Ceramic Industry September 2011

September 2011 | Volume 161 | Issue Number 9 www.ceramicindustry.com

MODERN Manufacturing Opportunities for Advanced Ceramics Processing Improvements

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Your kiln. Like no other. Your kiln needs are unique, and Harrop’s experienced staff will thoroughly analyze your process and objectives before recommending a final solution. This review often includes precise characterization of your ceramic materials and pilot testing at our in-house facility. After defining the most efficient thermal cycle for your product, Harrop then engineers an energy-efficient, properly sized kiln that is uniquely suited to your operation. Hundreds of customers will tell you that this expert application engineering is what separates Harrop from “cookie cutter” kiln suppliers. Learn more at www.harropusa.com, or call us at 614-231-3621 to discuss your special requirements.

Fire our imagination www.harropusa.com

³ TABLEOFCONTENTS September 2011 | Volume 161 | Issue Number 9

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DEPARTMENTS

FEATURES

Inside CI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

³Using Nanosilica to Strengthen Concrete Incorporating nanosilica in a new concrete mixture could lead to longer-lasting buildings, roadways, sidewalks, stairs, sewers and dams . . . . . . 11

International Calendar . . . . . . . . . . . . . . . . . 7 Ceramics in the News . . . . . . . . . . . . . . . . . . 7 People in the News . . . . . . . . . . . . . . . . . . . . 9 Investing in Ceramics . . . . . . . . . . . . . . . . . 10 Kiln Connection . . . . . . . . . . . . . . . . . . . . . . 28

³ Risks and Rewards Sourcing raw materials can provide both challenges and opportunities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ³3-D Printing Methods 3-D printing based on laser stereolithography opens up new application fields for advanced ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Product Spotlight . . . . . . . . . . . . . . . . . . . 35 What’s New . . . . . . . . . . . . . . . . . . . . . . . 35 Buyers’ Connection . . . . . . . . . . . . . . . . . 36

³ Integrating PLM and QM Systems Best-in-class companies are 111% more likely than their competitors to have real-time interoperability between their PLM and quality management systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Services Marketplace . . . . . . . . . . . . . . . 37 Classified Advertisements . . . . . . . . . . . 45 Advertiser Index . . . . . . . . . . . . . . . . . . . . 46

³Design and Form Optimization The design challenge for the use of ceramic materials in technical applications is the computation of their failure probability under prescribed boundary and loading conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ³Opportunities in Engineering Ceramics Markets Many sectors should see demand regain 2008 levels in 2011 or 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SPECIAL SECTION | MATERIALS HANDLING/ POWDER PROCESSING ³Understanding Powder Caking Powder rheometry can be used to determine the conditions that will help prevent powder caking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ³Modern Wet Milling and Material Processing Processes in a variety of industries now routinely demand particle sizes with an absolute maximum of well below 1 micron . . . . 29 ³Dust Explosion Hazards: Key Risks and Solutions Some 70% of dusts are explosible, given an adequate ignition source and appropriate dust/air concentration . . . . . . . . . . . 32

ON THE COVER: Cover design by Cory Emery.

CERAMIC INDUSTRY (ISSN 0009-0220) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (Int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: CERAMIC INDUSTRY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to CERAMIC INDUSTRY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

CERAMIC INDUSTRY ³ September 2011

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³ INSIDECI by Susan Sutton | Editor-in-Chief, Integrated Media

®

www.ceramicindustry.com 6075 B Glick Road • Powell, OH 43065 614-789-1880 (p)

EDITORIAL / PRODUCTION STAFF

Creating Success I’m often reminded these days of a quote from Henry David Thoreau, “What recommends commerce to me is its enterprise and bravery. It does not clasp its hands and pray to Jupiter.” It could be tempting for manufacturers to simply try to survive until the economy recovers. What differentiates the true successes is their willingness to push forward, take risks and really create their own opportunities. For example, many of today’s manufacturers don’t have the staff or the desire to stay on top of all the raw materials-related issues that are necessary for their operations. For these companies, working with a distributor might be the perfect solution. The role of distributors has evolved over the years to encompass much more than just raw material deliveries. Many distributors offer R&D, testing and product trial services to help manufacturers meet their goals. Read “Risks & Rewards” (pp. 13-14) to learn more. Other manufacturers might benefit from the incorporation of advanced fabrication methods in their operations. 3-D printing based on stereolithography can offer advanced ceramics manufacturers multiple benefits. See “3-D Printing Methods” (pp. 15-16) for the details. Expanding into new markets might offer the best opportunities for some manufacturers. According to a recent study, high-growth applications for advanced ceramics in Europe include bioceramics, bearings, diesel exhaust filters and wear parts. U.S. opportunities for growth are anticipated to be highest in bioceramics, bearings, membranes and general wear parts. Additional details can be found in “Opportunities in Engineering Ceramics Markets” (pp. 23-25). Today’s successful manufacturers are not expecting to emerge from this recession simply by hoping for the best. They’re actively working to increase efficiencies or focusing on new opportunities—or both! I’d love to hear what steps your company is taking to succeed despite the recession. Please contact me at (330) 336-4098 or [email protected] to share your story.

Amy Vallance, Publisher 281-550-5855 (p) • 248-283-6543 (f) • [email protected] Susan Sutton, Editor-in-Chief, Integrated Media 330-336-4098 (p) • 248-502-2033 (f) • [email protected] Teresa McPherson, Managing Editor 734-332-0541 (p) • 248-502-2102 (f) • [email protected] Kelsey Seidler, Associate Editor 614-789-1881 (p) • 248-502-2051 (f) • [email protected] Cory Emery, Art Director 248-391-2325 (p) • 248-502-2077 (f) • [email protected] Bryon T. Palmer, Production Manager 248-244-6435 (p) • 248-502-9113 (f) • [email protected] Ralph Ruark, Senior Technical Editor Charles Semler; Sandra Spence; Joe Cattaneo; George Muha, Contributing Editors

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EDITORIAL ADVISORY BOARD

INSIDE LOOK Take an Inside Look at upcoming industry events. This month, we feature GlassBuild America.

Surinder Maheshwary, Director, Quality Assurance/Process Improvement, Dal-Tile International; William Babik, Technical Sales Manager, Nabertherm Inc.; Charles Semler, Ph.D., Refractories Consultant, Semler Materials Services; Gary Childress, General Manager, Orton Ceramic Foundation; Matthew Centa, Technical Support Manager - Ceramics & Glass, Rio Tinto Minerals; James E. Houseman, Ph.D., President, Harrop Industries, Inc.

DAILY UPDATES The latest industry and company news, personnel announcements, new products, and more are updated every day to help you stay informed.

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September 2011 ³ WWW.CERAMICINDUSTRY.COM



³INTERNATIONALCALENDAR SEPT 12-14 GlassBuild America 2011 ³ Atlanta, Ga., www.glassbuildamerica.com SEPT 12-14 imX Interactive Manufacturing eXperience ³ Las Vegas, Nev., www.imxevent.com SEPT 13-14 Nanopolymers 2011 ³ Dusseldorf, Germany, http://ismithers.net/venue-details/ XNAN11 SEPT 20-22 Assembly & Automation Technology Expo ³ Rosemont (Chicago), Ill., www.aatexpo.com SEPT 21 Solar Exchange East ³ Raleigh, N.C., www.usa.siemens.com/solarexchange SEPT 27-29 Composites Europe ³ Stuttgart, Germany, www.composites-europe.com OCT 11-13 POWTECH 2011 ³ Nuremberg, Germany, www.powtech.de/en

³ INTHENEWS Harper Receives Contract for Pilot-Scale Carbon Fiber Line Harper International recently announced it has booked a contract for a fully integrated pilot-scale carbon fiber conversion line. The line will be installed in Europe to produce carbon fiber for use in advanced communications technology. The fully integrated line incorporates several progressive design features for the production of carbon fiber from 6K PAN precursor and is engineered for higher than traditional processing speeds. Harper will supply its advanced oxidation oven technology; LT and HT slot furnaces rated for 1000°C and 1600°C, respectively; fiber surface treatment and size application conditioning; waste gas abatement; and material transport systems. For more information, visit www.harperintl.com.

Wienerberger Receives Approval for Tondach Gleinstätten Acquisition

OCT 20-22 17th Annual Manufacturing in Mexico Summit ³ San Carlos, Sonora, Mexico, www.manufacturinginmexicosummit.com

Wienerberger AG recently announced it has received the approval of the responsible cartel authorities for the takeover of an additional 25% stake in Tondach Gleinstätten as part of a stock swap with the now former joint venture partner Monier. Wienerberger and Monier previously held common investments in the roof tile business through two joint ventures that were focused on Eastern Europe. This transaction will give Monier 50% of the shares in Bramac, and thereby the concrete roof tile business, while Wienerberger will receive a further 25% stake in Tondach Gleinstätten, as well as an additional cash payment. Wienerberger will then hold 50% of the shares in Tondach Gleinstätten; the remaining 50% will remain under the ownership of two families. For more information, visit www.wienerberger.com.

OCT 25-27 The Battery Show ³ Novi, Mich., www.iccnexergy.com

Rio Tinto Sees Increasing Bauxite Demand, Finalizes Talc Divestment

* OCT 16-20 Materials Science & Technology 2011 Conference and Exhibition (MS&T ’11), combined with the ACerS 113th Annual Meeting ³ Columbus, Ohio, www.ceramics.org OCT 18-19 Manufacturing with Composites ³ Fort Worth, Texas, www.sme.org/cgi-bin/get-event.pl?— 002084-000007-home—SME-

* OCT 30-11/2 13th Unified International Technical Conference on Refractories (UNITECR) ³ Kyoto, Japan, [email protected] OCT 31-11/4 2011 Fuel Cell Seminar & Exposition ³ Orlando, Fla., www.fuelcellmarkets.com NOV 9-10 The Composites Engineering Show ³ Birmingham, UK, www.compositesexhibition.com NOV 9-10 Mobile Power Technology Partnering Summit ³ Las Vegas, Nev., www.knowledgefoundation.com/viewevents.php?event_id=267&act=evt NOV 14-17 10th Annual LAV & Stryker Summit ³ Washington, D.C., www.LightArmoredVehiclesSummit.com JAN 23-26 36th Annual Conference on Composites, Materials and Structures ³ Cape Canaveral, Fla., http://advancedceramics.org * Look for Ceramic Industry magazine at these events! For a more detailed listing, visit our website at www.ceramicindustry.com.

Rio Tinto recently released its second quarter 2011 operations review. Bauxite production was 11% higher than the second quarter of 2010, notably at Weipa, driven by increased third-party demand. Alumina production is gradually recovering from the abnormally heavy rains between December 2010 and April 2011, which primarily impacted Queensland Alumina’s production, affecting bauxite and coal quality, equipment reliability, and freight costs. Rio Tinto also recently announced it has completed the divestment of its talc business to Imerys for an enterprise value of $340 million. The company acknowledged receipt of the binding offer from Imerys on February 23 and subsequently accepted the offer on June 10. The talc business has about 1000 employees at 20 locations in Europe, North America, Australia and Asia. For more information, visit www.riotinto.com or www.imerys.com.

Ceradyne Receives $36.2 Million ESAPI Body Armor Order Ceradyne Inc. recently announced that it has received a delivery order for approximately $36.2 million for enhanced small arms protective insert (ESAPI) ceramic body armor plates. Ceradyne says it will begin shipping this ESAPI production release in the CERAMIC INDUSTRY ³ September 2011

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IN THE NEWS

Unifrax Announces Multiple Acquisitions Unifrax I LLC recently announced it has entered into an agreement to acquire Super Saffil Ltd. and Saffil America Inc. from Dyson Group plc. Saffil develops, manufactures and sells innovative, high-temperature polycrystalline wool materials to a global customer base. It has two main business units: Saffil Automotive and Saffil Fiber. Saffil products are used in a variety of applications in both the industrial insulation and automotive emission control support mat markets. The Saffil business is headquartered in Widnes, UK, and has manufacturing operations in the UK and South Africa. Regional offices are located in the U.S., Japan and China, and the business also has sales representation in Brazil. Unifrax has also acquired three leading North American vacuum forming businesses: Refractory Specialties Inc. (RSI), Specialty Ceramics Inc. (SCI) and VacuForm Inc. (VFI). The three businesses specialize in the development, manufacture and sale of fiberbased, value-add shapes used in applications in both the industrial and hearth products markets. RSI and VFI are located in Sebring, Ohio, and SCI is located in Columbiana, Ohio. The three businesses employ approximately 140 people who will be joining the Unifrax North American team. For more information, visit www.unifrax.com.

fourth quarter of 2011, with full shipment expected to be completed early in the first quarter of 2012. For more information, visit www.ceradyne.com.

Johns Manville to Expand Glass Fiber Production Johns Manville (JM) recently announced plans to expand current fiber production capacities in its Trnava, Slovakia, facility. Additional trends in lightweight materials to improve fuel efficiency will further support composites growth and require investments in both thermoplastic and thermoset materials, the company reports. The expanded furnace, due to start up in the fourth quarter of 2012, will reportedly enable added production flexibility within JM’s product families and expand the production of selected products by as much as 40%. For more information, visit www.jm.com.

Sacmi Supplies Machines to Saudi Tile Producer Al Jawdah, a tile producer located in a new industrial district of Riyadh, Saudi Arabia, has chosen Sacmi to supply equipment for its plan to increase productivity in its grinding and spray drying departments. Al Jawdah installed a 92,000-liter MMC 092 high-efficiency mill and a 9000-liter/ hr ATM 90 spray dryer, the latter being 8

integrated with the existing spray drying system. Sacmi also supplied a new FMS kiln, which is able to produce 8000 square meters of finished product per day. Al Jawdah reportedly plans to not only boost sales, but also significantly augment its economies of scale. For more information, visit www.sacmi.com.

Belden Brick Acquires Lawrenceville Brick Belden Brick recently announced it has acquired virtually all the assets of the Lawrenceville Brick Co. Lawrenceville’s two relatively new brick manufacturing facilities, along with a significant source of clay reserves, will fit well into the Redland Brick umbrella of production, marketing and administrative services, according to William H. Belden, Jr., chairman of Belden Brick. Key management members at Lawrenceville will continue their roles of delivering high-quality products and services. For more information, visit www.beldenbrick.com or www.lawrencevillebrick.co.

Corning Expands Clean Air Products Facility in China Corning Inc. recently announced that its board of directors has approved a capital expenditure plan of approximately $170 million to further increase the capacity

September 2011 ³ WWW.CERAMICINDUSTRY.COM

of its clean air products plant in Shanghai, China. The investment will be used to expand the Corning Shanghai Co. Ltd. (CSCL) facility and to increase its capacity to manufacture emissions control substrates for light-duty (automotive) passenger vehicles. This expansion is expected to be complete and operational in the third quarter of 2013. CSCL, which is wholly owned by Corning, is a state-of-the-art, high-tech emissions control substrate facility that first began shipping product in early 2001. Corning first expanded the facility in 2007 and announced a $125 million second expansion last year. Production from this recent expansion is expected to begin shipping in the second half of 2012. For more information, visit www.corning.com.

Ceramic Fuel Cells Receives Order from German Government The German government has formally approved funding for an order of up to 200 of Ceramic Fuel Cells Ltd.’s integrated power and heat generators from German energy service provider EWE. The order is the largest that Ceramic Fuel Cells has received, with total revenue of up to €4.9 million (~ $7 million) over two years. Part of the funding for the order is being provided by the German government’s national hydrogen and fuel cell technology innovation program. Ceramic Fuel Cells is supplying the core Gennex fuel cell module and related components to its local manufacturing partner, Gebrüder Bruns Heiztechnik GmbH, which is integrating the fuel cell module with a boiler into an integrated power and heating product for supply to EWE. EWE will then install the units in homes in the Lower Saxony region of northern Germany. Visit www.cfcl.com.au for details.

