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alumina whiteware
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  Alumina ceramics are divided into high purity type and ordinary type two. Wear plate of high purity alumina ceramic Al2O3 content in ceramic materials in more than 99.9%, because of its high sintering temperature of 1650 ℃ - 1990 ℃, the transmission wavelength of 1 ~ 6 μ m, usually made of molten glass to replace the platinum crucible: the use of its transmission and alkali metal corrosion as sodium lamp; in the electronics industry can be used as the integrated circuit substrate and high-frequency insulation materials. The ordinary type of alumina ceramic system according to different Al2O3 content is divided into 99 porcelain, porcelain 95, 90 porcelain, porcelain and other varieties of 85, sometimes Al2O3 content in 80% or 75% are designated as ordinary alumina ceramic series. Among the 99 alumina ceramic materials used for high temperature crucible refractory furnace tube, and special wear-resistant materials, such as ceramic bearings, ceramic seals and valve piece; 95 alumina ceramics is mainly used for the corrosion, wear parts; 85 porcelain often doped with talc, improve the electric performance and mechanical strength, and molybdenum, niobium, tantalum metal sealing, some used as electric vacuum device. Following the production process
  A, powder preparation: the alumina plant products in accordance with the requirements of different with different forming processes is prepared into powder material. The particle size was about 1 μ m micron, if the production of high purity alumina ceramic products except alumina purity in the 99.99%, still need to ultrafine crushing and the uniform distribution of particle size. Wear plate by extrusion or injection molding, introducing the binder and plasticizer powder, usually weight than plastic plastic or resin in 10-30% heat? Organic binder with alumina powder in 150-200 ℃ uniform mixing, in order to facilitate the forming operation. Using the raw powder hot forming process is not required to join the binder. If the use of semi-automatic or full automatic dry pressing, require special technology of powder, the need for treatment, which caused the ball to powder by spray granulation, in order to improve the fluidity of the powder for automatically filling mold wall molding. In addition, in order to reduce friction powder and die wall, also need to add 1 ~ 2% lubricant? Such as stearic acid? And binder PVA. To dry pressing need for powder spray granulation, the introduction of PVA as a binder. In recent years, a Shanghai Research Institute to develop a binder water-soluble wax is used as the Al2O3 spray granulation, has good liquidity in the heating case. Powder spray granulation must have good fluidity, loose density, flow angle is less than 30 ℃ friction. The particle size ratio of ideal condition, in order to obtain high green density
  Two, molding method: alumina ceramic products forming method with dry methods, grouting, extrusion pressing, cold isostatic pressing, injection, casting, hot pressing and hot isostatic pressing. In recent years at home and abroad and the development of press forming, direct coagulation casting, gel casting, centrifugal casting and solid freeform fabrication and molding method. Products of different shape, size, complex shape and precision products require different forming methods. Abstract: 1 common molding injection molding method: injection molding is the earliest use of alumina ceramic. Due to the adoption of plaster mold, low cost and easy forming large size, complex shape parts. Injection molding is the key of alumina slurry preparation. Usually in water flux medium, adding solution of glue and adhesive after grinding, fully exhaust, then pour into the gypsum mould. Because of the plaster mold capillary water absorption, slurry and solidification in mould. Wear plate hollow grouting, the mould wall thickness of adsorption size requirements, also be surplus slurry poured out. In order to reduce body shrinkage, should as far as possible the use of high concentration slurry. 2 dry pressing: alumina ceramic dry pressing technology is limited to the shape simple and wall thickness exceeds 1mm, the length and diameter ratio greater than 4 ∶ 1 objects. Forming method with uniaxial or biaxial. Press has a hydraulic, mechanical type two, a semi-automatic or fully automatic forming method. Press a maximum pressure of 200Mpa. yield per minute up to 15 ~ 50. As the hydraulic press stroke uniform pressure, so there are differences in the powder filling when pressing different height. Mechanical type compressor pressure size because of the powder filling much change, easily lead to sintering shrinkage difference, affecting the quality of the products. Therefore, in the process of dry powder particle uniform distribution is very important for mold filling. The filling volume and the accuracy of manufacture of alumina ceramic parts size precision control influence. Powder particles with larger than 60 μ m, ranging from 60 to 200 mesh will be the largest free flow to achieve the best effect, pressure molding effect. Alumina ceramic slurry also need to add organic additive to make the surface slurry particles to form electric double layer to make slurry stable suspension does not precipitate. In addition also need to join the vinyl alcohol, methyl cellulose, alginate amines such as binder and polyacrylamide, Arabia gum divided powder, aim is to make slurry suitable for injection molding operation
  Three, firing technology: granular ceramic densification and formation of technical methods of solid material is sintered. Sintering the blank body cavity to exclude particles, a small amount of gas and impurities organic exclusion, the particles between the growth combined with the formation of new substances, methods. Burning heating device using the most widely used electric furnace. In addition to normal pressure sintering? That pressureless sintering, and hot pressing sintering and hot isostatic pressing sintering. Continuous Hot-pressing Sintering while increasing the yield, but the equipment and tooling cost is too high, in addition because the axial heat, product length is restricted. As the pressure transfer medium with high temperature and high pressure gas hot isostatic pressing sintering, has the advantages of homogeneous heating, sintering is very suitable for the shape of complex products. Because the uniform structure, material properties than that of cold pressing and sintering increased 30 ~ 50%. Than ordinary Hot-pressing Sintering increased 10 ~ 15%. Therefore, some of the special parts, alumina ceramic products or defense industry with high added value such as ceramic bearing, mirror, nuclear fuel and other products, the barrel field by hot isostatic pressing sintering method.
