technology metals | advanced ceramics - deutsche messe
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H.C. Starck - At a Glance
www.hcstarck.com
H.C. Starck Ceramics – New Applications for Si3N4
Hannover Messe 2013
Technology Metals | Advanced Ceramics
H.C. Starck - At a Glance
www.hcstarck.com
Location
Slide 2
H.C. Starck Ceramics GmbH, Selb
München
H.C. Starck - At a Glance
www.hcstarck.com
Company Profile
• Global player in the area of ceramic ready to press powders and fabricated ceramic products
• 22 M Euro sales (2011)
• 230 employees (2011)
Slide 3
H.C. Starck - At a Glance
www.hcstarck.com
Business lines / Product lines
Slide 4
Business lines
• Sealing Parts
• Foundry Parts
• Engineering Parts
• Dental
Product lines
• SOFC
• Metal Films
• Ceramic Films
• Nitrides
• Ceramic Carbides
• Other Ceramics
PowdersCeramic Parts CMF
H.C. Starck - At a Glance
www.hcstarck.com
Our Product portfolio
Foundry
Dental Engineering partsRenewable energy
Sealing parts Powder
H.C. Starck - At a Glance
www.hcstarck.com
H.C. Starck’s unique and comprehensive ceramic product portfolio contains:
Our material portfolio
H.C. Starck - At a Glance
www.hcstarck.com
Ceramics characteristics
H.C. Starck - At a Glance
www.hcstarck.com
Silicon NitrideSi3N4 microstructure
Edged Surface
Fracture Surface
H.C. Starck - At a Glance
www.hcstarck.com
• Quality (costs) of the
SN-Powder
• Kind and Quantity of sinter
aids
• Kind and Quantity of
secundary phases
• Sinter processes
• Quality (costs) of the
SN-Powder
• Kind and Quantity of sinter
aids
• Kind and Quantity of
secundary phases
• Sinter processes
=>
• Microstructure
• Properties like:
- RT- u. HT-Strength
- Hardness
- Corrosion Resistance
- Electrical Conductivity
• Costs of the engineering parts
• Microstructure
• Properties like:
- RT- u. HT-Strength
- Hardness
- Corrosion Resistance
- Electrical Conductivity
• Costs of the engineering parts
Silicon NitrideInfluence to the main Properties
H.C. Starck - At a Glance
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Silicon NitrideProperties in comparison to metallic materials
Density 18 [g/cm3]
Strength at RT 1800 [MPa]
Strength at 1000 °C 1200 [MPa]
Fracture toughness 60 [MPa m1/2]
Youngs-Modulus 600 [GPa]
Hardness 30 [GPa]
Thermal conductivity 60 [W/mK]
Thermal expansion 18 [10-6/K]
Si3N4
Steel
Hard metal
H.C. Starck - At a Glance
www.hcstarck.com
Silicon NitrideComparison to steel
Positive factor concerning rolling tools
Limitating factor concerning rolling tools
Property Si3N4
(100 bar) Steel
(35CrAlNi7)
Density [g/cm³] 3,23 7,6
Bending strength RT [MPa] 850 900
Bending strength 1200 °C [MPa] 500 None
Young’s Modulus [GPa] 300 210
Thermal expansion coefficient [1/K] 3,4 * 10-6
13 * 10-6
Thermal conductivity [W/mK] 25 100
Fracture toughness [MPam1/2] 6,5 80
Hardness HV10 [GPa] 15,2 9,5
Corrosion Resistance High Low
Wear factor [mm³/Nm] on Steel 2*10-6 1*10-5
Cost High Low
H.C. Starck - At a Glance
www.hcstarck.com
Silicon NitrideComparison to hard metal
Property Si3N4
(100 bar) Hard Metal
(WC)
Density [g/cm³] 3,23 15
Bending strength RT [MPa] 850 1600
Bending strength 1200 °C [MPa] 500 800
Young’s Modulus [GPa] 300 600
Poisson’s ratio 0,25 0,2 - 0,3
Thermal expansion coefficient [1/K] 3,4 * 10-6 6 * 10-6
Thermal conductivity [W/mK] 25 50
Fracture toughness [MPam1/2
] 6,5 20
Hardness HV10 [GPa] 15,2 22
Critical temperature difference R1 590 355
Cost High High
Positive factor concerning rolling tools
Limitating factor concerning rolling tools
αµσ
⋅−
=E
R)1(
1
H.C. Starck - At a Glance
www.hcstarck.com
Outer side: advantages
Inner side: disadvantages
Silicon Nitride Advantages and disadvantages in comparison to steel and hard metal
Steel
Hard metal
Silicon Nitride
Thermal
Expansion
Corosion
Resistance
Density
Temperature Stability
Workability
Costs/kg
Thermal Shock
Resistance
Fracture Toughness
Thermal Conductivity
Compression Strength Youngs Modulus
Wear
Resistance
Hardness
H.C. Starck - At a Glance
www.hcstarck.com
High PressureOxidizer Turbopump
Space Shuttle Main Engine (SSME)
Since 1995 all Space Shuttle missions have used silicon nitride balls and rollers inspected ultrasonically by H.C. Starck
Silicon Nitride applicationsExamples Ball and Roller Bearings
• Project Outline• Industries: Aerospace, Automotive, Tooling machines,