O-I Acquires VDL Glass Container Plant Owens-Illinois Inc. (O-I) recently announced the acquisition of VDL Co., a single-furnace glass container plant in Vergeze, France, effective August 1. The acquisition is the result of a new strategic relationship with Nestle Waters, which is reportedly the world’s leading bottled water company.

³ PEOPLEINTHENEWS Under the terms of the acquisition agreement, O-I will become the leading supplier of glass bottles for the Perrier brand, as well as Nestle Waters’ other water brands worldwide. For more information, visit www.o-i.com.

Tosoh Establishes Thin Film Sputtering Target Subsidiary in Shanghai Tosoh Corp. recently announced that Tosoh Group company Tosoh SMD Inc. has established a thin film sputtering target manufacturing subsidiary in Shanghai, China. Tosoh SMD (Shanghai) Co. Ltd. was established to expand Tosoh SMD’s global capacity and to better serve its semiconductor, flat-panel display, solar, and large area coating customers in China. In addition, the new subsidiary will reportedly be a key component in Tosoh SMD’s raw materials sourcing strategy and will strengthen its sales support to its Chinese customers. For more information, visit www.tosoh.com.

Alfred University Researcher Works with Rochester Manufacturer on SOFC Project Olivia Graeve, associate professor of materials science and engineering at the Kazuo Inamori School of Engineering at Alfred University, is working on the development of a ceramic nanopowder that could lead to better solid oxide fuel cells (SOFCs). Solid Cell Inc., which manufactures stationary and portable SOFCs for residential, commercial, and military applications at its plant in Rochester, announced it has kicked off a collaborative project with Graeve to “manufacture ceramic powders for Solid Cell’s patentpending SOFC interconnect.” Solid Cell says it anticipates that interconnect units fabricated from the nanopowders synthesized at Alfred University could be incorporated into prototype fuel cell units for durability testing before the end of the year. For more information, visit www.alfred.edu or www.solidcell.com.

ORNL Establishes Carbon Fiber Composites Consortium Oak Ridge National Laboratory (ORNL) recently announced that 14 companies have joined with the organization to establish the Oak Ridge Carbon Fiber Composites Consortium. The new endeavor will work to accelerate the development, demonstration, and commercial application of new low-cost carbon fiber and composites materials in several industry sectors. Charter members of the consortium include the Dow Chemical Co., 3M Co., Faurecia, Toho Tenax America, Plasan Carbon Composites, Composite Applications Group, Umeco Composites Structural Materials, Graftech International, United Technologies Research Center, Harper International, Hills Inc., Materials and Chemistry Laboratory, SSOE Group, Innovation Valley and UT-Battelle (the managing contractor for ORNL). The consortium will host its inaugural meeting this month in Oak Ridge, Tenn. Additional members are welcome to join the consortium. For more information, visit www.cfcomposites.org. 

Rio Tinto recently announced that John Varley has joined the boards of Rio Tinto plc and Rio Tinto Ltd. as a non-executive director, effective September 1. Varley’s career includes 28 years at global financial services provider Barclays, where he spent six years as chief executive. He currently holds non-executive directorships at AstraZeneca plc and BlackRock Inc. In addition, he remains a senior advisor to Barclays and is a member of the International Advisory Panel of the Monetary Authority of Singapore. Owens-Illinois Inc. (O-I) has named Steve Bramlage president of the company’s Asia-Pacific region. Bramlage succeeds Greg Ridder, who is leaving the company to pursue other interests. O-I’s Asia-Pacific region accounts for about $1 billion of the company’s global sales. The company has 13 plants employing 6000 employees in four countries in the region, including Australia, New Zealand, Indonesia and China. Bramlage will lead the region’s efforts to respond quickly and effectively in the marketplace. Ceramic Fuel Cells Ltd. announced it has appointed Janine Hoey as a non-executive director. In addition to sitting on the company’s board, Hoey will serve on Ceramic Fuel Cells’ Audit Committee. Hoey reportedly has had extensive experience in commercial, operations, and finance roles in the clean energy and airline industries over the last 20 years. She currently holds an executive role with Pacific Hydro Pty Ltd as the general manager of Group Operations and Commercial. Hoey is a director of a joint venture hydro company in Chile and a director of Perenia Pty Ltd in Australia, a carbon services joint venture company. The National Institute of Standards and Technology (NIST) has announced that manufacturing industry executive Michael F. Molnar has been appointed as the agency’s first-ever chief manufacturing officer. The manufacturing sector is critical to the U.S. economy, and the Obama Administration is committed to building domestic manufacturing capabilities to create the new products, industries, and jobs of the future. NIST is reportedly well-positioned to support this goal because of its unique mission to work closely with industry. This new position will leverage NIST’s strong relationships with industry to accelerate innovation that will create 21st-century manufacturing jobs and enhance the nation’s global competitiveness. As part of this effort, the position will support the broader Advanced Manufacturing Partnership recently launched by President Obama that brings industry, universities and the federal government together to invest in emerging technologies. 

Have News to Share with the Industry? E-mail news releases to Teresa McPherson at [email protected] CERAMIC INDUSTRY ³ September 2011

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CONTINUED ADVANCEMENT ➤ Visit highlights area’s high-tech employment opportunities.

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CHOTT North America Inc. recently hosted U.S. Rep. Lou Barletta (R-Hazleton) and other local leaders and elected officials at its Duryea, Pa., manufacturing facility to showcase its capabilities and research facilities and discuss with the congressman continued employment growth in the region. The Duryea facility opened in 1969 and manufactures a complete line of SCHOTT optical glass, filter glass, laser glass, and ZERODUR® glass-ceramic. The main production building fills 27,000 sq ft and another 3300 sq ft in another building is used for warehouse space.

“SCHOTT has been an integral part of Northeastern Pennsylvania for many years, and they are a tremendous addition to our local economy,” Barletta said. “I’m very impressed with what I saw today at the SCHOTT facility in Duryea,” Barletta said. “SCHOTT has been an integral part of Northeastern Pennsylvania for many years, and they are a tre10

(Left to right) Jim Stein, Keith Moss, Linda Mayer, John P. Blake, Lou Barletta, Heather Rayle, Eric Urruti, and Mike Carroll.

mendous addition to our local economy. I’m very proud of the work that’s done here at SCHOTT, and that’s a credit to the quality of the local workforce.” “We’re proud to highlight the hightech jobs SCHOTT has been creating in the region for the past four decades,” said Linda S. Mayer, president and CEO of SCHOTT North America. “Duryea has been an important facility for the production of high-quality glass and glass ceramic products for defense, government and industry, and we’re fortunate to have an advocate for area workforce development in Congressman Barletta.” Barletta was joined on a facility tour by State Sen. John Blake, State Rep. Mike Carroll and Duryea Mayor Keith Moss. In addition to viewing optical glass production, the tour visited the research and development area where materials scientists and engineers work to advance the glass industry. Among other projects, SCHOTT in Duryea works closely with the University of Scranton in a joint effort to

September 2011 ³ WWW.CERAMICINDUSTRY.COM

develop and refine specialty glasses for use in high-power laser facilities. “The company collaborates with Paul F. Fahey, Ph.D., a professor at the Department of Physics/Electrical Engineering at the university and his team, along with the researchers and engineers at the University of Texas in a unique confluence of technology, manufacturing, and academic excellence,” said Heather Rayle, Ph.D., vice president and general manager of SCHOTT North America. “The research generated by studying what this laser can do will lead to new ideas in cancer treatment therapies and alternative energy fuel sources, and could possibly open the door to Nobelprize winning physics.” In addition, Duryea has been instrumental in developing many unique products, including contrast enhancement filters for aircraft displays and laser glass for high-energy and integrated optics applications.  Visit www.us.schott.com/advanced_optics for additional information

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Using Nanosilica to Strengthen Concrete

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As a ubiquitous material that provides the literal foundation of modern urban landscapes, concrete has a major influence on construction practices, costs and environmental impact. However, at the fundamental level, concrete chemistry has remained strikingly similar to what was used by the ancient Romans. Now, researchers are capitalizing on nanotechnology to innovate a new generation of concrete materials that meet the demands of an aging infrastructure and a more sustainable society. Every day, concrete structures crack and erode prematurely due to alkali silica reactivity (ASR), a chemical reaction that causes fissures in the material as it sets. Jon Belkowitz, a concrete expert and doctoral student at Stevens Institute of Technology, aims to put an

➤ Incorporating nanosilica in a new concrete mixture could lead to longer-lasting buildings, roadways, sidewalks, stairs, sewers and dams. by Christopher Lisee, Staff Writer, Stevens Institute of Technology end to this problem through his study of chemical reactions within concrete at the nanoscale. Taking advantage of Stevens’ nanostructure characterization tools and materials, his research into the optimal use of nanosilica will create a new concrete mixture that will result in longerlasting buildings, roadways, sidewalks, stairs, sewers, and dams. “With the advent of nanotechnology, the material properties of concrete, including ASR mitigation, allows engineers and architects the ability to use concrete in applications that were once impossible,” Belkowitz says.

Understanding Concrete On the most basic level, concrete is a mixture of finely powdered cement, rock aggregate and water. A reaction between the cement and water yields calcium silicate hydrate, which gives concrete its strength, as well as ASR gel. The ASR gel forms at the interface of the alkaline cement and the noncrystalline silica found in the aggregate. As the concrete hardens, the ASR gel expands, causing residual stresses that weaken the concrete and cause it to deteriorate. As pressure builds at the interface, the concrete starts to crack and crumble from within, over a period spanning from days to years.

Above: Jon Belkowitz (far right) is a concrete expert and doctoral student at Stevens Institute of Technology studying chemical reactions within concrete at the nanoscale. CERAMIC INDUSTRY ³ September 2011

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NANOSILICA

“Using nanostructure characterization tools, we are now able to understand the many mysteries of concrete, for example, that there are three types of water in hydrated concrete, and those three different types of water have three different types of molecular movements, which means three different forces,” Belkowitz says. According to Belkowitz, the more you know about concrete, the more complex it becomes. He hopes his research will uncover new methods of increasing the mechanical properties of concrete.

Research Specifics Belkowitz’s research takes a three-tiered approach. “Not only am I using this new nanotechnology to stop ASR from being produced, I’m also using nanosilica to strengthen the hydrated cement matrix of concrete to resist the expansive nature of the ASR gel,” he explains. “I’m also trying to change the properties of the excess water within the concrete so that it can’t react with soluble alkalines in silica to cause ASR gel.” Despite the material’s ubiquity, the reactions within concrete as it dries and strengthens are difficult to control. “This is an ongoing problem in the concrete industry,” Belkowitz says. “In the past, we really had no way to understand the development of the crystallgraphic grains of the concrete matrix. We could set up models, or use other minerals to compare to calcium

Belkowitz says he hopes his research will uncover new methods of increasing the mechanical properties of concrete.

silica hydrate. We don’t create the same structure every single time. Through the use of nanostructure characterization tools, we now have the ability to gain a better understanding of the hydrated cement matrix that makes up concrete.” Belkowitz has 15 years of concrete experience: 10 years in the U.S. Air Force placing concrete on civil engineering projects around the world; and five years at LaFarge, where he designed new types of concrete in a lab and translated these into products with real-world applications. Currently, he owns Intelligent Concrete LLC, which is dedicated to concrete research, development and education. Belkowitz’s research is being conducted in the Nanomechanics and Nanomaterials Laboratory under the guidance of Frank Fisher, Ph.D., associate professor of Mechanical Engineering and co-director of the Nanotechnology Graduate Program. Though Belkowitz says he hopes to apply his research in civil engineering applications, his work is multidisciplinary, combining solid-state physics, mechanical engineering, polymer synthesis and chemical engineering. Belkowitz’s research is funded by the New Jersey Alliance for Engineering Education (NJAEE), through the National Science Foundation (NSF) Graduate Teaching Fellows in K-12 (GK-12) Program. He works in a local high school in Bayonne, NJ, for 10 hours a week as part of the program, and says he enjoys the opportunity to share his passion with students. “It’s exciting to open up their minds to new possibilities,” he says. “They eat it up.” This wide-ranging experience reportedly allows him to converse equally well with scientists, business and laypeople. It also gives him a realistic approach. “One of the hardest things to do in the concrete industry—or in any industry—is to take lab data and translate it into commercial industry,” Belkowitz says. “In the lab you have nearly perfect conditions. In the real world, it’s messy.” As he looks to the future, Belkowitz says he is confident that his work at Stevens studying the smallest reactions within concrete will yield big rewards in the future.  For additional details, visit www.stevens.edu/ses/me.

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Risks

and Rewards ➤ Sourcing raw materials can provide both challenges and opportunities. by David Carroll, Vice President, R.E. Carroll Inc., Trenton, N.J.

R

aw material sourcing is a lot like the game of Monopoly®— when all goes well, you pass “Go,” collect $200 and move on. But when the process doesn’t go well, it can feel like landing on the “Go to Jail” square. Depending on the situation at hand, “rolling the dice” is a great metaphor for what it takes to get the material you need, when and where you need it. Raw material sourcing is a science in its own right. When we factor in today’s emphasis on “just-in-time” manufacturing; inventory reduction goals to save costs; and the myriad economic, transportation, and environmental issues that could be in play at any given moment, it’s easy to see just how challenging it is to have everything fall into place to ensure a smooth raw-material-to-finished-product process.

Risks and Challenges There was a time when everything we needed to sustain our lives and livelihood was available within a few miles. In today’s world of interconnected economies and global distribution, however, raw material sources can be next door or on the other side of the world. The ideal situation is to have the manufacturing site located next to the raw materials

source and next to the customers, but how often does that really happen? Whatever the application, raw materials today can be affected by everything from politics to the weather. Supply chains have lengthened in both distance and the time required to obtain the materials. These impacting factors can be driven by cost, availability or both. The longer the supply chain, the greater the chance that something may go wrong. It’s not difficult to find examples of this today. Titanium dioxide supplies, which are widely used as a pigment and for “hiding” in a variety of industries, have become increasingly tight over the last year or so. Depending on the type and grade needed, a limited number of suppliers is available to choose from. Even if alternatives are available, challenges such as language, currency, and lead times still exist. In addition, it’s important to ensure that the product is what the supplier says it is. Do you have the resources (both time and money) to verify, qualify and test it? With all of these risks and challenges in obtaining raw materials, what are the rewards and opportunities? Are they worth it? Who can help, and what can be done to make this process run smoother?

Rewards and Opportunities The rewards involved with properly sourcing raw materials can be tangible (e.g., increased profit, happier customers) or intangible (e.g., a sense of accomplishment, the feeling of a job well done). Most businesses are focused on the tangible rewards of lowering their raw material costs to increase their profit. Local sources, while less expensive to transport, may in fact be more expensive to purchase due to other factors, such as labor costs. By obtaining raw materials from overseas, where labor costs are lower, the product cost is lower (theoretically); a manufacturer could thus obtain larger profits. Finding new or different sources of raw materials with different properties than the local supplies may provide opportunities for innovative products that can help separate your business from the competition. Opportunities can also come in the form of finding new uses or markets for your products based on a supplier’s knowledge of their product and where they sell. For example, if your materials are only sourced locally, the supplier may be unaware of an alternative use or market for their product that could be thousands of miles away. CERAMIC INDUSTRY ³ September 2011

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RISKS AND REWARDS

How can a manufacturer ensure they get the right material, at the right price, when they need it? Many can and do source their own materials, and have technical departments with the ability and resources to identify, qualify, and monitor their various raw materials and the products in which they are used. That said, no one person can know what materials are available from everywhere. Depending on the size of the manufacturer and their resources, they may not be willing or able to handle all of the sourcing themselves.

The Role of Distribution The simple economic law of distribution is to buy in bulk and sell in less than bulk quantities. Distributors service those manufacturers that either don’t have the need, space or desire to purchase large quantities of the material (or widget) in question.

