Wear resistant ceramic and composite materials based on zirconia - - PowerPoint PPT Presentation

Wear resistant ceramic and composite materials based on zirconia nanopowders for engineering and medicine

• Prof. Konstantinova Tetyana

Head of Material Science Department Donetsk Institute for Physics and Engineering named after O.O. Galkin

• f NAS of Ukraine

Donetsk, Ukraine

Products - ceramic and composite articles based on zirconia nanopowders

Advantages:

• high thermal stability;
• excellent mechanical properties;
• predetermined physical properties;
• excellent resistance to corrosion in

aggressive environments;

• high resistance to abrasive wear;
• the stability of properties;
• biocompatibility.

Scientific and technological jump Nanostructured ceramics and composites Fracture toughness Strength Traditional ceramics

The world market of structural ceramics and composites

Market for ceramic matrix composites, 2008-2015 ($ millions) Advanced structural ceramics market by application, 2010-2016 ($ millions) Global Consumption

• f nanocomposites, ($ millions)

Prices and characteristics of nanopowders

3 - 5 40 30 - 40

5;10;15;20;30;40

Particle size, nm

Molecular decomposition Hydrolysis

• Precipitation

Process type

3760

200 NANO- Oxides inc, USA

200 300 80 – 100*

Price, $/kg Agglomeration

16 10 - 15 200 - 15

BET, m2/g

Tosoh, Japan NexTech, USA DonIPhE NASU, Ukraine

Important product or technology characteristics

* cost price in laboratory conditions

Economic benefits from the use

• f wear resistant ceramics

Comparative Wear/Abrasion Resistance Volume loss/(mm3) Material Carpenter zirconia Tungsten carbide Alumina Stellite coating D-2 hardened steel 316 stainless steel Carbon steel 2 5-20 8-85 18-23 30-35 100-250 200-250

According to Carpenter Advanced Ceramics

Component MP liners Change frequency US $ per change

• No. of changes
• ver 36 months

Extended $ cost Chrome steel Monthly 500 36 18,000 Alumina Yearly 2,500 3 4,500 Zirconia 1× every 3 years 1,500 1 2,500

The demand for ceramic products in Ukraine

Plungers and friction pairs

• 100,000 units/year

Bearings

• 500,000 units/year

Nozzles

• 12500 units/year

Mill balls

• 60000 units/year

Kitchen knives

• 2000000 units/year

Surgical knives

• 100,000 units/year

Blocks for dental prostheses

• 1200 units/year

Heads of the hip joint

• 10000 units/year

Crucibles

• 250,000 units/year

How does it work?

Zirconia nanopowders Granulated powder Preform Products Nanopowder production pilot line 10 kg/month 2 people Granulator 1 kg/h Press HHP ∅180*350 Software control machine Sintering furnace

Intellectual property – know how

• getting a press powder;
• using a variety of methods;
• preform molding;
• use of CAD / CAM technology;
• low-temperature sintering.

Application: wear resistant plungers for mine oil stations

Wear resistance increased by 30-50 times!

Zirconia: lifetime - 108 months Steel 95X18: lifetime - 2 months

The plunger of mine hydraulic pump

СНТ-32

Application: wear resistant injectors for descaling at metallurgical plants

Ilyich Iron and Steel Works of Mariupol Wear resistance increased by 20-40 times!

Ceramics - 11 month Hard alloy - 10 days

Application: nozzles for sandblasters

Steel (0.3C;1.0Cr;1.0Mn;1.0Si) Zirconia insert Exploitation tests carried out at the OJSC Tushino machine-building plant (Moscow)

125362, г.Москва, ул. Свободы, д.35 Тел.: +7 (499) 493 50 53 Факс.: +7 (499) 497 53 51 130

ОАО ТУШИНСКИЙ МАШИНОСТРОИТЕЛЬНЫЙ ЗАВОД

Wear resistance increased by 20 times!

Application: wear resistant composite ball valves

Nanopowders provides to increase in wear resistance

• f ceramics and composites due to:
• homogeneity of phase and chemical composition;
• homogeneous distribution of the grains and the strengthening phase;
• hardened grain boundaries and absence of defects (pores, impurities,

stress concentrators).

