Aluminum oxide ceramic cylindrical groove roller is a special ceramic component with α – type alumina (α – Al ₂ O3) as the main crystal phase, manufactured through precision rolling forming and high-temperature sintering process.
Core performance indicators:
硬度と耐摩耗性： The Mohs hardness reaches level 9, second only to diamond, and is more than three times that of 304 stainless steel. In mining machinery, the wear of ceramic lining plates during continuous operation for 5 years is less than 0.5mm, significantly reducing the frequency of equipment shutdown and maintenance.
高温耐性と熱安定性： The melting point is as high as 1650 ℃, and the coefficient of thermal expansion is only 8.1 × 10 ⁻⁶/℃. It can be continuously stirred in glass melt at 1400 ℃ without deformation. After embedding ceramic lining in the powder discharge casing of thermal power plants, the service life is extended from 6 months to 6 years.
Corrosion resistance and chemical stability: In acidic and alkaline environments with pH 3-11, the annual corrosion rate is only 1/50 of stainless steel, making it suitable for strong corrosion scenarios such as semiconductor etching chambers and chemical reaction vessels.
Electrical insulation and precision machining: Volume resistivity>10 ¹⁴Ω· cm, supporting nanometer level precision machining, surface roughness Ra ≤ 0.1 μ m, meeting the stringent requirements of semiconductor wafer handling robotic arms.
Structural innovation: The cylindrical surface is designed with spiral or straight groove shaped grooves, with adjustable groove width of 0.1-10mm and groove depth accuracy of ± 0.01mm, achieving material grading, airflow guidance, or mechanical positioning functions.
Core application scenario: Cracking industrial pain points
- Semiconductor Manufacturing: Precise Control in Clean Environments
問題だ： Wafer processing needs to be completed in a vacuum dust-free environment. Traditional metal rollers are prone to particle contamination and have poor resistance to plasma corrosion.
解決策
High purity alumina ceramics (with Al ₂ O3 content>99.5%) are used to etch the inner lining of the cavity, reducing the metal contamination of the wafer by plasma.
The ceramic robotic arm is equipped with groove rollers to achieve contactless handling of wafers in a vacuum environment, with a positioning accuracy of ± 0.005mm.
In chemical mechanical polishing (CMP) equipment, ceramic rollers serve as supporting components for the polishing table, with a lifespan 10 times longer than metal parts. - Mineral processing and powder metallurgy: efficient grading and wear-resistant upgrading
問題だ： Traditional stainless steel grading wheels are prone to deformation under high pressure friction, leading to a decrease in material classification accuracy.
解決策
The compressive strength of the alumina ceramic grading wheel reaches 2000MPa, and it maintains shape stability under a pressure of 5MPa, with a grading particle size error of less than 2%.
The groove design optimizes the airflow distribution, increasing the recovery rate of ultrafine powder by 15%, and is widely used in the production of positive electrode materials for lithium-ion batteries. - Chemical and Energy: Long Life Operation in Corrosion Resistant Environments
問題だ： The roller of the sulfuric acid delivery pump corrodes at a rate of up to 0.5mm/year in a strong acid environment, resulting in frequent replacement.
解決策
The surface of the ceramic roller is coated with an alumina wear-resistant layer, which reduces the corrosion rate to 0.01mm/year in 98% concentrated sulfuric acid and extends the maintenance cycle to 5 years.
The groove structure enhances the liquid flow capacity, increases pump efficiency by 8%, and reduces energy consumption by 12%. - Aerospace and high-temperature industry: reliable support in extreme environments
Problem: Rocket engine nozzles need to withstand high temperatures of 3000 ℃, and traditional metal materials are prone to melting and failure.
解決策
The alumina ceramic roller serves as a support for the nozzle lining, dispersing thermal stress through groove design, and can be used at temperatures up to 1800 ℃.
In the heat treatment furnace, ceramic rollers replace graphite guide rails to avoid size changes caused by oxidation, and the product qualification rate is increased to 99.2%.
Customized Services: Full Link Support from Design to Delivery
- 材料配合のカスタマイズ
Purity Grading: We offer four purity levels of alumina ceramics: 95%, 99%, 99.5%, and 99.9%, to meet the needs of different industries.
Composite reinforcement: Adding silicon carbide (SiC) or silicon nitride (Si3N4) particles increases the fracture toughness from 3.5MPa · m ¹/² to 5.2MPa · m ¹/². - Structural design and simulation
Optimization of groove parameters: Based on CFD fluid simulation, adjust groove depth, groove width, and pitch to reduce airflow resistance by 20%.
Finite element analysis: Simulate 100000 high-pressure friction cycles to ensure that the roller has no crack propagation under extreme working conditions. - Precision machining and testing
Processing capability: Supports the processing of cylindrical shapes with an outer diameter of Φ 10-500mm and a length of 10-2000mm, with coaxiality ≤ 0.005mm.
Testing standards:
Hardness test: Vickers hardness tester (HV) ≥ 1500
Corrosion resistance: No corrosion after 720 hours of salt spray test
Surface defect: Laser scanning detected crack depth<0.02mm
Typical Case
A certain international semiconductor equipment supplier: customized groove rollers for 12 inch wafer transfer systems, reducing downtime losses by over 5 million US dollars annually.
Lithium mining giant: Ceramic grading wheel achieves micrometer level grading in lithium mica sorting line, with an annual efficiency increase of 120 million yuan.
European Chemical Group: Ceramic rollers for sulfuric acid pumps replace Hastelloy alloy parts, saving maintenance costs of 8 million euros in 5 years.
Aluminum oxide ceramic cylindrical groove rollers, with “hardcore performance+precise customization” as their core competitiveness, have become key components for upgrading and upgrading in fields such as semiconductors, minerals, and chemicals.
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