Medical Industrie, Chemical Industrie
• Benefit: wear resistance, overall impr. properties
• Success factors: accuracy, mass-production price
Silicon Nitride Rollers forhybrid bearings
H.C. Starck - At a Glance
www.hcstarck.com
Twin screw extruder forTungsten carburization• Tungsten particle range 0,45 – 2,5 µm
• Silicon Nitride screws and Silicon Carbide
cylinder
• Up to now 12 t are processed without any
problems
Silicon Nitride applicationsExamples Augers
H.C. Starck - At a Glance
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Silicon Nitride for tube welding systems
Usage of welding rollers SN-Roller New
• Tribochemical reaction with cooling medium reduced surface quality
• Sparkover at inductor tube seam is not welded right
Usage of ceramics without change of construction
Silicon Nitride rolling applicationsExamples
H.C. Starck - At a Glance
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Used steel rollerUsed SN-roller
Extended life time: 2,5
Da = 100 mm
B = 40 mm
Da
BAdvantage:
• lower up to no tribochemical reaction to the cooling medium
• No sparkover
• 3 fold higher lifetime in comparison to hard metal
Corrosion, Adhesion
Wear
Silicon Nitride rolling applicationsExamples
H.C. Starck - At a Glance
www.hcstarck.com
Sheet rolling
Silicon Nitride applications Examples Rollers
Tube rolling
SSN-roller after rolling
of 1000 t steel rods
Temperature > 900°C
Last Result:
successful rolling of 7000 t
H.C. Starck - At a Glance
www.hcstarck.com
• Important properties of Silicon Nitride are:low density, high toughness, high strength also at high temperatures
• Silicon nitride can be used in a wide range for engineering parts
• In dependence to the application, lifetime could be increased by using Silicon Nitride
First Summary
Silicon Nitride
• But: only diamond hard machiningdue to no electric conductivity, no EDM machining possible
H.C. Starck - At a Glance
www.hcstarck.com
10 bar 100 bar 2000 bar
Sinter process at N2 pressure
Density:
Strength σσσσ0:
Weibull m:
Electr. Conductivity:
3,92 g/cm³
700 MPa
15
0,00013 ΩΩΩΩm
3,95 g/cm³
680 MPa
31
0,00007 ΩΩΩΩm
3,95 g/cm³
715 MPa
31
0,004 ΩΩΩΩm
Silicon Nitride Electric conductive and wear resistant
H.C. Starck - At a Glance
www.hcstarck.com
Standard SN Density [g/cm³] 3,9 3,2Porosity [%] 0 0Av. Bending strength** RT [MPa] 700 800Weibullmodulus RT [-] >15 >15
Fracture toughness* [MPa√√√√m] 8-9 6-7Hardness (HV 10) [GPa] 14 15E-Modulus (RT) [GPa] 340 280
Poisson ratio νννν 0,21 0,27Thermal conductivity (RT) [W/mK] 45 20Thermal expansion(RT-1000°C) [x10-6K-1] 5,8 3,4Spec. electrical resistance at RT [Ωm] 10-3-10-4 1011-1012
Thermal shock R1 [K] 300 600Max usage temperature [°C] 900 (Air) 1100
* ICL-Method** 4 Point-Bending strength 40/20mm
Physical Properties
Silicon Nitride Electric conductive and wear resistant
H.C. Starck - At a Glance
www.hcstarck.com Slide 22
1,00E-09
1,00E-08
1,00E-07
1,00E-06
1,00E-05
N7000 N3000 N3050 ATZ SiC Steel
Wea
r m
m³/
Nm
50 N
200 N
Pin on Disc Test (Disc: Steel 1.2379, annealed to HRC60)
Silicon Nitride Electric conductive and wear resistant
H.C. Starck - At a Glance
www.hcstarck.com Slide 23
Pin on Disc Test (Disc: Steel 1.2379, annealed to HRC60)
Silicon Nitride Electric conductive and wear resistant
0,0E+00
2,0E-06
4,0E-06
6,0E-06
8,0E-06
1,0E-05
1,2E-05
Steel Starceram® N 7000 Starceram® N Grade E
Wear [m
m³/N
m)
H.C. Starck - At a Glance
www.hcstarck.com
Applications
Due to electric conductivity
• plunge and wire EDM
- Micro drill holes
- gears
- Tools for injection molding
• Deduction of electric loads
- bearings
- electrodes
Due to high wear resistance
• Usage for wear components
- Extrusion augers
- bearings
- Pressing tools
- Tools for injection molding
Silicon Nitride Electric conductive and wear resistant
H.C. Starck - At a Glance
www.hcstarck.com
Industry
• Extrusion Tools
• Gear Pumps
• Rolling
• Pressing Tools
Auger ElementInternal gearingby EDM possible
Dry pressing mould:-30.000 SiC Hexagons pressed- up to now no significant wear
Silicon Nitride Electric conductive and wear resistant
Tool for injection moulding
H.C. Starck - At a Glance
www.hcstarck.com
Thank you for your attention!
Slide 26
H.C. Starck Ceramics GmbH
L.-Hutschenreuther-Str. 81 95100 Selb
T + 09287/ 807 0, F -477
www.hcstarck-ceramics.de
Visit us at H06/B04