In addition, microwave sintering method, arc plasma sintering method, self-propagating sintering technology is also in development studies.
  Four, finishing and packaging process: some alumina ceramic material in the finished sinter, still need to be refined. If the product can be used as artificial bone surface has high smoothness, such as a mirror, to increase the lubricity. Because the alumina ceramic material with high hardness, grinding and polishing brick material wear plate needs more hard for finishing the. Such as SiC, B4C or diamond. Usually from coarse to fine abrasive level grinding, end surface polishing. The general use of <1 μ m micron Al2O3 powder or diamond paste polished. In addition, method of laser machining and ultrasonic grinding and polishing by. Some alumina ceramic parts required for processing and other packaging materials. Alumina ceramic strengthening process in order to enhance the alumina ceramic, significantly improve the mechanical strength, foreign on an alumina ceramic strengthening process. The process is simple and novel, technical means adopted in the alumina surface, using electron beam vacuum deposition, sputtering vacuum coating or chemical vapor deposition method, plating a layer of silicon compound film, in the heat treatment at 1580 ℃, 1200 ℃ ~, the alumina ceramics toughened. The mechanical strength of alumina ceramic reinforcement can greatly increase in the original basis, with super high strength of alumina ceramic
Alumina ceramics are divided into high purity type and ordinary type two. Wear plate of high purity alumina ceramic Al2O3 content in ceramic materials in more than 99.9%, because of its high sintering temperature of 1650 ℃ - 1990 ℃, the transmission wavelength of 1 ~ 6 μ m, usually made of molten glass to replace the platinum crucible: the use of its transmission and alkali metal corrosion as sodium lamp; in the electronics industry can be used as the integrated circuit substrate and high-frequency insulation materials. The ordinary type of alumina ceramic system according to different Al2O3 content is divided into 99 porcelain, porcelain 95, 90 porcelain, porcelain and other varieties of 85, sometimes Al2O3 content in 80% or 75% are designated as ordinary alumina ceramic series. Among the 99 alumina ceramic materials used for high temperature crucible refractory furnace tube, and special wear-resistant materials, such as ceramic bearings, ceramic seals and valve piece; 95 alumina ceramics is mainly used for the corrosion, wear parts; 85 porcelain often doped with talc, improve the electric performance and mechanical strength, and molybdenum, niobium, tantalum metal sealing, some used as electric vacuum device. Following the production process
A, powder preparation: the alumina plant products in accordance with the requirements of different with different forming processes is prepared into powder material. The particle size was about 1 μ m micron, if the production of high purity alumina ceramic products except alumina purity in the 99.99%, still need to ultrafine crushing and the uniform distribution of particle size. Wear plate by extrusion or injection molding, introducing the binder and plasticizer powder, usually weight than plastic plastic or resin in 10-30% heat? Organic binder with alumina powder in 150-200 ℃ uniform mixing, in order to facilitate the forming operation.   Using the raw powder hot forming process is not required to join the binder. If the use of semi-automatic or full automatic dry pressing, require special technology of powder, the need for treatment, which caused the ball to powder by spray granulation, in order to improve the fluidity of the powder for automatically filling mold wall molding. In addition, in order to reduce friction powder and die wall, also need to add 1 ~ 2% lubricant? Such as stearic acid? And binder PVA. To dry pressing need for powder spray granulation, the introduction of PVA as a binder. In recent years, a Shanghai Research Institute to develop a binder water-soluble wax is used as the Al2O3 spray granulation, has good liquidity in the heating case. Powder spray granulation must have good fluidity, loose density, flow angle is less than 30 ℃ friction. The particle size ratio of ideal condition, in order to obtain high green density
