La raison du prix élevé des composants structurels en céramique de nitrure de silicium

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Composants structurels en céramique de nitrure de silicium are playing an irreplaceable role in high-end manufacturing, semiconductors, aerospace, and new energy industries. However, many users have doubts about its high price when they first encounter it.

Why is silicon nitride ceramic “expensive”?
The high price of silicon nitride ceramics is not groundless, but is determined by the high cost of the entire process from raw materials to preparation techniques.

1. High cost of raw materials
   High purity powder: To prepare high-performance silicon nitride ceramics, the first step is to obtain silicon nitride powder with extremely high purity (usually>99.9%), uniform particle size, and sub micron size. The synthesis process of this high-purity powder is complex (such as direct silicon powder nitriding method, carbon thermal reduction method, etc.), requiring extremely high equipment and control requirements, resulting in its own high price.
2. The preparation process is complex and energy consumption is high
   Molding technology challenge: in order to obtain complex and precise shapes, advanced near net molding technologies such as injection molding and gel injection molding are needed. These technologies involve organic carriers, mold development, etc., with huge cost investments.
   Sintering technology is the core key: silicon nitride is a strong covalent compound with low diffusion coefficient, making densification extremely difficult. Special sintering processes such as pressure sintering or hot isostatic pressing must be used, carried out at high temperatures of up to 1700-2000 ° C and under nitrogen pressures of several or even tens of megapascals. This process requires extremely strict requirements for sintering furnace equipment (the equipment itself costs millions to tens of millions), and has huge energy consumption and long production cycles (up to tens of hours), making it a major part of the cost structure.
3. The subsequent processing is extremely difficult
   Silicon nitride has high hardness (second only to diamond and cubic boron nitride) and excellent wear resistance, which makes it extremely difficult to precision machine after molding. Diamond grinding tools must be used for grinding and polishing, resulting in low processing efficiency and fast tool wear, further increasing manufacturing costs.
4. Strict quality control and testing
   Products applied in high-end fields must undergo a series of strict tests such as non-destructive testing, density, hardness, fracture toughness, and Weibull modulus (reliability index). These testing equipment and processes also require high investment to ensure that every ceramic structural component leaving the factory meets stringent performance requirements.

Value embodiment: Why is it “valuable”?
Despite the high price, the value brought by silicon nitride ceramic structural components in specific application scenarios far exceeds their cost. It often solves pain points that traditional materials cannot solve.

Product advantages and problems that can be solved:
Ultimate thermal performance: high temperature resistance (up to 1200 ° C without deformation), heat shock resistance (extremely fast heating and cooling without cracking). This solves the problem of metal softening and oxidation in rapid cooling and heating environments, while ordinary ceramics can explode.
Excellentes performances mécaniques : high strength, high hardness, and ultra wear resistance. Solved the problem of short component life, frequent replacement, and affecting the continuous operation of equipment under high stress and high wear conditions.
Unique chemical stability: corrosion resistance, oxidation resistance, and compatibility with most molten metals such as aluminum, copper, and zinc. Solved the problem of materials being easily corroded and contaminated in corrosive environments or metal smelting.
Excellent electrical performance: good electrical insulation. Solved the contradiction between insulation and thermal conductivity in high temperature and high frequency environments.

Typical product applications:
Industrie des semi-conducteurs : electrostatic suction cup, heater base, process chamber lining. They need to remain stable in a plasma environment, not produce pollution, and have excellent insulation and thermal conductivity.
Bearing field: high-speed, high-precision all ceramic bearings and hybrid ceramic bearings. Solved the problem of short service life and poor reliability of steel bearings in non lubricated, high-speed, and corrosive environments.
Véhicules à énergie nouvelle : IGBT power module heat dissipation substrate. Its high thermal conductivity and low thermal expansion coefficient can be matched with the chip, ensuring the long-term reliable operation of the module.
Industrial field: wear-resistant sealing rings, sandblasting nozzles, rollers. Under extreme wear conditions, the lifespan is several to tens of times longer than that of hard alloys.

Why choose us? ——Value co creation, not simple buying and selling
Choosing a reliable partner is crucial in the face of high investment and technological barriers. We are not only suppliers, but also your partners in solving cutting-edge technological problems.
Deep cultivation of technology: We have been focusing on the research and production of high-performance silicon nitride ceramics for over ten years, mastering the complete set of core processes from powder processing to pressure sintering.
Quality commitment: We adopt full process automation control and strict SPC statistical process control to ensure consistency and high reliability of product performance, with a stable Weibull modulus at a high level.
Application experts: We have a senior team of engineers who can provide you with full process technical support from material selection, structural design to application verification, and work together to optimize solutions.
Cost effectiveness: Although silicon nitride is expensive, we are committed to providing customers with longer service life, lower downtime maintenance costs, and higher overall production efficiency through process optimization and large-scale production, ultimately achieving cost reduction and efficiency improvement.

Cas réel d'un client (anonyme)
Case 1 (Semiconductor Equipment Manufacturer):
A leading semiconductor equipment manufacturer, whose key component in etching equipment – ceramic heating plates, has long been limited by imported products, resulting in high prices and long delivery cycles. We collaborated with our engineering team to successfully develop a silicon nitride heating plate that meets the requirements by optimizing the material formula and sintering curve. The product has reached or even exceeded the import level in terms of thermal uniformity, plasma erosion resistance, and service life, helping customers break the technological monopoly, reduce procurement costs by 30%, and ensure supply chain security.
Case 2 (Industrial Pump Manufacturer):
A company that provides high-end pumps for the chemical industry has severe wear and tear on its mechanical seals when transporting highly corrosive and particulate media, requiring replacement every 2-3 weeks on average, resulting in frequent equipment shutdowns for customers. After adopting the silicon nitride sealing ring we provided, its service life has been extended to over 6 months. Significantly reduced downtime and maintenance costs, bringing significant economic benefits to customers.

Have you also encountered challenges in your product development and production due to material performance bottlenecks? Welcome to leave a comment in the comment section to discuss the difficulties you have encountered, perhaps we can find a breakthrough together!

Brudeze Ceramics fournit et vend une large gamme de verre de quartz de haute qualité, y compris des céramiques d'alumine, des céramiques de zircone, des céramiques de nitrure de silicium, des céramiques de nitrure d'aluminium, des céramiques de carbure de silicium, des céramiques de carbure de bore, des biocéramiques, des céramiques usinables, etc. Nous pouvons répondre aux exigences de personnalisation de divers produits céramiques.