Raw material distributors, on the other hand, can and do far more than just buy and resell. They source raw materials for customers in order to serve a need in the market. Distributors deal with all of the same challenges and risks that the manufacturers do and often shield the manufacturers from feeling the effects of a product shortage, whether it is due to transportation challenges or a production issue. Distributors can also bring new materials and new uses for existing materials to the attention of a manufacturer to aid in the creation of new business or opportunities for their customers. They can also act as the “warehouse” for a customer that does not have space or does not wish to deal with the costs of having inventory onsite. Distributors add value to the supply chain by enabling small manufacturers to purchase the same material as larger manufacturers; they also provide manufac-

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September 2011 ³ WWW.CERAMICINDUSTRY.COM

turers with a wider range of raw material sources to choose from. Distributors can provide material for developmental preproduction testing prior to full manufacturing scale-up, as well as benchmarking of materials vs. other offerings.

Depending on the size of the manufacturer and their resources, they may not be willing or able to handle all of the sourcing themselves. All of these services have a cost that is added to the cost of the original materials. Cost and pricing are frequently a matter of discussion between distributors and manufacturers. What is the cost of sourcing the raw material, taking delivery of the raw material (along with all the necessary transportation hurdles), stocking the raw material and delivering it to the manufacturer? What is the value of having the material in stock and available when the manufacturer gets a last-minute rush order and needs the raw material yesterday? What is the value of having an uninterrupted supply of a key raw material when the suppliers’ direct customers are on allocation? These are all questions that must be answered by the manufacturer when considering the added costs of using distribution. Distributors can be an important ally and business partner in staying ahead of the competition and developing innovative, profitable products for the marketplace. Sourcing raw materials is a challenging process in today’s world, but having a key partner in that process can help manufacturers continue their success and provide new opportunities for growth.  For additional information, contact R.E. Carroll, Inc. at 1570 North Olden Ave., Trenton, NJ 08638; call (800) 257-9365; fax (609) 6950102; email [email protected]; or visit www.recarroll.com.

3-D T

PRINTING METHODS ➤ 3-D printing based on laser stereolithography opens up new application fields for advanced ceramics. by Christophe Chaput, CEO, 3DCeram, Limoges, France; and JB Lafon, USA Product Manager, 3DCeram, Colorado Springs, Colo.

he design and development of advanced ceramics for high-performance applications, such as those in medical or aerospace, is one of the most challenging tasks of modern engineering. The widespread use of ceramics, however, depends on the availability of industrial processing routes to fabricate parts that often have extremely complex geometries. Owing to the difficulty of conventional ceramic manufacturing methods to produce complex-shaped ceramic parts with the desired microstructures and properties, novel processing techniques, such as solid free form (SFF) and ceramic 3-D printing based on laser stereolithography, are becoming increasingly important.

Dimensional Definition The development of ceramic 3-D printing methods has been mainly motivated by the need for shaping methods capable of producing functional yet complex ceramic parts with precise dimensional definition and without using tooling or costly secondary machining. Stereolithography involves laser polymerization of a curable system consisting of a suspension of ceramic particles in a photopolymer. Using computer-assisted design (CAD) information without breaking the digital design chain, the components are manufactured in successive layers with a laser that polymerizes a paste made of photosensitive resins and ceramic powders. The preparation of this paste is a key component of the stereolithography process; it requires a suspension of ceramic particles (mean grain size of about 1 μm) in a UV-reactive organic system with a high powder loading. The paste must also maintain a suitable rheology for the spreading of thin layers (down to 10 μm) and a sufficient reactivity to UV for polymerization. The paste is introduced in a piston, which delivers a controlled quantity onto the working area. A thin layer of suspension with a thickness varying from 10-200 μm, depending on the UV reactivity of the system and the desired dimensional resolution, is deposited by means of a specific device. Using CAD information, the laser beam radiation is focused on the top surface of the deposited paste and deflected by galvanometric mirrors to harden the crosssectional pattern and bond with the underlying previous layer.

Porosity-controlled bone substitutes.

The elevator table is then moved down a layer thickness, and a subsequent layer is deposited to reiterate the UV curing process. This procedure is repeated until the part is built. About 95% of the curing process can be carried out in the stereolithography equipment. The cured part is removed, rinsed clean of excess uncured resin, and then heat treated in debinding and sintering cycles to eliminate the cured resin and sinter the ceramic to near theoretical densities. After 3-D printing, the resulting ceramic parts do not require expensive secondary operations, like machining, to suit the intended applications. They exhibit the same properties as parts made by conventional die pressing or ceramic injection molding. No tooling or mold is necessary, so the manufacturing lead times are short. After short development periods, manufacturers are able to test and use a ceramic solution at lower costs. This technology is increasingly used for both rapid prototyping and volume production of final parts. Its aim is not to replace standard parts made by extrusion, dry pressing or ceramic injection molding (CIM), but to rapidly make extremely complex shapes, in prototype quantity or medium-sized lots, up to several thousand units per run. The process is also able to produce components consisting of different materials (e.g., metal and ceramic). Ceramic 3-D printing also expands the functionality of components.

Application Opportunities Available materials include high-grade alumina, zirconias of different colors, aluminum nitride, hydroxyapatite (HAP), tri-calcium CERAMIC INDUSTRY ³ September 2011

15

3-D PRINTING

phosphates (TCP) and manufacturers’ own powders (these must undergo a process development period to accommodate the properties of individual powders). 3-D printing can be applied to ceramics in multiple potential applications. In microelectronics, for example, 3-D printing can be used in the development of microwave devices (e.g., filters, resonators) with high dimensional resolution and pattern density. Another example is parts for the luxury industry, such as watches and jewelry. Biomedical applications are proving to be particularly exciting. Hydroxyapatite ceramic implants enable the replacement of the large osseous defects of the skull dome and the jawbone area. The method is also used in reconstructive surgery for patients who carry, or are likely to carry, a loss of cranio-facial osseous substance after a surgery. As an alternative to osseous grafts that often must come from the patient, ceramic implants prevent additional surgery, costs and pain.

In biomedical applications, 3-D printing makes it possible to control the location, distribution and geometry of the ceramic substitutes pores, unlike implants that are made porous by adding organic foam or porogens. The porosity is structured in three dimensions, and the diameter of the fully interconnected pores is constant. These unique features promote osteointegration and increase the substitute mechanical strength. Compressive mechanical strength is between three to five times higher than that of conventional porous structures. This production process can therefore significantly reduce the risk of post-operation inflammation caused by micro-debris that breaks when handling and positioning the implant.

Rapid Prototyping It is well known that ceramics offer a variety of desirable mechanical, magnetic, thermal, chemical and electrical properties. These properties translate into qualities that fit

the requirements of various industries, including telecommunications, electronics and aerospace, as well as research laboratories and manufacturers of video projection equipment, etc. When 3-D printing technology is used for rapid prototyping, it is possible to produce nearly any shape—simple or complex—that has been developed by the ceramic manufacturer; only a CAD component file is necessary. The intrinsic quality of the prototype is the same as that of the products made from conventional high-volume production processes. The process has been industrialized, and production runs in excess of 10,000 units per year are cost effective.  For more information, contact 3DCeram USA/Euro Industries at 3578 Hartsel Dr., Unit E 356, Colorado Springs, CO 80920; call (719)264-6111; fax (719)264-6333; email [email protected]; or visit www.3dceram.com.

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September 2011 ³ WWW.CERAMICINDUSTRY.COM

Europe

Tokuyama Europe GmbH Oststrasse 10,40211 Dusseldorf Germany Tel: +49-211-1754480

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Tokuyama Corporation Shapal Sales Department, Specialty products Business Division Shibuya Konno Bldg. 3-1, Shibuya 3-chome, Shibuya-ku, Tokyo 150-8383 Tel: +81-3-3597-5135 e-mail: [email protected] URL http://www.shapal.jp/index.html

➤ Best-in-class companies are 111% more likely than their competitors to have real-time interoperability between their PLM and quality management systems.

by Nuris Ismail, Research Associate, and Matthew Littlefield, Senior Research Analyst, Aberdeen Group, Boston, Mass.

Integrating PLM and QM Systems

A

recent study on collaboration and technology interoperability benchmarked over 300 manufacturing executives and found that best-in-class companies are 111% more likely than their competitors to have real-time interoperability between their product lifecycle management (PLM) and quality management systems (QMS). Indeed, this approach in technology delivers significant value to companies that have made the investment. Quality can be a powerful competitive advantage, but ensuring that quality products are delivered to market takes a team effort. Achieving closed-loop quality management allows organizations to attain this goal. It is valuable to identify how manufacturers with PLM and QMS software interoperability are able to effectively ensure quality and identify the differentiating capabilities that are supported through this interoperability.

Software Interoperability The impact quality can have on corporate performance is often misunderstood and underestimated by manufacturing organizations. If we examine the design-makedeliver processes, there are a number of workflows where the incorporation of a

closed-loop quality management initiative would yield tangible benefits. Interestingly, previous research has established that PLM and QMS software interoperability is a key technology enabler of closed-loop quality management. To better understand how well organizations that have invested in PLM and QMS software interoperability are achieving closed-loop quality management, it is useful to examine two types of firms: those that have invested in PLM and quality management, and those that haven’t. Manufacturers that have implemented a PLM and quality management interoperability solution are better able to manufacture products and subsequently get them to market quicker and at a higher quality—all while streamlining operations across the designmake-deliver process (see Table 1, p. 18). In fact, these manufacturers are able to achieve an 83% overall equipment effectiveness (OEE) rate across the board, which shows that these companies are better using their assets because of improved quality capabilities. They also enjoy 6% more successful new product introductions. In certain industries, even a 1% or 2% increase can have a significant impact; a 6% advantage can translate into millions of dollars of business. In addition, these

manufacturers were able to achieve a 90% on-time and complete shipment rate. Companies that have yet to implement system interoperability between PLM and QMS software can use the research presented here to understand the best practices implemented by those companies that have already done so. This information can be used in their strategic and tactical actions, and as a means for attaining sponsorship from senior management to implement these capabilities and technologies. The analysis will focus on some of the key elements required to implement comprehensive closed-loop quality management

Definitions of Key Performance Indicators • Overall equipment effectiveness (OEE) is a composite metric accounting for availability, performance and quality. • Successful new product introductions (NPI) is measured as the average share of new product introductions that hit quality, time and volume targets. • On-time and complete shipments are products delivered on time and complete, as compared to total original commitment, with no re-re-promise dates.

CERAMIC INDUSTRY ³ September 2011

17

INTEGRATING PLM AND QM

Defining Closed-Loop Quality Management Closed-loop quality management is a strategic framework aligning business processes and technology enablers to support quality management across product design, sourcing, manufacturing process planning, manufacturing execution, delivery, maintenance, and customer service. When these traditionally disparate business functions are aligned from a quality perspective, it enables the following business capabilities:

through the use of a PLM and quality management interoperability solution.

Business Capabilities While PLM and QMS software interoperability is a key enabler, achieving closed-loop quality management takes more than a technology implementation. It takes an enterprise-wide commitment to quality, a culture of operational excellence, and employees who are given the right quality information at the right time and in the right context. Table 2 presents the business process capabilities that companies with previously implemented closed-loop quality management are most likely to have. When studied in their entirety, this set of business processes enables the incorporation of quality management into the complete lifecycle of products and processes across engineering and manufacturing functions. Organizations with PLM and QMS software interoperability are 58% more likely than their competitors to have standard business processes to manage and respond to non-conformance and recall events. These manufacturers have procedures established in case of a non-conforming incident, which gives all the employees a clear understanding of the steps that need to be taken once an adverse event has occurred. This includes escalating adverse events to appropriate decision makers, depending on the type and the severity of the incident, and the actions that need to be initiated during such scenarios. Once these processes are standardized, all of the stakeholders are aware of their responsibilities and are able to intelligently act in a timely fashion. One of the ways to enable standardization of quality and operating processes across the enterprise is to have a strong executive vision and subsequent buy-in 18

• Collaboration and bi-directional feedback between procurement, manufacturing, supply chain, customer service, and product development on non-conformance issues • Control, visibility, and improvement of quality process across procurement, product development, manufacturing, supply chain, and service • Integrated root cause analysis of non-conformance and quality issues across the business

Table 1. Interoperability performance. Definition of Maturity Class Mean Class Performance Companies with PLM and QMS interoperability 83% Overall equipment effectiveness (OEE) 80% Successful new product introductions (NPI) 90% On-time and complete shipments Companies without PLM and QMS interoperability 81% OEE 75% Successful NPI 88% On-time and complete shipments Source: Aberdeen Group, November 2010

from stakeholders at different levels of the organization. Manufacturers with PLM and quality management interoperability are more likely than their competitors to have established executive sponsorship for improving operations and quality through investing in process improvement, collaboration, and technology interoperability. The key to success is to have senior executive sponsorship, as well as cross-functional teams to streamline quality and operations processes. Aligning the organization in such a way is crucial because it allows manufacturers to control the quality of the product both within the four walls of the plant and across the value chain. Another key capability is the ability of an organization to easily flow quality specification data between engineering and manufacturing. By ensuring that both engineering and manufacturing have easy access to up-to-date and accurate quality data, both groups are better equipped to continuously improve product performance. Closely related to this capability is quality planning, which provides the ability to identify all functional needs of the product early in the design phase and incorporate this information into each stage of the design cycle to ensure product quality. In addition, upfront quality planning provides the ability to identify failure

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modes, future risks associated with the product, improve manufacturability and identify impact on maintenance. While organizations that have PLM and QMS software interoperability are more than three times as likely as their competitors to have this capability, only 39% of them have actually adopted it. Indeed, the ability to identify all functional needs of the product ahead of time and incorporate this information into each stage of the design cycle is essential to ensuring product quality. The next set of capabilities is critical to enable better visibility, collaboration and control across business processes needed for closed-loop quality management. First, organizations that have PLM and QMS software interoperability are more likely to have real-time visibility between executives and global manufacturing operations, and between suppliers’ performance and manufacturing. Such architecture allows for improved decision-making in a number of different ways. It gives executives a view into operations that doesn’t rely on aggregations or assumptions that can distort decisions and result in sub-optimal manufacturing and engineering decisions regarding quality. PLM and QMS software interoperability also helps manufacturing operations

Table 2. Business capabilities. PLM and QM Interoperability

No PLM and QM Interoperability

Business process in place to manage non-conformance and non-compliance, and recall events across the enterprise

67%

42%

Executive sponsorship for initiatives on improving operations through process improvement, collaboration and technology interoperability

72%

57%

Cross-functional continuous improvement teams are focused on process improvement, collaboration and technology interoperability

72%

43%

Executives have real-time visibility into the performance of global operations

44%

25%

Real-time visibility between manufacturing operations and supplier performance (quality, inventory and WIP)

56%

22%

Quality testing and inspection data easily flows between product development and manufacturing systems

61%

27%

Quality Planning

39%

12%

Source: Aberdeen Group, November 2010

to have an accurate view (from a quality perspective) into the flow of demand and goods through the supply chain. This view improves visibility and control over the quality process across the manufacturing and supply chain, so manufacturers are able to detect problems before they occur. Finally, these manufacturers arm their employees with quality testing and inspection data, which easily flows between product development and manufacturing systems. Design engineers, manufacturing engineers and operations all have very different responsibilities when it comes to quality. Providing this critical data can greatly improve manufacturing efficiency and collaboration across these traditionally disparate groups. All these capabilities are critical for creating closed-loop quality management. Standardized operating procedures for adverse events, a culture toward quality, up-front quality planning, and real-time visibility into critical quality data to facilitate communication between disparate groups are all needed to foster the necessary control, collaboration, and continu-

ous improvement inherent in closed-loop quality management.