  Two, molding method: alumina ceramic products forming method with dry methods, grouting, extrusion pressing, cold isostatic pressing, injection, casting, hot pressing and hot isostatic pressing. In recent years at home and abroad and the development of press forming, direct coagulation casting, gel casting, centrifugal casting and solid freeform fabrication and molding method. Products of different shape, size, complex shape and precision products require different forming methods. Abstract: 1 common molding injection molding method: injection molding is the earliest use of alumina ceramic. Due to the adoption of plaster mold, low cost and easy forming large size, complex shape parts. Injection molding is the key of alumina slurry preparation. Usually in water flux medium, adding solution of glue and adhesive after grinding, fully exhaust, then pour into the gypsum mould. Because of the plaster mold capillary water absorption, slurry and solidification in mould. Wear plate hollow grouting, the mould wall thickness of adsorption size requirements, also be surplus slurry poured out. In order to reduce body shrinkage, should as far as possible the use of high concentration slurry. 2 dry pressing: alumina ceramic dry pressing technology is limited to the shape simple and wall thickness exceeds 1mm, the length and diameter ratio greater than 4 ∶ 1 objects. Forming method with uniaxial or biaxial. Press has a hydraulic, mechanical type two, a semi-automatic or fully automatic forming method. Press a maximum pressure of 200Mpa. yield per minute up to 15 ~ 50. As the hydraulic press stroke uniform pressure, so there are differences in the powder filling when pressing different height. Mechanical type compressor pressure size because of the powder filling much change, easily lead to sintering shrinkage difference, affecting the quality of the products. Therefore, in the process of dry powder particle uniform distribution is very important for mold filling. The filling volume and the accuracy of manufacture of alumina ceramic parts size precision control influence. Powder particles with larger than 60 μ m, ranging from 60 to 200 mesh will be the largest free flow to achieve the best effect, pressure molding effect. Alumina ceramic slurry also need to add organic additive to make the surface slurry particles to form electric double layer to make slurry stable suspension does not precipitate. In addition also need to join the vinyl alcohol, methyl cellulose, alginate amines such as binder and polyacrylamide, Arabia gum divided powder, aim is to make slurry suitable for injection molding operation
  Three, firing technology: granular ceramic densification and formation of technical methods of solid material is sintered. Sintering the blank body cavity to exclude particles, a small amount of gas and impurities organic exclusion, the particles between the growth combined with the formation of new substances, methods. Burning heating device using the most widely used electric furnace. In addition to normal pressure sintering? That pressureless sintering, and hot pressing sintering and hot isostatic pressing sintering. Continuous Hot-pressing Sintering while increasing the yield, but the equipment and tooling cost is too high, in addition because the axial heat, product length is restricted. As the pressure transfer medium with high temperature and high pressure gas hot isostatic pressing sintering, has the advantages of homogeneous heating, sintering is very suitable for the shape of complex products. Because the uniform structure, material properties than that of cold pressing and sintering increased 30 ~ 50%. Than ordinary Hot-pressing Sintering increased 10 ~ 15%. Therefore, some of the special parts, alumina ceramic products or defense industry with high added value such as ceramic bearing, mirror, nuclear fuel and other products, the barrel field by hot isostatic pressing sintering method.
In addition, microwave sintering method, arc plasma sintering method, self-propagating sintering technology is also in development studies.
  Four, finishing and packaging process: some alumina ceramic material in the finished sinter, still need to be refined. If the product can be used as artificial bone surface has high smoothness, such as a mirror, to increase the lubricity. Because the alumina ceramic material with high hardness, grinding and polishing brick material wear plate needs more hard for finishing the. Such as SiC, B4C or diamond. Usually from coarse to fine abrasive level grinding, end surface polishing. The general use of <1 μ m micron Al2O3 powder or diamond paste polished. In addition, method of laser machining and ultrasonic grinding and polishing by. Some alumina ceramic parts required for processing and other packaging materials. Alumina ceramic strengthening process in order to enhance the alumina ceramic, significantly improve the mechanical strength, foreign on an alumina ceramic strengthening process. The process is simple and novel, technical means adopted in the alumina surface, using electron beam vacuum deposition, sputtering vacuum coating or chemical vapor deposition method, plating a layer of silicon compound film, in the heat treatment at 1580 ℃, 1200 ℃ ~, the alumina ceramics toughened. The mechanical strength of alumina ceramic reinforcement can greatly increase in the original basis, with super high strength of alumina ceramic