Precision Production Process of High-Quality Alumina Ceramics
Starting from the urgent demand for high-performance materials in modern industry, this article elaborates on the core production processes, including the treatment of high-purity alumina powder, precision forming, and strictly controlled sintering technology. It also explores the precision machining and quality inspection techniques essential for ensuring the outstanding performance of the final products. The purpose of this article is to reveal how alumina ceramic materials transform from raw powder into key components that support high-end manufacturing.
Keywords:
Alumina ceramics, powder preparation, dry pressing, isostatic pressing, sintering, precision machining, performance testing
In high-end semiconductor manufacturing, a critical etching component is required to operate continuously for hundreds of hours in a high-temperature, highly corrosive plasma environment. Any tiny particle detachment or dimensional change could lead to the scrapping of an entire batch of chips worth tens of millions of yuan.
In the field of new energy, the load-bearing roller for lithium battery separator coating must be extremely wear-resistant, smooth, and non deformable to ensure the yield and efficiency of trillion level battery production.
These demanding application scenarios place almost contradictory requirements on materials: extremely high hardness and strength, excellent corrosion resistance, outstanding thermal stability, and complex customizable shapes. Traditional metals or plastics are powerless in the face of these demands. This is precisely the context in which high-quality alumina ceramics come into play—it is the key solution to these industrial pain points.
Solution: Precision production process for high-quality alumina ceramics
The production of high-quality alumina ceramics by Yunxing is an interconnected system engineering, and precise control of each link is the guarantee of final performance.
Phase 1: "Fine carving" of powder - raw material preparation and processing
The quality of raw materials directly determines the ceiling of ceramics. The purity of alumina ceramic powder used for high-performance ceramics is usually required to be above 99% (such as 99.5%, 99.7%, 99.99%), and strict control is required on the particle size, particle size distribution, and morphology of the powder.
Phase 2: Forming Process
The purpose of molding is to make loose powder into a "green body" with a predetermined shape, uniform density, and certain strength.
1. Dry pressing molding
2. Isostatic pressing forming
3. Grouting and Injection Molding
Phase Three: Sintering Process
These demanding application scenarios place almost contradictory requirements on materials: extremely high hardness and strength, excellent corrosion resistance, outstanding thermal stability, and complex customizable shapes. Traditional metals or plastics are powerless in the face of these demands. This is precisely the context in which high-quality alumina ceramics come into play—it is the key solution to these industrial pain points.
Stage Four: Ultimate "Perfection" - Precision Machining and Testing
1. Alumina ceramics are renowned for their high hardness and brittleness, making their machining a universally recognized challenge. To achieve micron-level or even submicron-level dimensional tolerances and nanoscale surface roughness, it is necessary to use diamond grinding wheels for grinding, diamond micropowder for lapping and polishing, and even adopt special processes such as laser cutting and ultrasonic machining.
2. Every batch of products must undergo strict quality inspection, including:
●Non destructive testing: using X-ray inspection, ultrasonic scanning, etc. to detect internal cracks and defects.
●Performance testing: Sampling tests are conducted on its bulk density, apparent porosity, Rockwell hardness, flexural strength, fracture toughness, dielectric constant, and loss to ensure that all indicators meet high standards.
Summary:
It is this rigorous and complex production process that transforms alumina ceramics from a pile of ordinary white powder into an indispensable "backbone" material supporting cutting-edge fields such as modern electronic information, aerospace, new energy, and biomedicine. Its journey of creation is a vivid portrayal of human wisdom converting natural minerals into industrial treasures, and also an epitome of China's continuous advancement in the field of advanced materials as it strides from a "manufacturing power" to a "world manufacturing power."