Overview of Ceramics Industry

A ceramic is an inorganic solid material, made up of either metal or non-metal compound. Traditionally ceramics were shaped and then hardened by heating to high temperatures. In general, they are hard, corrosion-resistant and brittle material.

What are Traditional ceramics?

The Traditional ceramics can be categorized as porcelain, earthenware, and stoneware. Pottery is one of the oldest used ceramic applications.

• Earthenware is used widely for ceramic such as tableware and decorative objects. It is one of the oldest Abrasion Resistant Material used in pottery.
• Stoneware clay is non-porous, glaze material applied only for decoration. It is a sturdy, chip-resistant and durable material.
• Porcelain is a very hard, translucent white ceramic. It also known as fine china products.
• Bone china – which is easier to make and is stronger than porcelain. It is made by adding ash from cattle bones to clay, or fine silica sand.

What are advanced ceramic materials? 

The Advanced ceramics are not clay-based material; however, these are highly advanced oxides or non-oxides or combinations materials used in various industrial applications:

• Oxides: alumina (Al2O3) and Zirconia (ZrO2).
• Non-oxides: Boron carbide (B4C), Silicon carbide (SiC) and Molybdenum disilicide (MoSi2).

Applications of advanced ceramics:

Advanced ceramic materials have been established in many areas of everyday use. These have utilization from fridge magnets to an increasing range of industries. Industries like including metals production and Abrasion Resistant Ceramic processing, aerospace, electronics, personnel protection and automotive have advanced ceramics application.

 

Quick Overview of CNC Machining Services

CNC stands for Computer Numerical control machining services that comprises of the computer which acts as the controller unit of the machine. In CNC machines the program of instructions is fed directly into the computer via keyboard. The programs are stored in the memory of the computer that can edit the programs as per the requirements. Traditionally, these machines were operated by experts in the operation of machining. In the CNC machines the role of the operators is minimized. These programs can be used for different parts, and can be repeated again and again. The CNC machine offers flexibility and computational capability.

Working of a CNC Machine:

The CNC Milling machine is comprised of the computer in which the programs are fed for metal cutting. All the cutting processes should be carried out according to the final dimensions to be fed into the computer via the program. The computer decides the operations to be performed and cutting processes.

Tools that run on the CNC are:

• Milling Machines
• Lathe
• Deep Hole Drilling 

The main purpose of these machines is to scrub off the metal and them a proper shape such as round, rectangular, etc. Most of the jobs need to be machined accurately, and the operator must be specialized to make the precision jobs. The operators have to feed the program of in the computer and load tools in the machine. Rest of the work is done automatically by CNC machine. 

Different Types of Machining Techniques

Those automated refinery devices which utilize industrial components without direct human support are the CNC machines. They make use of coded instructions sent to an internal computer, to allow fabrication of parts. This technology allows quick and accurate fabrication services to make a wide variety of parts. There are several types of CNC machines, ranging from plasma cutters to simple drills.

Types of Machines:

• Milling machines: These can automatically cut materials, including metal and cutting spindle. By following a computer controlled instructions, milling cutter can move to different positions and depths as directed.

• Lathes: It is the most prominent CNC machining tools, that is used for detailed machining operations. It makes use of automated tools that spin to shape the material in symmetrical sections.

• Grinders: It uses a spinning wheel to grind down materials. Grinders are very easy to program and are used where same precision is not required as mills or lathes.

In addition to above machining tools, there are also CNC routers, which are used for a variety of materials such as machining Thermal shock resistant materials. It makes use of computer programmable 3D printers, turret punches etc.

If you are seeking for quality the machining services, choose an industrial unit that has been in operation for a considerable length of time. In terms of machining a Thermal shock resistant material, experience matters for work quality. You must choose a reliable and trustworthy company for the best experience.

Various Applications of Machining Sapphire

Sapphire is an attractive substance, often considered a precious gemstone.  It  can be produced in comparatively large dimensions due to its inertness and therefore can be machined at high temperatures. It is often used as a material for the epitaxial deposition of Gallium and Silicon Nitride.

In the Machining Sapphire process require materials to be grounded to an appropriate size, tolerance and finely polished so that the material will be useful as planned. This process creates lots of difficulties in manufacturing challenge, it is always recommended to machine sapphire under expert supervision in order to succeed.

Industrial Applications of Sapphire: 

• It can be used for insulating substrate applications in high-frequency, high-power CMOS integrated circuits. 
• The resistance of sapphire to phosphoric or hydrofluoric acid is also significant.
• In endoscopic inspection tools, sapphire is often used as a window material.
• The fine microstructure of sapphire combined with polishing and skilled machining techniques produces cutter edges and ultra fine blade.
• Sapphire has a high degree of impact erosion, therefore it is used as a material for premium transparent watch face.
• Used in devices where corrosion resistance and high temperature is required.
• Stiffness, high hardness and single crystal structure lead to use of sapphire material in many engineering or industrial components. 
• Sapphire lenses can be used in imaging applications, laser optics, and sapphire medical optics.

