What is the Processing Method of Whisker-Reinforced Ceramics Cutting
I . Definition of whisker reinforced ceramics
Whisker reinforced ceramics are basically an upgraded type of ceramic-matrix composite reinforced material. Whisker reinforced ceramics are prepared by dispersing micron-level single crystal fiber "whiskers" several microns ~ tens of microns in length uniformly into traditional ceramics matrix like alumina ceramic (SiC whiskers, Al2O3 whiskers). Whiskers refer to materials that are single crystals with certain aspect ratios (generally larger than 10) and diameters ranging from nano to micro meters in size. Silicon carbide whisker and silicon nitride whisker are common examples. Whiskers are embedded into the ceramic as “micro reinforcing bars”. At high temperature, whiskers sinter together with the ceramic matrix through appropriate sintering so that the two are combined firmly to form whisker reinforced ceramics. Whisker reinforced ceramics solved the defects of traditional ceramics materials by changing its microstructure, making ceramics have extraordinary properties at macro scale. For example, traditional ceramics are usually extremely brittle and hard; Whisker reinforced ceramics maintain hardness while also increasing toughness
II. Properties of whisker reinforced ceramics
Superior mechanical properties:
The flexural strength is 2 ~ 3 times that of ordinary engineering ceramics. The whiskers in the ceramic matrix hinder the cracks like steel bars. When force is applied on the outside, cracks appear on the material’s surface. The whiskers put forward resistance by means of pull-out and bridging to consume energy, thus improving the fracture toughness of the material and allow the material to absorb more mechanical energy without breaking.
Excellent high temperature capabilities:
The material’s mechanical properties hardly deteriorate even at 1200 degrees. Whisker reinforced ceramics don’t easily deform under high temperatures, and still have stable mechanical properties and chemical properties.
Excellent wear resistance and thermal shock resistance:
Due to high hardness and strength of whiskers. When there is friction between materials, the surface of materials will not be easily worn out. Whisker reinforced ceramics have excellent wear resistance and thermal shock resistance, which can be used in places where wear resistance requirements are extremely high, such as mechanical seals and cutting tools.
Wide applications:
Nowadays, whisker reinforced ceramics have become an important structural material in the field of aerospace, precision machinery, high-end electronics, new energy vehicles, semiconductor chips, etc. Such as high-performance sealing,wear-resistant cutting tools, aerospace heat-resistant materials, new energy insulation parts, substrate materials of chips that can dissipate heat. Whisker reinforced ceramics are developing at a rate of more than 20% per year in the market.
III . Why choose TKD CO., LTD fiber laser cutting machine to cut whisker reinforced ceramics?
Advantages of TKD laser cutter and Precision of whisker ceramics Processing
Resolve traditional process problems: The traditional processing methods of whisker reinforced ceramics are diamond grinding and water cutting. The chipping rate of grinding was more than 20%. If you process small precision parts, the yield is often less than 60%. In addition, grinding requires secondary polishing processes, which greatly prolongs the production cycle and increases the cost of tool wear. The kerf width of water cutting is generally greater than 0.3 mm, which does not meet the requirements of parts with tolerances within 0.05 mm; In addition, the water medium is easy to enter the pore structure of ceramics and cause poor performance. Fiber laser cutting adopts non-contact heat processing, which avoids structural damage caused by mechanical action.
Meet high precision processing requirements: With the continuous development of technology, users’ requirements for processing precision and quality of whisker reinforced ceramics are becoming higher and higher. Using the excellent beam quality and ultra-high energy density of the fiber laser cutting machine produced by TKD CO., LTD, we can instantly melt and vaporize ceramics. Benefit from true non-contact processing to meet the high precision processing requirements of high-end fields such as aerospace ceramics processing, ceramic cutting and electronics and information.
IV . Benefits of Using TKD Laser Cutter to Cut Whisker Reinforced Ceramics
Ultra-high processing precision:
The laser focal point spot can be processed into micron level. Combined with TKD CO., LTD’s precision motion control system, you can make the kerf width reach 0.1 mm and edge chipping is controlled within 0.03 mm. Clean processing of various contours can be realized to meet the tolerance requirements of precision parts. The yield rate is above 95%, which can also meet the requirements of high precision parts such as semiconductor and new energy vehicle industry;
Almost no heat affected zone (HAZ):
By properly adjusting the pulse parameters and auxiliary gas, we can make the thermal damage to the material only reach several tens of microns. We can further optimize the pulse frequency and power parameters to make the heat-affected zone as small as possible, so that the cut surface is flat and smooth. It can better maintain the strengthening effect of whiskers, and almost no need for grinding or polishing after processing. **High process flexibility: ** Fiber laser provides users with the flexibility to adjust power, frequency and scanning path through software. One machine can process different thickness materials, from plates to sheets. There is no need to change the cutting tool for cutting. Whether it is shaped holes, irregular contours or customized processing. We only need to modify the CAD drawing file, and the mold making can be skipped. Production can be started. It is extremely suitable for small batches of customized production. Compress the small batch trial production response time from the original 7 days to less than 1 day.
High processing efficiency: For 1mm thick whisker ceramics, the cutting speed can reach 200mm/min. It’s 3 ~ 4 times the speed of traditional grinding. The surface roughness (Ra) after cutting is ≤1.6μm, that is to say, most of the parts do not need to perform post-processing.
Low processing costs: Zero tool wear, no need to replace various consumables for each production batch. Processing costs are reduced by more than 40% compared to grinding. At the same time, fiber lasers have small maintenance costs and high electro-optical conversion efficiency. In the long run, it will also help reduce the per-unit cost of machine tool manufacturing.
