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Main Applications of the Wear-Resistant Ceramics

Alumina ceramics have good wear resistance, corrosion resistance and mechanical properties, and excellent production capacity. The most important thing is that alumina ceramics have a relatively low price and higher cost performance, which makes them more effective in practical use. So it has become the most widely used wear-resistant ceramic material.

We will introduce some applications of wear-resistant ceramic.

1. Application in conveying and coal conveying system
The equipment of the coal conveying and material conveying system are easy to wear and even wear through. The use of alumina wear-resistant ceramics will greatly increase the service life and bring significant improvements in safety production and economic benefits.

2. Application in pulverizing system
Most of the abrasion of the pulverizing system of coal-fired power plants is mainly caused by the collision and impact of pulverized coal. The high-speed pulverized coal airflow particularly severely wears the outlet of the coal mill, the inlet and outlet of the coarse and fine powder separator, and the elbow of the primary air duct of the pulverizing equipment. The same phenomenon occurs in the air pipe elbow of the powder selection system of the cement plant. By using wear-resistant alumina ceramics, it will have a positive impact on actual production.

3. Application in ash system
In power plants that use hydraulic ash removal and slag discharge systems, the ash pump, ash ditch, nozzle, and other inlet and outlet pipe sections are severely worn. After using wear-resistant alumina ceramics, they can be used for a long time and have good wear resistance, which solves the task of mechanical repair. Problems such as the heavy and poor environment.

4. As a grinding medium
Due to the characteristics of high hardness, moderate density, wear resistance, corrosion resistance, and low price, alumina grinding balls are widely used in the raw materials of cement, minerals, ceramics, electronic materials, magnetic materials, and coatings, paints, and other industries. Grinding and processing is a high-quality grinding medium. In the building ceramic industry, the wear efficiency of alumina grinding balls is 20%-40% higher than that of natural flint and pebbles. With the reduction of high-quality natural ball resources and the high wear rate of ordinary ceramic balls, alumina grinding balls will be used by more and more manufacturers.

5. Oil and gas extraction
Alumina wear-resistant ceramics can be adapted to work in harsh environments, especially those ceramics with an alumina content of 97% (mass) or more, which can be used in oil and natural gas drilling equipment. Typical applications are nozzles, valve seats, adjusting devices, pump accessories, and even drill bit accessories that can vibrate in high-pressure environments, in oil and mud and mortar, and sometimes work in the presence of acids and salts. It is resistant to wear and the requirements for corrosion resistance are more stringent.

If you have more interests, pls feel free to contact us.

Innovacera Always Has Different Silicon Nitride Ceramic Balls Sizes In Stock

Innovacera develops all kinds of ceramic balls including the zirconia ceramic, silicon nitride ceramics and alumina ceramics. Many silicon nitride balls have stock.

Silicon nitride ceramic balls are precision ceramic balls which are forming in the non-oxidizing atmosphere with high-temperature sintered. At 800°C, the strength, hardness are almost unchanged, the density is 3.20g/cm3, only 1/3 weight of the steel bearing when rotating, the centrifugal force is small, can achieve high-speed operation. It can be used as a non-lubricating medium with a high pollution environment. It is ceramic bearings, hybrid ceramic ball bearings preferred balls. So it is widely used in the Bearing, Chemical, Oil industries.

Advantages:

High strength
High wear resistance
Excellent self-lubricating
High electrical insulation
Resistance to high temperature
Good magnetic insulation performance
Corrosion resistance, resisting acid and alkali, it can be long-term used in seawater.

Silicon Nitride Ceramic Ball Grades:

G3, G5, G10, G16, G20, G50, G100

General sizes:

from diameter 0.794 mm to 101.600 mm.

Based on the stock feature, Innovacera has a short lead time and competitive price advantages for our silicon nitride ceramic balls. Click to buy now

What is the oxygen sensor made of?

The oxygen sensor consists of an internal ceramic material called zirconia, with a porous platinum coating, and is protected by a metal casing. Its performance is based on changing the properties of ceramics at high temperatures, allowing oxygen to diffuse from the air.

It operates according to the difference in oxygen concentration between exhaust gas and outside air and generates a voltage of 50 mV to 900 mV.