Summary Manufacturers can take several actions associated with improvements in a number of key performance indicators to achieve closed-loop quality management. First, companies should standardize processes for responding to adverse events across the enterprise. Manufacturers that have PLM and QMS software interoperability are 58% more likely than their competitors to adopt such a capability, which is an important step to viewing quality as an enterprise-level issue rather than a plant-level issue. Manufactures should also obtain executive sponsorship for closed-loop quality management. Quality can be a powerful competitive advantage, but ensuring quality takes a team effort. In particular, quality management needs an executive to lead the charge. This capability will enable manufacturers to secure resources from senior management to streamline quality operations across the enterprise. It will also lend legitimacy to continuous

improvement team efforts in the area of closed-loop quality management. Quality planning should be performed early. Quality needs to be managed early in the design stages and consistently throughout the process using cross-functional, collaborative methods so that quality information can be highly visible throughout the design chain. In doing so, companies can identify all functional needs of the product ahead of time and incorporate this information to ensure product quality. Manufacturers should invest in PLM and QMS software interoperability. Research shows that such a technology enabler elevates quality management to an enterprise-level business process, transcending traditional functional areas. Specific areas for investing in interoperability include the flow of quality data, risk management processes, corrective and preventive action processes, and compliance.  For more information, contact the authors at [email protected] or [email protected], or visit www.aberdeen.com. CERAMIC INDUSTRY ³ September 2011

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e g D si n

and Form Optimization

by Serkan Nohut, Faculty of ➤ The design challenge for the use of ceramic materials in Engineering, Zirve University, Kizilhisar technical applications is the computation of their failure Kampusu, Gaziantep, Turkey probability under prescribed boundary and loading conditions.

I

n recent years, efficiency improvements in many mechanical systems have become more important, and this situation has introduced new demands on certain mechanical components. Particularly for applications at high temperatures and corrosion and wear rates, the design of mechanical components using advanced ceramics has become very popular.1 Advanced ceramics provide numerous advantages compared to other materials: durability, hardness, high mechanical strength at high temperature, stiffness, low density, electrical insulation and conductivity, thermal insulation and conductivity, etc. Most ceramic materials are almost entirely immune to corrosion. Ceramics show a different fracture behavior than that of metals and polymers because of their brittle nature. Therefore, ceramic engineers should be aware of this behavior when designing reliable ceramic components. The design challenge for the use of ceramic materials in technical applications is the computation of their failure probability under prescribed boundary and loading conditions.2

The Weibull Theory Ceramic materials exhibit strength scatter, and the failure of a ceramic begins with pre-existing defects in the material. The material’s strength therefore depends 20

on the size of the most critical flaw in the material, which varies from specimen to specimen. Essentially, the scatter of the ceramic strength is caused by the scatter of the flaw size. Since the strength of ceramics is not a constant value, design with ceramic materials cannot be done deterministically. Instead, a probabilistic approach should be used in which a ceramic component’s failure probability is calculated. More than 70 years ago, Weibull derived a statistical theory of brittle fracture.3-4 Since that time, the Weibull distribution function has become the most widely used function in the mechanical design of ceramic components. The simplest form of the so-called Weibull function5 is given in Equation 1 for a uniaxial homogeneous tensile stress state: (1) where PF,V(m, V) is the failure probability of a ceramic component due to the volume flaws; V is the volume of the component; V0 is the unit volume containing average number of cracks; m is uniaxial applied stress; m is the Weibull modulus, which describes the scatter of the strength; and m0 is the cumulative mean stress, at which the failure probability is 63.2% for a specimen with a volume V = V0. In general, the stress distribution within a ceramic component is not con-

September 2011 ³ WWW.CERAMICINDUSTRY.COM

stant but takes different values at different positions. In addition, the true orientation of the cracks in ceramic components is randomly distributed. As a result, normal and shear stresses acting in the crack plane cause Mode-I, Mode-II and Mode-III loading of the cracks. A proper account of the spatial variation in the stress triaxiality (e.g., effect of shear stresses) must therefore be taken using a multiaxial failure criterion.6-8 In this article, the normal stress criterion will be used for the computation of failure probability.9

The failure of a ceramic begins with pre-existing defects in the material. Stirling Engines The Stirling engine is a thermal engine in which the displacing piston separates the expansion area from the compression area. The displacing piston shifts the work gas from the hot area to the cold area through thin tubes. To be effective, the piston must fulfill two requirements: its contact surface with the cylinder should

Figure 2. Variables of piston displacing (a). The boundary and loading conditions used in FEM analysis of displacing piston (b).

Figure 1. Phillips MP1002C Stirling engine.

be gas-tight, since the flow of gas reduces the efficiency; and it should exhibit low heat conductivity, since a large temperature difference exists between the cold and hot areas. In this work, a reliable design of a displacing piston will be applied (taking into account the second requirement). The heat loss of the displacing piston, the friction between the body of the engine, and the displacing piston will not be considered. Under these conditions, due to the low heat conductivity and high temperature stability, 3 mol % yttria-stabilized zirconia is particularly suitable for the production of the displacing piston.10 In addition to low heat conductivity, properties such as better wear resistance and lower density compared to conventionally used material (e.g., chromium-nickel stainless steel), enable the use of 3 mol % yttria-stabilized zirconia to offer many advantages in this application. The geometry and the boundary conditions of the displacing piston have been realized according to a beta series Stirling engine,11 as represented in Figure 1, where Th is the temperature of the hot part, Tc is the temperature of the cold part, Ph is the pressure of the hot part, and Ph is the pressure of the cold part.

FEM Model In general, Th = 873 K, Tc = 333 K, Ph = 17.67 bar, and Pc = 3.2 bar. The diameter of the displacing piston is Ddp = 55 mm and Hdp = 80 mm. The technical drawing and

the geometric variables of the displacing piston are given in Figure 2(a), where t1 = 12.5 mm, t2 = 20 mm, t3 = 10 mm, d1 = 24 mm, d2 = 36 mm and d3 = 24 mm. Using these variables, a parametric study was performed, and the form was optimized related to minimum failure probability.

As the ceramic material, 3 mol % yttria-stabilized zirconia was used due to its low heat conductivity, high temperature strength and good Weibull parameters. The stress analysis was performed by ABAQUS, a commercial finite element program, and the failure probability of each model was calculated by STAU (STatistische AUswertung), a post-processor for ABAQUS. STAU was developed by the Probabilistic Group at the IZSM at Karlsruhe University, in cooperation with several partners.12

Figure 3. Stress distribution in the displacing piston.

The loading and boundary conditions used in FEM analysis are shown in Figure 2(b). The temperature boundary conditions were Th = 900 K and Tc = 300 K. The mechanical boundary conditions were Ph = 18 bar, Pc = 3 bar and Pps = 1100 bar, which is the pre-stressing due to the used screw. In the calculations, an M10 screw was selected, which produces a prestressing force of 26 kN according to the strength class of 8.8. As the ceramic material, 3 mol % yttriastabilized zirconia was used due to its low heat conductivity, high-temperature strength and good Weibull parameters. The material parameters of 3 mol % yttria-stabilized zirconia used for the FEM and calculation of failure probability include: Young’s Modulus E = 210 GPa, Poisson’s ratio i = 0.3, Weibull modulus m = 20, mean strength m0 = 600 MPa, heat conductivity h = 1.5 W/mK and thermal expansion coefficient _30-1000 = 12.5 x 10-6 K-1.

Results and Discussion The stress distribution in the displacing piston with the boundary and loading conditions given in Figure 2(b) is shown in Figure 3. In order to find the optimized form, all geometrical variables given in Figure 2(a) were changed one by one, and the effects of the variables on the failure probability were investigated. According to the results, it was observed that the parameters t1 and t2 have the most significant effects on the failure probability. Thus, the failure probability of the ceramic displacing piston was calculated for t1 intervals of 2.5-15 mm and t2 intervals of CERAMIC INDUSTRY ³ September 2011

21

DESIGN AND FORM

For more information, contact the author at (90) 0342-2116789; fax (90) 0342-2116677; or email [email protected].

References 1.

Figure 4. Failure probabilities for the investigated t1 and t2 intervals.

10-65 mm. The failure probability values for different combinations of t1 and t2 are shown in Figure 4. The region where the failure probability is PF,V > 10-4 is shown with a red color, since it is not acceptable for practical applications. According to these results, a displacing piston with t1 = 2.5 mm and t 2 = 55 mm gives the lowest failure probability, which is PF,V = 2.7 x 10-7. As previously stated, the main aim of this work was to find the optimum shape of a zirconia displacing piston according to the calculation of the probability of failure, which occurs due to the stresses that are mainly caused by the temperature difference between the hot and cold part of the displacing piston. From a fracture mechanics point of view, it is possible to use 3 mol % yttriastabilized zirconia for the displacing piston in a Stirling engine; by changing the shape, the failure probability can be reduced to an order of 10-6. A Stirling engine uses the temperature difference between its hot end and cold end to establish a cycle of a fixed mass of gas—heated-expanded and cooledcompressed—to convert thermal energy into mechanical energy. The greater the temperatures difference between the hot and cold sources, the greater the thermal efficiency. The maximum theoretical efficiency is equivalent to the Carnot cycle. According to the Carnot cycle, the theoretical efficiency can be calculated as: (2)

22

Figure 5. Strength of 3 mol % yttria-stabilized zirconia as a function of service temperature.13

2.

where Tc is the temperature of the cold reservoir and Th is the temperature of the hot reservoir. According to these conditions, the maximum theoretical efficiency of the Stirling engine is equal to 66.7%. When the temperature of the hot reservoir is increased, the efficiency of the Stirling engine can also be increased. Next, the temperature of the hot reservoir was increased from 900 to 1100 K, and the failure probability of the optimized form was calculated. Here, it is important to take into account the strength change of the 3 mol % yttria-stabilized zirconia with the temperature for the calculation of failure probability. Figure 5 illustrates the strength of the 3 mol % yttriastabilized zirconia as a function of service temperature.13 It can be seen that increasing the temperature from 900 to 1100 K did not influence the strength of the 3 mol % yttria-stabilized zirconia. Therefore, the same Weibull parameters can be used for this calculation. When the temperature of the hot reservoir is increased by 200 K, the maximum theoretical efficiency of the Stirling engine increases from 66.7% to 72.7%, which results in an approximately 9% increase in efficiency. The failure probability of the optimized form with t1 = 2.5 mm and t2 = 55 mm is equal to PF,V = 1.4 x 10-5. This means that increasing the temperature by 200 K increases the efficiency while keeping the displacing piston in the reliable region. In the future, a more comprehensive reliability analysis should be done by taking into account the heat loss of the displacing piston and the friction between the body and the displacing piston.

3.

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4.

5.

6.

7.

8.

9.

10. 11.

12.

13.

Nohut S., and Schneider, G. A., “Failure Probability of Ceramic Coil Springs,” Journal of the European Ceramic Society, 2009, 29, 1013-1019. Andreasen, J. H., “Reliability-Based Design of Ceramics,” Materials and Design, 1994, 15[1], 3-13. Weibull, W., “A Statistical Theory of the Strength of Materials,” Ingeniörsvetenskapsakademiens Handlingar, Stockholm, 1939, 151, 1-45. Weibull, W., “A Statistical Representation of Fatigue Failures in Solids,” Transactions of the Royal Institute of Technology, Stockholm, Sweden, 1949, 27, 5-50. Danzer, R., Supancic, P., Pascual, J. & Lube, T., “Fracture Statistics of Ceramics—Weibull Statistics and Deviations from Weibull Statistics,” Engineering Fracture Mechanics, 2007, 74, 2919-2932. Danzer, R., Lube, T., Supancic, P. and Damani, R., “Fracture of Ceramics,” Advanced Engineering Materials, 2008, 10[4], 275-298. Batdorf, S. B. & Crose, J. G., “A Statistical Theory for the Fracture of Brittle Structures Subjected to Nonuniform Polyaxial Stresses,” Journal of the Applied Mechanics, 1974, 41, 267-272. Evans, A. G., “A General Approach for the Statistical Analysis of Multiaxial Fracture,” Journal of the American Ceramic Society, 1978, 61, 302-308. Nohut, S., Usbeck, A., Özcoban, H., Krause, D., and Schneider, G. A., “Determination of the Multiaxial Failure Criteria for Alumina Ceramics under Tension-Torsion Test,” Journal of the European Ceramic Society, 2010, 30[16], 3339-3349. Ashby, M. F., Materials Selection in Mechanical Design, 3rd Ed. Elsevier, 2005. Organ, A. J., Thermodynamics and Gas Dynamics of the Stirling Cycle Machine, University Press, Cambridge, 1992. Brückner-Foit, A., Heger, A., Heiermann, K., Hülsmeier, P., Mahler, A., Mann, A., and Ziegler, C., STAU 5-User’s Manual, Institut für Materialforschung, Karlsruhe, 2005. Ingel, R. P., Microfilms., Ph.D. Thesis, Catholic University, Washington D.C. University, Int. No. 8302474, 1982.

Opportunities in Engineering Ceramics Markets T he overall value of the 2010 engineering ceramics market (including medical, environmental and process applications) in Europe was estimated to be €2.6 billion (approximately $3.2 billion). Several of the market sectors are mature, but other applications are expected to experience strong growth during the 2011-2016 period. An average annual growth rate (AAGR) of around 3.1% for the sector as a whole is anticipated for Europe (see Table 1, p. 24). The applications in which the highest growth rates are expected include bioceramics, bearings, diesel exhaust filters and wear parts. The overall value of the market for engineering ceramics in the U.S. in 2010 is estimated at $1.7 billion, with an AAGR of 2.7%. Engineering ceramic product applications with good growth prospects in the U.S. in the period 2011-2016 include bioceramics, bearings, membranes and general wear parts. The mechanical and wear parts group includes bioceramics (orthopedic and dental ceramics), armor, bearings, cutting tools, seals, milling media and other wear-resistant components. The high-temperature process parts include filters for molten metals, kiln furniture and continuous casting parts for steel.

Trends and Opportunities The collapse in demand for engineering ceramics over the 2008-2009 period was dramatic in virtually all countries. However, many sectors should see demand regain 2008 levels in 2011 or 2012. The strength of the recovery varies from country to country. Overall growth rates in the period 2011-2016 are not expected

➤ Many sectors should see demand regain 2008 levels in 2011 or 2012. by John Briggs, Enceram to reach the levels of 2003-2008, but the speed of recovery has been impressive in Germany and neighboring countries. In spite of the large number of companies manufacturing and/or supplying engineering ceramics, more than 59% of the market in Europe is supplied by just six companies. Similarly, six companies provide more than 67% of the market in the U.S. Several key companies, namely CoorsTek (since the acquisition of SaintGobain’s activities), Vesuvius, Corning and NGK Insulators, are among the top suppliers in both geographic regions. Corning is the largest supplier in the U.S., mainly as a result of its dominance in the automotive catalyst support markets. Ibiden is the largest supplier to the European market on the basis of its diesel particulate filter sales. Environmental legislation in both the U.S. and Europe has been a major stimulus to the commercialization of many engineering ceramic products, such as catalyst supports of many kinds, gas and exhaust filters, nozzles, membranes, pump seals, cutting tools, and bearings. Environmental factors will continue to play an important role in the future, especially in areas such as diesel engines, zero-emission pumps and high-temperature plants, which will have a positive impact on the

development and commercialization of engineering ceramics.

