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2025/12/22

What percentage of ceramic structural components are used in new energy vehicles?

The proportion of ceramic structural components in new-energy vehicles needs to be described from three dimensions: weight proportion, cost proportion, and market structure proportion.

2025/12/22

What is the achievable machining accuracy for grinding ceramic structural parts?

The grinding accuracy of ceramic structural components depends on equipment performance, abrasive selection, process parameters, and the ceramic material itself. There is a significant difference in accuracy between conventional precision grinding and ultra-precision grinding. In conventional precision grinding, diamond grinding wheels are used in conjunction with high-rigidity machine tools, enabling dimensional tolerances to be controlled within **±1–5 μm**. Flatness/parallelism can reach 1–3 μm, cylindricity/circularity is 1–2 μm, and surface roughness (Ra) remains at 0.1–0.4 μm, meeting the precision requirements for most industrial wear-resistant parts and insulating supports. Ultra-precision grinding—such as ELID online electrolytic dressing technology—can achieve sub-micron-level accuracy, reducing dimensional tolerances to **±0.1–1 μm**. Flatness/circularity can be controlled within 0.1–0.5 μm, and surface roughness (Ra) can be as low as 0.01–0.05 μm, making it suitable for high-end components such as semiconductor substrates and precision bearings. To enhance accuracy, three key factors must be carefully managed: First, select diamond grinding wheels with a grit size of ≥200#, set the linear velocity at 15–30 m/s, and adjust the feed rate to 0.5–2 μm/pass; second, maintain a constant-temperature, vibration-isolated environment and use a laser interferometer for real-time monitoring; third, tailor process parameters according to different materials such as alumina and silicon carbide to prevent thermal deformation and brittle cracking.

2025/12/22

What are the machining processes for ceramic structural components?

The manufacturing process for ceramic structural components must be carried out in stages, covering the entire workflow from raw materials to finished products. The core process can be broadly divided into two major categories: forming processes and post-processing techniques, as detailed below: Forming Processes (the Core Stage of Green Body Preparation) Dry Pressing: Ceramic powder mixed with a small amount of binder is placed into a mold and then pressed to form the green body. This method boasts simplicity, high efficiency, and low cost, making it suitable for medium- and small-sized parts with regular shapes (such as ceramic wear-resistant plates and insulating shims). However, it is difficult to produce parts with complex geometries using this technique. Slip Casting: A ceramic slurry is poured into a plaster mold, where the mold's water-absorbing properties cause the slurry to solidify into a green body. This method is ideal for thin-walled and complex-shaped parts (such as ceramic pipe fittings and custom brackets). However, the green bodies produced by slip casting have lower density, so the slurry concentration must be carefully controlled. Injection Molding: Ceramic powder is mixed with a thermoplastic binder, heated until melted, and then injected into a mold. This process enables the production of highly precise parts with intricate structures (such as miniature ceramic gears and electronic component bases), making it well-suited for mass production. However, the subsequent removal of the binder adds extra steps to the process. Isostatic Pressing: In a high-pressure vessel, uniform pressure is applied to the ceramic green body, resulting in a dense and uniformly compacted green body. This method is particularly suitable for parts requiring high performance and high density (such as ceramic cutting tools and high-temperature structural components). Nevertheless, the equipment required for this process is relatively expensive. Post-Processing Techniques (the Finishing Stage After Sintering) Grinding: Using diamond grinding wheels, sintered ceramic parts are ground to achieve fine finishing. This is the primary method for precision finishing of ceramics, improving dimensional accuracy and surface smoothness. It is widely used for precision seals, bearings, and other components that demand tight tolerances. Polishing: Through mechanical or chemical polishing, the surface roughness of ceramics is reduced to meet the surface requirements of optical components and precision parts. Drilling and Cutting: Diamond tools are used for drilling and cutting ceramic parts to achieve the desired hole positions and external dimensions. Care must be taken to control the feed rate to prevent brittle cracking due to the inherent fragility of ceramics.

