원형 구조의 내마모성 알루미나 세라믹 링: a wear-resistant core component for high-precision industrial scenarios
In high load industrial scenarios such as mechanical transmission, fluid control, and precision machining, traditional metal or plastic rings often experience equipment downtime and increased maintenance costs due to wear, corrosion, or high temperature failure. The annular structure wear-resistant alumina ceramic ring, with its excellent physical and chemical properties, has become a key solution to solve problems such as short ring life and accuracy degradation under extreme working conditions.
Product Introduction
The wear-resistant alumina ceramic ring with a ring-shaped structure is made of high-purity alumina (Al ₂ O3) as the substrate, and is produced through precision molding and high-temperature sintering processes. Its core performance indicators far exceed traditional materials:
- Super hard and wear-resistant, doubling the lifespan
The Vickers hardness of alumina ceramics reaches 1800-2000 HV, which is three times that of quenched steel and five times that of stainless steel. In the application of bearing rings in mining machinery, the wear of ceramic rings after continuous operation for 5000 hours is only 0.02mm, while the wear of metal rings reaches 2mm, resulting in excessive equipment vibration and forced replacement. This wear resistance extends maintenance cycles by more than 10 times and reduces lifecycle costs by 60%. - Temperature and corrosion resistance, fearless of extreme environments
The strength retention rate of ceramic rings exceeds 90% at a high temperature of 1600 ℃, far exceeding the softening threshold of metal materials at 600 ℃. In the application of the guide roller ring in the continuous casting machine of the steel plant, the ceramic ring can withstand direct flushing of 1200 ℃ molten steel, and the service life is extended from 3 days of the metal ring to 2 months, saving more than 200 hours of downtime and maintenance time per year. At the same time, its corrosion resistance to strong acids such as hydrochloric acid and sulfuric acid is 15 times that of 316L stainless steel, which can avoid medium pollution and ensure product purity in chemical pump sealing ring scenarios. - Self lubricating low friction, energy-saving and efficiency increasing
Through nanoscale surface polishing technology (Ra ≤ 0.1 μ m), the friction coefficient of ceramic rings is as low as 0.1-0.2, close to the level of polytetrafluoroethylene. In the application of textile machinery spindle rings, the use of ceramic rings reduces equipment energy consumption by 18%, and the yarn breakage rate decreases from 5 times/10000 meters to 0.5 times/10000 meters, significantly improving production efficiency. - High precision and stability coexist
By using CNC machine tools for precision machining, the inner and outer diameter tolerances of ceramic rings can be controlled within ± 0.005mm, and the roundness error is ≤ 0.003mm. In the application of vacuum chamber sealing rings in semiconductor equipment, the stability of their form and position tolerances ensures that the vacuum degree is maintained below 10 ⁻⁶ Pa for a long time, avoiding wafer contamination caused by ring deformation.
Typical Applications
The technological advantages of wear-resistant alumina ceramic rings with circular structures have penetrated into multiple high demand industries, forming differentiated solutions:
- In the field of mechanical transmission: bearings and gear rings
Problem: Metal bearing rings are prone to fatigue wear under high-speed and heavy loads, leading to excessive equipment vibration and increased noise.
Solution: The ceramic ring has a bending strength of over 500MPa and can withstand a contact stress of 50MPa, extending the bearing life from 5 years to 15 years in wind turbine gearbox applications and reducing the risk of unplanned downtime.
Case: According to statistics from a wind power enterprise, after switching to ceramic bearing rings, the gearbox failure rate decreased from 12% to 2%, and annual maintenance costs were saved by over 3 million yuan. - Fluid control field: Sealing and guide rings
Problem: The sealing ring of chemical pumps is prone to leakage in corrosive media, leading to environmental pollution and production interruption.
Solution: The corrosion resistance of ceramic rings can prevent medium penetration, extending the sealing life from 3 months to over 3 years in sulfuric acid transfer pump applications, and reducing the leakage rate from 0.5% to 0.01%.