Sapphire is a form of the material Alumina (Aluminium Oxide – Al2O3). It is the single crystal form of Machining alumina used in engineering ceramics. Its single crystal structure has no porosity or grain boundaries. Saphire products have a measured density, which is close to the hypothetical value of pure Alumina material.

Various Methods Used in Machining Ceramics

A ceramic is non-metallic, inorganic, crystalline oxide of nitride or carbide material. These materials are hard, brittle, and sturdy in compression and posses weak shear tension. When subjected to acidic or caustic environments, these can withstand chemical erosion. The most common type advanced ceramic materials are- Silicon Carbide, Alumina and Zirconia.

Methods of machining ceramic products involve:

1. Hot Pressing
2. Dry Pressing
3. Cold Static Pressing
4. Extrusion
5. Sintering and firing

• Hot pressing: This method involves application of pressure at high temperatures, to reduce voids. It helps in production of dense sintered bodies. It yields Thermal Conductivity Ceramics bodies of simple shapes.
• Dry Pressing: In this machining method, filling of the die is done with dried and granulated raw materials. Granulated raw materials fill a metallic mold cast and pressure is applied from the top. This method is ideal for mass-production of semi-complex machinery parts.
• Cold static Pressing: In this technique of machining ceramic, the granulated raw materials are poured into a rubber casting mould. This is later are subjected to hydraulic pressure, the pressure if applied evenly from all directions, results in Isostatic pressing.
• Extrusion: In Extrusion method dried and granulated raw materials are mixed with water and binder, plasticizing agent and dispersing agent. The resulting clay body is then extruded to final shape. This method is ideal for Thermal Conductivity Ceramic having a long product having continuous cross-sections.
• Sintering or firing: During the firing or sintering process, raw materials are heated below their melting point temperature to produce a sinter powder. Depending on the intended application, sintering methods are of types —vacuum sintering, atmosphere sintering and non-oxidizing sintering.

Tantalum- Most Unheard But Important Metal

Tantalum is the element sits between hafnium, niobium and tungsten in the transition metal section of the periodic table. It is discovered in 19^th century, named after Tantalus, a figure from Greek mythology. It has atomic number 73, atomic weight 180.94, atomic symbol ‘Ta’ and it is a high density metal. Tantalum is increasingly becoming important in the 21^st century, as it plays a crucial role in making electronic devices smaller. It naturally fights corrosion.

Tantalum is rarely found in its elemental form. It is one of the high density metals, found with niobium and other radioactive elements uranium and thorium. Several industrial processes are required to extract   pure tantalum. Australia and South America account for over two-third of the world’s tantalum production. A single mine in Brazil accounts for 20% of the total annual supply. Due to the increase in the use of tantalum in electronics devices,   the cost of capacitor grade tantalum has also increased over the past decade.

This element remains very stable at temperature lower than 150 degree Celsius. It has a natural protective layer created by  tantalum oxides to protect it from corrosion. Due to the corrosion resistant property it is highly used in making of bridges and water tanks. Tantalum capacitors have very high capacitance packed in a small volume which makes it perfect for reducing the size of the electronic devices. It is found in DVD players, cell phones, hard drives, laptops and PS3.

Tantalum is used in making devices used in television, cell phones and surface acoustic wave filters. The average cell phone has about 40 milligrams of tantalum inside it. Its capacitors has very low failure rate making them accurate for manufacturing of medical equipment.  It is also used in making knee, hip and other orthopedic implants.

Benefits of CNC Machining

The CNC stands for Computer Numerical Control, is a process of machining substances  that involves computer aided technology to control tools. Tools that can be controlled in this manner include grinders, lathes, mills and routers. In this technology the computer's unique software and control console sets the system apart for use in CNC machining.

In CNC Machining the machine tools function through numerical control in which a computer program is customized for an object to be machined. The machines are programmed with a CNC machining language called G-code. This controls all features like location, feed rate, coordination, and speeds. This technology is utilized in manufacturing both metal and plastic parts for Custom Machining Services.

The main benefits of using CNC Machining is that, this process is more precise than manual machining methods. As it delivers precision machining, this process can produce complex shapes that would be almost impossible to achieve with manual machining

Below are major benefits of CNC Machining Process:

1)      Cost savings:  It  allows the operator to take full advantage of raw materials. More accuracy is delivered and less waste is produced. Therefore, it minimizes the loss and increases profit over costs.

2)      Speed:  This technology has fastened the machining process. It can quickly produce parts that would normally take multiple steps to manufacture by manual process.

3)      Improved Efficiency:  CNC machines are the most efficient mean to deliver quality and Precision machining services. The minute an error can be detected in the product therefore leads to optimum raw material usage.

4)      Safety:  As the entire process is automated, There is complete safety of operators and workers, allowing a safer work environment.

This technology is also utilized for the jobs that need a high level of precision. It is because of these qualities that CNC Machining is used for the production of many complex three-dimensional shapes.