both gas and electric kilns are used.
  • Smaller kilns are used for specialty firing cycles. Small orders are also fired in order to meet delivery dates. Testing is usually done in small kilns as well.
  • Glazing is done in order to keep the ceramic clean. Electrical properties of glazed products are sometimes tested. Other coatings can be applied to ceramics as well. Glaze can be formulated to accommodate application use temperatures. Hi-temp 2500F, standard 2300 F and low temp ~1800 F glaze is available.
  • Diamond grinding is necessary because as parts shrink in the kiln they distort.
  • Substrate Materials Plated On: Kovar Copper-Tungsten Molybdenum Copper Brass Stainless Steel Titanium Plastic Ceramic
  • Stc overview (pre brd)

    1. 1. Superior Technical CeramicsSuperior Technical Ceramics St. Albans, VermontSt. Albans, Vermont A WORLD LEADER IN ADVANCEDA WORLD LEADER IN ADVANCED MATERIALS SOLUTIONSMATERIALS SOLUTIONS
    2. 2. Vital Statistics BUSINESS: Ceramic material technology with complex forming and machining capabilities to manufacture technical ceramic components and assemblies. EMPLOYEES: Approximately 130 AGE: 113 years old SIZE: 135,000 ft2 in St. Albans location – two buildings OWNERSHIP: Privately held – American owned and operated Location: St. Albans, VT – headquarters and primary manufacturing Partners: INTA Technologies - Santa Clara, CA –– plating / metalizing, brazed assemblies Anderman Ceramics Ltd.- Supplier of Industrial Ceramics
    3. 3. STC at a Glance…STC at a Glance… • SuperiorTechnical Ceramics has beenproducingceramics forSuperiorTechnical Ceramics has beenproducingceramics for 113years113years • In1975, thebusiness movedfromNew York/New JerseytoitsIn1975, thebusiness movedfromNew York/New Jerseytoits current locationintheSaint Albans IndustrialParkcurrent locationintheSaint Albans IndustrialPark • Thetwo facilities inSt. Albans haveapproximately135,000Thetwo facilities inSt. Albans haveapproximately135,000 squarefeet of manufacturing, warehouse, andofficespacesquarefeet of manufacturing, warehouse, andofficespace • STC expands its capabilities bycontinuallyre-investinginnewSTC expands its capabilities bycontinuallyre-investinginnew machinery, labequipment, andtechnologymachinery, labequipment, andtechnology
    4. 4. Two Manufacturing FacilitiesTwo Manufacturing Facilities STC 2 STC 1
    5. 5. Company DirectionCompany Direction • Tomaintainahighlevel of customersatisfactionthroughTomaintainahighlevel of customersatisfactionthrough thecontinuedexcellenceof quality, ontimedelivery, andthecontinuedexcellenceof quality, ontimedelivery, and exceptionalCustomerService.exceptionalCustomerService. • Toinsurethat Superior’s TechnicalSales ForceandinToinsurethat Superior’s TechnicalSales Forceandin houseEngineeringForceis interfacingwithcurrent andhouseEngineeringForceis interfacingwithcurrent and perspectivecustomers toperspectivecustomers to • ResolvedesignandcostingissuesResolvedesignandcostingissues •Considerform, fit andfunctionalcriteriaareutilizedConsiderform, fit andfunctionalcriteriaareutilized withaneyeonmanufacturingwithaneyeonmanufacturing •Minimizecost of ownershipMinimizecost of ownership
    6. 6. Diverse Engineering StaffDiverse Engineering Staff • Designing and processing ceramics are different than metals or plastics. • Our team of engineers consists of: • Ceramic Engineers • Mechanical Engineers • Materials Scientists • Material property analysis • Product development • Failure analysis 0 .5 0 0 " ø 0 .4 4 0 " 0 .2 5 0 " 0 .1 0 0 " S a p p h ir e I T E M # 1 0 .5 0 0 " ø 0 .4 4 0 " 0 .1 0 0 " S a p p h ir e 0 .2 5 0 " 0 .1 5 0 " I T E M # 2
    7. 7. • Aviation & Military • Semiconductor • Telecommunications • Pumps and Valves • Medical • Lamps/Lighting • Electro-Optics • Plasma Cutting • Industrial Ignition • Textile/ Wire Feed • Laser Systems • Refractories • Nuclear • Appliance Insulators • Electrical Feed thru • Scientific Instruments • Water Treatment • X-Ray Systems • Mass Spectroscopy • Conveyor Systems Markets ServedMarkets Served
