Erodible Ceramic Body with Conductive Particles
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Solution Overview
Problem
The production of ceramic bodies with electrically conductive hard material particles in an aluminum oxide/zirconia matrix faces challenges such as difficult compaction, high costs of fine hard material powders, and negative effects on thermal conductivity, especially at high zirconium dioxide concentrations, limiting their applicability and machinability.
Innovation Solution
Ceramic bodies with zirconium dioxide content of up to 45% by volume, stabilized with oxides like yttrium oxide, and containing hard material particles like TiC, WC, and TiN, are produced with a metallic phase to enhance machinability and thermal conductivity, allowing for homogeneous distribution and improved material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high concentration of hard material particles (25-60% by volume) is used to achieve electrical conductivity for eroding technology, then erodibility is improved, but compaction difficulty increases and manufacturing cost rises
Solution Approach 1:
The patent changes the concentration parameter of hard material particles from the conventional 25-60% range to a lower range of 1-25% by volume. This parameter change resolves the contradiction by achieving the required electrical conductivity for eroding technology while significantly reducing compaction difficulty and manufacturing cost.
Solution Approach 2:
The patent uses a composite material system consisting of aluminum oxide matrix with dispersed hard material particles (such as TiC, WC, TiN). This composite structure allows the material to achieve electrical conductivity through the conductive particles while the aluminum oxide matrix provides structural integrity and reduces the overall hard material concentration needed, thereby easing compaction.
2Reliability
If high concentration of hard material particles (25-60% by volume) is used to achieve electrical conductivity, then erodibility is improved, but manufacturing cost increases due to high cost of fine hard material powders
Solution Approach 1:
The patent reduces the volume concentration of expensive hard material particles from 25-60% to 1-25% by volume. This parameter change directly addresses the cost issue by using significantly less of the expensive fine hard material powders while maintaining the essential electrical conductivity required for eroding technology through optimized distribution and morphology of the particles.
3Strength
If high zirconium dioxide concentration is used to improve material properties, then corrosion and wear resistance is improved, but thermal conductivity deteriorates
Solution Approach 1:
The patent employs a composite material system where aluminum oxide serves as the primary matrix material instead of zirconium dioxide. This composite approach allows incorporation of hard material particles (TiC, WC, TiN) that provide both mechanical strength for wear resistance and maintain thermal conductivity, overcoming the thermal insulation problem associated with high zirconium dioxide concentrations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The approach enables the production of erodible ceramic bodies with stable material properties, improved machinability, and enhanced thermal conductivity, suitable for various applications including tool and mold making, and the production of thin-walled components with delicate geometry, while reducing the risk of aging and failure under thermal loads.
Implementation Method 1
electrically conductive hard material particles dispersed in an aluminum oxide/zirconia matrix
Implementation Method 2
the zirconium dioxide particles are partially stabilized with 3 mol% Y2O3
Implementation Method 3
The production of ceramics, as disclosed in the aforementioned EP 0 773 201 B1
Data Source
Figure 1
AI summary
The invention relates to an erodable ceramic body having electrically conductive hard material particles dispersed in an aluminum oxide / zirconium dioxide matrix. Advantageous potential adaptations to different requirements arise in that the zirconium dioxide and the hard material particles are homogenously distributed in the aluminum oxide matrix, and the proportion of zirconium dioxide that is partially or completely stabilized at a proportion of at least 10% by volume is up to 45% by volume, and that of the hard material particles is no greater than 25% by volume.