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

Wear resistant ceramic and composite materials based on zirconia nanopowders for engineering and medicine Prof. Konstantinova Tetyana Head of Material Science Department Donetsk Institute for Physics and Engineering named after O.O. Galkin of NAS of Ukraine Donetsk, Ukraine

Products - ceramic and composite articles based on zirconia nanopowders Advantages: • high thermal stability; Nanostructured ceramics and • excellent mechanical properties; composites • predetermined physical properties; Strength • excellent resistance to corrosion in aggressive environments; Scientific and technological • high resistance to abrasive wear; jump Traditional • the stability of properties; ceramics • biocompatibility. Fracture toughness

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

Prices and characteristics of nanopowders Important DonIPhE NANO- NexTech, Tosoh, product or NASU, Oxides inc, technology USA Japan Ukraine USA characteristics 5;10;15;20;30;40 30 - 40 40 3 - 5 Particle size, nm 200 - 15 10 - 15 16 200 BET, m 2 /g Size distribution(s) % in class Agglomeration 30 20 10 5 10 50 100 500 1000 Diameter (nm) Precipitation - Hydrolysis Molecular Process type decomposition 80 – 100* 300 200 3760 Price, $/kg * cost price in laboratory conditions

Economic benefits from the use of wear resistant ceramics Comparative Wear/Abrasion Volume loss/(mm3) Resistance Material 2 Carpenter zirconia 5-20 Tungsten carbide 8-85 Alumina 18-23 Stellite coating 30-35 D-2 hardened steel 100-250 316 stainless steel 200-250 Carbon steel Component Change US $ per No. of changes Extended $ MP liners frequency change over 36 months cost Chrome steel Monthly 500 36 18,000 Alumina Yearly 2,500 3 4,500 1 × every Zirconia 1,500 1 2,500 3 years According to Carpenter Advanced Ceramics

The demand for ceramic products in Ukraine Plungers and friction pairs - 100,000 units/year Bearings - 500,000 units/year Nozzles - 12500 units/year Mill balls - 60000 units/year Kitchen knives - 2000000 units/year Surgical knives - 100,000 units/year Blocks for dental prostheses - 1200 units/year Heads of the hip joint - 10000 units/year Crucibles - 250,000 units/year

How does it work? Products Zirconia nanopowders Granulated powder Preform Sintering furnace Nanopowder Software control machine production pilot line 10 kg/month 2 people - getting a press powder; Granulator - using a variety of methods; Press HHP 1 kg/h - preform molding; ∅ 180*350 - use of CAD / CAM technology; Intellectual property – know how - low-temperature sintering.

Application: wear resistant plungers for mine oil stations Wear resistance increased by 30-50 times! СНТ -32 The plunger of mine hydraulic pump Zirconia: lifetime - 108 months Steel 95X18: lifetime - 2 months

Application: wear resistant injectors for descaling at metallurgical plants Wear resistance increased by 20-40 times! Ceramics - 11 month Hard alloy - 10 days Ilyich Iron and Steel Works of Mariupol

Application: nozzles for sandblasters ОАО ТУШИНСКИЙ МАШИНОСТРОИТЕЛЬНЫЙ 125362, г . Москва , ул . Свободы , д .35 ЗАВОД Тел .: +7 (499) 493 50 53 Факс .: +7 (499) 497 53 51 130 Steel (0.3C;1.0Cr;1.0Mn;1.0Si) Wear resistance increased by 20 times! Exploitation tests carried out at the Zirconia insert OJSC Tushino machine-building plant (Moscow)

Application: wear resistant composite ball valves Wear for different materials Ball valve Nanopowders provides to increase in wear resistance of ceramics and composites due to: • homogeneity of phase and chemical composition; • homogeneous distribution of the grains and the strengthening phase; • hardened grain boundaries and absence of defects (pores, impurities, stress concentrators).

Application: refractory products for the metallurgical, chemical and jewelry industries Glasses-dispenser for continuous Ceramics crucibles based on ZrO 2 -Y 2 O 3 casting of steel from composite ceramics based on ZrO 2 -MgO 10 mm Advantages: 10 mm - high refractoriness > 1800 o C; Developing for GIR - high resistance to thermal shock; and «Puyang-Ceramet» - lack of interaction of the melt with the crucible walls.

Application: Ceramic heads for osteosynthesis of bone tissue joints Zirconia is the best biocompatible material Heads of hip joints The results of tribological tests: amount of cycles -1 000 000; friction coefficient - 0,04 - 0,08; wear - 70 μ m after 1 000 000 cycles. The tests under the guidance of prof. Rosenberg O.A., Radom (Poland) Prosthesis installation scheme In collaboration with ISM NASU (Finishing processing)

Application: dental prostheses and implants Crowns and bridges from ZrO 2 Preforms for CAD/CAM processing Advantages: Implants • zirconia is a product of high strength and durability; • it combines the highest aesthetic with high biocompatibility; • allergic reactions are not known, what important for people who sensitive to metal; • low conduction of heat, the unpleasant temperature sensitivities are virtually excluded; • visible edges and the grey metal-ceramic crowns belong to the past; • zirconium oxide can be colored since its manufacture. Implants from ZrO 2

Prevention of phase degradation of zirconia ceramics Tosoh, Japan 100 90 Donetsk, Ukraine Nanoceramics 80 Tetragonal phase, % 70 NO degradation !!! 60 1,4 µm 50 40 Donetsk, Ukraine 30 20 Large-grain ceramics 10 Tosoh, Japan 0 0 10 20 30 40 50 t, hour 1,4 µm

Our capabilities : On the basis of the pilot line and the section for the production of ceramic products is realized: - production of small batches of products made to order; - development of technologies for series production of products; - development and use of new composite materials; - production of non-serial products; - products for the replacement of expensive imported component parts. joints thread feeders draw plates thread feeders porous ceramics

Our proposals : In Ukraine there is no production of advanced ceramics and composites . Sale of ceramic products of small batches for technique and medicine (DonIPhT) Ceramics and Organization of industrial production of composites based wear resistant ceramic products on zirconia for technical purpose (investment) Organization of the company to develop new technologies and manufacturing of special products (DonIPhT) For the production are available raw materials base, equipment, personnel and developed technologies.

Organization of the enterprise for the production of oxide nanopowders, ceramic and composite articles (business plan) The volume of production - 1 ton/month after 3 years to 2 tons/m The total cost - 37.4 mln Construction and installation - 3 years and 2 months Project payback period - 4 years and 7 months (from the start of production capacity) Discounted payback period - 7.9 years. The average net income for 5 years - 13,546,768 UAH per year. Profitability of production - 84%.

Interested organization and customers International Centre for Electron Beam Technologies - preforms for spraying; "SE Ivchenko-Progress" - SiC nozzles for reactive aircraft engines; "VIRIAL" - wear resistant ceramic ZrO 2 -MgO; LLC "DTS-Invest" - nozzles for waterjet cutting; Ilyich Iron and Steel Works of Mariupol - nozzles for descaling; TMZ - nozzles for sandblasters; GIR and “Puyang-Keramet” - nozzles for UNRS, ISM NASU - ceramics for orthopedic prostheses; Dental Centers "Maestro" and "Suite Dent" - dental prostheses and implants; Branch of SRI ‘”Orion” – functional ceramics.

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