Market Assessment by Application In terms of the main applications, stark differences exist in the sale of engineering ceramics in the two regions. Europe, for example, produces far more ceramic hip prostheses than it consumes (exporting many to the U.S.), while ceramic armor is produced in larger quantities in the U.S. Automotive oxidation catalysts and particulate traps for small diesel engines are far more common in Europe than in the U.S. Automotive catalyst supports (ceramic honeycombs to be coated with noble metals) are now the most important market for engineering ceramics in the U.S., and the second most important in Europe, with a combined value of $760 million in 2010. All cars in Europe and the U.S. are now fitted with exhaust catalysts, including diesel cars (oxidation catalysts); therefore, the future demand for honeycomb supports will follow the changes in automobile production. This will include cars for export to markets outside the U.S. and Europe, where similar environmental legislation is being adopted. By 2010, most diesel cars and light vehicles in Europe were being fitted with particulate filters, most of which were made with silicon carbide. Some also incorpoCERAMIC INDUSTRY ³ September 2011

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ENGINEERING CERAMICS Table 1. Markets for engineering ceramics in the U.S. and Europe in 2010, and average annual growth rates (AAGRs) to 2016. U.S. $ (million)* Mechanical and wear parts 826 High temperature process parts 224 Catalyst supports, membranes, diesel particulate and other filters 687 Total 1,737

AAGR (%) 4.3% 1.0% 1.0% 2.7%

Europe (EU27) $ (million) 937 510 1,795 3,242

AAGR (%) 3.8% -0.3% 3.6% 3.1%

€ (million) 764 416 1,463 2,643

*$1=€0.815, June 2010

rated mixed oxide materials (e.g., aluminum titanate or, more rarely, cordierite). Growth in demand for filters for heavy-duty diesel engine exhausts is expected to increase in anticipation of Euro 6 legislation in 2013. An additional incentive is the establishment of “low-emission zones” by large numbers of European cities. In the U.S., most heavyduty diesel exhausts are already fitted with ceramic exhaust filters. In terms of automobile engine components, engineering ceramics still do not represent a significant market, even after more than 30 years of intense research and testing. The main factor that limits the use of ceramics in the automotive engine sector is cost, which is affected by expensive powders and the fact that the components are difficult to manufacture using mass-production methods. Other common applications have seen better success, however. For instance, Ceradyne’s sintered reaction-bonded silicon nitride is now used in various valve train components, mainly for large diesel engines. Enceratec’s zirconia fuel pump components for Cummins engines are also noteworthy.

Starbar and Moly-D elements are made in the U.S.A. with a focus on providing the highest quality heating elements and service to the global market.

Over 40 years of service and reliability I Squared R Element Co., Inc. Akron, NY Phone: (716)542-5511 Fax: (716)542-2100

Email: [email protected] www.isquaredrelement.com 24

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Engineering ceramics have gained significant niche markets in the aero-engines sector, especially in areas where costs are less of a consideration and in demanding environments where they outpace their metal counterparts. Examples include nozzles, combustors, seals and main bearings in military aircraft. Ceramic bearings are another technical and commercial success story. Despite slow beginnings in the 1980s, the advantages of ceramic bearings in aggressive or high-performance conditions are now universally acknowledged in applications such as hybrid bearings for spindles in machine tools. Electric motors, especially the high-voltage or small models, are also now a major application area. Annual growth in the European and U.S. markets for the 2011-2016 period is estimated at 6% and 4% per year, respectively. The main explanation for the difference in percentages is the state of the machine tools industry in the two regions. In addition to the diesel particulate filters already mentioned, ceramic filters are used in many kinds of aggressive environments, including filters for molten metals; filters for hot gas streams in power stations, incinerators and other industrial plants; and ceramic membranes for microfiltration or ultrafiltration in the food, drink, petrochemicals or other industries. Growth in demand for ceramic hot gas filters has been disappointing in recent years, but it may take off in the future if coal gasification or biofuels become more widespread. Demand for ceramic membranes is expected to continue to grow at a high rate as well. Filters for molten metals are mainly for ferrous and nonferrous castings but also primary aluminium production, where larger, more expensive filters are required. The foundry industry is recovering on both sides of the Atlantic, but demand for filters in foundries is still not back to 2008 levels. It is hard to draw a sharp distinction between high-value refractory components and engineering ceramics because highpurity, synthetic refractory products and kiln furniture can also be categorized as engineering ceramics. Demand for these items reflects the output of the roof tiles or pottery/whitewares industries. The markets for kiln furniture as a whole are expected to fall over the next few years as the production of whitewares moves away from Europe and the U.S. The consumption of kiln furniture is roughly three times as great in Europe as it is in the U.S.; this does not include silicon carbide parts for semiconductor processing equipment. Over the past decade, the refractories industry has undergone massive rationalization and consolidation in both the U.S. and Europe. The outlook for the surviving refractory producers is much brighter than the relatively modest growth prospects

might indicate. The use of better performing, longer lasting refractory products for the continuous casting of steel means that growth prospects for these high-value materials should now follow the steel sector production levels. Large quantities of alumina milling media are consumed, especially in the traditional clay-based ceramics sector. Micro-milling media, such as zircon or zirconia beads, are now widely used in the rapid, efficient grinding of pigments, glazes, inks, paints, etc.

•

•

•

Additional Areas of Change The status and outlook for additional engineering ceramics markets is given below: • The demand in the U.S. for ceramic armor (boron carbide, silicon carbide and alumina) increased rapidly to a peak in 2008. It is now much lower and will remain roughly flat in the next few years. The market for

•

armor in the US is nevertheless much higher than it is in Europe. The markets for bioceramics, particularly hip prostheses, have continued to increase. The European market in number terms is now more than twice that of the U.S. The use of zirconia ceramics in dental restorations (e.g., implants, abutments, bridges and crowns) is growing at a high rate in both Europe and the U.S. The introduction of CAD/CAM processing of pre-sintered blanks is significant. Demand for silicon nitride cutting tools for cast iron milling and whiskerreinforced alumina, the preferred tool for machining nickel alloys, have both recovered along with the mechanical engineering sector. The investment in de-NOx catalysts in electricity plants in the U.S. was high in the past; the rate of installation has now slowed down.

• Ceramic pump seals (silicon carbide and alumina) now constitute an established market. The trend to replace alumina with silicon carbide continues. • Healthy growth in the demand for ceramic wear parts, including wear plates, pump parts, faucet/tap plates, nozzles, valve parts and other items, has now resumed. Imports from China are increasing significantly in this market.  Engineering Ceramics in Europe and the USA is a 300-page report covering the markets, trends and technology in 2010, with growth projections through 2016. The report contains 130 tables and reviews the activities of over 125 companies. The report was published by Enceram in June 2011. For more information, contact Enceram at Mount Pleasant, Menith Wood, Worcester WR6 6UB; call (44) 1584-881216; or email [email protected].

CERAMIC INDUSTRY ³ September 2011

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Understanding

Powder Caking ➤ Powder rheometry can be used to determine the conditions that will help prevent powder caking. by Tim Freeman, Director of Operations, Freeman Technology Ltd., Worcestershire, England

M

anipulating the properties of powdered materials can help make ceramic processing easier and faster while supporting improvements in product quality. One of the variables often controlled is particle size. However, this may be complicated by the tendency of powders to agglomerate and cake, which can increase particle size away from the design intent and ultimately compromise production. Powder rheometry can be used to determine the conditions that will help prevent powder caking.

Particle Size and Powder Flow Modern ceramic powders undergo careful processing to ensure that factors such as purity and particle size do not adversely affect production. Powders often require mixing with water or additives to make them suitable for different forming methods such as extrusion, slip casting, or injection molding. When forming a green body from the resulting ceramic mixture, the sizes of any pores within it relate directly to the size of the ceramic particles present. Larger particles pack inefficiently and can result in pores that weaken the finished product, while powders with smaller particles (or a mix of particle sizes where the fine particles fill the voids between larger particles) can be used to control pore formation. Compared with smaller particles that provide a high surface area, the presence of larger particles can also increase the time and temperature required for the product to achieve full density during firing or sintering. Manipulating particle size (and, potentially, particle size distribution) in ceramic manufacturing processes is therefore important for achieving greater process control. Once the appropriate particle size specification is identified, the focus shifts to achieving and maintaining the most advantageous powder properties during manufacturing. Here, caking and agglomeration can be a complicating factor, since these processes increase particle size, thereby reducing the beneficial impact of early processing steps or of a carefully selected feed material.

Characterizing Powders A widespread problem in many areas of powder processing, agglomeration occurs through mechanical or chemical interac26

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tions between particles during storage. Many of the raw materials used in the ceramic industry exist in powdered forms, with caking compromising both process and end use performance. The particles that make up a ceramic powder can range from the nanometer to the micrometer scale, so an initial granulation step is often required to make them uniform in size. This step presents an opportunity to improve powder flow and reduce caking through the careful blending of powders and any added constituents. However, making the most of this opportunity in order to develop strategies that reduce the risk of caking over the longer term requires the means to characterize the powders involved and to understand their behavior under specific conditions. Caking is primarily an issue related to powder storage. Humidity, temperature and consolidation are all factors that may promote caking, which can occur through a number of different mechanisms. Temperature changes that lead to condensation in a keg, container or tanker, for example, can result in particles dissolving, enabling the formation of agglomerate bridges through chemical bonding. Alternatively, particles forced together by consolidation may eventually simply mechanically aggregate. Whatever the mechanism, the end result is the same: changes in the way the powders flow, which leads to problems with storage, supply and potentially compromised product quality.

Powder Rheometers The reliable analysis of powders and their behavior has logistical and economical benefits in many instances, for both processing and product quality. However, powder behavior is complex. Many physical, environmental and chemical factors affect powders, making it difficult to reproducibly measure properties and predict behavior. With a number of traditional tests, accuracy, reproducibility and/or process relevance are not always guaranteed. Powder rheometers* offer multi-faceted powder characterization that delivers an array of powder properties designed to support process optimization studies. Such systems allow for repeatable and robust measurements that sensitively differentiate between physically and chemically similar samples. Dynamic powder measurement, one of the methodologies used by a powder * Including the FT4 from Freeman Technology.

special section | materials handling/powder processing

Figure 1. Measuring BFE with a powder rheometer.

rheometer, has been shown to be an especially reliable method of analyzing powders when investigating the impact of factors such as aeration, compaction and attrition. Dynamic measurement involves recording the axial and rotational forces acting on a helical blade as it traverses through a sample (see Figure 1). Basic flowability energy (BFE) is the key dynamic baseline measure of a powder and is defined as “the energy required to rotate a blade down through a sample at a controlled rotational and vertical velocity.” Powder rheometers use well-defined and automated test methodologies that make BFE measurements highly reproducible for many different types of powders.

Experimental Caking Data Experiments based on measuring changes in the BFE of a powder under different conditions provide information about the likely severity of caking in the variety of environmental conditions encountered during storage. The study described here, which examines the effect of consolidation on caking activity, illustrates how successful this experimental approach can be. Similar protocols can be used to study the impact of elements such as humidity or temperature, for example, or to inform decisions taken during the formulation stage or when setting granulation targets. In the experiment described, duplicate sets of a powder blend were stored for periods of up to 10 days. One sample set was stored without consolidation, while the other was subjected to compaction with a consolidating stress of 9 kPa. BFE was measured as a function of storage time for each set of samples (see Figure 2). For both the consolidated and the unconsolidated samples, BFE increased only marginally during the first four days of the experiment. However, after five-and-a-half days, the BFE of the consolidated samples showed that the powder was twice as resistant to flow as it was when first loaded into the storage vessel—a state that the unconsolidated samples did not reach until day eight. The BFE continued to rise for both sample sets with no sign of leveling off. The implication for this blend is that shorter storage times under low stress conditions are advantageous, and consequently should be the target within the process environment.

Figure 2. Investigating the impact of consolidation on caking by tracking changes in BFE as a function of time.

Mass Flow vs. Funnel Flow Experimental data of this type can be used to inform storage design or selection. If the powder blend described previously is stored in a vessel that operates under mass flow conditions, for example, then reducing storage times and only partly filling the container will help alleviate problems associated with caking. With mass flow, material transitions uniformly through a container on a “first in, first out” basis, a condition achieved through the appropriate matching of the geometry of a storage vessel with the properties of a powder. On the other hand, if this powder is stored in a hopper that exhibits funnel flow, then the results of the experiment suggest that problems are likely. Funnel flow occurs when the hopper walls are too shallow and/or the outlet is too small compared to the optimum conditions for a powder. A “funnel” forms within the center of a surrounding “stagnant” region where powder is static. Material trapped in this stagnant region and toward the base of the container is subject to consolidating pressure, creating ideal caking conditions for susceptible powders. In this instance, steps would be needed to modify or change the hopper, preferably toward a mass flow regime.

Caking Management Caking can quickly reduce the value of an expensive product, and it is important to develop strategies that reduce its occurrence. Understanding how powders behave in specific circumstances can play an essential role in process optimization. The advent of powder rheometers has delivered the means to sensitively differentiate between even very similar samples and to examine how various environmental factors affect the behavior of particular powders. The resulting information aids in the management of caking and in ameliorating the impact of factors such as humidity and consolidation, encouraging the development of storage conditions that fully meet the requirements of the powder.  For more information, contact Freeman Technology Ltd. at Boulters Farm Centre, Castlemorton Common, Welland, Worcestershire, England WR13 6LE; call (44) 01684-310860; fax (44) 01684-310236; or visit www.freemantech.co.uk. CERAMIC INDUSTRY ³ September 2011

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³ KILNCONNECTION by Ralph Ruark | Senior Technical Editor

Pressure Control in Tunnel Kilns

F

eeling the pressure lately? New boss, job, wife or kid? How about a new kiln? I can’t help you with the first four, but I hope that I can help you to see kiln pressure in an entirely new way. Why is pressure so important? In tunnel kilns, changing the kiln pressure is probably the fastest way to modify the firing and cooling characteristics of the entire kiln. Clients frequently ask me about the “correct” pressure for their tunnel kiln—without fully understanding the importance of kiln design, sensor location and sensor elevation. Pressure controls the primary and fundamental airflow within the tunnel kiln. It has a dramatic influence on temperature uniformity, soaking time and energy consumption. Measurement and control of pressure is imperative to maintaining consistently good firing characteristics.

Basic Pressure Characteristics Pressure within a tunnel kiln varies along its length, and is elevation- and temperature-dependent. Pressure is important because it influences airflow direction within the kiln and affects air infiltration and outflow. Airflow direction is always from positive to less positive, and it is important to remember that kiln pressure is measured relative to the air pressure outside of the kiln. In Figure 1, it is evident that the kiln pressure is relatively negative within a few feet of the entrance of the kiln and then gradually rises; the pressure becomes positive through the firing and cooling zones, and is “neutral” at the kiln exit. As previously stated, this pressure curve is only relative to the pressure in the room where the kiln is located. In fact, there is no negative pressure—only more positive or less positive areas. The absolute pressure within the kiln actually varies hour by hour with normal barometric changes in the atmosphere. Under proper control conditions, however, the relative pressure within the kiln stays the same.

Finding a Balance Once the basic concept is understood, how do you adjust the kiln pressure to provide the proper balance between temperature uniformity, temperature control, kiln car overheating and energy consumption? The first step is to develop a set of readings on your tunnel kiln. Select a manometer with sufficient sensitivity—0.001 in. resolution—so you can develop an internal pressure curve of the kiln. Try to measure the pressure in

Figure 1. Kiln pressure is relatively negative within a few feet of the entrance of the kiln and then gradually rises.

the kiln every 20 ft, and measure the pressure at the same elevation (preferably close to the kiln car base). At the same time, measure the oxygen level at each of these locations, as this supplemental data will be quite useful as we begin the analysis of changes that must be made. This data can be used to help improve the operational characteristics of the kiln. Because pressure controls the primary and fundamental airflow within the tunnel kiln, it has a dramatic influence on temperature uniformity, soaking time, and energy consumption. Measurement and control of pressure is imperative to maintain consistently good firing characteristics. Adjustment of the kiln pressure curve must take into account the whole kiln—not just one position. When changing any input or exhaust, whether it is cooling or heating, it is necessary to consider the impact and make the appropriate balance adjustments.  Editor’s note: Future installments of this column will discuss additional factors related to kiln pressure.