Case: Data from a chemical plant shows that ceramic sealing rings have reduced the annual maintenance cost of a single pump from 80000 yuan to 10000 yuan, while also reducing the cost of hazardous waste disposal. - Semiconductor manufacturing field: Vacuum and clean environment
Problem: Metal rings are prone to releasing metal ions in a vacuum environment, which can contaminate the surface of the wafer.
Solution: The ion precipitation rate of ceramic rings is less than 0.01ppb, which reduces the particle contamination level from level 100 to level 10 in the application of 12 inch wafer transfer chambers, and improves chip yield by 5%.
Case: A semiconductor manufacturer’s test shows that ceramic vacuum rings increase the overall equipment efficiency (OEE) by 22% and increase the monthly production capacity of a single line by 12000 pieces. - New energy field: high temperature and insulation ring
Problem: The guide roller ring of the lithium battery roller press is prone to deformation at high temperatures, resulting in uneven thickness of the electrode sheets.
Solution: The thermal expansion coefficient of the ceramic ring is only 1/5 of that of the metal, and the deformation at a working temperature of 60 ℃ is less than 0.01mm, reducing the thickness tolerance of the pole piece from ± 3 μ m to ± 1 μ m.
Case: Data from a power battery company shows that ceramic guide roller rings increase cell capacity consistency by 8% and reduce product grading rate by 15%.
맞춤형 서비스:
full process support from requirement analysis to mass production delivery
We provide three customized services to meet the personalized needs of different industries:
- 구조 치수의 사용자 지정
Support range: Any circular structure with an outer diameter of 10-1000mm and a height of 5-200mm can be designed with complex shapes such as stepped rings and irregular rings.
Delivery cycle: Standard parts are shipped within 3 days, and customized parts are completed within 7-15 days.
Case: A large ceramic guide ring with a diameter of 500mm customized for an aerospace enterprise, achieved ultra-high precision with a tolerance of ± 0.02mm through segmented sintering and precision splicing technology. - Performance parameter optimization
Wear resistance enhancement: By adding silicon carbide (SiC) particles, the hardness is increased to 2200 HV, suitable for strong wear scenarios such as sand and gravel transportation.
Temperature resistance upgrade: Yttrium oxide (Y ₂ O3) stabilizer is used to increase the operating temperature from 1600 ℃ to 1800 ℃, meeting the requirements of hot end components in aviation engines.
Conductive modification: By doping barium titanate (BaTiO3), the volume resistivity is reduced from 10 ¹⁵Ω· cm to 10 ⁶Ω· cm, which is suitable for special scenarios such as electrostatic elimination rings. - Surface treatment process
Polishing grade: Ra ≤ 0.05 μ m, suitable for ultra clean scenarios such as semiconductor vacuum chambers.
Coating treatment: Diamond coating is deposited on the surface, reducing the friction coefficient to 0.05 and extending the service life of textile machinery spindle rings by three times.
Micro hole processing: Customized filter rings with a pore size of 0.1-1mm and a pore density of 10-100 pores/cm ² are achieved through laser drilling technology.
The widespread application of wear-resistant alumina ceramic rings with circular structures is essentially a revolution in replacing traditional metal ring components with advanced ceramic materials. From wind turbine gearboxes to semiconductor vacuum chambers, from chemical pump seals to lithium battery guide rollers, their technological advantages are reshaping equipment reliability standards in multiple industries. Contact us immediately for sample testing and customized solutions!
브루드세 세라믹 는 알루미나 세라믹, 지르코니아 세라믹, 질화 규소 세라믹, 질화 알루미늄 세라믹, 실리콘 카바이드 세라믹, 탄화 붕소 세라믹, 바이오 세라믹, 기계 가공 가능 세라믹 등 다양한 고품질 석영 유리를 공급 및 판매합니다. 다양한 세라믹 제품의 맞춤형 요구 사항을 충족할 수 있습니다.
태그: 탄화붕소 세라믹