The probe has a limitation: to start operation, it must be heated to approximately 300°C. In older probes, it is the exhaust gas itself that heats them, so you must wait a few minutes before putting the sensor into operation. Currently, there is a heating resistor next to the ceramic, even if the exhaust gas is in a low-temperature state, it can be heated for up to 10 seconds.

We have to make a thimble type and planar type of ceramic heater for the oxygen sensor.

Blow is the thimble type oxygen sensor structure drawing.

This is the structure drawing for the planar type

If you want to know more about oxygen sensor heaters, pls contact us at any time.

Why the oxygen sensor is air leakage?

The oxygen sensor is a very important sensor. The function of the oxygen sensor is to sense the oxygen content of the exhaust gas discharged from the engine and give a signal to the engine computer in the form of voltage. The engine computer uses the signal of the oxygen sensor to control the fuel injection volume. If the oxygen sensor is damaged, it will have a problem of increased fuel consumption. If the oxygen sensor is loose, it is not acceptable, because it will leak. After the leak, the signal from the oxygen sensor to the computer may be inaccurate, affecting the engine’s power and fuel consumption, so if it is loose, it should be repaired as soon as possible.

But do you know why the oxygen sensor will leak when assembling the ceramic heater chip?

There are two of the reasons:

One is the chip sealing is not doing well. Around the oxygen sensor piece, the power ring needs to be crushed to fill the gap. If there is no powder ring compaction, there will be a gap leakage problem.

The other is due to the high pressure of the pressing powdering ring, about 10 tons, and the oxygen sensor plate is not straight, which may break the oxygen sensor plate.

How to prevent the leak?

Our products will be 100% tested before leaving the factory, such as withstand voltage test, so there is no possibility of air leakage before leaving the factory.

Should you have more questions, please contact us at any time.

Pyrolytic Boron Nitride (PBN) MBE Crucible for epitaxial growth of Ⅲ-V and Ⅱ-VI semiconductor crystals

The purity of the Pyrolytic Boron Nitride (PBN) product is extremely high, and the purity of the gaseous feedstock is easier to control. Generally, the total impurities of PBN products are <100 ppm, which means that the purity is not less than 99.99%. This high-purity PBN product is ideal for the semiconductor industry and vacuum systems.

Molecular beam epitaxy (MBE) is one of the most important epitaxial growth processes of group III-V and group II-VI semiconductor crystals in the world. It is a method of growing thin films layer by layer along the crystal axis of the substrate material under appropriate substrates and conditions.

PBN crucible is the best container for evaporating elements and compounds in the MBE process.

The following is the schematic diagram of MBE technology.

Note:
Molecular Beam Epitaxy (MBE) is a technology that sprays a certain proportion of the various components and doping atoms (molecules) that make up the crystal onto the surface of the hot substrate at a certain thermal motion speed under ultra-high vacuum conditions to grow the crystal.

We provide custom PBN crucibles and VGF / LEC / Conical / MBE / OLED crucibles.

Announcement of Infringement

A statement about our website being maliciously plagiarized

Recently, our marketing department has discovered that our website has been illegally plagiarized, misappropriated, counterfeited by many same technical ceramics industry. This is very bad behavior, it has seriously violated our website copyright and has infringed upon our company’s reputation and our customers benefit.

The infringing company completely imitated and maliciously copied our official website, except for the company name and contact information. Their layout, color, pictures, and content, etc. are exactly the same as our company’s official website. What’s even more exaggerated is copying without making any changes.

Innovacera official website is an important external publicity platform for our company. Although in the Internet era, information is open and shared, and our company also supports communication and learning, plagiarism without a bottom line has constituted a serious infringement and has seriously damaged our legitimate rights and benefits. Innovacera believes that companies that use opportunistic means to plagiarize the results of other people’s websites cannot last for a long time, and at the same time cannot provide their customers with credible and good settlement services.

Our company hereby solemnly declares: We strongly despise and condemn this kind of opportunistic and unearned practice. Please immediately delete all infringing source codes and revoke all infringements of companies, platforms, and individuals who are suspected of plagiarizing, embezzling, counterfeiting, or plagiarizing our website, products, and Content, and stop all related infringements at the same time.