Ralph Ruark is a registered professional engineer with degrees in ceramic engineering and business, and 37 years of experience in the ceramic industry. He formed Ruark Engineering Inc. several years ago and serves as a technical consultant to a number of ceramic manufacturers and kiln companies. He is dedicated to assisting ceramic companies with a variety of kiln and firing needs, leading kiln analysis efforts, providing training expertise, and improving operations. Ruark can be reached at (941) 730-2253, fax (888) 370-2546, e-mail [email protected] or online at www.ruarkengineering.com. Any views or opinions expressed in this column are those of the author and do not represent those of Ceramic Industry, its staff, Editorial Advisory Board or BNP Media.

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special section | materials handling/powder processing

Wet Milling and Material Processing

➤ Processes in a variety of industries now routinely demand particle sizes with an absolute maximum of well below 1 micron. by Carl D. Yerger, President, Custom Milling & Consulting, Inc., Fleetwood, Pa.

T

he world of material processing and size reduction demands faster and more efficient methods to yield increasingly smaller sizes and narrower particle size distributions. Processes in a variety of industries now routinely demand particle sizes with an absolute maximum of well below 1 micron. Manufacturers are challenged to integrate a repeatable method of production that is capable of this level of size reduction while controlling labor and energy costs. The system must also be robust enough to handle the most abrasive of raw materials.

Traditional Milling The ceramic industry is no different from others in its search for modern manufacturing techniques. The traditional ball mill has been the primary method used to mill ceramic materials for hundreds of years, and is still considered to be one of the best mixers ever invented. Ball mills are generally batch units, which means that all ingredients are charged into the chamber and the mill is run unattended for a specified amount of time (or number of revolutions). The design of a typical ball mill only allows

for about a 65% (of total capacity) fill of product, which allows room for the grinding media to rise and fall for impact. Especially with smaller units, the labor and time required to batch and discharge the machine can become problematic and inefficient. Because of this inefficiency, a typical ball mill will only be available for grinding around 75% of the time, which does not take into consideration both scheduled maintenance and emergency breakdowns. Continuous ball mills are in use around the world, but they tend to be very large units suitable only for high-volume slurries and non-critical milling applications. Mills like this are commonly used in large ceramic tile factories to prepare slip for spray drying. Advancements in vertical ball mills have been made in recent years but also lack efficiency when compared to other methods. Another challenge involves finer and finer particle size demands. Traditional ball mills are generally limited to a finished particle size of approximately 5 microns, which can be achieved only with great attention to media size. Grinding media for ball mills ranges in size from 10-90 mm for most traditional applications. Typical ball mills use high-alumina or porcelain balls for their density, but wear is relatively high. Modern mono-size yttria-stabilized zirconium media is not a practical alternative due to the high cost per charge, as well as the frequent re-charge rate. Simply put, it is difficult for the traditional ball mill to put enough energy into the media charge to reduce particles to the sizes and distributions now required. In all milling processes, the ultimate performance of the mill is highly dependent on the media size and distribution.

Above: The horizontal media mill has a closed chamber that receives the pumped pre-mixed slurry in one end and discharges the milled product from the opposite end. CERAMIC INDUSTRY ³ September 2011

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MODERN WET MILLING Table 1. Effect of different media sizes on the number of cycles required. Theoretical Passes 0.0 1.2 2.4 3.6 4.7 5.9 7.1 8.3 9.5 10.7 11.8 13.0 14.2

Recirculation Time (Min) 0 15 30 45 60 75 90 105 120 135 150 165 180

Table 1 shows the effect of different media sizes on the number of cycles required.

Horizontal Media Mills The horizontal media mill has been used in the inks and coatings industries for over 30 years. Best described as a “high-energy continuous ball mill,” the machine’s design has undergone continuous changes since its introduction to keep up with the demands for finer particle sizes and narrower particle distributions. The horizontal media mill has a closed chamber that receives the pumped premixed slurry in one end and discharges the milled product from the opposite end. The mill uses a mechanically sealed shaft that is cantilevered from a heavy bearing housing. This shaft can be fitted with a variety of agitators, including discs, pegs or disc/pin combinations, depending on the particular process. The chamber is typically charged with grinding media to 60-90% of the net shell volume. The high energy imparted by the agitators on the grinding beads creates frictional heat, which is removed by chilled water circulating in the cooling jacket of the chamber. As the milling shaft rotates, the media is fluidized by the agitators positioned on the shaft. The peripheral agitator speed for this type of mill is typically 8-17 m/sec. The ceramic slurry passes through the length of the chamber under pump pressure while being milled through media-particle impact and shear, as well as particle30

1.7-2.1 mm d50 (μ) 2.606 2.310 1.985 1.637 1.411 1.271 1.094 0.950 0.862 0.778 0.673 0.602 0.573

1.0 mm d50 (μ) 2.606 1.959 1.413 1.059 0.820 0.655 0.477 0.423 0.381 0.376 0.346 0.329 0.307

particle impact and shear. At the exit end of the chamber, media is retained in the mill by a screen (also called a separator or filter) that is of such size that slurry particles can pass through. It is important to note that the screen plays no role in particle size distribution.

Benefits Determined by product type and particle size and distribution, these milling systems are unique to each application so design and setup are crucial for success. Equipment manufacturers must be able to supply the latest in wear-resistant materials as part of a successful installation. Selection of the proper construction materials is based on factors such as vehicle system, product end use and the abrasive nature of the raw materials. Materials of construction for milling wearing parts might include various types of ceramics, urethane and urethane coated, high polymer plastics, and composites. These milling systems are versatile and can be configured for one- or multipass operation through outfitting with the proper tanks and pumps. In addition, duplex systems with dual milling heads on a common frame combine the best of both by passing through a second chamber on the same machine that can be charged with media of a different size than the first chamber. Duplex milling (sometimes referred to as “cascading”) offers the advantage of operating two grinding chambers with one control system in a reduced footprint compared

September 2011 ³ WWW.CERAMICINDUSTRY.COM

0.6 mm d50 (μ) 2.606 0.978 0.550 0.552 0.454 0.440 0.367 0.291 0.284 0.277 0.268 0.260 0.258

0.3 mm d50 (μ) 2.606 0.427 0.336 0.316 0.297 0.273 0.260 0.251 0.244 0.232 0.221 0.218 0.214

to two mills. When nano-sized particles are specified, such as those required in ceramic inks used in inkjet applications, the mills are typically setup in high-flow recirculation. With the onset of digital technology in inkjet ceramic decoration, specially processed inks are critical to success. The higher resolutions created by today’s non-contact digital printing technology offers unlimited image variation for ceramic tile production. The digital inkjet printer is quickly becoming the standard on the modern glaze line, using specially formulated and milled pigmented ceramic inks in submicron particle sizes.

System Integration In today’s competitive environment, it’s not just about selecting the right wet grinding mill—integration to the overall system is important as well. Whereas a ball mill installation is fairly straightforward and uncomplicated, the successful installation of a high-energy attrition mill requires careful consideration of a number of factors: • Premix equipment selection for slurry preparation • Properly sized chiller system to remove BTU energy from the grinding process • Pump systems sized for optimum flow and resistance to abrasive ceramic materials • Feed and receiving tanks equipped with mixers for adequate suspension and batch turnover

• Process plumbing designed to minimize waste and optimize product yield • Controls and instrumentation packages are crucial for process control and automation, as well as data acquisition and product repeatability • If post milling filtration is required, the selection of a filter system is crucial to upstream mill efficiency • Moving materials to and away from milling system in the most efficient manner possible High-energy media (attrition) mills are commonly used in the manufacture of inks, coatings, agricultural, nutraceuticals and pharmaceuticals, electronics, and many other fine-particle products. Ceramic processes using media (attrition) mills include tape casting, specialty ceramic coatings and the milling of digital ceramic inks. As material processing innovations require finer and finer particle sizes, the use of these systems will grow, especially where high strength gains through the use of nano-sized materials are possible. The special requirements of ceramic materials require the manufacturer to design systems capable of withstanding the abrasion and wear inherent in most processes. If the materials of construction and systems are designed correctly, there is a high probability that high-energy media mills will find new homes in both advanced and traditional ceramics. Industries such as ceramic tile, brick, refractory coatings, oil and gas materials, glass, whitewares, pigments, electronics, polishing compounds, ceramic inks, and crucible manufacturing may use formulas requiring near- and sub-micron particle sizes, opening new avenues to achieving enhanced material properties.  For additional information, contact Custom Milling & Consulting, Inc. at 1246 Maidencreek Rd., Fleetwood, PA 19522; or email [email protected].

Integration is important to the overall system.

Hi-Vac Proud ®

Thhere’s There’s ’ a ffeeling eeling you get when whh n you ou own any Hi-Vac product. Maybe be it’s the confidence you gain knowing wing that your Hi-Vac product will perform efficiently and flawlessly ssly every day. Maybe it’s your pride de in knowing that your decision to buy Hi-Vac helps create a cleaner, safer, healthier, more productive environment. All you ou know is that when it comes to the highest quality, most respected industrial vacuum systems on the market, you are 100% Hi-Vac Proud. ®

Industrial Vacuum Systems

Acknowledgment The author would like to thank OPF Enterprises (www.ontheplantfloor.com) for their assistance with developing this article. OPF is Custom Milling & Consulting, Inc.’s ceramic consultant.

Want to feel that Hi-Vac Pride for yourself? Visit us online at

www.hi-vacproducts.com

800.752.2400

ENVIRONMENTAL PRODUCTS FOR A CLEANER WORLD www.hi-vac.com

740.374.2306

[email protected]

CERAMIC INDUSTRY ³ September 2011

31

Dust Explosion Hazards:

Key Risks and Solutions ➤ Some 70% of dusts are explosible and, given an adequate ignition source and appropriate dust/air concentration, can cause a dust explosion.

M

aterials such as silica, limestone, sand, cement, flyash, etc., are inert materials in their pure form (i.e., these materials will neither burn nor support combustion and do not pose a risk of fire or dust explosion). However, during the ceramic manufacturing process, other ingredients (such as organic materials and metallic powders) are often added to create the final product. These additional ingredients are generally in powder/dust form and may be combustible. In general, some 70% of dusts are explosible and, given an adequate ignition source and appropriate dust/air concentration, can cause a dust explosion. Most finely divided metal dusts are also explosible. Some materials will not present a dust explosion hazard due to their granular nature. However, it is possible during the processing of these materials to create finely divided dust that could be explosible. This applies to the operations where fine dust is intentionally generated (e.g., during milling) and/or unintentionally generated (e.g., during grinding, sawing, polishing or due to material attrition). Non-explosible materials such as sand or silica could become explosible if mixed with other explosible material (such as organic and/or metal dust) in adequate quantities. Hence, it is important to screen representative samples to determine and document if a mixture of material is explosible or not. 32

Case in Point In a foundry operation, powdered sand was being mixed with a water-based liquid and plasti-flakes to create resin-coated sand, which was then used in a core-making process. Sand is a known inert material; however, information on the explosibility of plasti-flakes was not available. During the operation, the plasti-flakes generated fine particulate dust due to material attrition. The dust generated from plasti-flakes was tested, and it was determined that the fine particulate dust was explosible. The discovery led to more questions regarding a safe operation and the coated fine sand was also tested. The test results showed that the fine coated sand was also explosible. A dust collection system that was used to collect dust from various locations of the sand coating process was also at risk of dust explosion and required an explosion-protection system to be installed. Deciding to test the representative samples of fine dust led to the discovery that the overall process was inherently unsafe, and certain improvements were implemented to abate the risks.

Dust Explosion Conditions A number of conditions must exist simultaneously for a dust explosion to occur (see Figure 1): • Dust must be combustible • Dust must be airborne • Dust concentrations must be within explosible range

September 2011 ³ WWW.CERAMICINDUSTRY.COM

by Muhammad M.R. Qureshi, Ph.D., Process Safety Specialist, Chilworth Technology, Inc., Princeton, N.J.

special section | materials handling/powder processing

Figure 1. Conditions required for a dust cloud explosion.

• Dust must have particle size distribution capable of propagating a flame • The atmosphere in which the dust cloud is present must be capable of supporting combustion • An ignition source with sufficient energy to initiate flame propagation must be present To assess the likelihood of an explosion in a facility and to select the most appropriate basis of safety, the explosion characteristics of the dust(s) that are being handled/processed in the facility should be determined.

Testing Procedures The key to establishing whether a process is at risk is to have an understanding of the explosion and thermal properties of powder materials and mixtures. It’s important to consider some guidelines to ensure that meaningful results are produced: • Don’t assume that your powder is nonexplosible • Don’t use old test results (some early test methods are no longer valid) • Don’t rely solely on published results • Don’t use results whose sample origins and test methods aren’t defined or don’t precisely match yours Several tests are necessary to determine the explosion properties of a powder/mixture. The selection of the appropriate tests depends on the nature of the powder and/ or processing activities. Tests that may be required are discussed below. Explosion Screening Test This is the first test generally performed for powders whose explosibility is not

Dust explosion test using a modified Hartmann apparatus.

readily known. The test is conducted in general accordance with American Society for Testing and Materials (ASTM) E1226. The objective is to determine the combustion of a dust cloud in the presence of a suitable ignition source. Trials are performed at varying dust concentration, and a sample is labeled as either “explosible” or “non-explosible” at the end of the testing. In other words, this is a “go/no-go” test; no quantification of the explosion is made. If the powder is non-explosible (“nogo”), it might not be necessary to run further tests. However, some “no-go” powders can be explosible at high temperatures. If it is understood that a suspended powder will be exposed to higher-than-ambient temperatures during processing, it is essential to conduct the explosion screening test at the processing temperature. It is also important to remember that some dusts pose a fire hazard even though they do not pose a dust cloud explosion hazard, and different testing may be required to assess this hazard. Dust Explosion Severity In order to assess dust explosion risks, both the severity of a possible explosion and the likelihood of ignition must be determined. To determine the dust explosion severity, the tester suspends a powder sample in a 20-liter spherical explosion chamber and a high-energy ignition source is introduced to cause an explosion. The sample size CERAMIC INDUSTRY ³ September 2011

33

DUST EXPLOSION HAZARDS

Prevention and Protection The risk of an explosion can be minimized when one of the following measures is ensured: • An explosible dust cloud is never allowed to form • The atmosphere is sufficiently depleted of oxidant (normally the oxygen in air) that it cannot support combustion • All ignition sources capable of igniting the dust cloud are removed • People and facilities are protected against the consequences of an explosion by “protection measures” such as explosion containment, explosion suppression or explosion relief venting

A plant destroyed by a secondary dust explosion.

is varied to determine the optimal dust cloud concentration. The maximum pressure and rate of pressure rise are measured and used to determine the deflagration index (Kst) value of the material, which indicates the level of the explosion violence. These data are used to design dust explosion protection measures such as relief venting, suppression or containment. The Kst test is performed in accordance with ASTM E1266. Minimum Explosible Concentration The minimum explosible concentration (MEC) test determines the lowest concentration of a dust/air suspension (cloud) that can give rise to flame propagation upon ignition. The MEC test is performed in accordance with ASTM E1515 or International Standards Organization (ISO) method 6184-1. This ignition sensitivity test allows an understanding of the ease of formation of an explosible dust cloud within equipment. The control of dust/air concentration is a significant hazard management method. Minimum Ignition Energy The minimum ignition energy (MIE) test determines the lowest spark energy that is capable of igniting a dust cloud at its optimum concentration for igni34

tion. The MIE test is performed in accordance with ASTM E2019, British Standard 5958, and International Standard: IEC 61241-2-3, and indicates the type of ignition source that is of concern for a material. Minimum Ignition Temperature of a Dust Cloud The minimum ignition temperature of a dust cloud (MITCloud) test determines the lowest temperature capable of igniting a dust dispersed in the form of a cloud. The MIT is an important factor in evaluating the ignition sensitivity of dusts to ignition sources such as heated environments, hot surfaces and friction sparks. The MIT test is performed in accordance with ASTM E1491 and European Standard 61241-2-1. Minimum Ignition Temperature of a Dust Layer The minimum ignition temperature of a dust layer (MITLayer) test determines the lowest temperature capable of igniting a dust layer of standard thickness (5-12.7 mm). The MIT is an important factor in evaluating the ignition sensitivity of a dust layer to ignition sources such as heated environments, hot surfaces and friction sparks. The lower value of MITCloud or MIT Layer is also used to specify the maximum surface temperature of

September 2011 ³ WWW.CERAMICINDUSTRY.COM

electrical devices in hazardous areas, per the National Electric Code.