Ball valve

Wear for different materials

Application: refractory products for the metallurgical, chemical and jewelry industries

Glasses-dispenser for continuous casting of steel from composite ceramics based on ZrO2-MgO Developing for GIR and «Puyang-Ceramet» Ceramics crucibles based on ZrO2-Y2O3

Advantages:

• high refractoriness > 1800oC;
• high resistance to thermal shock;
• lack of interaction of the melt with

the crucible walls.

10 mm 10 mm

Application: Ceramic heads for

• steosynthesis of bone tissue joints

In collaboration with ISM NASU (Finishing processing)

The results of tribological tests:

amount of cycles -1 000 000; friction coefficient - 0,04 - 0,08; wear - 70 μm after 1 000 000 cycles. The tests under the guidance of prof. Rosenberg O.A., Radom (Poland)

Zirconia is the best biocompatible material

Heads of hip joints

Prosthesis installation scheme

Application: dental prostheses and implants

Preforms for CAD/CAM processing Crowns and bridges from ZrO2 Implants from ZrO2

Implants

Advantages:

• zirconia is a product of high strength and durability;
• it combines the highest aesthetic with high biocompatibility;
• allergic reactions are not known, what important for people who

sensitive to metal;

• low conduction of heat, the unpleasant temperature sensitivities

are virtually excluded;

• visible edges and the grey metal-ceramic crowns belong to the

past;

• zirconium oxide can be colored since its manufacture.

10 20 30 40 50 10 20 30 40 50 60 70 80 90 100 Donetsk, Ukraine Donetsk, Ukraine Tosoh, Japan Tosoh, Japan Tetragonal phase, % t, hour

NO degradation !!!

Prevention of phase degradation

• f zirconia ceramics

1,4 µm 1,4 µm

Nanoceramics Large-grain ceramics

Our capabilities:

On the basis of the pilot line and the section for the production of ceramic products is realized:

• production of small batches of products made to order;
• development of technologies for series production of products;
• development and use of new composite materials;
• production of non-serial products;
• products for the replacement of expensive imported component parts.

thread feeders porous ceramics thread feeders joints draw plates

Our proposals:

In Ukraine there is no production of advanced ceramics and composites. Ceramics and composites based

• n zirconia

Sale of ceramic products of small batches for technique and medicine (DonIPhT) Organization of industrial production of wear resistant ceramic products for technical purpose (investment) Organization of the company to develop new technologies and manufacturing of special products (DonIPhT) For the production are available raw materials base, equipment, personnel and developed technologies.

Organization of the enterprise for the production of oxide nanopowders, ceramic and composite articles (business plan)

The volume of production

• 1 ton/month after 3 years to 2 tons/m

The total cost

• 37.4 mln

Construction and installation

• 3 years and 2 months

Project payback period

• 4 years and 7 months

(from the start of production capacity)

Discounted payback period

• 7.9 years.

The average net income for 5 years

• 13,546,768 UAH per year.

Profitability of production

• 84%.

Interested organization and customers

International Centre for Electron Beam Technologies - preforms for spraying; "SE Ivchenko-Progress" - SiC nozzles for reactive aircraft engines; "VIRIAL" - wear resistant ceramic ZrO2-MgO; LLC "DTS-Invest" - nozzles for waterjet cutting; Ilyich Iron and Steel Works of Mariupol - nozzles for descaling; TMZ - nozzles for sandblasters; GIR and “Puyang-Keramet” - nozzles for UNRS, ISM NASU - ceramics for orthopedic prostheses; Dental Centers "Maestro" and "Suite Dent" - dental prostheses and implants; Branch of SRI ‘”Orion” – functional ceramics.

Contact information

• Prof. Konstantinova Tetyana

+380 (62)342-75-13 +380(50)567-06-57 matscidep@aim.com Donetsk Institute for Physics and Engineering named after O.O. Galkin of NAS of Ukraine Donetsk, Ukraine