Welcome to the ACE blog! Today, we will be diving deep into one of our specialties – the sintering process of alumina ceramics. As a leading company in the production and design of precision and technical ceramics, we at Advanced Ceramic Engineering Ltd (or ACE for short) have over 40 years of experience in perfecting this crucial step in the manufacturing of alumina components.
But first, let’s start with the basics – what exactly is sintering?
Sintering is a process by which a material, in this case alumina, is compressed and heated to a high temperature to form a solid mass. It is a crucial step in ceramic production as it allows for the creation of a dense and strong ceramic material with high temperature resistance and excellent electrical insulation properties.
At ACE, we use raw milled alumina as our starting material, which is then isostatically pressed into its desired shape. Isostatic pressing is a technique that ensures uniform pressure is applied to the material from all directions, creating a homogeneous and defect-free material. This is a critical step in the sintering process as any flaws or inconsistencies in the material can lead to weak or flawed final products.
Next comes the sintering temperature, which can vary depending on the desired properties of the final product. Typically, alumina is sintered at temperatures above 1650°C, which is known as the alumina’s melting point. However, for better control and to avoid overheating, we use a slower heating ramp rate to reach the sintering temperature gradually. This allows for better control over the shrinkage and density of the material.
Once the material reaches the sintering temperature, it goes through a process of shrinkage, where it reduces in size, and the individual particles fuse together to create a solid and dense structure. The sintering process also helps to eliminate any remaining pores in the material, making it impermeable and resistant to cracks.
But what makes our sintering process at ACE stand out?
One of the key factors that set us apart is our use of diamond grinding. This technique allows us to achieve precision machining in the final stage of production, resulting in smooth surfaces and tight tolerances for complex shapes. This is important in industries such as aerospace, electronics, and medical, where the functionality and precision of the alumina components are critical.
Another aspect that makes our sintering process unique is our expert workforce. As mentioned earlier