Secondary Dust Explosions The majority of serious dust explosions over the years have not been caused by the initial/primary explosion inside the plant, but from a secondary explosion or a series of secondary explosions within the building. A small initial event causes a pressure wave to propagate into the workplace, and dust deposits around the workroom are dispersed into a cloud, which ignites. This can happen in a series of connected rooms and areas that have dust accumulations due to poor housekeeping. Housekeeping activities must ensure that secondary fuel sources are not available. Of key importance is an evaluation of dust release points and exhaust ventilation needs. It is also important to understand the characteristics of dust to ensure that correct tools, equipment and methods are applied during housekeeping efforts. If in doubt, it is highly recommended to seek the advice of a dust explosion hazard safety expert.  For more information, contact Chilworth Global at (609) 799-4449, email [email protected] or visit www.chilworth.com.

³PRODUCTSPOTLIGHT Crystex Composites Installs Lucifer Furnaces The furnaces are constructed with reinforced and welded sheet metal shells lined with firebrick and mineral wool insulation.

C

rystex Composites, producer of Mykroy/Mycalex glassbonded mica material used for electrical and thermal-insulating, recently approached Lucifer Furnaces Inc. looking for a reliable, economical single chamber heat treating unit. The company decided on the Red Dev il ser ies. The RD7-H14 models complement two existing units in use for glass-ceramic parts annealing and lab testing in Crystex’s ISO 9001-certified facility. These furnaces are reportedly economical and durable units constructed with reinforced and welded sheet metal shells lined with 4½ in. of multilayered firebrick and mineral wool insulation. The firebrick is precision dry-fit inside the 9 x 12 x 14-in. chambers, with staggered seams for reduced heat loss while allowing for thermal expansion. A ceramic hearth plate supports a 25-lb workload per square foot of hearth area and protects the floor brick. An adjustable latch on the horizontal swing door allows for a positive seal. Easy-to-replace heavy-gauge, lowwatt-density heating elements, regulated with a Honeywell Digital Temperature Controller, provide uniform heat. The Red Devil series is available as a single-chamber unit or a dualchamber model w ith a heat treating furnace above a tempering oven in one space-saving unit, according to Larry Jones, president of Lucifer Furnaces. The single-chamber unit can be built as a bench model or a floor model depending on the customer’s requirements.

³ WHAT’SNEW CHARLES ROSS & SON CO. Explosion-Proof Control Panels Ross SysCon recently announced its new line of explosion-proof control panels. Pictured is a 10-HP sing leaxis control system (SACS) in an explosion-proof panel supplied for variable-speed control of a Ross ultra-high-shear mixer. The operator station includes a digital readout for speed and cycle time in a new interface, and a more compact design. It is designed to be mounted close to the mixer in a hazardous area and wired to a variablefrequency drive that is installed outside the mixing room. Type X or Z purge control panels are also available for users who require mixer portability with no remote wiring. Call (800) 243-ROSS or visit www. mixers.com.

FERRO ELECTRONIC MATERIALS Jones says Lucifer Furnaces strives t o m e e t c u s t o m e r s’ n e e d s . Wi t h Cr y s te x Co m p o s i te s , t h a t m e a n t adjusting the depth of the furnaces to meet space restrictions. Crystex Composites ordered two furnaces and was pleased with them. Later, when the company wanted to increase its heat treating capability, they returned to Lucifer and ordered two more units. Charles Clement, Ph.D., vice president of Engineering at Crystex Composites, says he chose to add to the Lucifer furnaces cur rently in use because of their simple and compact design and high temperature capability, as well as the long life of the heating elements and insulating materials— despite hundreds of thermal cycles. In addition, he says he finds the Lucifer models to be very reliable, easy to maintain and competitively priced.  For additional details, call Lucifer Furnaces at (800) 378-0095 or visit www.luciferfurnaces.com.

Silver Conductor Pastes Two new rear silver conductor pastes are now available that reportedly reduce cost per watt while maintaining the same adhesion, solderability, and field reliability as current commercial products. The new pastes have pure silver metallurgy and can enable fast printing at speeds of more than 200 mm per second. They are compatible with the company’s back surface aluminum pastes and can be co-fired in a wide processing window. Both provide robust soldering behavior with excellent adhesion to silicon wafers and have demonstrated field-proven module performance. PS 2130 and PS 2131 silver pastes are RoHS- and REACHcompliant and are free of lead, cadmium, and phthalates. Visit www.ferro.com.

MORGAN TECHNICAL CERAMICS Pressure Sensor A new tube contact sensor is now available for accurate detection of occlusions in medical infusion lines. The sensor reportedly allows non-invasive detection of pressure changes in a flexible tube without the CERAMIC INDUSTRY ³ September 2011

35

WHAT’S NEW

³ BUYERS’

CONNECTION NETZSCH introduces the new LFA 457 MicroFlash® system to measure thermal diffusivity, thermal conductivity and specific heat of advanced materials, including advanced ceramics, metals, polymers, liquids and more. Using the laser flash principle, the instrument operates from -125 to +1100°C, in pure gas atmospheres or in vacuum, and includes an automatic sample changer for unattended overnight operation. For details please visit: http://netzsch-thermal-analysis.com

requirement for disposable cassettes; as a result, it can provide medical device OEMs with a simple and reliable method of recognizing when the tube is blocked. The pressure sensor can be used with soft thin-walled tubing and can be clipped on and removed. It reportedly can detect both negative and positive changes in pressure from -0.5 to 1 bar with a sensor accuracy of ± 0.05 bar. The pressure sensor combines MEMS silicone machined technology with a precision machined lid and catch. It is suitable for a 4-4.7 mm outside diameter x 0.8 mm wall thickness medical grade silicone rubber tubing. Visit www.morgantechnicalceramics.com.

Phosphate Precursor Process

FURNACES AND KILNS

One System - PM, SO2, HCl, Hg, & NOx

UltraCat Catalyst Filter Controls NOx at 350°F to 700°F Particulate to less than 2.0 mg/Nm3 • One system for PM, NOx , SO2 , HCl, dioxins, mercury, or any combination • Low temp NOx control by catalyst-embedded filters eliminates costly SCR

This Akron-based equipment maker has developed a two-phase process for grinding and dispersing the phosphate precursor required for lithium-ion batteries. The first phase uses the company’s S-series attritors to grind and disperse the coarse precursor powder to a 1-3 μm particle size range. The second phase runs through the company’s DMQ series horizontal media mills, dispersing the finished material to a primary particle size range of 200-300 nm. “Thorough testing of this two-phase method of processing lithium-ion phosphate precursor has shown a high level of repeatability,” said Arno Szegvari, CEO. “As transportation choices become more eco-friendly, we are pleased that we can contribute to the continuing expansion of green technology.” Visit www.unionprocess.com. 

Have Product News to Share with the Industry? E-mail news releases to Teresa McPherson at [email protected].

36

• High Temp Furnaces for ceramic firing • Compact design, rapid heat • Uniform temperature and precision control • Front and bottom load models to 1700º

(800) 378-0095 www.luciferfurnaces.com

• Project sizes up to 200,000 cfm

Call or email today... Ph: 801.294.5422 [email protected] ®

Since 1960

Tri-Mer

Ceramic Fiber Filter, New 10 ft. Length

UNION PROCESS

Netzsch Instruments Burlington, MA 01803 Ph: 781-272-5353 • Fax: 781-272-5225 E-mail: [email protected]

®

6 in.

Meets MACT Regulations

CORPORATION

Factory Headquarters: Owosso, Michigan

www.tri-mer.com © 2011 Tri-Mer Corp.

Make the Commerce Connection! CI BUYERS’ CONNECTION Reinforce your sales message and showcase your • Literature • Home page • Product sheets • New products • Specialty products and accessories Economical, 1/9 page color mini-ad. Space still available in June, Sept, Oct, Nov, Dec Contact Ginny Reisinger 614-760-4220 • [email protected]

September 2011 ³ WWW.CERAMICINDUSTRY.COM

CI’s November 2011 EQUIPMENT DIGEST Position your company for success and put the power of Ceramic Industry to work for you!

Ad Closing: October 6, 2011

Call TODAY! Ginny: 614-760-4220 [email protected]

³ SERVICESMARKETPLACE ³CONSULTING & ENGINEERING SERVICES

³MAINTENANCE/SERVICES

Brinks Hofer Gilson & Lione . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Ceramic Maintenance Services, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Ceralink, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Ceramics Consulting Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

³PROCESSING SERVICES

Jonathan Kaplan Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

AVEKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Ragan Technologies, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

CCE Technologies, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Richard E. Mistler, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Powder Processing and Technology, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Ruark Engineering, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Powder Technology, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Semler Materials Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Union Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

³CONTRACT MANUFACTURING SERVICES

³RECYCLING SERVICES

Coalition Technology Co., Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

A-Ten-C, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

CoorsTek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Superior Technical Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

³REFRACTORY SERVICES Fuse Tech/Hot Tech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

³FINISHING & MACHINING SERVICES Advanced Ceramic Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

³SPRAY DRYING

Bullen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

General Spray Drying Service, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

EBL Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Ferro-Ceramic Grinding, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

³CONSULTING & ENGINEERING SERVICES

Machined Ceramics, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 O’Keefe Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 PremaTech Advanced Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Sonic-Mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

³FIRING & DRYING SERVICES Allied Kiln Service Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 American Isostatic Presses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Centorr/Vacuum Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Harrop Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Ipsen Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Experts in Ceramic Engineering & Materials Science • Microwave & RF Process Development • Scale-up • Equipment Design

• Materials Engineering Ceramics, Glass, Composites

• Research and Innovation • Prototyping

518-283-7733 * Fax: 518-283-9134 * [email protected] * www.ceralink.com

I Squared R Element Co., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SBL Kiln Services, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 TevTech, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

³GLASS SERVICES Ceradyne VIOX, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Fuse Tech/Hot Tech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Phone: 480-895-9830 FAX: 480-895-9831 e-Mail: [email protected]

Glass Inc. International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SEM-COM Co., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Dr. Charles E. Semler

Specialty Glass, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

³INDEPENDENT AGENTS Tape Casting Warehouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Taylor Tunnicliff Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

President/Consultant SEMLER MATERIALS SERVICES 10153 E. Elmwood Dr. Chandler, AZ 85248

³LABORATORY & TESTING SERVICES Activation Laboratories Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Geller Microanalytical Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Harrop Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 JTF Microscopy Services, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Micron Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Netzsch Instruments NA LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 NSL Analytical Services Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Quantachrome Lab QMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 West Penn, Spectrochemical Labs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

CERAMIC INDUSTRY ³ September 2011

37

³CONSULTING & ENGINEERING SERVICES / CONTRACT MANUFACTURING SERVICES ³CONTRACT MANUFACTURING SERVICES

High Shear Compaction— Superior Tape Forming Process • Full thickness single layer tapes: • HSC efficient high-volume 0.1 mm to greater than 13 mm process compatible with any powder: ceramic, glass, metal • Aqueous binder systems— extreme thickness control or plastic Ragan Technologies Inc. • Tape Development > Toll • Improvement over roll compac978-297-9805 Manufacturing > Turnkey tion —Isotropic tapes are [email protected] Installations never brittle & fire flat www.ragantech.com

INNOVATIVE SOLUTIONS FROM CONCEPT TO PRODUCTION • • • •

Delivering solutions for diverse applications & industries Extrude, dry press, iso press, precision machine AS9100 & ISO9001:2008 Certified Plantwide Customer-Focused Culture

802-527-7726 • [email protected] • www.ceramics.net

Alumina • Zirconia • ZTA • Steatite • Cordierite • BN • Macor

Jeff Zamek Ceramics Consulting Services

6 Glendale Woods Drive Southampton, MA 01073

Precision Ceramic Components fj^X`"ijgc egdidine^c\

Telephone 413 527 7337 Fax 413 529 2674 [email protected] www.fixpots.com ]^\]"kdajbZ bVcj[VXijgZg

Ceramic Product Design and Development Whitewares and Tabletop Custom Molds and Models Veea^XVi^dc Zc\^cZZg^c\

3520 Brighton Blvd., Denver CO 80216 (303) 909-5488 www.plinthgallery.com [email protected]

Michael S. Gzybowski Intellectual Property Attorney 734.302.6046 [email protected]

Suite 200 | 524 South Main Street | Ann Arbor, MI 48104 usebrinks.com

Ruark Engineering, Inc. Customer Oriented Expert Kiln Assistance • • • •

CONTINUOUS IMPROVEMENT OF KILN OPERATIONS KILN UPGRADE AND MODIFICATIONS NEW KILN PROCUREMENT SPECIALIZED TRAINING ON SITE

Ralph Ruark, PE 10506 Cypress Point Drive Bradenton, FL 34202

38

P: 941-730-2253 F: 941-360-3211 [email protected] http://www.ruarkengineering.com

September 2011 ³ WWW.CERAMICINDUSTRY.COM

CoorsTek is the largest US-owned technical ceramics manufacturer in the world. Call 303-271-7006 or email [email protected] for expert assistance on your next project. Visit us on the web www.coorstek.com

³FINISHING & MACHINING SERVICES

WORLD LEADER IN PRECISION CERAMICS in nd

g

ri G & f C ion Machining era ials

Pre o cis

r mic s & Advanced Mate

PremaTech Advanced Ceramics is a highly respected, world leader in advanced custom machining and grinding for the Semiconductor, Aerospace & Defense, Research, Life Sciences and Commercial industries. For all your ceramic needs, please call 508.791.9549 NEW Lapping & Polishing Capabilities

Over a Quarter Century of Precision Ceramic Machining Process Development, has resulted in hundreds of satisfied customers. Put our experience and knowledge to work for you and become one of our satisfied customers.

Advanced Ceramic Machining & Components Engineering and Design Support Grinding of Hard and Ultrahard Materials: Alumina, Boron Nitride, Ferrite, Quartz, Silicon Carbide, Silicon Nitrides and Zirconia

ISO 9001-2008 Certified ITAR & CCR Registered WBENC Certified

www.prematechac.com

719-687-0888 • [email protected] • www.okeefeceramics.com

YOUR OU U ULTRASOURCE SOU C FOR MACHINING HARD & BRITTLE MATERIALS

www.bullentech.com 1301 Miller Williams Rd. Eaton, Ohio 54320 USA Phone: (937) 456-7133 • Fax: (937) 456-2779 Email: [email protected]

EBL PRODUCTS, INC.