For the above plagiarism behavior, we hope that the plagiarism company will abide by the industry ethics and take the relevant pages offline as soon as possible. In order to protect the legitimate rights of our company, our company has collected fixed relevant evidence and reserves the right to pursue related economic losses. Our company will maintain zero tolerance for infringements in the same industry, and will continue to carry out rights protection activities in the future, and will pay attention to infringements on a regular basis. Here we also call on the majority of users and clients to believe firmly Innovacera’s official website at www.innovacera.com.

Other websites with similar layouts and similar content are not relevant to our company. Please do not be deceived. At the same time, we also welcome our clients to supervise and report the infringing company for us and jointly resist this bad behavior. How can a company that has copied its official website win the trust of its customers? The following is an example of some plagiarized page content for reference:

What’s new about the laminated planar oxygen sensor?

The advocated global environmental preservation has brought the increasing stringent on emission regulations. How to reduce hydrocarbon (HC) emission at engine cold start is essential for an automotive, therefore, it’s necessary to control engine exhaust air to fuel (A/F) ratio and warm up the catalyst as quickly as possible. Oxygen sensors are widely used to control the A/F ratio at around the stoichiometric point, where three-way catalysts are most effective.

The traditional oxygen sensor is made of alumina and inserts into a zirconia ceramic tube and commonly takes some 20 seconds to activate.

New laminated planar oxygen sensor combined alumina and zirconia together, heater element was embedded in the zirconia substrate of the sensor element adopting alumina for the heater substrate material, solve the problem of low thermal conductivity of zirconia while guarantee the good heating:

– High thermal conductivity and superior dielectric characteristic, by the direct joining of the alumina ceramic heater substrate and the sensor element zirconia electrolyte.
– Low heat stress at temperature rise, due to optimized heater design.
– Superior sensor protection from water droplets, and improved sensor response, due to optimized arrangement of intake holes in the sensor cover.

With these characteristics, the oxygen sensor can be activated in 10 seconds after a cold start.

Porous Ceramics Cleaning and Machining Guidance and Precautions

1. Machining guidance and precautions:

The porous ceramic plate is soaked in clean tap water for 5 minutes, and then processed.
So as to prevent the oil from penetrating into the dry ceramic plate and not being washed away.
The porous ceramic is cut by a diamond blade and uses a grinding wheel or grinding head to grind.
After processing, use neutral detergent and ultrasonic cleaning. Pls avoid processing with oily coolant, otherwise, it will be difficult to clean.
Last step: drying natural or drying water with an electric fan.

2. To clean the porous ceramic plate:

Using ultrasonic cleaning with neutral detergent to clean. The neutral detergent is not strong acid or alkaline, that is fine. Like washing powder, dishwashing liquid.
After cleaning, drying natural, or drying water with an electric fan. Please don’t use oven dry for avoiding deformation.

Process Comparison of the Ceramic Substrate

The metallized ceramic substrate is a kind of circuit board. It has a thermal expansion coefficient close to that of semiconductors and high heat resistance. It is suitable for products with high heat generation (high-brightness LED, solar energy), and its excellent weather resistance is more suitable for harsh outdoor environments. Because it has the characteristics of lead-free, non-toxic, and good chemical stability, it will not cause harm to environmental protection, so it is more and more widely accepted by the public.

Due to different processes, the ceramic substrate is mainly divided into DBC (Direct Bonded Copper), DPC (Direct Plated Copper), AMB (Active Metal Brazing), and Thick film.

We will introduce each of the processes and the advantages, disadvantages of each process.

DBC (Direct Bonded Copper)

It is composed of the ceramic substrate, bonding layer, and conductive layer. It refers to the special process of copper foil directly bonding to alumina or aluminum nitride ceramic substrate surface at high temperature.

The advantages are as below:

The copper layer is thick;
The processing is fast;
The price is cheap;
Can make multilayer;
Suitable for large area consumption;
High thermal conductivity;
High adhesion strength;
Excellent soft brazing;
Excellent electrical insulation

The disadvantages are as below:

Can not pass through the hole;
Poor accuracy;
Low flatness (surface roughness);
Suitable for the device in the large distance of the product, can not be done in the precise occupation.

