1. Applications of
Advanced Ceramics
By Mitch Rozen
Dynamic-Ceram Lim
ic ited
DYNAMIC-CERAMIC
2. Material Types Dynamic-Ceramic
Provides
q Zirconia (Te chnox)
–Partially Stabilised Zirconia (PSZ)
–Tetragonal Zirconia Polycrystals (TZP)
–critical applications
–not suited to large surface area applications
q Alum (Dy nallox)
ina
–94 - 99.9% Purity
q Silicon Nitride
–Reaction Bonded Silicon Nitride (RBSN)
–Sintered Silicon Nitride (SSN)
DYNAMIC-CERAMIC
3. Manufacturing Route
Pow RawM
der aterials
Pressing (Die/Isostatic) Casting or Moulding
green machining
firing/sintering
precision machining
inspection
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4. Raw Materials
q Highly purified and refined ceram raw
ic
m aterials
q The pow der rawm aterials are in the
region of 1000 tim sm
es aller than
conventional clay based ceram ics
q Particle sizes of around 70nm
DYNAMIC-CERAMIC
5. Die Pressing
Top Tool Mould
q RawM aterials are Body
com pacted using
die pressing
techniques at
pressures up to
30,000 p.s.i.
powder
compact
Bottom Tool
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6. Iso-Pressing Outline
Flexible
Fluid Bag
Applied
Powder
Pressure
Steel
M andrel
Bungs
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7. Wet Bag Isostatic Pressing
Cold 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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8. Dry- Bag Iso-Pressing
Inner
Fluid Flexible
Bag
Applied
Powder
Pressure
Outer
Flexible Steel
Bag M andrel
Bungs
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10. Sintering
q The m achined
pow com
der pact is
fired or sintered in
furnaces at
tem peratures up to
1800°C.
q During the sintering
process the pow der
com pact shrinks ≈
25%.
DYNAMIC-CERAMIC
11. Precision Machining
• Once sintered the
advanced ceram ic
com ponent is extrem ely
hard and can only be
m achined w diam
ith ond.
Dim ensional tolerances of
less than 1/100 of the
thickness of a hum hair
an
are possible
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12. Inspection
q All com on inspection
m
techniques can be used
q Difficult to detect defects
w ithin the com ponent -
g ood proce s s ing re quire d
q Crack detection
perform on surface.
ed
q Rem ber Ceram
em ics
have “ elephant like”
m ories
em
DYNAMIC-CERAMIC
13. Microstructure
q Fine, uniform &
hom ogeneous
m icrostructure
(Technox 2000)
q Toughened by
“Transform ation
Toughening”
DYNAMIC-CERAMIC
14. Temperature (C)
3000
Liquid (L) L+F
2500
Cubic (F)
2000 Transformable 1600 C Tie Line
Tetragonal (T)
1400 C Tie Line
1500
T+F
1000 M
+
T
500
Non-Transformable
0 Cubic
Monoclinic (M) Tetragonal (T')
5 10 15
Mol % Yttria
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15. Crystal Structure
Monoclinic Tetragonal Cubic
1172C
o
2370C
o
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22. The Reality
q The Com bination of
Strength &
Toughness w ith
defect free processing
q Impact resistance into
the regim of
e
m etallics
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23. Performance in Aggressive
Environments
q Erosive Wear Tests
q High Pressure Sand & Water
–25 m 90° against direction of
/s,
impact for 30 minutes.
q Volum lost is com
e pared to a
Standard Stainless Steel
control pin
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29. Flow Control
q Flowcontrol valves
and chokes
q Reduce cavitation
and erosion
q steel ceram ic
assem blies
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30. Cutting Edges
q Technox
zirconia
blades last
up to 1000
tim es
longer than
steel
blades.
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31. Oil & Gas Exploration
q Solid Technox 3000
pum body
p
q Located sub-sea
and pum un-
ps
filtered sea water
q “innovation aw ard”
w inner
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32. NEW AREAS OF PETROLEUM
EXPLORATION FOR DYNAMIC
q Ceram Cutting Inserts (a.k.a.
ic
buttons) for Heads –(Not y e t be ing
manufacture d pre s e ntly )
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33. Other Deep Water Alternatives
for Future Ceramic Development
q Split Shot Covers
q Ceram Pipe
ic
Com ponents
q Gaskets in BOP
Annular Preventers
q Liners
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34. Hydrocyclones
q Slip cast alum ina
bow ls
q Large Diam eters
–1m
q Bonding and
installation
im portant
25cm
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36. Solids Handling
Hang e r Be aring s
q Used in journals of screw
conveyors
q Have replaced W Stellite in
C/
m any applications
qUsed in aggressive
environm ents;
q Cem ent Industry
q Quarries
q Pow Generation
er
qM etal Refineries
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