28 Years of Precision Ceramic Grinding

PIEZOCERAMICS

• Custom forming of technical ceramics * Built to customer print * • Prototype, short run and high volume production quantities • Multiple C.N.C. Capabilities

Serving our customers for over 50 years PRECISION CUSTOM DESIGN for:

• • • •

piezoceramic tubes piezo composites lead zirconate titanates matching layers & wearplates

EBL Products, Inc. 22 Prestige Park Circle, E Hartford CT 06108 Phone: 860-291-2537 • Fax: 860-291-2533 www.eblproducts.com [email protected]

Phone: 714-538-2524 Fax: 714-538-2589 Email: [email protected] Website: www.advancedceramictech.com

CERAMIC INDUSTRY ³ September 2011

39

³FINISHING & MACHINING SERVICES / FIRING & DRYING SERVICES

ISOSTATIC PRESSING Specializing in

Contract Machining Company and Ceramic Component Supplier

HIP, CIP, Service and Equipment

• ISO 9001:2000 & AS9100B • CAD/CAM CNC Machining • Extensive Material Inventory • Material/Technical Support • Over 40 Years of Service

Visit us on the Web: www.aiphip.com Call toll free: 800-375-7108

Specializing in BN, SiC, Macor, Si N , Al O , ZrO , Quartz, Ferrites and other related materials 3

4

2

3

2

American Isostatic Presses 1205 S. Columbus Airport Rd. Columbus, Ohio 43207 Phone (614) 497-3148 Fax (614) 497-3407

TEVTECH, LLC MATERIALS PROCESSING SOLUTIONS Custom Vacuum Furnaces & Hot Zone Refurbishment for Sintering • CVD • Purification • Brazing 100 Billerica Ave., N. Billerica MA 01862 Tel. (978) 667-4557 • Fax. (978) 667-4554 www.tevtechllc.com

³FIRING & DRYING SERVICES

TOLL FIRING SERVICES

• Sintering, calcining, heat treating to 1700°C • Bulk materials and shapes • R&D, pilot production • One-time or ongoing

TOLL FIRING and CERAMIC REFRACTORIES

• Multiple kilns and furnaces for optimal firing options • Screening, surface area, and bulk density testing available • Custom and standard ceramic refractories • Alumina and Fused Silica formulas • Shapes include saggers, tiles, crucibles, kiln furniture [email protected] • (815)239-2385 ext. 105 www.ipsenceramics.com

I SQUARED R ELEMENT CO., INC. AKRON, NY USA

EQUIPMENT

• Atmosphere electric batch kilns to 27 cu. ft. • Gas batch kilns to Columbus, Ohio • 614-231-3621 57 cu. ft. www.harropusa.com e-mail: [email protected]

40

September 2011 ³ WWW.CERAMICINDUSTRY.COM

• Custom Designed Silicon Carbide & Molybdenum Disilicide Heating Elements for Your Application • Engineering Assistance & Trouble Shooting • Customized Accessories

Visit our Web Site: www.isquaredrelement.com Phone: (716) 542-5511 • Fax: (716) 542-2100

BUS.: (608) 783-4455 ALLIED FAX: (608) 783-4420 KILN EMAIL: [email protected] SERVICE INC. TIMOTHY J. TOBIN

SERVICESMARKETPLACE

³FIRING & DRYING SERVICES / GLASS SERVICES / INDEPENDENT AGENTS

Electronic and Specialty Glass Frits & Powders • • • • • • • • • •

New Kiln Design and Manufacturing Roller Hearth - Shuttle - Car Bottom - Tunnel • Installations • Combustion

• Refractory/Fiber • Electrical

• Instrumentation • Profile/Balancing

www.alliedkilnservice.com 1349 Moorings Dr. • La Crosse, WI 54603

Standard compositions Custom melt capacity Glass development Calcinations Toll processing Test sample availability Production volumes Tailored particle sizes Press-ready granulation ISO 9001:2000 registered

³GLASS SERVICES

ALBERT LEWIS PRESIDENT

GLASS

INCORPORATED INTERNATIONAL 14055 LAURELWOOD PL • CHINO, CA 91710 email: [email protected] website: www.glassint.com Phone 909-628-4212

SEM•COM

Fax 909-628-2771

GLASS TECHNOLOGY Design • Development • Manufacturing

6701 Sixth Ave. S. Seattle, WA 98108 (206) 763-2170 E-mail: [email protected] www.viox.com

³ INDEPENDENT AGENTS

COMPANY, INC.

SPECIALTY & ELECTRONIC GLASS MANUFACTURING We provide the following services:

Q GLASS MELTING Q GLASS FABRICATION Q COMPOSITION DEVELOPMENT Q CONSULTING Contact us for further information:

Ph: 419-537-8813 Fax: 419-537-7054 E-mail: [email protected] www.sem-com.com

Refractory Repair Specialists • Ceramic Welding & Periscope Surveys • Port & Checker Cleaning • Hot Refractory Sawing & Drilling • Furnace Overcoating • Hot & Cold Refractory Repair

CERAMIC INDUSTRY ³ September 2011

41

³INDEPENDENT AGENTS / LABORATORY & TESTING SERVICES G E L L E R M I C ROA NA LY T I C A L USA McCuen & Associates Ph: 330 482-1074 Fax: 330 482-4560 Email: [email protected] www.davemccuen.com

BULLERS RINGS • Improve Kiln Yields • Reduce Loss • Improve Production Profits • Guarantee Consistent Firings

UK Taylor Tunnicliff Limited. Normacot Road Longton Stoke-on-Trent ST3 1PA

w w w.t ayl o r tunni clif f.co m

³LABORATORY & TESTING SERVICES

Your Partner in Ceramics Analysis Experiennced analysis of Adva Experienced Advanced anc n ed cceramic erramicc materials matterialss including inncluudi ding alumina, magnesia, zirconia, carbides, nitrides, and oxides. Specialized Testing Capabilities Compositional Analysis Elemental and Chemical Analysis Microscopy and SEM Thermal Analysis

LABORATORY Analytical Services & NIST Traceable Magnification Standards SEM/X-ray, Electron Mircoprobe, Surface Analysis (Auger), Metallography, Particle Size Counting, and Optical Microscopy for Ceramics and Composite Materials Specializing in quantitative analysis of boron, carbon, nitrogen, oxygen, etc. in micrometer sized areas. Elemental mapping, diffusion studies, failure analysis, reverse engineering and phase area determinations. IS O 9 0 0 1 & 1 7 0 2 5 C ert i fi ed Put our years of experience to work on your specimens! 426 Boston St. Topsfield, MA 01983 Tel: 978-887-7000 Fax: 978-887-6671 www. gellermicro.com Email: [email protected]

Thermal Analysis Materials Testing • Dilatometry • ASTM Testing • Glass Testing

• Thermal Gradient • Custom Testing • Clay Testing

• Firing Facilities • Refractories Creep • DTA/TGA

Columbus, Ohio • 614-231-3621 www.harropusa.com e-mail: [email protected]

Analytical Expertise Trace Level Analysis Bulk Composition Thermal Conductivity Contaminants Inclusions Failure Analysis

www.nslanalytical.com

NSL Analytical Services, Inc. 4450 Cranwood Parkway, Cleveland, Ohio 44128 4OLL&REEsMRJS$RWPEREP]XMGEPGSQ

Trust

|

Technology

|

Turnaround

Powder and Porous Materials Characterization Laser diffraction particle size BET surface area Density DVS www.labqmc.quantachrome.com [email protected] 1-800-989-2476

42

September 2011 ³ WWW.CERAMICINDUSTRY.COM

LOWER COST MILLING SOLUTIONS

JTF Microscopy Services, LLC Microscopy, Petrographic Analysis, Training & Consulting • Glass defect analysis and source identification • Furnace refractory failure investigations • Glass technology support services related to glass defect issues • Training seminars – on-site, on your own equipment

• Raw material contaminant identification • Trouble-shooting and correction of microscope equipment problems • Consulting for equipment purchases: microscope, camera & sample preparation • Expert witness services in legal actions

phone: 607.292.6808 • mobile: 607.731.8863 email: [email protected] • website: www.jtfmicroscopy.com

Holding off on capital purchases? Union Process still has several low cost options for you to get the job done economically and efficiently using the finest size reduction equipment on the market.

TOLL MILLING Save on capital equipment, personnel and space. Let Union Process toll grind your product in our Pilot Plant.

REBUILDING Got a used Attritor in need of an update? Talk to Union Process about our 8-step refurbishing process using all OEM parts.

³MAINTENANCE SERVICES

"EFORE !FTER

• Mill Lining Installation • Ball & Pebble Mill Parts • Field Service & Installation

Ceram

ic Maintenance Services, In

MILL LINING INSTALLATION GRINDING MEDIA

• Thickness Testing • Mill Doors & Gaskets

c.

Providing Quality Service for Over 25 Years

• Grinding Media • Buy/Sell Used Process Equipment

PO Box 119 • Conneaut PA 16316 • Cell: 412-818-1379 Email: [email protected] • www.ceramicservicesonline.com

³PROCESSING SERVICES

ENGINEERED PARTICLES Custom Particle Processing featuring: • • • • •

Spray Drying Particle Coating & Surface Modification Wet & Dry Ball Milling Bead Milling Research & Development

Our approach: • • • •

Innovation Collaboration Exceptional Customer Service Quality

[email protected] ISO 9001: 2008 Registered 2045 Wooddale Drive Woodbury, MN 55125 For more information visit: www.aveka.com 651-730-1729 | FAX 651-730-1826 or Call Toll Free: 1-888-317-3700

SPARE PARTS Make sure your Attritor is performing at peak efficiency. Order critical OEM spare parts today. Union Process stocks many parts ready for immediate shipping.

Partner with Union Process.

0HONEsWWWUNIONPROCESSCOM

Expanding the Possibilities for Size Reduction

place you!r ad here

CONTACT GINNY REISINGER @ 614/760.4220 or reisingerg@ bnpmedia.com to place yours today.

CERAMIC INDUSTRY ³ September 2011

43

SERVICESMARKETPLACE

³LABORATORY & TESTING SERVICES / MAINTENANCE SERVICES / PROCESSING SERVICES

³PROCESSING SERVICES / RECYCLING SERVICES

Your Source for Powder Processing We specialize in: • Spray Drying • Wet and Dry Milling • Calcining and Sintering Typical Applications: • Catalysts • Electronics • Ceramics • Fuel Cells For more information, please contact Alan Sukovich at 219-462-4141 x224 or [email protected] 5103 Evans Avenue | Valparaiso, IN 46383

www.pptechnology.com

'978318300463')77-2+ 7TIGMEPM^EXMSRMR%MV'PEWWM½GEXMSR ERH.IX1MPPMRK 7QEPPXS0EVKI4VSHYGXMSR0SXW ˆ.IX1MPPMRK4VIGMWIXSTWM^IGYXQMRMQEP½RIW ˆ%MV'PEWWM½GEXMSR'YXWJVSQQMGVSRWXSQMGVSRW

³ RECYCLING SERVICES

RECYCLE! Eliminate Disposal

Wanted: ceramics, refractories, abrasives, kiln furniture, SiC and hi alumina ceramic scrap

A-TEN-C, INC.

ˆ1IGLERMGEP1MPPMRK*VSQQMGVSRWXSQIWL ˆ:MFVEXSV]7GVIIRMRK1MRYWQIWLXSTPYWQIWL ˆ&PIRHMRK(V]ERHHV]PMUYMHFPIRHW )[MRK%ZI7 &YVRWZMPPI12 4L *E\

-736)+-78)6)( [[[TS[HIVXIGLRSPSK]MRGGSQ

WEPIW$TS[HIVXIGLRSPSK]MRGGSQ

8SPP*VII

DON’T FORGET! To keep receiving FREE issues you must renew your subscription. Renew online at: www.RenewForFree.com

Call: 412-821-5566 • [email protected] • www.ceramicrecycling.com

³REFACTORY SERVICES

Refractory Repair Specialists • Ceramic Welding & Periscope Surveys • Port & Checker Cleaning • Hot Refractory Sawing & Drilling • Furnace Overcoating • Hot & Cold Refractory Repair

³SPRAY DRYING

TOLL DRYING SPRAY DRYING Moisture & Particle Size Control • Dry Blending • Powder Cooling • Wet Milling SPIN FLASH DRYING Press Cake or Paste • Continuous Drying • No Post Grinding

The Most Experienced Custom Dryer of Ceramics, Chemicals and Metals GENERAL SPRAY/CVP DRYING SERVICES INC. Ph: 908-353-2477 • Fax: 908-353-0060 E-mail: [email protected] www.generalspraydrying.com

44

September 2011 ³ WWW.CERAMICINDUSTRY.COM

SERVICESMARKETPLACE

³BUY & SELL

Web: detroitprocessmachinery.com

SPECIALIZING IN BUYING AND SELLING CERAMIC EQUIPMENT Compacting Presses Isostatic Presses Piston Extruders Mixers/Blenders Spray Dryers Crushers/Pulverizers/Granulators Ball Mills/Grinding Mills Stokes Press Replacement Parts We buy equipment...one piece to an entire plant 1404 South Gratiot Ave., Suite B Mount Clemons, MI 48043 USA Ph: 586-469-0323 • Fax: 586-469-3393 Email: [email protected] ³BUY & SELL

³POSITIONS AVAILABLE

Quality & Service First BUY & SELL MACHINERY 586-790-1717 • [email protected] WWW.AADVANCEDMACH.COM

place yroeu!r ad he

CONTACT GINNY REISINGER @ 614/760.4220 or reisingerg@ bnpmedia.com to place yours today.

NEW RIBBON BLENDERS PRICED 30% LESS

World’s #1 Manufacturer! • All stainless, highest quality! • Sizes 1 to 500 cu.ft. • Many sizes in stock! Call now!

1-800-243-ROSS

USA Tel: 631-234-0500 • Fax: 631-234-0691 www.ribbonblenders.com

Trading/Sales Position An industrial Minerals & Specialty Chemicals Trading Company located in the Hartford County of Connecticut has a high energy Trading/Sales position open involving sourcing and selling industrial raw materials & chemical products to/for corporate accounts. Requirements: • Bachelor’s Degree in Material Science, Ceramic Eng, Chemical Eng. or Business Admin/Marketing with basic Chemistry. • Import/Export Trade in Industrial Minerals and/or Chemicals a plus • Excellent English a must. French & Spanish useful but not necessary. • Both domestic and international travel required Salary shall be based on qualification and experience. Please email resume: [email protected] Website: www.chivine-us.com

www.ceramicindustry.com CERAMIC INDUSTRY ³ September 2011

45

³ ADVERTISERINDEX ADVERTISER

PAGE NO.

ADVERTISER

PAGE NO.

Chem Show www.chemshow.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IBC

* I Squared R Element Co., Inc. www.isquaredrelement.com . . . . . . . . . . . . . . . . . . . . . . . . . 24

* Evans Analytical Group www.eaglabs.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

* Netzsch Premier Technologies LLC www.netzsch-grinding.com . . . . . . . . . . . . . . . . . . . . . . . . . . 25

* FLSmidth Inc. www.flsmidth.com. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SACMI www.sacmi.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC

Glass Build America www.GlassBuildAmerica.com . . . . . . . . . . . . . . . . . . . . . . . . . 3

* Tokuyama America Inc. www.tokuyama-a.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

* Harrop Industries Inc. [email protected] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

* Unimin Corp. [email protected] . . . . . . . . . . . . . . . . . . . . . . . . BC

* HI-VAC Corp. www.hi-vac.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 * See our ad in the 2011-2012 Ceramic Industry Data Book & Buyers’ Guide. This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and Ceramic Industry assumes no responsibility for its accuracy.

Spend less time searching for information

and more time using it

www.ceramicindustry.com/databook

Online Data Book & Buyers’ Guide s4HEBUYERSREFERENCEFORCERAMIC GLASSANDRELATEDINDUSTRIES s3EARCHBYPRODUCTCATEGORYORCOMPANYNAME s$OWNLOADABLEPRODUCTSPECSHEETS s!LPHACOMPANYLISTINGS s,IVEWEBEMAILLINKS

BROWSE

CLICK

CONNECT

3TARTYOURSEARCHTODAY
WWWCERAMICINDUSTRYCOMDATABOOK 46

September 2011 ³ WWW.CERAMICINDUSTRY.COM

Processing Solutions that Fit Conference Partner:

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November 1-3, 2011

Media Partner:


  
 


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