DPC (Direct Plated Copper)

Mainly by evaporation, magnetron sputtering and other surface deposition process to carry on the substrate surface metallization, first under the condition of vacuum sputtering, titanium, and then is copper particles, the plating thickness, then finish making line with ordinary PCB craft, and then to plating/electroless deposition way to increase the thickness of the line, the preparation of DPC way contains vacuum coating, wet deposition, Exposure development, etching, and other processes.

The advantages are as below:

In terms of shape processing, DPC ceramic plate needs to be cut by laser, the traditional drilling and milling machine, and punch machine can not be accurately processed, so the combined force and line width are also finer.
The crystal performance of the metal is good;
The flatness is good;
The line is not easy to fall off;
The line position is more accurate, the line distance is smaller, reliable, and stable, can be through the hole and other advantages.

The disadvantages are as below:

It can only make a thin plate (thickness < 300μm), and its cost is high, the output value is limited, resulting in frequent shipment time can not be on time.

AMB (Active Metal Brazing)

It is a method to realize the bonding of ceramic and metal by reacting a small number of active elements Ti and Zr in filler metal with ceramics to form a reaction layer that can be wetted by liquid filler metal.

The advantages are as below:

The combination is achieved by the chemical reaction between ceramic and active metal solder paste at high temperatures, so its bonding strength is higher and reliability is better.

The disadvantages are as below:

The reliability of the AMB process depends largely on the composition of active filler metal, brazing process, brazing layer structure, and many other key factors.

Thick film

Thick film technology is straight on ceramic substrate printed graphics, then direct sintering process.

The advantages are as below:

The bonding force with ceramic is much greater than that of the DPC process;
It is direct printing of graphics, no etching, and copper plating process, so the cost will be lower;
It is a one-time forming, so the flatness is smoother than that of the DPC.

The disadvantages are as below:

Because the thick film process is printed, it is generally not too thick. Due to different product requirements, different materials have a certain impact on the conductivity of the film.

So it is hard to say which process is best, it depends on the customer’s application and usage, customer could choose each of the processes according to their requirements.

Should you have more interests, pls feel free to contact us at any time.

How Many Oxygen Sensors Does a Car Have?

The oxygen sensor is a car part that you probably never think much about. In fact, you may be unsure of what it even does, yet it is essential for your vehicle to function normally or perform optimally.

An oxygen sensor, which is sometimes abbreviated as an O2 Sensor, generates a reading based on the oxygen level within the automotive exhaust system. The oxygen sensor is made of ceramics and includes a number of pores, which are electrodes coated in platinum and surrounded by a threaded casing. The sensor is effectively screwed into the exhaust pipe with half of it sticking out. Most sensors undergo a heat test, which ensures they can reach their optimal operating temperature promptly.

How Many Oxygen Sensors Does a Car Have?

Most new vehicles are required to have catalytic converters in each exhaust pipe. These catalytic converters take harmful gasses and turn them into less harmful gasses. Every catalytic converter is required to have a couple of oxygen sensors.

So if you have a single exhaust system, you probably have one catalytic converter and, thus, two oxygen sensors. Cars with double exhaust pipes, meanwhile, will be fitted with a total of four oxygen sensors.

The actual number of oxygen sensors for a car depends on the year, make, model and engine. However, most of the later model vehicles have four oxygen sensors. Note the following specific vehicles that have four oxygen sensors:

2013 Honda Civic 1.8L 4 cylinder
2010 Chevrolet Tahoe 6.0 L 8 cylinder
2004 Jeep Wrangler 4.0L 6 cylinder
2000 Toyota Land Cruiser 4.7L 8 cylinder

The number of sensors varies according to engine type:

Traditional V6 and V8 have three oxygen sensors including a left bank and right bank sensor upstream and a downstream O2 sensor
4 cylinder transverse has an upstream and a downstream O2 sensor
V6 and V8 transverse have four oxygen sensors including a left or front bank upstream; right or rear bank upstream; rear of the engine; and a downstream sensor
4 and 6 cylinders in-line have three oxygen sensors including a front and rear bank upstream and a downstream sensor

INNOVACERA specializes in the production of ceramic heating elements in oxygen sensors and has many years of experience. Please feel free to contact me if you need it.