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What is Ceramic Fabrication?

22 July 2021 kernel
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Ceramics are a hugely versatile material with products ranging in shape, size, complexity, structure, style and cost. Ceramics are made of various hard, heat-resistant materials, shaped and then permanently hardened by heat. The result is a robust and rigid product that is heat and corrosion-resistant. Ceramics have low electrical and thermal conductivity and chemical inertness, making them ideal for many industries. 

What are industrial ceramics?

Ceramics are heat resistant, long-lasting, tough insulators that are unreactive with other chemicals.  Thanks to these properties, industrial ceramics are resistant to wear from highly abrasive materials and are effective against impact resistance.  From dental implants and synthetic bones to spark plugs and wind turbines, ceramics are tried and tested as a trusted material in all applications. 

How does ceramic fabrication work?

Traditional ceramics are typically made up of clay, sand or other naturally occurring minerals and combined with water. These ceramics are then shaped and fired in a high-temperature kiln to produce the solid material.  However, modern advanced ceramics are fabricated in different conditions to their traditional counterpart.   Made in the laboratory, these modern ceramics are manipulated by various processing techniques to get the most out of the chemical bonds and atomic structure that make ceramic so strong. 

The chemical compounds found in industrial ceramics

In industrial ceramics, chemically prepared ceramic powders are used instead of naturally found minerals. These highly pure synthetic powders are able to be manipulated with specific chemical compositions and particle sizes to achieve the desired attribute. Rather than employing liquid-phase sintering in traditional ceramics, modern ceramics are thickened by either transient-liquid sintering or solid-state sintering. In this process, particle size is crucial! Anyone developing these ceramics ensures they are made with active ceramic powders with a smaller grain size. 

Moulding of ceramic powders

Next, the ceramic powders are moulded together using water or a binder and formed into the desired shape. The forming methods for industrial ceramics are called extrusion, pressing, tape casting, slip casting and injection moulding.  This begins the particle forming process, and the result is “green” ceramics. Green ceramics are used to describe the new generation of non-toxic, high-performance, engineered bio-composite ceramics ideal as a construction material.  Once the particles are bonded, these ceramics undergo heat-treatment called firing or sintering. The result? The tough and incredibly durable substance of ceramic we know and love.  At ACE, we produce ceramic wear liners to protect your industrial equipment. We know how effective ceramic is in overcoming excessive wear experienced in mining and other bulk materials handling applications. Rather than seeing the effects of abrasive matter over time, protect your assets with wear-resistant ceramic and metallic wear solutions. Reach out to our team to find out what we can offer you.

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