2025/12/22

How to Choose Ceramic Structural Components

The selection of ceramic structural components must revolve around three core dimensions: service conditions, material properties, and process compatibility, ensuring that performance precisely matches the specific application scenario. First, choose materials based on the operating environment: Alumina ceramics boast high hardness and low cost, making them ideal for general industrial applications requiring wear resistance and electrical insulation—such as wear-resistant parts for kitchenware processing equipment and electronic insulating brackets. Silicon nitride ceramics exhibit excellent thermal shock resistance, making them well-suited for high-temperature scenarios with frequent and rapid temperature fluctuations—such as components for metallurgical kilns. Silicon carbide ceramics, with their exceptional high-temperature resistance and strong thermal conductivity, are particularly appropriate for heavy-duty applications in aerospace, new energy, and other high-load environments. Second, pay close attention to key performance parameters: prioritize checking indicators such as hardness, flexural strength, and thermal expansion coefficient. In high-temperature applications, it’s crucial to verify the melting point and thermal stability; in corrosive environments, assess acid-alkali resistance and oxidation resistance. Finally, consider both manufacturability and assembly compatibility: select forming processes according to the complexity of the structure—for precision small parts, injection molding is a good choice; for large components, dry pressing is preferred. At the same time, match installation interface dimensions and allow sufficient thermal expansion clearance to prevent cracking caused by stress concentration. Additionally, take into account the cost budget and, while meeting performance requirements, opt for cost-effective solutions that strike a balance between service life and procurement costs.

2025/12/22

What should be noted when using ceramic metallized parts?

Ceramic-metalized components, which combine the insulating properties of ceramics with the conductive nature of metals, are widely used in harsh operating conditions. When using these components, it is crucial to pay close attention to four key aspects. First, thermal-matching control: Since ceramics and metals have different coefficients of thermal expansion, temperature changes must be gradual (a recommended rate of ≤5°C/min) to avoid sudden local cooling or heating that could induce interfacial stresses, leading to cracking or delamination. Particular care should be taken during the start-up and shut-down phases of high-temperature equipment to strictly manage the pace of temperature changes. Second, adaptation to corrosive environments: Select the appropriate material for the metallized layer based on the specific operating conditions. For example, in strongly acidic environments, platinum- or gold-plated layers are preferred to prevent corrosion and failure of the metal layer. In humid environments, ensure thorough sealing and protection to prevent oxidation and rusting of the metal layer, which could compromise both conductivity and sealing performance. Third, avoidance of mechanical stress: Given the inherent brittleness of ceramic substrates, avoid forceful tightening during installation. Instead, use elastic connectors to distribute stress evenly and prevent cracks caused by compression or impact. During transportation and storage, provide adequate shock absorption and cushioning to protect against bumps and impacts. Fourth, compliance with operating parameters: When using these components, strictly adhere to the specified limits for temperature, voltage, and pressure. Operating beyond these rated parameters will accelerate the aging of the metallized layer and reduce the reliability of the component. By following these guidelines, you can significantly extend the service life of ceramic-metalized components and ensure stable operation of your equipment.

2025/12/22

What are the application fields of ceramic metallized parts?

Ceramic metallized parts, with their core advantages of insulating-conductive composite properties, high-temperature resistance, and excellent hermeticity, are widely used in industrial fields with stringent material performance requirements. Specific applications are categorized as follows: Electronics and Semiconductor Industry This is the most critical application area. These parts can be used as electrical lead-out terminals for vacuum electronic devices (such as vacuum switches, electron tubes, and magnetrons), enabling hermetic connections between ceramic insulating casings and metal electrodes. They can also be fabricated into semiconductor package substrates and integrated circuit heat-sink bases, simultaneously meeting both insulation and thermal/conductive performance demands. Aerospace and Defense Industry These parts are suitable for insulating-conductive structural components in rocket engine combustion chambers and missile guidance systems, capable of operating stably under extreme conditions of high temperature, high pressure, and intense vibration. They can also be used for metallized edges of radar antenna radomes, enhancing signal transmission efficiency and structural strength. Energy and Power Industry In nuclear power equipment, they serve as insulating supports and signal transmission components in nuclear reactors, resistant to radiation and high-temperature corrosion. In high-voltage transmission and transformation equipment, they are used to fabricate metallized terminations for surge arresters and insulators, ensuring the safety and stability of high-voltage power transmission. Metallurgy and Chemical Industry These parts can be used to manufacture protective sheaths for temperature-measuring elements in high-temperature kilns and pipeline fittings in chemically corrosive environments. Leveraging their acid-alkali resistance and high-temperature tolerance, they are well-suited for harsh operating conditions. They can also be employed in vacuum induction furnaces used in metal smelting, achieving both hermetic sealing and conductive connections. Medical Device Industry They are used in high-frequency signal transmission components for medical imaging equipment (such as CT scanners and MRI machines), as well as ceramic-metal composite coatings for dental restorations and orthopedic implants, enhancing biocompatibility and structural stability.

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