    8. 8. Material SelectionMaterial Selection • Standard materials: • Aluminum Oxide • (85% to 99.9% purity) • Zirconium Oxide (Y-TZP and Mg Stabilized) • Zirconia Toughened Alumina (ZTA) • Steatite • Cordierite • Mullite • Bisque Alumina (machineable ceramic) • Porous • Machined materials: • Macor • Boron Nitride • Grade “A” Lava (hydrous alumina silicate)
    9. 9. Manufacturing ProcessManufacturing Process I s o s t a t i c P r e s s i n g D ia m o n d G r i n d in g In s p e c t & S h ip C o a t in g s A s s e m b l y F i r i n g G r e e n M a c h i n i n g E x t r u s i o n D r y P r e s s i n g R a w M a t e r i a ls M ix e d & B a t c h e d
    10. 10. • Inspection • Spray Drying • Mixing Raw MaterialsRaw Materials
    11. 11. Forming Methods: OverviewForming Methods: Overview  STC manufactures from prototype to large volume orders.  Which forming method is chosen depends upon cost effectiveness. Extrusion Cold Isostatic Pressing Dry Pressing
    12. 12. Blank Forming: ExtrusionBlank Forming: Extrusion  Pan mixed material is loaded then extruded or “squeezed” out of a metal die to form rods.  Pressures in excess of 200 tons are often required for this process.
    13. 13. Blank Forming: IsopressingBlank Forming: Isopressing  Dry bag isopressing is used for high volume production  Wet bag isopressing is done in a chamber press
    14. 14. Part Forming: Dry PressingPart Forming: Dry Pressing  Uniaxial dry pressing involves applying pressure from top and bottom punches.  Often only large volume orders are dry pressed because of tooling requirements.
    15. 15. • Milling • Turning • OD Grinding. Green Machining:Green Machining:
    16. 16. FiringFiring • Firing, also known as sintering, is the process used to densify the ceramic to achieve optimal properties . • Depending on the ceramic composition – also known as a “body” – temperatures for densification can be as high as 3100o F (1700o C)!
    17. 17. Shrinkage During FiringShrinkage During Firing • Ceramic components can shrink from 15-25% during the firing process! • Shrinkage is accounted for in green forming and machining to yield a near net shape after firing. • Typical “as fired” tolerances are +/- 1% or +/-0.005” whichever is
    18. 18. Designing for Ceramic MfgDesigning for Ceramic Mfg Typical “as fired” tolerances: • +/- 1% or +/-0.005” whichever is bigger • 0.006”/inch max camber allowance • Wall thicknesses of 1/16”min – (geometry dependant) • Fillets and edgebreaks - .025”max R or ch • 63 microinch surface finish
    19. 19. Bell-Jar Elevator KilnsBell-Jar Elevator Kilns
    20. 20. Applying glaze to parts creates a glossy smoothApplying glaze to parts creates a glossy smooth surface.surface.
    21. 21. Diamond GrindingDiamond Grinding • Ceramic components requiring tolerances tighter than +/-1% require diamond grinding. • By using the latest in automated CNC machines, STC reduces time and costs.
    22. 22. Diamond GrindingDiamond Grinding • ID and OD grinding • Cutting, reaming & honing • Lapping and finishing
    23. 23. Equipment & QualityEquipment & Quality • Quality Management System: • ISO 9001:2008 and AS9100 Certified • Calibration: Traceable to NIST • Sampling: ANSI/ASQ Z1.4-2003 • Manual & Programmable CMM • Touch Probe • Video • Laser • Non-destructive testing • Ultrasonic • Dye penetrant • Radiography
    24. 24. Materials SolutionsMaterials Solutions Superior Technical Ceramics Form ing Al2O3, ZrO2 Glazing Firing Machining INTA Technologies Plating HeatTreating Metallizing
    25. 25. INTA TechnologiesINTA Technologies Santa Clara, CASanta Clara, CA Plating & MetallizingPlating & Metallizing SolutionsSolutions
    26. 26. Specialty Plating ServicesSpecialty Plating Services  Substrate Materials:  Kovar  Copper-Tungsten  Molybdenum  Copper  Brass  Stainless Steel  Titanium  Plastic  Ceramic
    27. 27. Electrolytic & Electroless PlatingElectrolytic & Electroless Plating  Plating Materials:  Gold  Nickel  Silver  Copper  Rhodium  Tin  Platinum
    28. 28. Superior Technical CeramicsSuperior Technical Ceramics  Thank you for your time  This concludes the presentation